RETURN

ROBOT
190, 190HF, 1110, 1110HF

Problem Solving
Click the problem on the contents list to
take you to the answer
 Return
Problem Solving
Contents

The following pages are extracted from the Robot 190, 1110 Service Manual 9803/8530.
For more information, refer to the Service Manual.
Click on the appropriate title to go to the page. Start with Transmission or Loader Problems and Causes.

Transmission Problems Loader Problems

Transmission Problems and Causes
Checking for Faulty Pump or Motor
Checking Wheel Speed
Machine Veers to One Side When Travelling
Transmission Pump Neutral Adjustment
Checking Motor Leakage Rate
Pump High Pressure Relief Valves
Checking Joystick Hydraulic Lines
Tyres and Wheels
CPPV Flow/Pressure Check
Pump/Engine Coupling
Drive Chain Removal and Replacement
Adjusting Drive Chain Tension
Wheel Hub Assembly
Loader Problems and Causes
CPPV Flow/Pressure Check
Levelling Circuit Problem Solving
Main Relief Valve Pressure Test
Hydraulic Fluid Level
Changing Hydraulic Filter
Changing High-flow Hydraulic Filter
Changing Hydraulic Tank Breather
High-flow Circuit Flow/Pressure Check

9803/8530 Issue 1
 Section E Hydraulics Section E
10 - 1 Problem Solving CONTENTS
10 - 1

Hydrostatic Transmission
Before carrying out any problem solving or any tests on the machine, make sure that the hydraulic system is filled to the correct
level with the correct grade of hydraulic oil (see Section 3) and that the system is at the correct working temperature.

PROBLEM CAUSE

No drive in any direction 1, 2, 4, 5, 10, 16, 22, 23, 24

No drive in either forward or reverse 6, 8, 11, 18, 24
No spin turn either left or right 3, 4, 5, 11, 16, 18, 21, 24
No drive on one side 5, 6, 9, 11, 18, 21, 22, 24
Machine will not travel in straight line 3, 8, 9, 11, 16, 18, 19, 20, 21
No brakes 13, 14, 15, 17
Brakes on all the time 12, 13, 14, 15, 17
No tractive effort 4, 5, 6
Machine creeps in neutral 7

KEY TO CAUSE REMEDY PAGE REF.

1 No oil in hydrostatic system Check supply of oil to pump.

2 Restraint not in correct position Ensure restraint is in operating position,

check electrical wiring and switch as required.

3 Tyres worn or pressure incorrect Check tyre pressures and condition. 3/9-2

4 Charge pressure incorrect Charge pressure is controlled by the Priority Valve.

Carry out flow check. E22-1
Check that transmission pump charge valve is disabled.

5 No or low pump output Check pump - carry out wheel speed check. E10-5
If one pump suspect, swop motor feed hoses and notice
if problem changes sides - if ‘yes’, pump related fault;
if ‘no’, motor related fault. E10-4

*6 A high pressure ‘loop’ relief valve/tow valve Replace relief valve and re-check. E10-9
open/set incorrectly

7 Pump neutral position set incorrectly Adjust servo neutral position. E10-7

8 Pump servos incorrectly set Adjust servos. E10-6, E10-7

9 Feed hose failure Check motor feed hoses.

10 No hydraulic feed to joystick Check for feed to joystick. E10-10

11 No hydraulic feed from joystick to pump Check for feed from joystick to pump. E10-10

12 Brake hose failure Inspect brake hoses.

13 Brake release pressure incorrect Check charge/brake pressure. E22-1

14 Electrical failure (brake valve circuit) Check brake valve electrical circuit.

15 Brake valve inoperative Check valve (sticking spool, etc.)

16 Brakes not released Inspect motor brakes for seal damage. Repair as required.

9803/8530 Issue 2*
 Section E Hydraulics Section E
10 - 2 Problem Solving CONTENTS
10 - 2

KEY TO CAUSE REMEDY PAGE REF.

17 Mechanical brake failure Check brake components

(worn plates, spring damage, etc.).

* 18 Motor seal leakage Check motor case drain for confirmation of internal leakage E10-8
(compare one motor with the other). Check for shaft seal
leakage by checking chain case oil level.

19 Joystick inoperative Check joystick (plunger movement, leaking seals, etc.)

20 Chain tension Check chain tension. F3-2

21 Motor failure Inspect motor for damage. Repair as required.

22 Chain/sprocket damage Inspect chain and sprocket. Repair as required. F4-2

23 Pump/engine drive coupling failure Check coupling. E26-1

24 Mechanical linkage maladjusted Check linkage and adjust as required.

(manual machine)

9803/8530 Issue 2*
Section E Hydraulics Section E
10 - 3 Problem Solving CONTENTS
10 - 3

X1

382770

M1 LH MOTOR M2 RH MOTOR 10 SERVO CONTROL VALVE

T P1 FRONT PUMP P2 REAR PUMP

T
10a
FWD FWD FWD
SP1
B B D A P

10d LEFT T
SP2

RIGHT
SP4 REV 10b
M1c M2c SP3

10c
M1a M2a E F

M1b A A C B M2b
REV REV
D C
M5 M4 M5 M4 X Z

CT2 CT1 SOFT

SHIFT
VALVE

X1 6 7
P
T 1 CT3

TANK
9 F1
S P3
GEAR FILTER
PUMP X2
C T
OIL COOLER
TANK
382590

X2

382780

9803/8530 Issue 1
Section E Hydraulics
10 - 4 Problem Solving
Checking for Faulty Pump or Motor
If the transmission operates or is faulty on one side only then
swop the motor feed hoses to check if the fault is with the
pump or motor. If, after the hose swop, the suspect motor
then operates the fault lies in the relevant pump unit. If the
motor still does not operate then the motor itself is faulty.
Proceed as follows:
1 Stop the engine.
2 Remove the seat and floorplate to expose the pump.
3 To ensure correct replacement after the test is
complete, mark the motor feed hoses A and B for the
left hand motor, C and D for the right hand motor.
4 Swop the motor feed hoses from one side to the other
as indicated in the illustration, i.e. swop hoses A and C
then swop hoses B and D.
Note: It may be found more convenient to use separate
additional hoses to extend the existing feed hoses.
9803/8530
Section E
CONTENTS
10 - 4
5 Restart the engine and re-check the operation of left
and right motors. Note that when the left motor is
selected the right motor should now drive and the left
motor should drive when the right motor is selected. If
the previously faulty motor now functions then the fault
lies in the relevant pump unit. If the motor still does not
operate then the motor itself is faulty.
! WARNING
Hydraulic Fluid
Fine jets of hydraulic fluid at high pressure can penetrate
the skin. Do not use your fingers to check for hydraulic
fluid leaks. Do not put your face close to suspected
leaks. Hold a piece of cardboard close to suspected
leaks and then inspect the cardboard for signs of
hydraulic fluid. If hydraulic fluid penetrates your skin, get
medical help immediately.
INT-3-1-10/1
D
382790
Issue 1
Section E Hydraulics Section E
10 - 5 Problem Solving CONTENTS
10 - 5

Checking Wheel Speed

The pump output and general efficiency of the drive system
may be checked by raising the machine off the ground and
checking the wheel speeds.
! WARNING
The following procedure requires the machine to be
disabled (wheels raised off the ground, attachment
disconnected etc.) while the work is carried out.
HYD 8-1/2
Place the machine safely onto blocks, so that all four wheels
are clear of the ground. Ensure that the machine is stable.
Stick a piece of reflective tape on a wheel rim. Start the
engine and run at maximum speed then operate the drive
control. Using a stroboscopic meter, measure the speed of
wheel rotation in each direction which should be as follows:
Single Speed 70-75 rev/min.
2 Speed Low 60-66 rev/min.
2 Speed High 120-130 rev/min.
Track Sprocket 95-100 rev/min.
Check the speed of the wheels on the opposite side of the
machine.
Note that excessive wheel speed may result in cooling
problems due to overheating of the hydraulic oil.
Maximum Displacement Adjustment
If necessary the appropriate adjusting screws should be
screwed in 1/4 turn at a time until the correct wheel speed is
achieved. Stop the engine while adjustment is carried out.
1 Remove the seat and floorplate to expose the pump.
2 If the left hand wheels are rotating too fast, screw in
adjusters A (forward) or B (reverse) to achieve the
correct speed. If the right hand wheels are rotating too
fast, screw in adjusters C (forward) or D (reverse).
If all four wheels rotate slowly and cannot be corrected by
adjustment, the most likely cause would be internal wear of
the hydrostatic pump.
If the wheel speed is slow on one side only, the cause could
be a faulty servo or a faulty motor. Carry out procedure on
page E10-4 to determine which is faulty.
Following this procedure, further small adjustments may be
required to achieve correct straight line travel (see following
page).
Manual Machines
If the correct wheel speed cannot be achieved, check that
the control linkage is correctly adjusted and giving maximum
pump swash.

A
C

382800

9803/8530 Issue 1
Section E Hydraulics Section E
10 - 6 Problem Solving CONTENTS
10 - 6

Machine veers to one side when travelling.

This condition may be corrected by adjusting the pump servo units or manual controls but before attempting this, carry out the
following preliminary checks.

Check tyre pressures The pressure of one tyre may be low or one or both tyres on one side of the machine may be
and condition new and the other tyres worn. In both these cases the rolling circumference of the tyres will be
unequal causing the machine to veer to one side.

Check chain tension Chains which are tensioned unequally will cause the machine to veer to one side. Always adjust
the tension on all four chains, never just one.

Check the servo joystick Check that the joystick spools are not sticking and are correctly operated by the lever.

Check the manual controls Check that the manual control linkage is not sticking. Lubricate if necessary.

Adjustment

If the machine does not travel in a straight line, proceed as

follows:

Refer to illustration on previous page.

Fault

1 Machine veers excessively to left in forward travel Loosen locknut on adjuster screw C, screw in adjuster screw
1/4 turn and tighten locknut. Try machine. Keep adjusting 1/4
turn at a time until straight line travel is achieved.

2 Machine veers excessively to right in forward travel Proceed as for fault 1 but adjust screw A.

3 Machine veers excessively to left in reverse travel Proceed as for fault 2 but adjust screw D.

4 Machine veers excessively to right in reverse travel Proceed as for fault 3 but adjust screw B.

Note: If the fault cannot be rectified by any of the above checks or adjustment, then either the pump or motor could be faulty.
To identify which, swop the motor feed hoses at the pump as described on page E10-4. If the machine now veers in the
opposite direction then the pump is faulty. If the machine continues to veer in the same direction the motor is faulty.

9803/8530 Issue 1
Section E Hydraulics
10 - 7 Problem Solving
Transmission Pump Neutral Adjustment
This procedure may be carried out if the machine creeps
when the drive control is in the neutral position.
Adjustment
This fault may be due to an incorrect neutral setting of the
servo piston.
1 Identify which pump section requires adjustment.
If the machine veers to the left this could be caused by
either the right hand wheels moving forward or the left
hand wheels moving in reverse. Remember that pump
P1 drives the left hand motor and pump P2 drives the
right hand motor.
If the machine moves either straight ahead or behind
then both pump servos must be adjusted equally.
2 Stop the engine.
3 Remove the seat, seat base and pump cover.
B P1
P2
C
9803/8530
Section E
CONTENTS
10 - 7
4 If pump P1 requires adjusting, loosen locknut A and turn
the ‘neutral’ adjusting screw B 1/10 of a turn in the
required direction then re-tighten the locknut.
If pump P2 is to be adjusted, loosen locknut C and turn
adjusting screw D.
If the wheels are creeping forward, turn the adjusting
screws in an anti-clockwise direction (out). If the wheels
are creeping in reverse, turn the screws clockwise (in).
Note: This adjustment is very sensitive. Turn the adjusting
screw 1/10 of a turn at a time and re-check. A slight
movement when the wheels are raised is acceptable
provided that no movement occurs when the machine is
resting on the ground.
5 Start the engine and check that the wheels are
stationary.
6 Finally tighten locknuts A and C taking care to retain the
set position of adjusting screws.
7 Re-check for wheel movement.
Manual Machines
Check that the control linkage is correctly adjusted and not
sticking.
D
382810
Issue 1
Section E Hydraulics Section E
10 - 8 Problem Solving CONTENTS
10 - 8

Checking Motor Leakage Rate

If the motor speed is low and the pump output is normal, the
cause could be excessive internal wear in the motor which
would result in high leakage of oil into the motor casing. By
measuring the amount of oil leaking from the motor casing
back to tank, it is possible to determine if the motor is worn.

1 Stop the engine.

2 Remove the seat and floorplate to expose the motors.

3 Connect a flowmeter into the motor drain hose at the

motor.

4 Install a 0 - 400 bar (0 - 6000 lb/in2, 0 - 422 kg/cm2)

pressure gauge into the appropriate point on the pump
to measure the pressure generated in the motor feed
line (see next page for pressure test points). C
5 Start the engine and drive the machine forward against
a solid, immovable object as shown at C. Measure the
amount of oil expelled from the motor during one
minute’s operation.

At the maximum pressure of 414 bar (6000 lbf/in 2 ) the

normal oil leakage should be approx. 17 l/min (3.75 UK
gal/min, 4.5 US gal/min). 382830

Note: The motor leakage at zero pressure is much less than

the rate at higher pressures. This is because at higher
pressures the motor flushing spool is actuated causing the
oil flow through the motor casing to increase. The figure
quoted above is the combined leakage and flushing flows.

If the flow rate is higher than normal, the motor should be

dismantled for repair.

9803/8530 Issue 1
Section E Hydraulics Section E
10 - 9 Problem Solving CONTENTS
10 - 9

Pump High Pressure Relief Valves Testing High Pressure Relief Valves
The upper illustration shows the right hand side of the pump, To carry out a dynamic test of the high pressure relief valves
the lower illustration shows the left hand side of the pump. would require the wheels to be prevented from moving.
Because of the difficulty of doing this it is recommended that
A Left motor forward port the valves are tested by swopping them from one drive side
B Left motor reverse port to the other.
C Right motor reverse port
D Right motor forward port DO NOT attempt to blank off the drive to activate the relief
valves as the pump could be severely damaged.
! WARNING
Identify which drive circuit is faulty then proceed as follows:
Hydraulic Fluid
Fine jets of hydraulic fluid at high pressure can penetrate
1 Remove the seat and seat base.
the skin. Do not use your fingers to check for hydraulic
fluid leaks. Do not put your face close to suspected
2 Check for dirt trapped under the valve poppet by
leaks. Hold a piece of cardboard close to suspected
unscrewing the faulty valve by four turns then starting
leaks and then inspect the cardboard for signs of
the engine and operating the transmission control to
hydraulic fluid. If hydraulic fluid penetrates your skin, get
select the appropriate drive. Retighten the valve.
medical help immediately.
INT-3-1-10/1
3 Operate the transmission to see if the problem persists.

4 If the problem is still present, swop the valves from left

side to right side and recheck. If the problem changes
sides then the valve is faulty. If the problem remains on
the same side the fault lies elsewhere.

The valves are not adjustable. The faulty valve should be

removed and a new one fitted.
B

A
D

C 327490

9803/8530 Issue 2
Section E Hydraulics Section E
10 - 10 Problem Solving CONTENTS
10 - 10

Checking the Joystick Hydraulic Lines

If the machine does not respond to joystick movements,
check the hydraulic supply to and from the joystick as
follows:
1 Remove the seat and floorplate to access the hose
connections A and B.
2 Insert a tee piece and 0 - 40 bar (0 - 600 lb/in2, 0 - 42
kg/cm2) pressure gauge into the joystick supply hose at
the brake valve at position A.
3 Start the engine and observe the gauge reading which
should show the transmission pump charge pressure
(see Hydraulics Technical Data).
4 If the gauge shows no or little pressure it could indicate
a fault in the charge pressure priority valve.
6 Remove the tee piece and gauge.
7 Disconnect each servo feed line in turn from the pump
and connect the gauge to the end of the hose, as shown
at B.
8 Start the engine and move the joystick lever to
pressurise the relevant hose. The lever should be moved
fully diagonally as shown below.
9 The pressure gauge should show transmission pump
charge pressure with full joystick travel (see Hydraulics
Technical Data).
10 If any readings are not correct, check the hoses for
blockage. If the hoses are clear the joystick should be
dismantled for repair.

5 If the supply pressure is correct, check the feed hose to

the joystick for blockage.

FWD
1 2 B

3 REV
4
CT2 CT1 SOFT
SHIFT
BRAKE

1
VALVE
VALVE
6 7

CT3
4 3
A

2
T P T
382850

382841

9803/8530 Issue 2
Section E Hydraulics Section E
11 - 1 Problem Solving CONTENTS
11 - 1

Loader Circuit
The purpose of this section is to help you trace hydraulic problems to a faulty unit (valve, actuator, ram etc). Once you have
traced the faulty unit, refer to the appropriate dismantling, inspecting and test instructions given elsewhere in the manual.

To help identify circuits, valves, rams etc. mentioned in the problem solving procedures, refer to hydraulic schematic diagrams.

* Before you begin problem solving, read the Safety Information at the beginning of this manual.

* Make simple checks before say, stripping a major component.

* Make sure that the hydraulic fluid is at correct working temperature (50 °C, 122 °F).

* Whatever the fault, check the condition of the hydraulic fluid. Drain and replace if necessary.

* Be sure to remove ALL contamination and if possible identify its origin. It may be part of a component from elsewhere in the
circuit.

PROBLEM CAUSE (standard machines) CAUSE (High-flow machines)

Lack of power in all loader functions. 1, 2, 3, 4, 6, 18 1, 2, 3, 4, 6, 7, 18

All hydraulic rams slow to operate. 3, 4, 10 3, 4, 7 (servo only), 10

One hydraulic service fails to operate or 12, 13, 15, 15, 17 12, 13, 14, 15, 17
is slow to operate.

Engine tends to stall when hydraulics are under load. 3, 18 3, 7, 18

Valve spool sticking. 3, 19, 21, 22, 23, 24, 25, 26, 27, 28 3, 19, 21, 22, 23, 24, 25, 26, 27, 28

Ram creep. 15, 16 15, 16

Hydraulic oil becomes too hot. 5, 6, 11, 20 5, 6, 11, 20

Boom judders when used while machine is moving. 8 (servo only) 10

KEY TO CAUSE REMEDY PAGE REF.

1 Insufficient hydraulic fluid. Check for leaks and top up as required.

2 Hydraulic leaks in system. Check hoses, replace as required.

3 Main relief valve (MRV) setting incorrect. Check and adjust as required. E21-1

4 Low loader pump flow. Check pump flow, if necessary service or replace pump.

5 Hydraulic filter clogged. Change hydraulic filter. 3/8-1

6 Charge filter by-pass valve leaking. Check condition of hydraulic filter. 3/8-1
Check operation of by-pass valve.

7 Charge pressure priority valve pressure Check pressure setting of charge pressure priority valve. E22-1
setting incorrect.

8 Servo pressure low Carry out charge pressure priority valve check. E22-1
Check for blocked service feed hose or faulty joystick.

..... continued

9803/8530 Issue 1
Section E Hydraulics Section E
11 - 2 Problem Solving CONTENTS
11 - 2

KEY TO CAUSE REMEDY PAGE REF.

9 Non priority pressure/flow low. Carry out charge pressure priority valve flow check. E22-1

10 Neutral circuit or low pressure lines leaking, Check pipe lines and replace as required.
damaged, trapped or kinked.

11 Restriction in neutral circuit lines. Check hoses and pipes, replace as necessary.

12 Service pipe lines leaking, damaged, Check hoses and pipes, replace as required.
trapped or kinked.

13 Ram or pipe lines from ram leaking. Check and rectify as required.

14 Valve spool not operating. Check for leaks, rectify as required.

Make sure that spool lock-out is operating (check for
faulty wiring, solenoid sticking, burr on spool, etc.)
Make sure that associated load hold
check valve is operating.

On servo machines, check operation of

joystick and feed hoses.
On manual machines, check that control lever
and associated linkage is operating the spool,
rectify as required.

15 Valve spool not moving fully from Spool movement should be 5.5 mm (0.22 in)
neutral to full selection. On servo machines, check servo (charge) pressure. E26-3

16 Valve spool leaking Rectify, check for contamination.

17 Piston rod bent. Replace piston rod. Check pressure setting of MRV.
Check that associated pivot pins are adequately greased.

18 Poor engine performance. Check engine performance.

19 Manual control linkage bent. Disconnect linkage. Repair linkage or renew.

20 Oil cooler obstructed. Remove debris from cooler fins.

21 Oil temperature abnormally high. Check for correct fluid, see Lubricants and
Capacities. Check oil cooler and grille for blockage.

22 Hydraulic fluid dirty. Clean tank strainer. If strainer badly clogged, drain and
flush hydraulic system then fill with clean hydraulic fluid.

23 Service pipe connection over tightened. Check tightness.

24 Valve housing twisted during installation. Loosen retaining bolts and tighten to correct torque.

25 Bent spool. Dismantle control valve. Renew spool as necessary.

26 Spool return spring broken. Renew as necessary.

27 Spool return spring or cap out of alignment. Remove cap, check that spring is in correct position.
Refit cap and torque tighten bolts.

28 Temperature distribution within Warm up entire system before using service.

control valve not uniform.

9803/8530 Issue 1
Section E Hydraulics Section E
12 - 1 Problem Solving CONTENTS
12 - 1

Levelling Circuit
PROBLEM PROBABLE CAUSE REMEDY

1 Boom delay at start of self-level A Air in system A Cycle boom and bucket slowly
or unstable self-level to rid system of air

2 Loaded bucket dumps or raises A Unloading spool is leaking A Remove and inspect unloading
when control valve is in neutral spool for damage

3 Insufficient self-level A Pin X is out of adjustment A Re-adjust pin to achieve proper

flow split

B Broken unloading spool spring B Replace unloading spool spring

C Flow divider spool stuck C Remove flow divider spool and

towards port B check for damage

4 Bucket dumps faster than boom A Pin X out of adjustment A Re-adjust pin to achieve proper
raises. Too much self-level flow split

B Flow divider spool stuck B Remove flow divider spool and

towards port B check for damage

C Flow divider spool installed C Remove spool and install with

incorrectly internal orifice towards port B

5 With bucket dumped, boom is A Dampening orifice in the A Remove unloading spool and
slow in starting to raise unloading spool is blocked clean dampening orifice

6 Bucket does not move in self-level A Pin X is screwed in all the way A Re-adjust pin to achieve proper
flow split

B Dampening orifice in the B Remove unloading spool and

unloading spool is blocked clean dampening orifice

C Ports A and B cross connected C Reverse hoses to ports A and B

7 Bucket raises in self-level A Ports A and B cross connected A Reverse hoses to ports A and B

8 External leakage A Damaged ‘O’ ring A Replace ‘O’ ring

382881

9803/8530 Issue 2
Section E Hydraulics Section E
13 - 1 Problem Solving CONTENTS
13 - 1

382900

9803/8530 Issue 1
Section E Hydraulics Section E
13 - 2 Problem Solving CONTENTS
13 - 2

High-flow Circuit
In the event of poor attachment performance or hydraulic
overheating when using the High-flow circuit, the following
procedure should be followed to ensure optimum machine
and attachment performance.
If poor attachment performance is still experienced after
resetting the High-flow valve and the flow rates and pressure
are correct, then the problem is with the attachment.
Consult the attachment service manual for corrective action.

Checking Flow and Pressure
1 Check the flow requirement of the attachment fitted
and compare it to the machine specification. Note that
the flow at the High-flow circuit is a combination of the
high flow pump and the auxiliary pump. If the
attachment flow rate requirement exceeds the total
machine flow then the attachment is unsuitable for use.
An example of a problem may be excessive back pressure.
No more than 12 bar (175 lbf /in2) should be seen at the
High-flow valve block. To check this insert a tee piece and a
40 bar (600 lbf /in2) pressure gauge into the return line at B.
Check the pressure recorded by the gauge with the
attachment running.

2 Check the pressure requirement of the attachment. If

this exceeds the machine specification then the
attachment is unsuitable.

3 Only when attachment suitability has been confirmed

can the cause of the problem be established.

4 Check the flow and pressure setting of the High-flow

circuit as detailed below:

4.1 Connect a flow meter, 400 bar (6000 lbf /in2) pressure
gauge and load valve between the high flow couplings
on the loader arm as shown.

4.2 With the hydraulic oil at 50 °C (122 °F), the engine at

maximum speed and the load valve fully open, operate
the High-flow circuit and check that the flow reading is
as specified in the table below. Progressively close the
load valve and check the flow and pressure against the
figures in the table.

4.3 If necessary, adjust the High-flow relief valve A so that

the correct specified pressure is achieved.

Flow Rates - L/min (UK gal/min) [US gal/min]

Max. flow, no pressure 120 - 130 (26.4 - 28.6) [31.7 - 34.3]

100 bar (1450 lbf /in2) 115 - 125 (25.3 - 27.5) [30.4 - 33.0]
120 bar (1740 lbf /in2) 115 - 125 (25.3 - 27.5) [30.4 - 33.0]
140 bar (1740 lbf /in2) 115 - 120 (25.3 - 26.4) [30.4 - 31.7]

9803/8530 Issue 2
 Section E Hydraulics Section E
21 - 1 Pressure Testing CONTENTS
21 - 1

Main Relief Valve (M.R.V.)

Remove the seat and seat base.

Connect a 0 - 400 bar (0 - 6000 lb/in2, 0 - 422 kg/cm2)

pressure gauge to test connector A located on the charge
pressure priority valve.

With the engine running at maximum speed, check the

M.R.V. setting by raising or lowering the loader arm until the
rams are fully open or closed and noting the maximum
gauge reading. Keep clear of the loader arm. The A
maximum pressure should be as stated in Technical Data.

* If the pressure is incorrect, remove cap B from the M.R.V.

Slacken lock nut C and turn adjusting screw D clockwise to
increase the pressure or anti-clockwise to decrease the
pressure. Tighten lock nut C and recheck the pressure.
When the pressure is correct, refit cap B.

Remove the pressure gauge and refit the seat and seat
base.

382780

D C

B
385021

9803/8530 Issue 2*
Section E Hydraulics Section E
22 - 1 Pressure Testing CONTENTS
22 - 1

Charge Pressure Priority Valve Flow/Pressure Check

1 Install a flow meter and 0 - 40 bar (0 - 600 lb/in2, 0 - 42
kg/cm2) pressure gauge into the priority line from the
Charge Pressure Priority Valve (CPPV) right hand port to
the transmission pump.
! WARNING
The following procedure requires the machine to be
raised off the ground while the work is carried out.
Support the machine safely on blocks. Keep clear of
rotating wheels.
0082
2 Place the machine safely onto blocks so that all four
wheels are clear of the ground. Ensure that the machine
is stable.
3 Start the engine and run at max. revs. then select drive.
Observe the reading on the pressure gauge then, using
the graph below, plot a horizontal line from the pressure
reading and check that the flow recorded on the
flowmeter is as indicated on the graph for that pressure.
7 Operate a loader service and check that the priority line
pressure is not affected.
8 If the priority line pressure is below 20 bar (290 lb/in2;
20kg/cm 2 ) or the pressure is affected by loader
operation the CPPV or the gear pump could be faulty.
To check which unit is faulty proceed as follows.
9 Connect a flow meter and load valve into the non-
priority line from the CPPV left hand port to the valve
block. Alternatively the flow meter and load valve can be
connected across the quick release couplings.
Note: The machine must remain static during the following
tests. If the transmission control levers are moved the motor
flushing flow will increase and the non priority rate will drop.
10 With the load valve open and the engine at max. revs,
the flow reading should be above 85 litres/min (18.7 UK
gal/min; 22.5 US gal/min). If the flow reading is below
this figure the gear pump is faulty.

4 If the flow is higher than indicated on the graph suspect 11 Using the load valve, gradually increase the pressure in
excessive leakage within the hydrostatic system. Check the non-priority line. The flow and pressure readings
that the hydraulic filter element is not blocked causing should be as indicated in the table below.
the by-pass valve to open. DO NOT EXCEED 180 Bar (2610 lb/in2, 184 kg/cm2).

5 Lower the machine to the ground and repeat test in Table of Non-priority flow/Pressure
paragraph 3 whilst driving the machine against a solid
immovable object. Pressure Flow
bar lb/in2 kg/cm2 l/min UK gal/min US gal/min
6 If the flow is higher than indicated on the graph suspect
excessive leakage within the motors. 100 1450 102 81-83 17.8-18.3 21.4-21.9
150 2175 153 78-80 17.2-17.6 20.6-21.1
180 2610 184 77-79 16.9-17.4 20.3-20.9

US gal/min
0 1.3 2.6 3.9 5.3 6.4 7.9 9.2 10.5
30

25
Bar

20

15
0 5 10 15 20 25 30 35 40
Litres/Min 390080

9803/8530 Issue 2
Section E Hydraulics Section E
26 - 1 Pumps CONTENTS
26 - 1

Pump/Engine Coupling
This is a flexible coupling comprising an outer coupling A,
bolted to the engine flywheel, and an inner coupling B
clamped to the input shaft of the pump unit.

The outer coupling A is bolted to the engine flywheel with six

setscrews C. The inner section B is tightened onto the pump
shaft spline with grub screws D.

When fitting the outer coupling to the flywheel insert mandrel

X (see service tools) before fitting setscrews C.

Coat threads of setscrews C with JCB Threadlocker and

Sealer and torque tighten to 28 Nm (21 lbf ft, 2.8 kgf m).

Slide inner coupling B fully onto the pump input shaft. Coat
threads of grub screws D with JCB Threadlocker and Sealer
and torque tighten to 70 Nm (52 lbf ft, 7.1 kgf m).

A
D

X
B

382920 385040

9803/8530 Issue 1
Section F Transmission Section F
3-2 Wheel Hubs CONTENTS
3-2

12

11

10
9
8 13
7
5

4
6

3
1
4
5 5
X 13 Y 13
4
8 7 6 3
2

385490

9803/8530 Issue 1
Section F Transmission Section F
3-3 Wheel Hubs CONTENTS
3-3

Wheel Hub Assembly

Dismantling

Remove bolt 1, plain washer 2 and preload washer 3.
Remove drive sprocket 4.
Support the casing assembly on its outer flange with the
wheel hub facing downwards and press out the axle shaft
assembly 5. Bearing 6 will remain in the casing 13 and can
be removed separately if necessary. The outer race of
bearing 7 will also be left in the casing and can be removed
if necessary. Shaft seal 8 should be removed and discarded.
If fitted and if necessary, remove bolts 9 with washers 10
and remove twine cutter 11.
Inspection
Fit a torque meter to the head of stud C and check the
torque required to rotate the axle shaft. The correct rolling
torque should be 80 Nm (59 lbf ft, 8.2 kgf m). Continue
tightening stud C until the correct rolling torque is achieved.
Rotate the axle shaft 1 full revolution to ensure that the
bearings are fully seated then recheck the rolling torque and,
if necessary, tighten further to 80 Nm (59 lbf ft, 8.2 kgf m).
Position a dial gauge against the flat face of the sprocket as
shown at D and zero the gauge. Reposition the dial gauge
onto the end of the axle shaft as shown at E and note the
reading. Remove the gauge and assembly tool.

Thoroughly clean and dry all components. Examine the continued

bearings, axle shaft and casing for wear or damage. Renew
as necessary.

Assembly

Assemble the twine cutter, if previously removed, and

tighten bolts 9 to the correct torque.

Lubricate outer bearing 7 and seal 8 with JCB Special HP B

Grease before assembly. Inner bearing 6 should be A
assembled without grease.

Press bearing 7 into casing 13 ensuring that the outer race is

pressed fully home.

Assemble outer race of bearing 6 into casing 13. Ensure it is

pressed fully home.
A
Fit the two halves of the oil seal installer A (825/10003)
around the axle shaft 5 and position a new oil seal 8, with
the seal lip facing inwards, against the installer. Feed axle
shaft 5 into the casing. 333181

Assemble the inner race of bearing 6 onto axle shaft 5 and

slide sprocket 4 onto the splines of the axle shaft.

Note: The front sprocket should be assembled with its boss

towards the casing, as at X. The rear sprocket should be
D
assembled with its boss away from the casing, as at Y.

Screw threaded stud C of assembly tool B (825/10002) fully

into the end of the axle shaft as shown then continue turning C
the stud to pull the axle shaft into the casing so that the oil
seal is fully installed. Release the assembly tool and remove
the oil seal installer. Note that it may be necessary to gently
tap the end of the shaft to release the installer.

Reassemble tool B and continue pulling the axle shaft into

position by tightening stud C to preload the bearings. Rotate
the shaft during this process to seat the bearings. E
333191

9803/8530 Issue 1
Section F Transmission Section F
3-4 Wheel Hubs CONTENTS
3-4

Wheel Hub Assembly

Assembly (continued)

Preload washer 3 is available in various thicknesses to allow

for the correct preload of bearings 6 and 7 as follows:

Part No. Thickness

242/00096 0.025 - 0.045 mm
823/10303 0.05 - 0.11 mm
823/10304 0.115 - 0.175 mm
823/10254 0.18 - 0.24 mm
823/10255 0.245 - 0.305 mm
823/10256 0.31 - 0.37 mm
823/10257 0.375 - 0.435 mm
823/10258 0.44 - 0.50 mm
823/10259 0.505 - 0.565 mm
823/10317 0.57 - 0.63 mm

Select the preload washer which gives the closest match to

the dial gauge reading.

Assemble the preload washer 3 onto the axle shaft with the
stepped face towards the shaft (part numbered face away
from the shaft). Fit washer 2 and bolt 1. Tighten bolt 1 to the
correct torque whilst rotating the shaft to seat the bearings.

Fit a torque meter to the head of bolt 1 and check the rolling
torque is still 80 Nm (59 lbf ft, 8.2 kgf m).

Torque Settings

Item Nm lbf ft kgf m

1 220 162 22.4
9 28 21 3

9803/8530 Issue 1
Section F Transmission Section F
4-1 Drive Chains CONTENTS
4-1

Removal and Replacement

Removal Replacement

It is assumed that roadwheels are removed and the machine
is correctly supported.
Drain the oil from the chain case (see Drive Chain
Lubrication, Section 3).
Replacement is the reverse of the removal sequence.
The chains should be positioned as shown. The upper
illustration shows the right hand side of the machine, the
lower illustration shows the left hand side.

Remove the chain case access cover X (right hand side Refit the wheel hub assembly (see Wheel Hubs, this
shown). section).

Remove the hub assemblies D and E (see Wheel Hubs, this Adjust the chains (see Drive Chain Adjustment, this
section). section).

Lift the chains B and C from the sprockets on the drive Refit the chaincase access cover X using a new gasket.
motor A and withdraw the chains from the chaincase. Refill the chaincase with the correct oil (see Fluids,
Capacities and Lubricants, section 3).

B A

385740
X

385730

A C

385750

9803/8530 Issue 1
Section F Transmission Section F
4-2 Drive Chains CONTENTS
4-2

Adjustment
Note: The drive chains are pre-tensioned during
manufacture and do not require routine adjustment in
service. The following procedure should be carried out
whenever the chains are disturbed or renewed.

Chain Adjustment D
Adjust as follows:
E
1 Drain the oil from the chaincase.

2 Remove the chaincase access cover A.

C
3 Loosen the eight hub mounting bolts B. A
4 Slacken locknut D and screw adjustment bolt E out to
push the hub away from the centre of the machine and
so tighten the chain. The hub will pivot about dowel C.

5 Rotate the sprocket so that one side of the chain is taut.

Position the hub to give 25 mm (1 in) of slack on the
opposite side of the chain at the midway point. B
6 When the correct tension is achieved, tighten the
second locknut to the adjustment bolt E. 385480

7 Torque tighten bolts B to 220 Nm (162 lbf ft, 22.4 kgf m).

8 Refit the chaincase access cover A using a new gasket.

Refill the chaincase with the correct oil.

9803/8530 Issue 1
 Section 3 Routine Maintenance Section 3
8-1 CONTENTS
8-1

Hydraulic System

! WARNING
Fine jets of hydraulic fluid at high pressure can penetrate
the skin. Do not use your fingers to check for hydraulic X
fluid leaks. Do not put your face close to suspected
leaks. Hold a piece of cardboard close to suspected
leaks and then inspect the cardboard for signs of
hydraulic fluid. If hydraulic fluid penetrates your skin, get
medical help immediately.
INT-3-1-10/1

Checking the Fluid Level - for interval see Service Schedule

* The oil level should be checked when the oil is cool or cold.

1 Lower the lift arm and fully crowd the shovel/

attachment as shown at X. Stop the engine.

2 Look at the fluid level in the sight glass A. The level

should be at the mark on the sight glass.
B
If the fluid in the sight glass appears cloudy, then water
or air has entered the system. The hydraulic pump could
be severely damaged if the machine is operated. A
*3 If more fluid is needed, open the hydraulic tank filler cap
B and top up with engine oil.

378170

Changing the Filter - for interval see Service Schedule

1 Stop the engine and wait until the system has cooled.

2 Open the engine top cover.

3 Loosen the hydraulic tank filler cap B and allow all

pressure to dissipate. Remove the filler cap.

4 Unscrew the old filter canister C, using a chain wrench if

necessary, and discard.
C
5 Lubricate seal D on the new filter canister with clean
engine oil.

6 Screw on the new filter canister hand tight only.

7 Refit cap B, run the engine for a few minutes, then re- D
check the fluid level.

Note: Old filters should be disposed of in accordance with

local Health and Safety regulations.

378180

9803/8530 Issue 2*
Section 3 Routine Maintenance Section 3
8-2 CONTENTS
8-2

Hydraulic System (cont’d)

Changing the High-flow Filter - for interval see Service
Schedule

1 Stop the engine and wait until the system has cooled.
F
2 Open the engine compartment top cover.

3 Loosen the hydraulic tank filler cap B and allow all

pressure to dissipate. Remove the filler cap.

4 Remove the seat base and floor plate.

E
4 Unscrew the old filter canister E, using a chain wrench if
necessary, and discard.

5 Lubricate seal F on the new filter canister with clean

engine oil. 378190

6 Screw on the new filter canister hand tight only.

7 Add engine oil through filler point B. (See Fluids,

Capacities and Lubricants).

8 Refit cap B, run the engine for a few minutes, then re-
check the oil level.

9 Replace the floorplate and seat base.

Note: Old filters should be disposed of in accordance with

local Health and Safety regulations.

Changing the Hydraulic Tank Breather - for interval see

Service Schedule

1 Stop the engine and wait until the system has cooled.

2 Open the engine top cover. G

3 Loosen the hydraulic tank filler cap B and allow all
pressure to dissipate.
B
4 Clean the area around the tank breather G.

5 Unscrew the old breather and discard.

6 Screw on the new breather and tighten securely.

7 Refit filler cap B.

382380

9803/8530 Issue 1
Section 3 Routine Maintenance Section 3
9-2 CONTENTS
9-2

Transmission (cont'd)
Tyres and Wheels Replacing Segments of Optional Non-Inflatable Tyres

Inflating the Tyres
! WARNING
Over-inflated or overheated tyres can explode. Do not
cut or weld the rims. Get a tyre/wheel specialist to do
any repair work.
5-3-2-4
These instructions are for adding air to a tyre which is
already inflated. If the tyre has lost all its air pressure, call in
a qualified tyre mechanic. The tyre mechanic should use a
tyre inflation cage and the correct equipment to do the job.
Non-inflatable tyres are available as an option for use in
environments where a puncture could have serious
consequences. These tyres consist of a number of individual
segments bolted to the wheel rim.
Damaged segments can be renewed individually. Loosen
and remove the four nuts and washers A (two each side of
the wheel). Lift the segment clear by extracting its fixing
studs from the holes in the wheel rim.
Fit a new segment in reverse order to removal, then tighten
the retaining nuts to a torque of 28 Nm (21 lbf ft, 3 kgf m).

1 Prepare the Wheel

Before you add air to the tyre, make sure it is correctly

fitted on the machine or installed in a tyre inflation cage.

2 Prepare the Equipment

A
Use only an air supply system which includes a pressure
regulator. Set the regulator no higher than 1.38 bar (20
lbf/in 2 , 1.4 kgf/cm 2 ) above the recommended tyre
pressure. See Table below.

Use an air hose fitted with a self-locking air chuck and
remote shut-off valve.
3 Add the Air
Make sure that the air hose is correctly connected to the
tyre valve. Clear other people from the area. Stand
behind the tread of the tyre while adding the air.
Checking the Wheel Nut Torques
On new machines, and whenever a wheel has been
removed, check the wheel nut torques every two hours until
they stay correct.
Every day, before starting work, check that the wheel nuts
are tight.

Inflate the tyre to the recommended pressure. Do not The correct torque is shown in the table below.
over-inflate.
Front and Rear

Tyre Pressure Table Nm lbf ft kgf m

244 180 25

Make Size Pressure

bar (lbf/in2) ! WARNING
If, for whatever reason, a wheel stud is renewed, all the
Omega HD 12 x 16.5 x 10 Ply 3.5 (50) studs for that wheel must be changed as a set, since the
remaining studs may have been damaged.
Omega HD WT 12 x 16.5 x 10 Ply 3.5 (50) 2-3-2-8

Galaxy 12 x 16.5 x 10 Ply 3.5 (50)

Galaxy WT 12 x 16.5 x 10 Ply 3.5 (50)

Galaxy 33/1550 x 16.5 x 12 Ply 4.0 (60)

9803/8530 Issue 1