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ROBOT
190, 190HF, 1110, 1110HF
Problem Solving
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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.
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
3 Tyres worn or pressure incorrect Check tyre pressures and condition. 3/9-2
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
11 No hydraulic feed from joystick to pump Check for feed from joystick to pump. E10-10
14 Electrical failure (brake valve circuit) Check brake valve electrical circuit.
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
* 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.
9803/8530 Issue 2*
Section E Hydraulics Section E
10 - 3 Problem Solving CONTENTS
10 - 3
X1
382770
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
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 Section E
10 - 4 Problem Solving CONTENTS
10 - 4
D
382790
9803/8530 Issue 1
Section E Hydraulics Section E
10 - 5 Problem Solving CONTENTS
10 - 5
A
C
382800
9803/8530 Issue 1
Section E Hydraulics Section E
10 - 6 Problem Solving CONTENTS
10 - 6
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
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 Section E
10 - 7 Problem Solving CONTENTS
10 - 7
If the machine veers to the left this could be caused by Note: This adjustment is very sensitive. Turn the adjusting
either the right hand wheels moving forward or the left screw 1/10 of a turn at a time and re-check. A slight
hand wheels moving in reverse. Remember that pump movement when the wheels are raised is acceptable
P1 drives the left hand motor and pump P2 drives the provided that no movement occurs when the machine is
right hand motor. resting on the ground.
If the machine moves either straight ahead or behind 5 Start the engine and check that the wheels are
then both pump servos must be adjusted equally. stationary.
2 Stop the engine. 6 Finally tighten locknuts A and C taking care to retain the
set position of adjusting screws.
3 Remove the seat, seat base and pump cover.
7 Re-check for wheel movement.
Manual Machines
B P1
P2
D
C
382810
9803/8530 Issue 1
Section E Hydraulics Section E
10 - 8 Problem Solving CONTENTS
10 - 8
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.
A
D
C 327490
9803/8530 Issue 2
Section E Hydraulics Section E
10 - 10 Problem Solving CONTENTS
10 - 10
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 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.
One hydraulic service fails to operate or 12, 13, 15, 15, 17 12, 13, 14, 15, 17
is slow to operate.
Valve spool sticking. 3, 19, 21, 22, 23, 24, 25, 26, 27, 28 3, 19, 21, 22, 23, 24, 25, 26, 27, 28
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.
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
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.
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
17 Piston rod bent. Replace piston rod. Check pressure setting of MRV.
Check that associated pivot pins are adequately greased.
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.
24 Valve housing twisted during installation. Loosen retaining bolts and tighten to correct torque.
27 Spool return spring or cap out of alignment. Remove cap, check that spring is in correct position.
Refit cap and torque tighten bolts.
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
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
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
7 Bucket raises in self-level A Ports A and B cross connected A Reverse hoses to ports A and B
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 If poor attachment performance is still experienced after
overheating when using the High-flow circuit, the following resetting the High-flow valve and the flow rates and pressure
procedure should be followed to ensure optimum machine are correct, then the problem is with the attachment.
and attachment performance. Consult the attachment service manual for corrective action.
Checking Flow and Pressure An example of a problem may be excessive back pressure.
No more than 12 bar (175 lbf /in2) should be seen at the
1 Check the flow requirement of the attachment fitted High-flow valve block. To check this insert a tee piece and a
and compare it to the machine specification. Note that 40 bar (600 lbf /in2) pressure gauge into the return line at B.
the flow at the High-flow circuit is a combination of the Check the pressure recorded by the gauge with the
high flow pump and the auxiliary pump. If the attachment running.
attachment flow rate requirement exceeds the total
machine flow then the attachment is unsuitable for use.
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.
9803/8530 Issue 2
Section E Hydraulics Section E
21 - 1 Pressure Testing CONTENTS
21 - 1
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
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.
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
Remove bolt 1, plain washer 2 and preload washer 3. Fit a torque meter to the head of stud C and check the
Remove drive sprocket 4. torque required to rotate the axle shaft. The correct rolling
torque should be 80 Nm (59 lbf ft, 8.2 kgf m). Continue
Support the casing assembly on its outer flange with the tightening stud C until the correct rolling torque is achieved.
wheel hub facing downwards and press out the axle shaft
assembly 5. Bearing 6 will remain in the casing 13 and can Rotate the axle shaft 1 full revolution to ensure that the
be removed separately if necessary. The outer race of bearings are fully seated then recheck the rolling torque and,
bearing 7 will also be left in the casing and can be removed if necessary, tighten further to 80 Nm (59 lbf ft, 8.2 kgf m).
if necessary. Shaft seal 8 should be removed and discarded.
Position a dial gauge against the flat face of the sprocket as
If fitted and if necessary, remove bolts 9 with washers 10 shown at D and zero the gauge. Reposition the dial gauge
and remove twine cutter 11. onto the end of the axle shaft as shown at E and note the
reading. Remove the gauge and assembly tool.
Inspection
Assembly
9803/8530 Issue 1
Section F Transmission Section F
3-4 Wheel Hubs CONTENTS
3-4
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
9803/8530 Issue 1
Section F Transmission Section F
4-1 Drive Chains CONTENTS
4-1
It is assumed that roadwheels are removed and the machine Replacement is the reverse of the removal sequence.
is correctly supported.
The chains should be positioned as shown. The upper
Drain the oil from the chain case (see Drive Chain illustration shows the right hand side of the machine, the
Lubrication, Section 3). 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.
7 Torque tighten bolts B to 220 Nm (162 lbf ft, 22.4 kgf m).
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
* The oil level should be checked when the oil is cool or cold.
378170
1 Stop the engine and wait until the system has cooled.
7 Refit cap B, run the engine for a few minutes, then re- D
check the fluid level.
378180
9803/8530 Issue 2*
Section 3 Routine Maintenance Section 3
8-2 CONTENTS
8-2
1 Stop the engine and wait until the system has cooled.
F
2 Open the engine compartment top cover.
8 Refit cap B, run the engine for a few minutes, then re-
check the oil level.
1 Stop the engine and wait until the system has cooled.
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 Non-inflatable tyres are available as an option for use in
environments where a puncture could have serious
! WARNING consequences. These tyres consist of a number of individual
Over-inflated or overheated tyres can explode. Do not segments bolted to the wheel rim.
cut or weld the rims. Get a tyre/wheel specialist to do
any repair work. Damaged segments can be renewed individually. Loosen
5-3-2-4 and remove the four nuts and washers A (two each side of
the wheel). Lift the segment clear by extracting its fixing
These instructions are for adding air to a tyre which is studs from the holes in the wheel rim.
already inflated. If the tyre has lost all its air pressure, call in
a qualified tyre mechanic. The tyre mechanic should use a Fit a new segment in reverse order to removal, then tighten
tyre inflation cage and the correct equipment to do the job. the retaining nuts to a torque of 28 Nm (21 lbf ft, 3 kgf m).
Use an air hose fitted with a self-locking air chuck and Checking the Wheel Nut Torques
remote shut-off valve.
On new machines, and whenever a wheel has been
3 Add the Air removed, check the wheel nut torques every two hours until
they stay correct.
Make sure that the air hose is correctly connected to the
tyre valve. Clear other people from the area. Stand Every day, before starting work, check that the wheel nuts
behind the tread of the tyre while adding the air. 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
9803/8530 Issue 1