JCB Robot 190 1110 Skid Steer Workshop Service Manual (2004-2007) – 389 Pages | Instant PDF

JCB Robot 190 and 1110 Service Manual - 2004 Edition

This factory-issued Service Manual provides essential technical data and repair procedures for the JCB Robot 190 and 1110 skid steer loaders. A critical uptime factor involves the utilization of specialized 25 mm 'L' Blades for the 992/12800 cut-out knife during glass replacement; maintaining a stock of these replacement blades ensures rapid restoration of the cab’s structural integrity following window damage.

Technical Applicability & Machine Identification

The manual defines applicability based on the Product Identification Number (PIN) architecture. Service procedures are valid for machines manufactured between 2004 and 2007, distinguished by the following technical configurations:

JCB Robot 190 Series (Radial Lift)

• Standard-flow (S): PIN Prefix SB7L
• High-flow (H): PIN Prefix HB7L
• Chassis Variants: Available in Canopy (Build A) or Cab (Build B) configurations.

JCB Robot 1110 Series (Radial Lift)

• Standard-flow (S): High-capacity vertical lift series.
• High-flow (H): Equipped with tandem gear pump for advanced attachment drive.

Engine Series Support

• JCB 444 Series (4.4 Litre): Naturally Aspirated (SA) 63 kW / 85 bhp.
• JCB 444 Series (4.4 Litre): Turbocharged (SB) 74 kW / 100 bhp.

Operational Investment & Safety Proof Points

• Precision Calibration: Includes full voltage and frequency benchmarks for the Power Management System (PMS) to prevent engine stalling under high tractive loads.
• Hydraulic Integrity: Detailed ISO 16/13 cleanliness standards and 5-micron filtration procedures are provided to extend component life.
• Structural Certification: Specific inspection protocols for ROPS/FOPS structures ensure compliance with site safety regulations.
• Fastener Standardization: Explicit torque differentials between Zinc-plated and Dacromet-coated fasteners prevent thread failure and corrosion.

Document Metadata

• Publication Number: 9803/9460-1
• Total Page Count: 389 Pages
• Primary Sections: General Information, Care and Safety, Maintenance, Attachments, Framework, Electrics, Controls, Hydraulics, Transmission, Brakes, Tracks, Engine.

System Architecture & Factory Benchmarks

This manual details the high-pressure hydrostatic transmission and loader systems. Technical specifications include:

• Transmission Charge Pressure: 17 - 18 bar at idle; 25 - 27 bar at maximum RPM.
• Main Relief Valve (MRV) Setting: 225 bar (3265 lbf/in²) for standard loader functions.
• High-Flow Auxiliary Circuit: 220 bar (3190 lbf/in²) relief setting with a combined flow of 120-130 L/min.
• Hydrostatic Loop Protection: Four high-pressure relief valves preset to 414 bar (6000 lbf/in²).

Navigation & Visual Schematics

Technical personnel are guided by comprehensive visual aids, including:

• Hydraulic Schematic Symbols: Full key for ISO 1219/BS2917 compliant symbols.
• Electrical Harness Mapping: Color-coded wiring diagrams with unique identification numbers (e.g., 000-199 for ignition feeds).
• Logic Flow Charts: Step-by-step diagnostic paths for the Power Management System (PMS) using LED blink codes.

Detailed Table of Contents

• Section 1: General Information - Machine identification, torque settings (UNF Grade S, Metric 8.8/10.9/12.9), and specialized service tools.
• Section 2: Care and Safety - Hazard classifications, operating limits, and hazardous material handling (Viton/Fluoroelastomeric safety).
• Section 3: Maintenance - Service schedules (10h to 4000h), fluid capacities, and lubricant specifications.
• Section A: Attachments - Quickhitch maintenance, pallet forks, and 6-in-1 shovel hydraulics.
• Section B: Body and Framework - Loader arm removal and rivet nut installation procedures.
• Section C: Electrics - Alternator/starter motor overhaul and circuit diagrams.
• Section E: Hydraulics - Pump and motor dismantling, servo joystick testing, and PMS calibration.
• Section F-K: Powertrain & Engine - Transmission drive, braking systems, track adjustment, and JCB 444 engine data.

Operational Limits & Fluid Specifications

• Engine Oil: 15.0 Litres (MAX) - SAE 15W/40 (API CH-4/SG).
• Hydraulic System: 140 Litres - JCB High Performance 10W/30.
• Cooling System: 22 Litres - ASTM D6210 Antifreeze/Water mixture.
• Fuel Capacity: 107 Litres - Standard Diesel Oil.
• Wheel Nut Torque: 680 Nm (500 lbf ft) for front and rear studs.

FAQ

Does this manual cover the newer electronic common rail fuel engines? This documentation specifically focuses on the JCB 444 Series 4.4 litre engines with SA (Naturally Aspirated) and SB (Turbocharged) designations. While it establishes the mechanical foundations for these Tier 2 compliant units, it directs technicians to publication 9806/3000 for full technical data and service information regarding other specific electronic engine variants.

What are the required torque settings for the main relief valve (MRV) and road wheel nuts? The manual mandates a precise torque of 680 Nm (500 lbf ft) for the road wheel nuts to ensure chassis stability. Additionally, when servicing the hydraulic control valve block, the main relief valve and loader check valves must be tightened to a range of 41 to 49 Nm (30 to 36 lbf ft).

Is there a specific procedure for calibrating the Power Management System (PMS)? Section E details a comprehensive calibration sequence for the Power Management System, which requires the use of a specialized PMS Test Button (JCB part number 701/80490). This procedure is vital for adjusting the machine's anti-stall characteristics by setting the voltage thresholds at which the transmission pump swash plates begin to destroke under high engine load.

Does this manual detail the hydraulics for heavy-duty attachments like the 6-in-1 shovel? Detailed coverage of the 6-in-1 shovel and other auxiliary attachments is found in Section A, which provides instructions for hydraulic hose routing and lubrication of the four primary grease points. It also specifies that high-flow auxiliary circuits must be used for power-intensive tools like Earth Drills to maintain a flow rate of approximately 120 liters per minute.

What are the technical utility benefits of using this digital service manual for electrical troubleshooting?