jcb 135 Service Manual

jcb 135 Service Manual

Skidsteer loader
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SERVICE MANUAL
SKIDSTEER LOADER
135, 155, 175, 190, 205
EN - 9813/6750 - ISSUE 1 - 04/2016
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
Copyright 2016 © JCB SERVICE
All rights reserved. No part of this publication may
be reproduced, stored in a retrieval system, or
transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise,
without prior permission from JCB SERVICE.
www.jcb.com
Foreword
The Operator's Manual
You and others can be killed or seriously injured
if you operate or maintain the machine without
first studying the Operator's Manual. You must
understand and follow the instructions in the
Operator's Manual. If you do not understand
anything, ask your employer or JCB dealer to
explain it.
Do not operate the machine without an Operator's
Manual, or if there is anything on the machine you
do not understand.
Treat the Operator's Manual as part of the machine.
Keep it clean and in good condition. Replace the
Operator's Manual immediately if it is lost, damaged
or becomes unreadable.
Contents
01 - Machine
03 - Attachments and Options
06 - Body and Framework
09 - Operator Station
12
-
Heating,
Conditioning (HVAC)
15 - Engine
18 - Fuel and Exhaust System
21 - Cooling System
24 - Brakes
27 - Driveline
30 - Hydraulic System
33 - Electrical System
72 - Fasteners and Fixings
75 - Consumable Products
78 - After Sales
Ventilating
and
Air-

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Summary of Contents for jcb 135

  • Page 1 Operator's Manual. You must understand and follow the instructions in the Operator's Manual. If you do not understand anything, ask your employer or JCB dealer to explain it. SERVICE MANUAL Do not operate the machine without an Operator's Manual, or if there is anything on the machine you do not understand.
  • Page 2 Notes: 9813/6750-1 Find manuals at https://best-manuals.com...
  • Page 3 Spine Cards SERVICE MANUAL SERVICE MANUAL Volume 1 Volume 2 135, 155, 175, 190, 205 135, 155, 175, 190, 205 EN 9813/6750 EN 9813/6750 SERVICE MANUAL SERVICE MANUAL Volume 3 Volume 4 135, 155, 175, 190, 205 135, 155, 175, 190, 205...
  • Page 4 Notes: 9813/6750-1 Find manuals at https://best-manuals.com...
  • Page 5: Table Of Contents

    01 - Machine Contents Page No. Acronyms Glossary ............................ 01-2 01-03 Safety 01-03-03 Safety - Yours and Others ....................01-3 01-03-06 Safety Warnings ....................... 01-4 01-03-09 General Safety ......................... 01-5 01-03-12 Maintenance Safety ......................01-6 01-03-18 Operating Safety ......................01-8 01-03-21 Worksite Safety ......................
  • Page 6: Acronyms Glossary

    Acronyms Glossary Parts Identification List ROPS Roll-Over Protective Structure 9813/6750-1 2016-04-18 Find manuals at https://best-manuals.com...
  • Page 7 01 - Machine 03 - Safety 03 - Safety Contents Page No. 01-03-03 Safety - Yours and Others ....................01-3 01-03-06 Safety Warnings ....................... 01-4 01-03-09 General Safety ......................... 01-5 01-03-12 Maintenance Safety ......................01-6 01-03-18 Operating Safety ......................01-8 01-03-21 Worksite Safety ......................
  • Page 8 Notes: 01 - 2 9813/6750-1 01 - 2 Find manuals at https://best-manuals.com...
  • Page 9: Safety

    They inform you of potential hazards and how to avoid them. If you do not fully understand the warning messages, ask your employer or JCB dealer to explain them. Safety is not just a matter of responding to the warnings.
  • Page 10: Safety Warnings

    01 - Machine 03 - Safety 06 - Safety Warnings 06 - Safety Warnings Introduction In this manual and on the product, there are safety notices. Each notice starts with a signal word. The signal word meanings are given below. The signal word 'DANGER' indicates a hazardous situation which, if not avoided, will result in death or serious injury.
  • Page 11: General Safety

    Keep long hair restrained. Remove altered in any way which could affect or invalidate its rings, watches and personal jewellery. compliance. For advice consult your JCB dealer. Alcohol and Drugs It is extremely dangerous to operate machinery when under the influence of alcohol or drugs.
  • Page 12: Maintenance Safety

    Repairs pressure must be discharged by a JCB dealer, as the sudden release of the hydraulic fluid or gas may If your machine does not function correctly in cause injury.
  • Page 13 Chemicals Certain seals and gaskets (e.g. crankshaft oil seal) on JCB machines contain fluoroelastomeric materials such Viton®, FluorelTM Technoflon®.
  • Page 14: Operating Safety

    Before doing any job not covered in this manual, find Parking out the correct procedure. Your local JCB distributor will be glad to advise you. An incorrectly parked machine can move without an operator. Follow the instructions in the Operator's Fuel Manual to park the machine correctly.
  • Page 15 01 - Machine 03 - Safety 18 - Operating Safety Electrical Power Cables Hands and Feet You could be electrocuted or badly burned if you get Keep your hands and feet inside the machine. the machine or its attachments too close to electrical When using the machine, keep your hands and feet power cables.
  • Page 16: Worksite Safety

    01 - Machine 03 - Safety 21 - Worksite Safety 21 - Worksite Safety An applicable worksite organisation is required in order to minimise hazards that are caused by restricted visibility. The worksite organisation is a Introduction collection of rules and procedures that coordinates the machines and people that work together in WARNING You or others can be killed or seriously the same area.
  • Page 17: Risk Assessment

    If you are unsure of the suitability of the machine for • Are any other machines or persons likely to be a specific task, contact your JCB dealer who will be in or to enter the area while operations are in pleased to advise you.
  • Page 18: Maintenance Positions

    01 - Machine 03 - Safety 27 - Maintenance Positions 27 - Maintenance Positions Introduction Introduction ............ 01-12 Make the machine safe before you start a Health and Safety .......... 01-17 maintenance procedure. Refer to (PIL 01-03). You can complete most of the maintenance procedures with the lift arm lowered.
  • Page 19 01 - Machine 03 - Safety 27 - Maintenance Positions Installing the Lift Arm Maintenance Strut 4. Raise the lift arm just far enough to install the strut. Figure 3. Stowage Radial Lift 5. Stop the engine and remove the ignition key. 6.
  • Page 20 01 - Machine 03 - Safety 27 - Maintenance Positions Figure 6. Figure 7. Before installing the lift arm maintenance strut remove any load on the forks and empty shovels or attachments. 1. Remove the shovel or attachment. C Stowage position 2.
  • Page 21 01 - Machine 03 - Safety 27 - Maintenance Positions 8. Unfold the cab/canopy maintenance strut from Figure 11. Stowed Position the stowed position. Position the cab/canopy maintenance strut to support the cab/canopy. 9. Replace the locking pin in the support position. Figure 9.
  • Page 22 Torque: 205N·m The compression plate is critical for ROPS (Roll-Over Protective Structure) integrity. Only replace with the correct JCB approved part. Never operate the machine with the cab/canopy in the raised position. Always secure the cab/canopy using the rear mounting nuts and compression plates tightened to the correct torque.
  • Page 23 01 - Machine 03 - Safety 27 - Maintenance Positions Health and Safety WARNING Maintenance must be done only by suitably qualified and competent persons. Before doing any maintenance make sure the machine is safe, it must be correctly parked on solid, level ground.
  • Page 24 01 - Machine 06 - About this Manual 06 - About this Manual Contents Page No. 01-06-06 Using the Manual ......................01-19 01 - 18 9813/6750-1 01 - 18...
  • Page 25 Introduction Information in this manual conforms to a standard Information within each PIL reference is included JCB service manual format. The format uses section under a set of standard headings such as headings taken from a PIL (Parts Identification Introduction, Health and Safety, Technical Data and List).
  • Page 26 01 - Machine 09 - Description 09 - Description Contents Page No. 01-09-12 Main Component Locations ................... 01-21 01-09-15 Service Point Locations ....................01-22 01 - 20 9813/6750-1 01 - 20...
  • Page 27 01 - Machine 09 - Description 12 - Main Component Locations 12 - Main Component Locations Introduction The illustration shows a typical machine model. Your machine may look different from the one shown. Figure 15. 1 ROPS/FOPS cab 2 Fuel tank filler point 3 Lift arm/boom 4 Front working lights 5 Quickhitch...
  • Page 28 01 - Machine 09 - Description 15 - Service Point Locations 15 - Service Point Locations Introduction Figure 16. A Coolant expansion bottle B Main fuel filter, Water separator C Air intake D Engine oil filler cap E Engine oil dipstick F Engine oil drain port G Hydraulic oil level indicator, Hydraulic oil filler H Battery isolator (if fitted)
  • Page 29 01 - Machine 09 - Description 15 - Service Point Locations The number of grease points on each machine model Figure 17. is indicated at the bottom of the label. A Grease points B Machine model 01 - 23 9813/6750-1 01 - 23...
  • Page 30 01 - Machine 09 - Description 15 - Service Point Locations Figure 18. 135, 155 01 - 24 9813/6750-1 01 - 24...
  • Page 31 01 - Machine 33 - Cleaning 33 - Cleaning Contents Page No. 01-33-00 General ........................... 01-27 01 - 25 9813/6750-1 01 - 25...
  • Page 32 Notes: 01 - 26 9813/6750-1 01 - 26...
  • Page 33 01 - Machine 33 - Cleaning 00 - General 00 - General Introduction WARNING When using cleaning agents, solvents Introduction ............ 01-27 or other chemicals, you must adhere to Preparation ............ 01-28 the manufacturer's instructions and safety precautions. CAUTION To avoid burning, wear personal protective equipment when...
  • Page 34 01 - Machine 33 - Cleaning 00 - General Preparation Notice: The engine and other components could be damaged by high pressure washing systems. Special precautions must be taken if the machine 1. Make the machine safe. is to be washed using a high pressure system. Make sure that the alternator, starter motor and 2.
  • Page 35 03 - Attachments and Options Contents Page No. 03-00 General 03-00-00 General ..........................03-3 03-09 Lift Arm Quickhitch 03-09-00 General ..........................03-7 03-09-03 Mechanical Quickhitch ..................... 03-9 03-09-09 Electronic Quickhitch ...................... 03-11 03-30 Shovel 03-30-00 General ........................... 03-15 03-33 Fork 03-33-00 General ...........................
  • Page 36 Notes: 9813/6750-1 2016-03-21...
  • Page 37 03 - Attachments and Options 00 - General 00 - General Contents Page No. 03-00-00 General ..........................03-3 03 - 1 9813/6750-1 03 - 1...
  • Page 38 Notes: 03 - 2 9813/6750-1 03 - 2...
  • Page 39: Attachments And Options

    A wide range of optional attachments are available Health and Safety ........... 03-4 to increase the versatility of your machine. Only JCB approved attachments are recommended for use with your machine. Consult your JCB Distributor for the full list of approved attachments available.
  • Page 40 00 - General 00 - General Health and Safety Attachments Use only the JCB approved attachments that are specified for your machine. Operating with non- specified attachments can overload the machine, causing possible damage and machine instability which could result in injury to yourself or others.
  • Page 41: Lift Arm Quickhitch

    03 - Attachments and Options 09 - Lift Arm Quickhitch 09 - Lift Arm Quickhitch Contents Page No. 03-09-00 General ..........................03-7 03-09-03 Mechanical Quickhitch ..................... 03-9 03-09-09 Electronic Quickhitch ...................... 03-11 03 - 5 9813/6750-1 03 - 5...
  • Page 42 Notes: 03 - 6 9813/6750-1 03 - 6...
  • Page 43: General

    03 - Attachments and Options 09 - Lift Arm Quickhitch 00 - General 00 - General Introduction Introduction ............03-7 Quickhitches are used on machines to allow the rapid Health and Safety ........... 03-8 change of buckets, shovels and other attachments on the machine.
  • Page 44 03 - Attachments and Options 09 - Lift Arm Quickhitch 00 - General Health and Safety WARNING Do not lean out of the cab to operate the Quickhitch levers. If the controls are moved accidentally you could be killed or injured. 03 - 8 9813/6750-1 03 - 8...
  • Page 45: Mechanical Quickhitch

    03 - Attachments and Options 09 - Lift Arm Quickhitch 03 - Mechanical Quickhitch 03 - Mechanical Quickhitch Disconnect and Connect Connect 6.1. If the keyless ignition option is installed, stop the engine and wait. 1. Align the machine square to the shovel/ Duration: 15s attachment.
  • Page 46 03 - Attachments and Options 09 - Lift Arm Quickhitch 03 - Mechanical Quickhitch Disconnect 6. Pull the levers (one each side of quickhitch plate) fully out, as at position, to retract the quickhitch 1. Stop and park the machine on level ground. locking pins.
  • Page 47 03 - Attachments and Options 09 - Lift Arm Quickhitch 09 - Electronic Quickhitch 09 - Electronic Quickhitch Introduction Introduction ............ 03-11 The electronic powered quickhitch can be used for Disconnect and Connect ....... 03-12 faster attachment changeover, it has the following advantages: •...
  • Page 48 03 - Attachments and Options 09 - Lift Arm Quickhitch 09 - Electronic Quickhitch Disconnect and Connect Figure 22. Disconnect 1. Rest the attachment on the ground. 2. Press and hold the unlock switch located in the left hand panel. 3.
  • Page 49 03 - Attachments and Options 09 - Lift Arm Quickhitch 09 - Electronic Quickhitch 3. Drive the machine slowly forward. Stop when the quickhitch plate just touches the shovel/ attachment. 4. Visually verify that the quickhitch actuator is fully extended prior to engaging the hitch plate into the attachment.
  • Page 50 03 - Attachments and Options 30 - Shovel 30 - Shovel Contents Page No. 03-30-00 General ........................... 03-15 03 - 14 9813/6750-1 03 - 14...
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