jcb 135 HD Service Manual

jcb 135 HD Service Manual

Skidsteer loader
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SERVICE MANUAL
SKIDSTEER LOADER
135 HD, 155 HD
EN - 9813/4450
ISSUE 2 - 03/2017
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
Copyright 7-03-08 © 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, Couplings and Load
Handling
06 - Body and Framework
09 - Operator Station
12
-
Heating,
Conditioning (HVAC)
15 - Engine
18 - Fuel and Exhaust System
21 - Cooling System
24 - Brake System
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 HD

  • 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: 9813/4450-2 Find manuals at https://best-manuals.com...
  • Page 3 Spine Cards SERVICE MANUAL SERVICE MANUAL Volume 1 Volume 2 135 HD, 155 HD 135 HD, 155 HD EN 9813/4450 EN 9813/4450 SERVICE MANUAL SERVICE MANUAL Volume 3 Volume 4 135 HD, 155 HD 135 HD, 155 HD EN 9813/4450...
  • Page 4 Notes: 9813/4450-2 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 01-03-15 Safety Practice ......................... 01-8 01-03-18 Operating Safety ......................
  • Page 6: Acronyms Glossary

    Acronyms Glossary Parts Identification List ROPS Roll-Over Protective Structure 9813/4450-2 2017-02-28 Find manuals at https://best-manuals.com...
  • Page 7: Safety

    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 01-03-15 Safety Practice ......................... 01-8 01-03-18 Operating Safety ......................
  • Page 8 Notes: 01 - 2 9813/4450-2 01 - 2 Find manuals at https://best-manuals.com...
  • Page 9: Safety - Yours And Others

    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 machine, 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: Safety Practice

    01 - Machine 03 - Safety 15 - Safety Practice 15 - Safety Practice 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 15: 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 16 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 17: 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 18: 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 19: Maintenance Positions

    01 - Machine 03 - Safety 27 - Maintenance Positions 27 - Maintenance Positions Introduction Introduction ............ 01-13 Make the machine safe before you start a Health and Safety .......... 01-18 maintenance procedure. Refer to (PIL 01-03). You can complete most of the maintenance procedures with the lift arm lowered.
  • Page 20 01 - Machine 03 - Safety 27 - Maintenance Positions Installing the Lift Arm Maintenance Strut Figure 4. Figure 3. Stowage Radial Lift C Stowage position 1. Remove the shovel or attachment. A Strut B Strap 2. Park the machine on level, solid ground. Stop the engine.
  • Page 21 01 - Machine 03 - Safety 27 - Maintenance Positions If you raise the cab/canopy to get access for 6. Raise the cab/canopy by lifting the corner of the maintenance you must install the cab/canopy cab/canopy behind the operator's door. Do not try maintenance strut.
  • Page 22 Torque tighten to Torque: 205N·m The compression plate is critical for ROPS (Roll-Over Protective Structure) integrity. Only replace with the correct JCB approved part. B Locking pin D Cab/canopy maintenance strut 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 Figure 11. Figure 12. A Mounting nut C Compression plate 01 - 17 9813/4450-2 01 - 17...
  • Page 24 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 25: About This Manual

    01 - Machine 06 - About this Manual 06 - About this Manual Contents Page No. 01-06-03 Model and Serial Number ....................01-21 01-06-06 Using the Manual ......................01-22 01 - 19 9813/4450-2 01 - 19...
  • Page 26 Notes: 01 - 20 9813/4450-2 01 - 20...
  • Page 27 01 - Machine 06 - About this Manual 03 - Model and Serial Number 03 - Model and Serial Number Introduction This manual provides information for the following model(s) in the JCB machine range: Model From: 135 HD 2431601 155 HD...
  • Page 28 06 - Using the Manual Introduction Information in this manual conforms to a standard List). These headings are assigned numerical JCB service manual format. The format uses section identification references. headings taken from a PIL (Parts Identification Table 1. Example...
  • Page 29 01 - Machine 09 - Description 09 - Description Contents Page No. 01-09-12 Main Component Locations ................... 01-25 01-09-15 Service Point Locations ....................01-26 01 - 23 9813/4450-2 01 - 23...
  • Page 30 Notes: 01 - 24 9813/4450-2 01 - 24...
  • Page 31 01 - Machine 09 - Description 12 - Main Component Locations 12 - Main Component Locations Introduction Figure 13. A Cab B Lift arm/boom C Fuel tank D Quickhitch E Hydraulic tank F Battery G Engine compartment rear door H Engine top cover 01 - 25 9813/4450-2 01 - 25...
  • Page 32 01 - Machine 09 - Description 15 - Service Point Locations 15 - Service Point Locations Introduction Figure 14. 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 33 01 - Machine 09 - Description 15 - Service Point Locations The number of grease points on each machine model Figure 15. is indicated at the bottom of the label. A Grease points B Machine model 01 - 27 9813/4450-2 01 - 27...
  • Page 34 01 - Machine 09 - Description 15 - Service Point Locations Figure 16. 135, 155 01 - 28 9813/4450-2 01 - 28...
  • Page 35 01 - Machine 33 - Cleaning 33 - Cleaning Contents Page No. 01-33-00 General ........................... 01-31 01 - 29 9813/4450-2 01 - 29...
  • Page 36 Notes: 01 - 30 9813/4450-2 01 - 30...
  • Page 37 01 - Machine 33 - Cleaning 00 - General 00 - General Introduction WARNING When using cleaning agents, solvents Introduction ............ 01-31 or other chemicals, you must adhere to Preparation ............ 01-32 the manufacturer's instructions and safety precautions. CAUTION To avoid burning, wear personal protective equipment when...
  • Page 38 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. Stop the machine and is to be washed using a high pressure system.
  • Page 39 03 - Attachments, Couplings and Load Handling Contents Page No. 03-00 Attachments 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 40 Notes: 9813/4450-2 2017-02-02...
  • Page 41 03 - Attachments, Couplings and Load Handling 00 - Attachments 00 - Attachments Contents Page No. 03-00-00 General ..........................03-3 03 - 1 9813/4450-2 03 - 1...
  • Page 42 Notes: 03 - 2 9813/4450-2 03 - 2...
  • Page 43: Attachments

    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 44 00 - Attachments 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 45: Lift Arm Quickhitch

    03 - Attachments, Couplings and Load Handling 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 9813/4450-2 03 - 5...
  • Page 46 Notes: 03 - 6 9813/4450-2 03 - 6...
  • Page 47: General

    03 - Attachments, Couplings and Load Handling 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 48 03 - Attachments, Couplings and Load Handling 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. WARNING Always install the quickhitch latch hook locking pin (mechanical only).
  • Page 49: Mechanical Quickhitch

    03 - Attachments, Couplings and Load Handling 09 - Lift Arm Quickhitch 03 - Mechanical Quickhitch 03 - Mechanical Quickhitch Disconnect and Connect WARNING Do not lean out of the cab to operate 5. Move the lift arm control lever to roll back the the quickhitch levers.
  • Page 50 03 - Attachments, Couplings and Load Handling 09 - Lift Arm Quickhitch 03 - Mechanical Quickhitch Disengaging the Shovel/Attachments 6. Pull 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.
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