jcb TM180 Service Manual
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SERVICE MANUAL
LOADER
TM180, TM220
EN - 9813/3150 - ISSUE 2 - 08/2018
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
Copyright 2018 © 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
25 - Steering 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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Table of Contents
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Summary of Contents for jcb TM180

  • 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: 9813/3150-2 Find manuals at https://best-manuals.com...
  • Page 3 Spine Cards SERVICE MANUAL SERVICE MANUAL Volume 1 Volume 2 TM180, TM220 TM180, TM220 EN 9813/3150 EN 9813/3150 SERVICE MANUAL SERVICE MANUAL Volume 3 Volume 4 TM180, TM220 TM180, TM220 EN 9813/3150 EN 9813/3150 9813/3150-2 Find manuals at https://best-manuals.com...
  • Page 4 Notes: 9813/3150-2 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 01-03-18 Operating Safety ......................01-8 01-03-21 Worksite Safety ......................
  • Page 6: Acronyms Glossary

    Acronyms Glossary Diesel Exhaust Fluid Parts Identification List 9813/3150-2 2018-07-24 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 9813/3150-2 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 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 serious injury or death.
  • 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

    Your doing. If you will be working with other people, local JCB distributor will be glad to advise you. make sure any hand signals that may be used are understood by everybody. Worksites can be noisy, do Fuel not rely on spoken commands.
  • Page 15 01 - Machine 03 - Safety 18 - Operating Safety Regulations clearly. Modification of the machine's configuration by the user (e.g. the fitting of large and non- approved attachments) may result in a restriction of Obey all laws, worksite and local regulations which the machine visibility.
  • Page 16 01 - Machine 03 - Safety 18 - Operating Safety has passed. Do not attempt to mount or enter the machine. If the machine is struck by lightning do not use the machine until it has been checked for damage and malfunction by trained personnel. 01 - 10 9813/3150-2 01 - 10...
  • 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 .......... 01-14 maintenance procedure. You can complete most of the maintenance procedures with the lift arm lowered.
  • Page 20 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 21: About This Manual

    01 - Machine 06 - About this Manual 06 - About this Manual Contents Page No. 01-06-03 Model and Serial Number ....................01-17 01-06-06 Using the Manual ......................01-18 01 - 15 9813/3150-2 01 - 15...
  • Page 22 Notes: 01 - 16 9813/3150-2 01 - 16...
  • Page 23: Model And Serial Number

    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: TM180 2096873 2097873 TM220...
  • Page 24: Using The Manual

    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 25: Description

    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 - 19 9813/3150-2 01 - 19...
  • Page 26 Notes: 01 - 20 9813/3150-2 01 - 20...
  • Page 27: Main Component Locations

    01 - Machine 09 - Description 12 - Main Component Locations 12 - Main Component Locations Introduction Figure 3. A Shovel B Boom C Engine coolant expansion tank D Fuel filter and water trap E Articulation lock F Engine oil filler G Engine oil dipstick H Fuel pump and filter J Trailer socket (if installed)
  • Page 28: Service Point Locations

    01 - Machine 09 - Description 15 - Service Point Locations 15 - Service Point Locations Introduction Figure 4. A Battery B Window washer tank C Hydraulic oil tank sight glass D Fuel tank filler E Hydraulic filter F Hydraulic oil filler 01 - 22 9813/3150-2 01 - 22...
  • Page 29 01 - Machine 33 - Cleaning 33 - Cleaning Contents Page No. 01-33-00 General ........................... 01-25 01 - 23 9813/3150-2 01 - 23...
  • Page 30 Notes: 01 - 24 9813/3150-2 01 - 24...
  • Page 31 01 - Machine 33 - Cleaning 00 - General 00 - General Introduction WARNING When using cleaning agents, solvents Introduction ............ 01-25 or other chemicals, you must adhere to Preparation ............ 01-26 the manufacturer's instructions and safety Clean ............. 01-27 precautions.
  • Page 32 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 33 01 - Machine 33 - Cleaning 00 - General Clean WARNING Airborne particles of light combustible material such as straw, grass, wood shavings, etc. must not be allowed to accumulate within the engine compartment or in the propshaft guards (when installed). Examine these areas frequently and clean at the beginning of each work shift or more often if required.
  • Page 34 Notes: 01 - 28 9813/3150-2 01 - 28...
  • Page 35 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 03-09-06 Hydraulic Quickhitch ......................03-8 03-30 Shovel 03-30-00 General ........................... 03-13 03-33 Fork 03-33-00 General ........................... 03-17 03-33-03 Carriage ..........................
  • Page 36 Notes: 9813/3150-2 2018-03-19...
  • Page 37 03 - Attachments, Couplings and Load Handling 00 - Attachments 00 - Attachments Contents Page No. 03-00-00 General ..........................03-3 03 - 1 9813/3150-2 03 - 1...
  • Page 38 Notes: 03 - 2 9813/3150-2 03 - 2...
  • Page 39 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: Attachments, Couplings And Load Handling

    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 41 03 - Attachments, Couplings and Load Handling 09 - Lift Arm Quickhitch 09 - Lift Arm Quickhitch Contents Page No. 03-09-00 General ..........................03-7 03-09-06 Hydraulic Quickhitch ......................03-8 03 - 5 9813/3150-2 03 - 5...
  • Page 42 Notes: 03 - 6 9813/3150-2 03 - 6...
  • Page 43: General

    03 - Attachments, Couplings and Load Handling 09 - Lift Arm Quickhitch 00 - General 00 - General Introduction Quickhitches are used on machines to allow the rapid change of buckets, shovels and other attachments on the machine. Quickhitches do not normally have a specific function themselves in that they do not carry out handling or digging operations, but when installed on a machine they become a part of the overall machine system.
  • Page 44: Hydraulic Quickhitch

    03 - Attachments, Couplings and Load Handling 09 - Lift Arm Quickhitch 06 - Hydraulic Quickhitch 06 - Hydraulic Quickhitch Lubricate Lubricate ............03-8 There are two greasing points for the lubrication of Remove and Install ......... 03-9 the quickhitch. Refer to Figure 7. Figure 7.
  • Page 45 03 - Attachments, Couplings and Load Handling 09 - Lift Arm Quickhitch 06 - Hydraulic Quickhitch Remove and Install Figure 9. Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before connecting or removing any hydraulic hose, residual hydraulic pressure trapped in the service hose line must be vented.
  • Page 46 03 - Attachments, Couplings and Load Handling 09 - Lift Arm Quickhitch 06 - Hydraulic Quickhitch 1. Use a press to install the new bush and then replace the seal. Figure 11. H Shims 2. Install the spacer shims as necessary. 03 - 10 9813/3150-2 03 - 10...
  • Page 47 03 - Attachments, Couplings and Load Handling 30 - Shovel 30 - Shovel Contents Page No. 03-30-00 General ........................... 03-13 03 - 11 9813/3150-2 03 - 11...
  • Page 48 Notes: 03 - 12 9813/3150-2 03 - 12...
  • Page 49: General

    03 - Attachments, Couplings and Load Handling 30 - Shovel 00 - General 00 - General Introduction Introduction ............ 03-13 A shovel can be installed on many different types of Health and Safety .......... 03-14 earthmoving machines. The shovel can be directly mounted on to a lift arm assembly or mounted to the lift arm via a quickhitch assembly.
  • Page 50 03 - Attachments, Couplings and Load Handling 30 - Shovel 00 - General Health and Safety CAUTION This component is heavy. It must only be removed or handled using a suitable lifting method and device. 03 - 14 9813/3150-2 03 - 14...
  • Page 51 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...

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