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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: Component Identification
18 - Fuel and Exhaust System 18 - Injection 21 - Governor Component Identification Operation Figure 268. Governor control mecha- The fuel rack is connected to the linkage, which nism in the front housing without a BCD controls the fuel injection pump. This linkage is located in the front case. - Page 3 18 - Fuel and Exhaust System 18 - Injection 21 - Governor Figure 271. Governor control mecha- A spring connects the linkage to the fuel injection nism in the front housing with a BCD pump and the mechanical stop control. When the engine is first started, the spring automatically increases the fuel flow to the cylinders.
- Page 4 18 - Fuel and Exhaust System 18 - Injection 21 - Governor Adjust Figure 273. Special Tools Description Part No. Qty. Digital Tachometer 892/00284 The setting of the front case is only necessary if the front case is damaged or if the front case is renewed. Record the Governor Settings 1.
- Page 5 18 - Fuel and Exhaust System 18 - Injection 21 - Governor Figure 274. Figure 276. K Calibration spring L Start spring U Front case 7. Install the front case. Refer to (PIL 15-51). V Gasket 7.1. Do not install a gasket. Refer to Figure 274. 4.
- Page 6 18 - Fuel and Exhaust System 18 - Injection 21 - Governor 12. Install the DTI into the DTI holder until the 2. Remove the crankcase adaptor. Refer to Figure extension on the DTI touches the rack of the fuel 277.
- Page 7 18 - Fuel and Exhaust System 18 - Injection 21 - Governor Calibrate 20. Install the tamperproof cap to the high idle trimmer screw and the high idle screw. 21. Carefully install the tamperproof cap to the fuel Setting the Fuel Screw screw.
- Page 8 18 - Fuel and Exhaust System 18 - Injection 21 - Governor 5. Turn the Allen head screw until the DTI reads the specified dimension. Dimension: 2 ± 0.01mm 6. Tighten the locknut to the correct specified torque value. Torque: 6N·m 7.
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Page 9: Remove And Install
K Adjuster unit Install 1. Apply threadlocker on the first two threads of the adjuster unit. Consumable: JCB Threadlocker and Sealer (Medium Strength) 2. Install the adjuster unit to the lever assembly. 3. Tighten the adjuster unit to the correct torque value. - Page 10 18 - Fuel and Exhaust System 21 - Fuel Pump 00 - General Remove and Install 4. Disconnect the electrical connector from the fuel pump. 5. Plug all the open ports and hoses to prevent Observe all the health and safety information. Refer contamination.
- Page 11 18 - Fuel and Exhaust System 21 - Fuel Pump 00 - General 5. Lubricate the operating plunger of the fuel pump with clean engine oil. 6. Position the fuel pump on the crankcase. 7. Make sure that the operating plunger is positioned correctly on the camshaft lobe.
- Page 12 18 - Fuel and Exhaust System 35 - Turbocharger 00 - General 00 - General Introduction Introduction ............ 18-63 A turbocharger increases the temperature and the Component Identification ....... 18-64 density of the air sent to the engine cylinder. This condition causes a lower temperature of ignition Operation ............
- Page 13 18 - Fuel and Exhaust System 35 - Turbocharger 00 - General Component Identification Figure 290. A Air inlet hose B Hose clamp C Screw D Exhaust elbow E Turbocharger F Gasket 1 G Banjo bolt H Washer J Tube clips K Bolt1 L Tube assembly 1 M O-ring...
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Page 14: Check (Condition)
18 - Fuel and Exhaust System 35 - Turbocharger 00 - General Operation Check (Condition) 1. Inspect the compressor and turbine for damage. The turbocharger is installed between the exhaust manifold and the intake manifold. The turbocharger 2. Make sure that the compressor blades do not rub is driven by exhaust gases which flow through the on the housing and rotate freely. -
Page 15: Check Operation
18 - Fuel and Exhaust System 35 - Turbocharger 00 - General Check (Operation) To maximise the duration of the turbocharger follow the rules described below. Start-up Start the engine and keep it at idle speed for about a minute. The oil operating pressure is reached within a few seconds, but it is useful to allow the moving parts to warm up in good lubrication conditions. - Page 16 18 - Fuel and Exhaust System 35 - Turbocharger 00 - General Remove and Install Remove 9. Remove the bolt 1 and remove the tube assembly 1 from the crankcase. 1. Make sure you obey the special instructions 10. Remove and discard the O-ring. on handling, operation and installation of the turbocharger.
- Page 17 18 - Fuel and Exhaust System 35 - Turbocharger 00 - General Install 22. Keep the tube assembly 1 at its correct position on the turbocharger. 1. Make sure that all the parts are clean and free 23. Install the tube clips with the fasteners and from contamination.
- Page 18 18 - Fuel and Exhaust System 35 - Turbocharger 00 - General Store and Recommission allowing the oil and bearings system to work satisfactorily. 3. Low temperature air or engine inactivity: If the What to do engine has been inactive for a certain period of time or the air temperature is very low, start the •...
- Page 19 18 - Fuel and Exhaust System 35 - Turbocharger 06 - Wastegate Valve Operation Check (Condition) WARNING Hot oil and engine components can The wastegate controls the amount of exhaust gas burn you. Make sure the engine is cool before that is allowed to bypass the turbine side of the doing this job.
- Page 20 11. Make sure that the DTI returns to zero when the air pressure is released. 12. Repeat the test several times to make sure that you get an accurate reading. 13. If the wastegate does not operate correctly, contact your JCB dealer. 18 - 72 9813/4450-2 18 - 72...
- Page 21 Download the full PDF manual instantly. Our customer service e-mail: aservicemanualpdf@yahoo.com...
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