jcb 135 Service Manual
Skidsteer loader
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Also See for 135:
- Service manual (51 pages) ,
- Operator's manual (31 pages) ,
- Operator's manual (31 pages)
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SERVICE MANUAL
SKIDSTEER LOADER
135 [T4F], 150T [T4F], 155 [T4F],
175 [T4F], 190T [T4F],
205T [T4F], 210 [T4F], 215 [T4F]
EN - 9813/9750
ISSUE 1 - 05/2017
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
Copyright 2017 © 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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Table of Contents
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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 15 - Engine 09 - Bedplate 00 - General 00 - General Introduction Introduction ............ 15-41 The bedplate acts as the main strength component Remove and Install ........15-42 of the engine. it maintains the correct alignment and supports the weight of the internal components. Figure 122.
-
Page 3: Before Removal
15 - Engine 09 - Bedplate 00 - General Remove and Install 16. Remove the fuel injection drive gear. Refer to (PIL 15-51). For: KDI 1903 TCR Elec Engine 17. Remove the intermediate drive gear. Refer to ........... Page 15-42 (PIL 15-51). -
Page 4: Before Installation
15 - Engine 09 - Bedplate 00 - General Figure 124. available prior to assembling the components. The parts must be installed and tightened to the correct torque value within 5min minutes (with a maximum permissible time of 15min). Important: BEFORE you install the bedplate: DO NOT rotate the crankshaft. -
Page 5: After Installation
15 - Engine 09 - Bedplate 00 - General Figure 127. Figure 129. D Lower bearing shells (x4) F Shoulder half-rings (x2) G Guide pins 12. Install the bedplate peripheral bolts (x13). 6. Apply a 1.0mm (0.04in) thick bead of Loctite 5188 around the crankcase/bedplate mating face as 13. - Page 6 15 - Engine 09 - Bedplate 00 - General Table 37. Torque Values 14. Remove the timing gear front case. Refer to (PIL 15-51). Item Description Main bearing bolts (x8) (1st 15. Remove the fuel injection pump. Refer to (PIL Stage) 18-18).
- Page 7 15 - Engine 09 - Bedplate 00 - General Figure 132. sure that all the necessary tools, bolts etc. are readily available prior to assembling the components. The parts must be installed and tightened to the correct torque value within 5min minutes (with a maximum permissible time of 15min).
- Page 8 15 - Engine 09 - Bedplate 00 - General Figure 135. Figure 137. D Lower bearing shells (x5) F Shoulder half-rings (x2) G Guide pins 12. Install the bedplate peripheral bolts (x17). 6. Apply a 1.0mm (0.04in) thick bead of Loctite 5188 13.
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Page 9: Technical Data
15 - Engine 12 - Crankshaft 00 - General Technical Data Component Identification Figure 139. Table 39. Main bearing journal di- ameter (x4) - min 63.981mm (2.5189in) - max 64.00mm (2.5196in) Connecting rod bearing journal diameter - min 54.035mm (2.1274in) - max 54.066mm (2.1286in) Maximum wear and... -
Page 10: Operation
15 - Engine 12 - Crankshaft 00 - General Operation Refer to Camshaft-Operation (PIL 15-15). diameter of the upper main bearing shell allows oil transfer to cross drillings in the crankshaft to feed Lubrication each of the big end bearings. Crankshaft gear is 'splash' lubricated. -
Page 11: Check (Condition)
15 - Engine 12 - Crankshaft 00 - General Check (Condition) 1. Check the main bearing surfaces for damage and Blocked or restricted oilways will cause oil excessive wear. starvation at the big end bearings. 2. Measure the crankshaft diameters to confirm 4. - Page 12 15 - Engine 12 - Crankshaft 00 - General Calibrate Axial clearance check 2. Measure the axial shift of the crankshaft with a dial gauge. The axial shift must range between 1. To measure the axial clearance of the crankshaft, 0.18-0.38mm (0.007-0.015in).
- Page 13 15 - Engine 12 - Crankshaft 00 - General Dimensional Check 6. Measure the diameter of the crank-pins and main journals with a micrometer. 1. Make sure that you clean the crankshaft 7. Measure the internal diameter of the connecting thoroughly with a suitable detergent.
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Page 14: Remove And Install
15 - Engine 12 - Crankshaft 00 - General Remove and Install Consumables 2. Make sure that the engine is safe to work on. If the engine has been running, let it cool before Description Part No. Size you start the service work. Cleaner/Degreaser 4104/1557 0.4L... - Page 15 Our support email: ebooklibonline@outlook.com...