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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).

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, Ventilating and Air-

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

Содержание 135

Страница 1: ...t 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 th...

Страница 2: ...9813 6750 1 Notes Find manuals at https best manuals com ...

Страница 3: ...e 1 135 155 175 190 205 EN 9813 6750 SERVICE MANUAL Volume 2 135 155 175 190 205 EN 9813 6750 SERVICE MANUAL Volume 3 135 155 175 190 205 EN 9813 6750 SERVICE MANUAL Volume 4 135 155 175 190 205 EN 9813 6750 Find manuals at https best manuals com ...

Страница 4: ...Notes 9813 6750 1 Find manuals at https best manuals com ...

Страница 5: ...03 12 Maintenance Safety 01 6 01 03 18 Operating Safety 01 8 01 03 21 Worksite Safety 01 10 01 03 24 Risk Assessment 01 11 01 03 27 Maintenance Positions 01 12 01 06 About this Manual 01 06 06 Using the Manual 01 19 01 09 Description 01 09 12 Main Component Locations 01 21 01 09 15 Service Point Locations 01 22 01 33 Cleaning 01 33 00 General 01 27 Find manuals at https best manuals com ...

Страница 6: ...9813 6750 1 2016 04 18 Acronyms Glossary PIL Parts Identification List ROPS Roll Over Protective Structure Find manuals at https best manuals com ...

Страница 7: ...ty 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 01 10 01 03 24 Risk Assessment 01 11 01 03 27 Maintenance Positions 01 12 Find manuals at https best manuals com ...

Страница 8: ...Notes 01 2 9813 6750 1 01 2 Find manuals at https best manuals com ...

Страница 9: ... 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 All the time you are working on or with the product you must be thinking of what hazards there might be and how to avoid them Do not work with the product until you are sure that you can control it Do not start ...

Страница 10: ...tion which if not avoided could result in death or serious injury The signal word CAUTION indicates a hazardous situation which if not avoided could result in minor or moderate injury The signal word Notice indicates a hazardous situation which if not avoided could result in product damage The safety alert system shown also helps to identify important safety messages in this manual and on the prod...

Страница 11: ...ware of medicines which can cause drowsiness Feeling Unwell Do not attempt to operate the machine if you are feeling unwell By doing so you could be a danger to yourself and those you work with Mobile Phones Switch off your mobile phone before entering an area with a potentially explosive atmosphere Sparks in such an area could cause an explosion or fire resulting in death or serious injury Switch...

Страница 12: ...eer 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 Make sure the hose service line has been vented before connecting or removing hoses Make sure the engine cannot be started while the hoses are open O rings Seals and Gaskets Badly installed damaged or r...

Страница 13: ...idence of decomposition e g charring is found refer to the next paragraph for safety instructions Do not touch component or surrounding area Used fluoroelastomeric components subjected to temperatures greater than 300 C 571 6 F e g engine fire must be treated using the following safety procedure Make sure that heavy duty gloves and special safety glasses are worn Thoroughly wash contaminated area ...

Страница 14: ...or bystanders if they are inhaled Do not operate the machine in closed spaces without making sure there is good ventilation If possible install an exhaust extractor If you begin to feel drowsy stop the machine at once and get into fresh air Worksites Worksites can be hazardous Examine the site before working on it You could be killed or injured if the ground gives way under your machine or if pile...

Страница 15: ... s configuration by the user e g the fitting of large and non approved attachments may result in a restriction of the machine visibility Hands and Feet Keep your hands and feet inside the machine When using the machine keep your hands and feet clear of moving parts Keep your hands and feet within the operator compartment while the vehicle is in motion Controls You or others can be killed or seriou...

Страница 16: ... leak is suspected contact the local gas company immediately and warn all personnel on the site Ban smoking make sure that all naked lights are extinguished and switch off any engines which may be running You are strongly advised to make sure that the safety arrangements on site comply with the local laws and regulations concerning work near buried gas pipes CAUTION Before you start using the mach...

Страница 17: ...and is there sufficient fuel to complete the job if applicable The Load How heavy is it Is it within the capabilities of the machine How bulky is it The greater the surface area the more affected it will be by wind speeds Is it an awkward shape How is the weight distributed Uneven loads are more difficult to handle Is there a possibility of the load shifting while being moved Loading Unloading Are...

Страница 18: ... arm and install the maintenance strut on the lift arm Release the hydraulic pressure Refer to PIL 30 00 Figure 2 A B C A Lift arm lowered B Lift arm raised C Lift arm and cab raised Lift Arm Lowered 1 Park the machine on level solid ground Refer to PIL 01 03 2 Lower the lift arm 3 Put the attachment flat on the ground 4 Stop the engine and remove the ignition key If the keyless ignition option is...

Страница 19: ...osition with the strap Figure 5 A Strut B Strap 7 To prevent any chance of the lift arm creeping down and trapping your fingers the lift arm should be lowered onto the strut Lower the arm carefully to prevent possible damage to the strut Stop as soon as the weight of the lift arm is on the strut 8 Disconnect the battery to prevent accidental operation of the engine Refer to PIL 33 03 9 If necessar...

Страница 20: ...opy 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 2 Park the machine on level solid ground 3 Install the lift arm maintenance strut 4 Stop the engine and remove the ignition key If the keyless ignition option is installed stop the engine and wait Duration 15s 5 Remove the two rear mounting n...

Страница 21: ...gure 11 Stowed Position B D B Locking pin D Cab canopy maintenance strut Figure 12 Support Position D B B Locking pin D Cab canopy maintenance strut Operation Position 1 Make sure the area between the cab canopy and the chassis is clear before you lower the cab canopy 2 Fold the cab canopy maintenance strut back into the stowed position and fix in place with pin from a safe position 3 Lower the ca...

Страница 22: ...N 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 If they are not installed the cab canopy could tip forward unexpectedly Figure 13 ...

Страница 23: ...e correctly parked on solid level ground To prevent anyone starting the engine remove the ignition key Disconnect the battery when you are not using electrical power If you do not take these precautions you could be killed or injured WARNING Make the machine safe before getting beneath it Make sure that any attachments on the machine are correctly attached Engage the park brake if installed remove...

Страница 24: ...01 Machine 06 About this Manual 01 18 9813 6750 1 01 18 06 About this Manual Contents Page No 01 06 06 Using the Manual 01 19 ...

Страница 25: ...on in this manual can help you diagnose machine faults Before attempting to diagnose possible faults check the following Ensure that the operator understands the machine controls functions and use Refer to the applicable Operator Manual Check that the maintenance record complies with the applicable schedule for the operating environment Refer to PIL 78 24 Check that the fuel and hydraulic oil in u...

Страница 26: ...01 Machine 09 Description 01 20 9813 6750 1 01 20 09 Description Contents Page No 01 09 12 Main Component Locations 01 21 01 09 15 Service Point Locations 01 22 ...

Страница 27: ...ponent Locations Introduction The illustration shows a typical machine model Your machine may look different from the one shown Figure 15 3 7 6 1 8 2 5 4 1 ROPS FOPS cab 2 Fuel tank filler point 3 Lift arm boom 4 Front working lights 5 Quickhitch 6 Engine top cover 7 Wheels tyres 8 Exhaust ...

Страница 28: ...or It is a visual representation of the daily weekly and six monthly service checks The label serves as a reminder of these service checks and their intervals Use the label and the service schedule in this manual to perform the service checks on time The 1 000h and 2 000h checks which are represented by the outer track are described in this manual only The label shows a picture of the machine On t...

Страница 29: ...chine 09 Description 15 Service Point Locations 01 23 9813 6750 1 01 23 The number of grease points on each machine model is indicated at the bottom of the label Figure 17 A B A Grease points B Machine model ...

Страница 30: ...01 Machine 09 Description 15 Service Point Locations 01 24 9813 6750 1 01 24 Figure 18 135 155 ...

Страница 31: ...01 Machine 33 Cleaning 01 25 9813 6750 1 01 25 33 Cleaning Contents Page No 01 33 00 General 01 27 ...

Страница 32: ...Notes 01 26 9813 6750 1 01 26 ...

Страница 33: ...the machine inoperable Remove dirt using a brush or damp cloth Clean the product with water and or steam Do not let mud debris etc to collect on the product Before you do any service procedures that require components to be removed The cleaning must be done either in the area of components to be removed or in the case of major work or work on the fuel system the whole engine and the surrounding pr...

Страница 34: ...ot aim the water jet directly at bearings oil seals or the engine air induction system Use a low pressure water jet and brush to remove dried mud or dirt Use a pressure washer to remove soft dirt and oil The product must always be greased if appropriate after pressure washing or steam cleaning Preparation 1 Make the machine safe 2 Stop the engine and let it cool for at least one hour Do not try to...

Страница 35: ...ons 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 03 21 ...

Страница 36: ...Notes 9813 6750 1 2016 03 21 ...

Страница 37: ...03 Attachments and Options 00 General 03 1 9813 6750 1 03 1 00 General Contents Page No 03 00 00 General 03 3 ...

Страница 38: ...Notes 03 2 9813 6750 1 03 2 ...

Страница 39: ...ich it is safe to operate or the safe distance from power lines Practice using attachments off the job before working with them for the first time JCB attachments are designed and manufactured specifically to suit the machine s hydraulic system mounting arrangements and safe load requirements Attachments which are not designed for use with this machine may cause damage and create safety hazards fo...

Страница 40: ...l do not install it use it or remove it until you have obtained read and understood the pertinent information Install attachments only on the machines for which they were designed WARNING Load and unload on firm level ground Always be alert for possible hazards Take special care when turning or reversing DANGER Before lowering the attachments to the ground make sure that the machine and the area a...

Страница 41: ... Attachments and Options 09 Lift Arm Quickhitch 03 5 9813 6750 1 03 5 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 ...

Страница 42: ...Notes 03 6 9813 6750 1 03 6 ...

Страница 43: ...apid 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 They are usually mounted on the machine by means of pins that would otherwise be the mountings for the shovel or attachment ...

Страница 44: ... Options 09 Lift Arm Quickhitch 00 General 03 8 9813 6750 1 03 8 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 ...

Страница 45: ...the plate is engaged 5 Move the lift arm control lever to roll back the shovel attachment slightly 6 Stop the engine and remove the ignition key 6 1 If the keyless ignition option is installed stop the engine and wait Duration 15s 7 Raise the safety control locks and dismount the machine 8 Push the levers fully in to engage the quickhitch locking pins Check that the levers are locked into the dete...

Страница 46: ...f appropriate disconnect the attachment hydraulic hoses lift arm pipework 6 Pull the levers one each side of quickhitch plate fully out as at position to retract the quickhitch locking pins 7 Return to the cab seat lower the control locks and start the engine 8 Operate the lift control lever as if to roll forward the shovel attachment When the quickhitch plate has disengaged from the lips on the s...

Страница 47: ...h Introduction 03 11 Disconnect and Connect 03 12 Introduction The electronic powered quickhitch can be used for faster attachment changeover it has the following advantages Positive Engagement No risk of hydraulic leaks or loosening in the event of hydraulic failure No risk of going over relief if the pins become clogged ...

Страница 48: ...ic hoses lift arm pipework 5 Lower the lift arm fully to bring the quickhitch plate below the level of the lips on the shovel attachment 6 Operate the lift arm control lever as if to roll forward the shovel attachment When the quickhitch plate has disengaged from the lips on the shovel attachment reverse the machine clear Figure 22 A B ISO H A Unlock switch B Lock switch Connect 1 Align the machin...

Страница 49: ...tended prior to engaging the hitch plate into the attachment 5 Raise the lift arm and engage the quickhitch plate in the lips on the shovel attachment Stop the movement as soon as the plate is engaged 6 Move the lift arm control lever to roll back the shovel attachment slightly 7 Once the quickhitch plate is engaged press and hold the lock switch 8 Ensure the actuator is fully retracted and visual...

Страница 50: ...03 Attachments and Options 30 Shovel 03 14 9813 6750 1 03 14 30 Shovel Contents Page No 03 30 00 General 03 15 ...

Страница 51: ...This as a preview PDF file from best manuals com Download full PDF manual at best manuals com ...

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