jcb 135 HD, Service Manual

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 Do not operate the machine w...

Page 2: ...9813 4450 2 Notes Find manuals at https best manuals com...

Page 3: ...ANUAL Volume 1 135 HD 155 HD EN 9813 4450 SERVICE MANUAL Volume 2 135 HD 155 HD EN 9813 4450 SERVICE MANUAL Volume 3 135 HD 155 HD EN 9813 4450 SERVICE MANUAL Volume 4 135 HD 155 HD EN 9813 4450 Find...

Page 4: ...Notes 9813 4450 2 Find manuals at https best manuals com...

Page 5: ...15 Safety Practice 01 8 01 03 18 Operating Safety 01 9 01 03 21 Worksite Safety 01 11 01 03 24 Risk Assessment 01 12 01 03 27 Maintenance Positions 01 13 01 06 About this Manual 01 06 03 Model and Ser...

Page 6: ...9813 4450 2 2017 02 28 Acronyms Glossary PIL Parts Identification List ROPS Roll Over Protective Structure Find manuals at https best manuals com...

Page 7: ...ers 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 01 9 01 03 21 Worksite Safety 01 11 01 03 2...

Page 8: ...Notes 01 2 9813 4450 2 01 2 Find manuals at https best manuals com...

Page 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...

Page 10: ...ion 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 N...

Page 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...

Page 12: ...er 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 Mak...

Page 13: ...composition 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 tha...

Page 14: ...eak 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 runni...

Page 15: ...y kill you 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 dro...

Page 16: ...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...

Page 17: ...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 runn...

Page 18: ...nd 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 wi...

Page 19: ...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...

Page 20: ...gers 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 t...

Page 21: ...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 nuts and c...

Page 22: ...ion 3 Lower the cab canopy by slowly pushing on the front steel tubes of the cab canopy frame Do not push on the front glass if installed The glass could break 4 Install the two rear mounting nuts and...

Page 23: ...01 Machine 03 Safety 27 Maintenance Positions 01 17 9813 4450 2 01 17 Figure 11 Figure 12 A C A Mounting nut C Compression plate...

Page 24: ...ust be 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 prec...

Page 25: ...01 Machine 06 About this Manual 01 19 9813 4450 2 01 19 06 About this Manual Contents Page No 01 06 03 Model and Serial Number 01 21 01 06 06 Using the Manual 01 22...

Page 26: ...Notes 01 20 9813 4450 2 01 20...

Page 27: ...Manual 03 Model and Serial Number 01 21 9813 4450 2 01 21 03 Model and Serial Number Introduction This manual provides information for the following model s in the JCB machine range Model From To 135...

Page 28: ...Diagnostics Information 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...

Page 29: ...01 Machine 09 Description 01 23 9813 4450 2 01 23 09 Description Contents Page No 01 09 12 Main Component Locations 01 25 01 09 15 Service Point Locations 01 26...

Page 30: ...Notes 01 24 9813 4450 2 01 24...

Page 31: ...Component Locations 01 25 9813 4450 2 01 25 12 Main Component Locations Introduction Figure 13 A C D F G H E B A Cab B Lift arm boom C Fuel tank D Quickhitch E Hydraulic tank F Battery G Engine compar...

Page 32: ...r 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...

Page 33: ...hine 09 Description 15 Service Point Locations 01 27 9813 4450 2 01 27 The number of grease points on each machine model is indicated at the bottom of the label Figure 15 A B A Grease points B Machine...

Page 34: ...01 Machine 09 Description 15 Service Point Locations 01 28 9813 4450 2 01 28 Figure 16 135 155...

Page 35: ...01 Machine 33 Cleaning 01 29 9813 4450 2 01 29 33 Cleaning Contents Page No 01 33 00 General 01 31...

Page 36: ...Notes 01 30 9813 4450 2 01 30...

Page 37: ...ender 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...

Page 38: ...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 oi...

Page 39: ...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...

Page 40: ...Notes 9813 4450 2 2017 02 02...

Page 41: ...03 Attachments Couplings and Load Handling 00 Attachments 03 1 9813 4450 2 03 1 00 Attachments Contents Page No 03 00 00 General 03 3...

Page 42: ...Notes 03 2 9813 4450 2 03 2...

Page 43: ...ients on which 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 manufactu...

Page 44: ...r s Manual 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 Loa...

Page 45: ...nts Couplings and Load Handling 09 Lift Arm Quickhitch 03 5 9813 4450 2 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 Quick...

Page 46: ...Notes 03 6 9813 4450 2 03 6...

Page 47: ...w 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...

Page 48: ...a failure would result in the sudden release of an attachment from the machine and you or others could be killed or seriously injured WARNING The attachment will move when released Stand clear and to...

Page 49: ...ust touches the shovel attachment 4 Raise the lift arm and engage the hitch plate in the lips on the shovel attachment Stop the movement as soon as the plate is engaged 5 Move the lift arm control lev...

Page 50: ...e 5 If appropriate disconnect the attachment hydraulic hoses lift arm pipework 6 Pull levers one each side of quickhitch plate fully out as at position to retract the quickhitch locking pins 7 Return...

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