JCB 135, 155, 175, 190, 205, 150T, 190T, 205T Skid Steer Loader (ROBOT) Service Repair Factory Manual is an electronic version o

Copyright © 2004 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. World Class Customer Support 9813/1350 Publication No. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400 Service Manual Skid Steer Small Platform Service Manual - Skid Steer Small Platform Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section J - Tracks Section K - Engine

Section 0 - Front Cover 0-ii 0-ii 9813/1350 Notes:

Copyright © 2004 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. World Class Customer Support 9813/1350 Publication No. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400 Section 1 General Information Service Manual - Skid Steer Small Platform Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section J - Tracks Section K - Engine

Section 1 - General Information 1-0 1-0 9813/1350 Notes:

Page No. Contents Section 1 - General Information 1-i 1-i Introduction About this Publication ................................................................................ 1-1 Machine Model and Serial Number ....................................................... 1-1 Using the Service Manual ..................................................................... 1-1 Section Numbering ................................................................................ 1-1 Left Side, Right Side .............................................................................. 1-2 Cab/Canopy .......................................................................................... 1-2 Machine Description .................................................................................. 1-3 The JCB Skid Steer Loader ................................................................... 1-3 Intended Use ......................................................................................... 1-3 Component Locations ........................................................................... 1-3 Identifying Your Machine ........................................................................... 1-5 Machine Identification Plate .................................................................. 1-5 Component Identification ....................................................................... 1-6 ROPS and FOPS .................................................................................. 1-7 Torque Settings Zinc Plated Fasteners and Dacromet Fasteners ....................................... 1-9 Introduction ............................................................................................ 1-9 Bolts and Screws ................................................................................... 1-9 Hydraulic Connections ............................................................................. 1-13 'O' Ring Face Seal System .................................................................. 1-13 Service Tools Numerical List .......................................................................................... 1-15 Tool Detail Reference .............................................................................. 1-17 Section B - Frame and Bodywork ........................................................ 1-17 Section C - Electrics ............................................................................ 1-21 Section E - Hydraulics ......................................................................... 1-22 Section K - Engine ............................................................................... 1-26 Service Aids Sealing and Retaining Compounds ......................................................... 1-27

Section 1 - General Information Contents 1-ii 1-ii Page No. Contents

Section 1 - General Information Introduction About this Publication 1-1 1-1 9813/1350 Introduction About this Publication Machine Model and Serial Number This manual provides information for the following model(s) in the JCB machine range: – Skid Steer Loader - 135, 155, 175, 190, 205, 150T, 190T, 205T from serial number 1755000. Using the Service Manual T11-004 This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training by JCB Technical Training Department. These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated with the maintenance and repair of hydraulic earthmoving equipment. The illustrations in this publication are for guidance only. Where the machines differ, the text and/or the illustration will specify. General warnings in Section 2 are repeated throughout the manual, as well as specific warnings. Read all safety statements regularly, so you do not forget them. Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt. Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry threads, hence for lubricated threads may be reduced by one third. The manufacturer's policy is one of continuous improvement. The right to change the specification of the machine without notice is reserved. No responsibility will be accepted for discrepancies which may occur between specifications of the machine and the descriptions contained in this publication. Finally, please remember above all else safety must come first! Section Numbering T11-005 The manual is compiled in sections, the first three are numbered and contain information as follows: The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for example: Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each alphabetically coded section. 1 General Information - includes torque settings and service tools. 2 Care and Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc. 3 Maintenance - includes service schedules and recommended lubricants for all the machine. A Attachments B Body and Framework, etc.

Section 1 - General Information Introduction About this Publication 1-2 1-2 9813/1350 Left Side, Right Side In this manual, 'left' A and 'right' B mean your left and right when you are seated correctly in the machine. T055600-2 Fig 1. Cab/Canopy T1-003_2 This manual frequently makes references to the cab. For instance, 'do not operate the machine without a manual in the cab'. It should be noted that these statements also apply to canopy build machines. B A

Section 1 - General Information Introduction Machine Description 1-3 1-3 9813/1350 Machine Description The JCB Skid Steer Loader P12-1004 The Skid Steer Loader is a self propelled skid steer machine fitted with either wheels or tracks. The main structural support is designed to carry a front mounted carriage onto which a shovel or an approved attachment can be fitted. Note: The illustration(s) show a typical machine model; your machine may look different from the model shown. Intended Use The machine is intended to be used under normal conditions for the applications described in this manual. If the machine is used for other purposes or in dangerous environments, for example in a flammable atmosphere or in areas with dust containing asbestos, special safety regulations must be followed and the machine must be equipped for use in these environments. When used normally with a shovel fitted, the machine loads or excavates through forward motion of the machine and lifts, transports and discharges material. This machine is not intended for object handling. Component Locations 1 ROPS/FOPS Cab 2 Fuel Tank 3 Loader Arm 4 Front Working Lights 5 Quickhitch 6 Rubber Tracks 7 Battery 8 Hydraulic Tank 9 Hydraulic Sight Glass 10 Engine Compartment Rear Door 11 Engine Top Cover

Section 1 - General Information Introduction Machine Description 1-4 1-4 9813/1350 T054330 Fig 2. 1 2 5 4 3 6 8,9 7 10 11

JCB 135, 155, 175, 190, 205, 150T, 190T, 205T Skid Steer Loader (ROBOT) Service Repair Factory Manual is an electronic version o

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