JCB TM180 TM220 Telescopic Wheeled Loader Service Repair Manual INSTANT

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 9803/9995-03 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 TM180/220 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 G - Brakes Section H - Steering Section K - Engine

Section 1 - General Information 1-0 1-0 9803/9995-02 Notes:

Page No. Contents Section 1 - General Information 1-i 1-i Use Introduction ............................................................................................. 1-1-1 Scope ..................................................................................................... 1-1-2 Personnel ...........................................................................................1-1-2 Applications ........................................................................................1-1-2 Newest Data .......................................................................................1-1-2 Format .................................................................................................... 1-1-3 Left and Right Sides ............................................................................... 1-1-4 Hydraulic Schematic Codes ................................................................... 1-1-5 Colour Codes .....................................................................................1-1-5 Electrical Device Codes .......................................................................... 1-1-6 Machine Identification Introduction ............................................................................................. 1-2-7 Related Topics ........................................................................................ 1-2-8 Machine Identification Plate .................................................................... 1-2-9 Typical Product Identification Number (PIN) ......................................1-2-9 Component Identification Plates ........................................................... 1-2-12 Typical Engine Identification Number ...............................................1-2-12 Typical Transmission Identification Plate ..........................................1-2-12 Typical Axle Identification Plates - TM180 Machines .......................1-2-13 Typical Axle Identification Plates - TM220 Machines .......................1-2-14 FOPS Data Plate ..............................................................................1-2-15 ROPS Data Plate .............................................................................1-2-15 Torque Settings Introduction ........................................................................................... 1-3-17 Zinc Plated Fasteners and Dacromet Fasteners .................................. 1-3-18 Introduction .......................................................................................1-3-18 Bolts and Screws ..............................................................................1-3-18 Hydraulic Connections .......................................................................... 1-3-22 'O' Ring Face Seal System ...............................................................1-3-22 'Torque Stop' Hose System ..............................................................1-3-25 `Positional Type' Hydraulic Adaptors .................................................... 1-3-26 Fitting Procedure ..............................................................................1-3-26 Service Tools Introduction ........................................................................................... 1-4-27 Numerical List ....................................................................................... 1-4-28 Tool Detail Reference ........................................................................... 1-4-31 Rivet Nuts ............................................................................................. 1-4-50 Fitting Procedure ..............................................................................1-4-51 Slide Hammer Kit .................................................................................. 1-4-52 Fitting Procedure ..............................................................................1-4-52 Service Consumables Introduction ........................................................................................... 1-5-53 Sealing and Retaining Compounds ...................................................... 1-5-54 Fuel Introduction ........................................................................................... 1-6-55 Related Topics ...................................................................................... 1-6-56

Section 1 - General Information Contents 1-ii 1-ii Page No. Contents Acceptable and Unacceptable Fuels .................................................... 1-6-57 Additives ...........................................................................................1-6-58 Service Requirements for use of B20 Biodiesel ...............................1-6-58 Warranty ...........................................................................................1-6-58 Fuel Types ........................................................................................1-6-59 Usage and Effects of Fuels ..............................................................1-6-60 Sulphur Content ...............................................................................1-6-61 Effects of Fuel Contaminates ...........................................................1-6-62 Applications Introduction ........................................................................................... 1-7-63 Tables ................................................................................................... 1-7-64 Section 1 - General Information .......................................................1-7-64 Section 2 - Care and Safety .............................................................1-7-64 Section 3 - Routine Maintenance .....................................................1-7-65 Section B - Body and Framework .....................................................1-7-66 Section C - Electrics .........................................................................1-7-67 Section E - Hydraulics ......................................................................1-7-68 Section F - Transmission ..................................................................1-7-70 Section G - Brakes ...........................................................................1-7-71 Section H - Steering .........................................................................1-7-72 Section K - Engine ............................................................................1-7-73 Section M - Electronic Data Systems ...............................................1-7-74

Section 1-1 - General Information 1-1-1 1-1-1 9803/9995-02 Use Introduction This topic contains information about the structure of the manual and how to use the manual. K Scope ( T 1-1-2) K Personnel ( T 1-1-2) K Applications ( T 1-1-2) K Newest Data ( T 1-1-2) K Format ( T 1-1-3) K Left and Right Sides ( T 1-1-4) K Hydraulic Schematic Codes ( T 1-1-5) K Colour Codes ( T 1-1-5) K Electrical Device Codes ( T 1-1-6)

Section 1-1 - General Information Use Scope 1-1-2 1-1-2 9803/9995-02 Scope Personnel 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. Finally, please remember above all else SAFETY MUST COME FIRST! Applications This manual contains data relevant to a range of machines. Make sure you reference the data for the correct machine. K Applications ( T 1-7-63) Newest Data From time to time new machines, systems or devices require the manual to be re-issued. Make sure you have the newest issue. Always check the on-line JCB data system for relevant technical information.

Section 1-1 - General Information Use Format 1-1-3 1-1-3 9803/9995-02 Format The manual is compiled in sections, the first three are numbered and contain information as follows: 1 General Information - Use the Applications Tables at the front of the section to see which topic in the manual is applicable to which machine model. The section also includes general information such as torque settings and service tools. 2 Care & Safety - includes warnings, cautions and general procedures related to aspects of workshop procedures contained in the manual. 3 Routine Maintenance - includes service schedules and recommended lubricants for all the machine. The remaining sections are alphabetically coded and deal with dismantling, overhaul etc. of specific components, for example: The sections contain topics. Each topic is a self contained set of data about a machine System or Device. Some topics are only applicable to some machine models. Use the Applications Tables in this section to see which topic is applicable to which machine model. Each topic contains data such as specifications, descriptions, fault finding and test procedures. Device topics also contain removal, replacement, dismantle and assemble procedures. Some topics contain procedures and specifications for different variants. This happens because of market requirements, or when the machine specification changes after a period of time. Where applicable, a table in the introduction of each topic contains information to help you identify the correct specifications or procedures. Each topic also contains a Related Topics table. This table lists all the topics that contain related data. For example a hydraulic system contains devices such as valves and pumps. These devices have their own topics and they are listed in the system related topics table. A Attachments B Body and Framework...etc.

Section 1-1 - General Information Use Left and Right Sides 1-1-4 1-1-4 9803/9995-02 Left and Right Sides 'Left Hand' sand 'Right Hand' are as viewed from the rear of the machine facing forwards. C087420 Fig 1.

Section 1-1 - General Information Use Hydraulic Schematic Codes 1-1-5 1-1-5 9803/9995-02 Hydraulic Schematic Codes Colour Codes The following colour coding, used on illustrations to denote various conditions of oil pressure and flow, is standardised throughout JCB Service Publications. Red Full Pressure: Pressure generated from operation of a service. Depending on application this may be anything between neutral circuit pressure and LSRV operating pressure. Pink Pressure: Pressure that is above neutral circuit pressure but lower than that denoted by Red. Orange Pilot: Oil pressure used in controlling a device (Pilot). Blue Neural: Neutral circuit pressure. Green Exhaust: Light Green Cavitation: Oil subjected to a partial vacuum due to a drop in pressure (cavitation). Yellow Lock Up: Oil trapped within a chamber or line, preventing movement of components (lock up).

Section 1-1 - General Information Use Electrical Device Codes 1-1-6 1-1-6 9803/9995-02 Electrical Device Codes This manual uses a code system to help you identify the electrical devices on the machine. When the electrical system is designed at the factory codes are given to the electrical connectors on the electrical harnesses. The system allows the same code to be used for different connectors. For this reason a different system is used in this manual. Each main category of devices is given a code type: Each device is given one code and the code is used throughout the manual. The same code is given to both the device and its electrical connector. Important: The electrical schematics and the harness drawings in Section C are reproduced from the factory drawings. For this reason they retain the factory connector codes. Code Type Category -000 Earth points +000 Power (from battery or alternator) 1000 Switches 2000 Relays 3000 Valves/Coils 4000 ECU’s 5000 Sensors 6000 Indicators/Lamps 7000 Other devices 8000 Harness Interconnections 9000 Fuses

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JCB TM180 TM220 Telescopic Wheeled Loader Service Repair Manual INSTANT

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