jcb 135 User manual

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, Ventilating and Air-
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

15 - Engine
09 - Bedplate
00 - General
15 - 41 9813/9750-1 15 - 41
00 - General
Introduction .................................................... 15-41
Remove and Install ....................................... 15-42
Introduction
The bedplate acts as the main strength component
of the engine. it maintains the correct alignment and
supports the weight of the internal components.
Figure 122.
1
2
1Bedplate
2Crankcase

15 - Engine
09 - Bedplate
00 - General
15 - 42 9813/9750-1 15 - 42
Remove and Install
For: KDI 1903 TCR Elec Engine
................................................... Page 15-42
For: KDI 2504 TCR Elec Engine
................................................... Page 15-45
(For: KDI 1903 TCR Elec Engine)
Consumables
Description Part No. Size
Cleaner/Degreaser
- General purpose
solvent based parts
cleaner
4104/1557 0.4L
CAUTION This component is heavy. It must only
be removed or handled using a suitable lifting
method and device.
Before Removal
1. This procedure requires service parts. Make
sure you have obtained the correct service parts
before you start, refer to Parts Catalogue.
2. Make sure that the engine is safe to work on. If
the engine has been running, let it cool before
you start the service work.
3. Get access to the engine.
4. Remove the drive belt. Refer to (PIL 15-18).
5. Remove the oil sump. Refer to (PIL 15-45).
6. Remove the turbocharger. Refer to (PIL 18-35).
7. Remove the exhaust manifold. Refer to (PIL
18-24).
8. Remove the starter motor. Refer to (PIL 15-75).
9. Remove the flywheel housing. Refer to (PIL
15-51).
10. Remove the crankshaft rear oil seal flange. Refer
to (PIL 15-12).
11. Remove the EGR (Exhaust Gas Recirculation).
Refer to (PIL 18-27).
12. Remove the inlet manifold. Refer to (PIL 18-24).
13. Disconnect and remove the high and low
pressure fuel pipes. Refer to (PIL 18-96).
14. Remove the timing gear front case. Refer to (PIL
15-51).
15. Remove the fuel injection pump. Refer to (PIL
18-18).
16. Remove the fuel injection drive gear. Refer to
(PIL 15-51).
17. Remove the intermediate drive gear. Refer to
(PIL 15-51).
18. Remove the high duty PTO (Power Take-Off)
device (if installed).
19. Remove the fuel injectors. Refer to (PIL 18-18).
20. Remove the rocker cover. Refer to (PIL 15-42).
21. Remove the rocker assembly including the push
rods. Refer to (PIL 15-42).
22. It is not necessary to remove the cylinder head
assembly to remove the bedplate. If however,
the cylinder head needs to be removed for other
reasons (for piston and connecting rod removal
for example) remove it now. Refer to (PIL 15-06).
23. Position the engine upside down in a suitable jig
or fixture, supported at the front of the crankcase.
Remove
1. Remove the main bearing bolts in the sequence
shown.
Figure 123.
B
A
ABedplate
BMain bearing bolts (x8)
2. Remove the bedplate peripheral bolts in the
sequence shown.

15 - Engine
09 - Bedplate
00 - General
15 - 43 9813/9750-1 15 - 43
Figure 124.
C
CPeripheral bolts (x13)
3. Carefully separate the bedplate from the
crankcase. Use suitable lifting equipment (if the
bedplate is lifted manually, two people will be
required). Do not use a lever to separate the
bedplate.
4. Carefully remove the lower bearing shells from
the bedplate.
Figure 125.
A
D
ABedplate
DLower bearing shells (x4)
Before Installation
1. Clean off all traces of the old sealant compound
from the crankcase and bedplate mating faces.
2. Use a suitable degreasing agent to carefully
clean the main bearing saddles in the bedplate
and crankcase. Take care not to block the oil
ways or the piston cooling jets.
Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner
Important: Anaerobic sealant will not start to cure
whilst it is open to the atmosphere, however when
air is excluded (for instance when the two parts are
put together) it will immediately start to harden. Make
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).
Important: BEFORE you install the bedplate: DO
NOT rotate the crankshaft. Make sure that the upper
main bearing shells are flush with the bottom face of
the crankcase.
Install
Important: The crankshaft half bearings are made of
special material. Therefore, they must be replaced
every time they are removed to prevent seizures.
The lower and upper crankshaft half bearings cannot
be replaced singularly, and both halves must be
replaced together.
1. Make sure that all items are clean and free from
damage and corrosion.
2. Use a suitable degreasing agent to clean both
sides of the lower bearing shells.
Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner
3. Install the lower bearing shells into the bedplate.
Make sure that the reference notches are at the
correct location.
Figure 126.
E
D
A
ABedplate
DLower bearing shells (x4)
EReference notch
4. Lubricate the lower bearing shells with clean
engine oil.
5. Install the two shoulder half-rings onto the lower
crankcase. Apply two dots of ITP GX100 grease
to hold the rings in position.

15 - Engine
09 - Bedplate
00 - General
15 - 44 9813/9750-1 15 - 44
Figure 127.
G
D
F
DLower bearing shells (x4)
FShoulder half-rings (x2)
GGuide pins
6. Apply a 1.0mm (0.04in) thick bead of Loctite 5188
around the crankcase/bedplate mating face as
shown.
Figure 128.
L
K
J
H
HCrankcase
JLoctite 5188
KOil feed holes
LReturn oil grooves
7. Make sure that you do not block the oil feed holes
and the return oil grooves.
8. Assemble the bedplate to the crankcase. Make
sure that the guide pins on the crankcase are
engaged properly in the slots on the bedplate.
9. Note: The bedplate is heavy. Two people will be
required to lift and rotate the bedplate safely on
to the crankcase.
10. Install the main bearing bolts (x8).
11. Tighten the bolts to the correct torque value in
three stages. Strictly follow the torque sequence
shown.
Figure 129.
12. Install the bedplate peripheral bolts (x13).
13. Tighten the bolts to the correct torque value in
two stages. Strictly follow the torque sequence
shown.
Figure 130.
Important: If the parts have not been tightened to the
correct torque value within the maximum 15min time
period, then the parts must be separated, thoroughly
cleaned and fresh sealant should be applied.
After Installation
1. Check that the crankshaft can be freely rotated
by hand.
2. Measure the crankshaft end float. Make sure that
the end float is between 0.18mm (0.007in) and
0.38mm (0.015in).
3. Carry out the procedures listed in the 'Before
Removal' section in reverse order.

15 - Engine
09 - Bedplate
00 - General
15 - 45 9813/9750-1 15 - 45
Table 37. Torque Values
Item Description Nm
B Main bearing bolts (x8) (1st
Stage)
40
B Main bearing bolts (x8) (2nd
Stage)
70
B Main bearing bolts (x8) (3rd
Stage)
120
C Peripheral bolts (x13) (4th
Stage)
20
C Peripheral bolts (x13) (5th
Stage)
35
(For: KDI 2504 TCR Elec Engine)
Consumables
Description Part No. Size
Cleaner/Degreaser
- General purpose
solvent based parts
cleaner
4104/1557 0.4L
CAUTION This component is heavy. It must only
be removed or handled using a suitable lifting
method and device.
Before Removal
1. This procedure requires service parts. Make
sure you have obtained the correct service parts
before you start, refer to Parts Catalogue.
2. Make sure that the engine is safe to work on. If
the engine has been running, let it cool before
you start the service work.
3. Get access to the engine.
4. Remove the drive belt. Refer to (PIL 15-18).
5. Remove the oil sump. Refer to (PIL 15-45).
6. Remove the turbocharger. Refer to (PIL 18-35).
7. Remove the exhaust manifold. Refer to (PIL
18-24).
8. Remove the starter motor. Refer to (PIL 15-75).
9. Remove the flywheel housing. Refer to (PIL
15-54).
10. Remove the crankshaft rear oil seal flange. Refer
to (PIL 15-12).
11. Remove the EGR. Refer to (PIL 18-27).
12. Remove the inlet manifold. Refer to (PIL 18-24).
13. Disconnect and remove the high and low
pressure fuel pipes. Refer to (PIL 18-96).
14. Remove the timing gear front case. Refer to (PIL
15-51).
15. Remove the fuel injection pump. Refer to (PIL
18-18).
16. Remove the fuel injection drive gear. Refer to
(PIL 15-51).
17. Remove the intermediate drive gear. Refer to
(PIL 15-51).
18. Remove the high duty PTO device (if installed).
19. Remove the fuel injectors. Refer to (PIL 18-18).
20. Remove the rocker cover. Refer to (PIL 15-42).
21. Remove the rocker assembly including the push
rods. Refer to (PIL 15-42).
22. It is not necessary to remove the cylinder head
assembly to remove the bedplate. If however,
the cylinder head needs to be removed for other
reasons (for piston and connecting rod removal
for example) remove it now. Refer to (PIL 15-06).
23. Position the engine upside down in a suitable jig
or fixture, supported at the front of the crankcase.
Remove
1. Remove the main bearing bolts in the sequence
shown.
Figure 131.
B
A
ABedplate
BMain bearing bolts (x10)
2. Remove the bedplate peripheral bolts in the
sequence shown.

15 - Engine
09 - Bedplate
00 - General
15 - 46 9813/9750-1 15 - 46
Figure 132.
C
CPeripheral bolts (x17)
3. Carefully separate the bedplate from the
crankcase. Use suitable lifting equipment (if the
bedplate is lifted manually, two people will be
required). Do not use a lever to separate the
bedplate.
4. Carefully remove the lower bearing shells from
the bedplate.
Figure 133.
A
D
ABedplate
DLower bearing shells (x5)
Before Installation
1. Clean off all traces of the old sealant compound
from the crankcase and bedplate mating faces.
2. Use a suitable degreasing agent to carefully
clean the main bearing saddles in the bedplate
and crankcase. Take care not to block the oil
ways or the piston cooling jets.
Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner
Important: Anaerobic sealant will not start to cure
whilst it is open to the atmosphere, however when
air is excluded (for instance when the two parts are
put together) it will immediately start to harden. Make
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).
Important: Before installing the bedplate: Do not
rotate the crankshaft. Make sure that the upper main
bearing shells are flush with the bottom face of the
crankcase.
Install
Important: The crankshaft half bearings are made of
special material. Therefore, they must be replaced
every time they are removed to prevent seizures.
The lower and upper crankshaft half bearings cannot
be replaced singularly, and both halves must be
replaced together.
1. Make sure that all items are clean and free from
damage and corrosion.
2. Use a suitable degreasing agent to clean both
sides of the lower bearing shells.
Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner
3. Install the lower bearing shells into the bedplate.
Make sure that the reference notches are at the
correct location.
Figure 134.
E
D
A
ABedplate
DLower bearing shells (x5)
EReference notch
4. Lubricate the lower bearing shells with clean
engine oil.
5. Install the two shoulder half-rings onto the lower
crankcase. Apply two dots of ITP GX100 grease
to hold the rings in position.

15 - Engine
09 - Bedplate
00 - General
15 - 47 9813/9750-1 15 - 47
Figure 135.
G
D
F
DLower bearing shells (x5)
FShoulder half-rings (x2)
GGuide pins
6. Apply a 1.0mm (0.04in) thick bead of Loctite 5188
around the crankcase/bedplate mating face as
shown.
Figure 136.
L
K
J
H
HCrankcase
JLoctite 5188
KOil feed holes
LReturn oil grooves
7. Make sure that you do not block the oil feed holes
and the return oil grooves.
8. Assemble the bedplate to the crankcase. Make
sure that the guide pins on the crankcase are
engaged properly in the slots on the bedplate.
9. Note: The bedplate is heavy. Two people will be
required to lift and rotate the bedplate safely on
to the crankcase.
10. Install the main bearing bolts (x10).
11. Tighten the bolts to the correct torque value in
three stages. Strictly follow the torque sequence
shown.
Figure 137.
B
A
12. Install the bedplate peripheral bolts (x17).
13. Tighten the bolts to the correct torque value in
two stages. Strictly follow the torque sequence
shown.
Figure 138.
C
Important: If the parts have not been tightened to the
correct torque value within the maximum 15min time
period, then the parts must be separated, thoroughly
cleaned and fresh sealant should be applied.
After Installation
1. Check that the crankshaft can be freely rotated
by hand.
2. Measure the crankshaft end float. Make sure that
the end float is between 0.18mm (0.007in) and
0.38mm (0.015in).
3. Carry out the procedures listed in the 'Before
Removal' section in reverse order.

15 - Engine
12 - Crankshaft
00 - General
15 - 52 9813/9750-1 15 - 52
Technical Data
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
ovality on journals(1)
Crankshaft end float
- min 0.18mm ( 0.0070in)
- max 0.38mm ( 0.0149in)
(1) No visible damage/wear or marks
Component Identification
Figure 139.
B
A
ACrankcase
BCrankshaft

15 - Engine
12 - Crankshaft
00 - General
15 - 53 9813/9750-1 15 - 53
Operation
Refer to Camshaft-Operation (PIL 15-15).
Lubrication
Oil is fed from the main gallery via five drillings, one
to each of the main bearings. A groove around the
diameter of the upper main bearing shell allows oil
transfer to cross drillings in the crankshaft to feed
each of the big end bearings. Crankshaft gear is
'splash' lubricated. Front and rear crankshaft oil seals
prevent oil leakage from, and dirt ingress to, the
engine.
Figure 140.
1Main gallery 2Drillings (x5)
3Main bearings 4Big end bearings
5Cross drillings 6Crankshaft gear
7Crankshaft oil seal 8Crankshaft oil seal

15 - Engine
12 - Crankshaft
00 - General
15 - 54 9813/9750-1 15 - 54
Check (Condition)
1. Check the main bearing surfaces for damage and
excessive wear.
2. Measure the crankshaft diameters to confirm
they are within service limits. Refer to
Crankshaft- Technical Data (PIL 15-12).
3. Check that the oilway cross drillings in the
crankshaft are clear and free from debris.
Blocked or restricted oilways will cause oil
starvation at the big end bearings.
4. Check that the piston cooling oil sprayers are
clear (if installed). If the sprayers cannot be
cleared remove the fixing screws. Remove the
sprayers and discard them.
Figure 141.
D
C
A
B
E
ACrankshaft BShoulder half-rings
COil spray jets (if installed) DFixing screws
EMain bearing shells

15 - Engine
12 - Crankshaft
00 - General
15 - 55 9813/9750-1 15 - 55
Calibrate
Axial clearance check
1. To measure the axial clearance of the crankshaft,
it is necessary to assemble the shaft in the
crankcase.
2. Measure the axial shift of the crankshaft with a
dial gauge. The axial shift must range between
0.18-0.38mm (0.007-0.015in).
3. If the value is more than or less than the specified
range, replace the shoulder rings.
Figure 142.
A
B
ACrankshaft BDial gauge

15 - Engine
12 - Crankshaft
00 - General
15 - 56 9813/9750-1 15 - 56
Dimensional Check
1. Make sure that you clean the crankshaft
thoroughly with a suitable detergent.
2. Use a pipe cleaner into the lubrication ducts to
remove any residual dirt.
3. Use a compressed air jet to thoroughly clean the
oil passages.
4. Check the surfaces of the main journals and
crank-pins for wear limit, to see whether grinding
is necessary.
5. Install the half-bearings on the semi-crankcases,
without crankshaft, and couple the semi-
crankcases by tightening the fixing screws.
6. Measure the diameter of the crank-pins and main
journals with a micrometer.
7. Measure the internal diameter of the connecting
rod and crankshaft half-bearings with a dial
gauge.
8. Lubricate the contact surfaces with oil to prevent
oxidation.
9. The crankshaft and connecting rod half-bearings
must necessarily be replaced every time they are
disassembled.
10. Make sure that the measurements are within the
allowable limits.
Figure 143.
A
B
C
D
ACrank-pin BMain journal
CConnecting rod half-bearing DCrankshaft half-bearing

15 - Engine
12 - Crankshaft
00 - General
15 - 57 9813/9750-1 15 - 57
Remove and Install
Consumables
Description Part No. Size
Cleaner/Degreaser
- General purpose
solvent based parts
cleaner
4104/1557 0.4L
CAUTION This component is heavy. It must only
be removed or handled using a suitable lifting
method and device.
Before Removal
1. This procedure requires service parts. Make
sure you have obtained the correct service parts
before you start, refer to Parts Catalogue.
2. Make sure that the engine is safe to work on. If
the engine has been running, let it cool before
you start the service work.
3. Get access to the engine.
4. Remove the bedplate. Refer to (PIL 15-09).
5. If the pistons and connecting rods have not been
removed, then remove the main bearing caps.
Refer to (PIL 15-12).
Figure 144.
D
C
B
B
A
E
F
ACrankshaft BThrust Washers

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