JCB TM180, TM220 Telescopic Wheeled Loader Service Repair Manual Instant Download (TM180 SN from 2096873 to 2097873; TM220 SN from 2128886 to 2129886, from 2679851 to

1
Foreword
SERVICE MANUAL LOADER TM180,
TM220 EN - 9813/3150 - ISSUE 2 -
08/2018 This manual contains original
instructions, verified by the manufacturer (or
their authorized representative). Copyright
2018 Â 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
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
Handling 06 - Body and Framework 09 - Operator
Station
and Load
12 -
Heating, Ventilating and Air-
Conditioning (HVAC) 15 - Engine
18 - Fuel and Exhaust System 21 - Cooling
System 24 - Brake System 25 - Steering System 27
- Driveline 30 - Hydraulic System 33 - Electrical
System 72 - Fasteners and Fixings 75 - Consumable
Products 78 - After Sales
2
15 - Engine 42 - Rocker and Fittings 00 - General
Operation
When the camshaft lobe raises the push-rod, the
push-rod pushes the rocker arm up. Due to this
the rocker arm presses down on the valve stem to
open the valve. When the rocker arm returns due
to the camshafts rotation, the valve spring
closes the valve.
head to a small transfer gallery under the rocker
shaft pedestal. The oversize rocker shaft fixing
bolt hole allows oil to pass into a drilling in
the centre of the rocker shaft. Further cross
drillings transfer oil to each of the rocker
pivot bushes. A cross drilling in each rocker
transfers oil to the top of the rocker where it
flows by gravity along a groove to the rocker tip.
Lubrication Oil is fed from the main gallery
through a drilling which passes up through the
crankcase and cylinder
Figure 229.
1 Main gallery 3 Shaft pedestal 5 Centre rocker
shaft drilling 7 Rocker pivot bushes 9 Groove
2 Small transfer gallery 4 Rocker shaft fixing
bolt hole 6 Cross drillings 8 Cross drilling
15 - 131
3
15 - Engine 42 - Rocker and Fittings 00 - General
Check (Condition)
Remove and Install

• Check the rocker shaft and rocker bushings for
  signs of damage and excessive wear. Measure the
  rocker shaft diameter and rocker bearing bushes
  to confirm they are within service limits. Refer
  to Technical Data. Note The rocker bearing
  bushes are not renewable. If a rocker bearing
  bush is damaged or worn the rocker must be
  renewed as a complete assembly.
• Refer to PIL 15-42.
• Make sure that all oil-ways and cross drillings
  in the rocker shaft, rocker arms and pedestals
  are clear and free from debris. Use an air line
  to blow through cross drillings.

Before Removal

• 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.
• Get access to the engine.
• Disconnect and remove the fuel pipes from the
  fuel injectors.
• Refer to PIL 18-96.
• Remove the rocker cover. Refer to PIL 15-42-06.

Remove 1. Remove the rocker shaft fixing
screws. Figure 230. B A C

• Rocker shaft fixing screw (x4)
• Rocker arm assembly
• Cylinder head
• Make sure that you keep all the fixing screws in
  their original positions.
• Lift the rocker arm assembly from the cylinder
  head completely.

15 - 132
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5
15 - Engine 42 - Rocker and Fittings 00 - General
Figure 231.
5. Remove the push rods from the crankcase.
B
Before Installation

1. Make sure that all items are clean and free from
   damage and corrosion. If components within the
   rocker assembly are damaged or worn.
2. Make sure that all oilways and cross drillings in
   the cylinder head, rocker shaft and pedestals
   are clear and free from debris. Use an air line
   to blow through the cross drillings.
3. Use a suitable degreasing agent to clean the top
   of the cylinder head.

C

• Install
• The installation procedure is the opposite of the
  removal procedure. Additionally do the following
  steps.
• Insert the push rods into the crankcase. Make
  sure that they engage with the camshaft tappets.
• Figure 233.

E
E

1. Rocker arm assembly
2. Cylinder head

4. Lift off the valve bridge pieces from the
pairs of inlet and exhaust valves. Figure 232.
F
D

• Push rod
• Camshaft tappet
• 3. Install the bridge pieces on to the pairs of
  inlet and exhaust valves in the cylinder head.

E

1. Valve bridge (x6)
2. Push rod (x6)

6
15 - Engine 42 - Rocker and Fittings 00 - General
Figure 234.

• Make sure that the rocker arm assembly is seated
  properly on the push rod.
• Make sure that you put the crankshaft gear key
  in the position as shown to avoid the rocker arm
  rod bending at the time of tightening the fixing
  screws.
• Figure 237.

D
D
J
C

• Cylinder head
• Valve bridge
• Align the rocker arm assembly on a level surface.
• Make sure that you install the rocker arm
  assembly on the cylinder head with respect to
  the plug and the holder.
• Figure 235.

J Gear key 8. Put the rocker arm fixing screws
and tighten the screws in the sequence
shown. Figure 238. A 2 1 3
E
H
4
E Push rod H Plug Figure 236.
B

• Rocker shaft fixing screw
• Rocker arm assembly
• 9. Tighten the screws to the correct torque
  value.

B
After Installation

1. Measure and adjust the valve clearances. Refer
   to PIL 15-30.
2. Install the rocker cover. Refer to PIL 15-42-06.

G
B Rocker arm assembly G Holder
7
15 - Engine 42 - Rocker and Fittings 00 - General
Disassemble and Assemble Special Tools
3. Install and connect the fuel pipes to the
fuel injectors. Refer to PIL 18-96.
Description Part No. Qty.
Insertion Pliers for Hydraulic Tappets 892/12425 1
Table 76. Torque Values
Item Nm
A 25

• Before Disassembly
• Remove the rocker cover. Refer to PIL 15-42-06.
• Remove the rocker assembly. Refer to PIL
  15-42-00.
• Disassemble
• Remove the retainer ring.
• Figure 239.

B
A
C
D

• Discharge rocker arm
• Hydraulic tappet
• Retainer
• Shoulder ring
• Remove the shoulder ring.
• Remove the rockers and the holders from the
  rocker shaft.

8
15 - Engine 42 - Rocker and Fittings 00 - General
Figure 240.
Figure 242.
A
F
J
E
H
G
A
B

• A Discharge rocker arm
• Rocker shaft
• Holder
• Holder 1
• Label the rockers and the holders to make sure
  that they are installed in the correct positions
  on assembly.
• Remove the tappets from the rocker.
• Figure 241.

• A Discharge rocker arm
• B Hydraulic tappet
• H Chamber
• J Pad
• Position the rocker arm in the pliers.
• Use the pliers to push the tappet through the
  rocker arm until the tappet is properly
  inserted.
• Lubricate the rocker shaft with clean engine oil.
• Install the rocker arms in the correct position,
  turn the rocker shaft with the lower height
  towards the timing gear system side.
• Put the lock ring into the seat of the rocker
  shaft.
• Figure 243.

B
A
D
L
E

• Discharge rocker arm
• Hydraulic tappet
• 6. Check (Condition) of the rocker arm assembly
  for signs of damage and excessive wear.
• Refer to PIL 15-42-00.

K
C
E

• Assemble
• The assembly procedure is the opposite of the
  disassembly procedure. Additionally do the
  following steps.
• Install the tappets into the rocker arm.
• Insert the tappets into the hydraulic tappet
  insertion pliers.
• Special Tool Insertion Pliers for Hydraulic
  Tappets (Qty. 1)
• Fill the chamber of the tappet with oil.
• Put the pad on the tappet.

C

• Retainer
• Shoulder ring
• Rocker shaft
• Seat
• Rocker shaft lower height
• Position the fixing screw support surface facing
  upwards.
• Put the two shoulder rings on the rocker shaft.
• Sequentially put the suction rocker arm, the
  holder and the discharge rocker arm on the
  rocker shaft.

9
15 - Engine 42 - Rocker and Fittings 00 - General
Figure 244.
E
M
A
C
N
D
F
G

• A Discharge rocker arm
• Retainer
• Shoulder ring
• Rocker shaft
• Holder
• Holder 1
• Spring
• Suction rocker arm
• The discharge rocker arm is shorter than the
  suction rocker arm.
• Install the spring on the rocker shaft.
• Do the steps 8 and 10 for all the remaining
  rocker arms.
• Install the holder 1 with the last pair of rocker
  arm towards the flywheel.
• The spring makes sure that the holder and the
  holder 1 are kept in place.
• Make sure that the rockers are installed in their
  original positions along the rocker shaft.
• Put the shoulder rings and the lock ring to lock
  all the components on the rocker shaft.
• After Assembly
• Install the rocker assembly. Refer to PIL
  15-42-00.
• Install the rocker cover. Refer to PIL 15-42-06.

10
15 - Engine 42 - Rocker and Fittings 06 - Rocker
Cover
Remove and Install Special Tools
Figure 246. 1 3
7
5
Description Part No. Qty.
Rocker Arm Cover Mounting Studs 892/12426 1

• Before Removal
• 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.
• Clean the engine. Refer to PIL 15-00-00.
• Figure 245.
• A

2
8
4
6

1. Lift the rocker cover from the cylinder head
2. Discard the gasket.
3. The rocker cover injector seals must be replaced.
   Refer to PIL 18-18-03.

B
Install

• Remove all oil and sludge contamination from
  inside the valve chamber.
• Use a new rocker arm cover gasket.
• Make sure you align the gasket on the cylinder
  head with the rocker cover fastening screws.
• Locate the two guide pins before mounting the
  rocker arm cover.
• Special Tool Rocker Arm Cover Mounting Studs
  (Qty. 1)
• Put sleeves/covers on the four injectors to
  prevent from damage.
• Apply a Vaseline lubricant to the seals.

C

1. Rocker arm cover
2. Screws
3. Gasket

Remove

• Get access to the engine.
• Remove the high pressure fuel pipes. Refer to
  PIL 18-96-03.
• Remove the fuel bleed off fuel pipes. Refer to
  PIL 18-96-06.
• Disconnect the electrical connectors at the fuel
  injectors.
• Refer to PIL 18-18-03.
• Disconnect the electrical connector at the
  coolant temperature sensor.
• Refer to PIL 15-84-33.
• Move the electrical harness away from the rocker
  cover.
• Progressively remove the rocker arm cover screws
  from 1 to 8 in reverse order, starting at bolt 8.

15 - 141
11
15 - Engine 42 - Rocker and Fittings 06 - Rocker
Cover
Figure 247. B
E
D
F
A
C

• D
• Rocker arm cover
• Screws
• Gasket
• Guide pins
• Seal (lubricate upper part)
• Seal (lubricate inner part)
• Install the rocker arm cover and put the screws
  in sequence from 1 to 8.
• Tighten the screws to the correct torque value.
• Remove the sleeves/covers.
• After Installation
• The high pressure fuel pipes must be replaced
  with new parts.
• Refer to PIL 18-96-03.
• Start the engine and check for oil and fuel
  leaks.
• Table 77. Torque Values

Item Nm
B 10
15 - 142
12
15 - Engine 42 - Rocker and Fittings 21 - Tappet
Technical Data Tappets Dimensions Figure 248.
A
C
B
Table 78.
Item Dimension Aspect Dimension
A Perpendicularity 0.02mm (max)
B Length 46.5 0.2mm
Clearance between Tappet and Housing Figure
249. F D E

1. Tappet
2. Tappet housing

Table 79.
Item Dimensions Clearance Wear Limit
C 11.966-11.984mm 0.060-0.105mm 0.080mm
D(1) 12.000-12.018mm 0.060-0.105mm 0.080mm
(1) Measure the diameter at two points. The
difference between the two values measured must
not be more than be 0.02mm.
15 - 146
13
15 - Engine 42 - Rocker and Fittings 21 - Tappet
Component Identification
Figure 250.
C
A
D
F
E
B
H
G
A Low pressure chamber C Hydraulic tappets oil
refill pipe E Piston G Tappet body
B High pressure chamber D Retaining ring F
Unidirectional valve H Spring
15 - 147
14
15 - Engine 42 - Rocker and Fittings 21 - Tappet
Operation
requires the removal and replacement of oil and
hydraulic tappets.
Hydraulic Tappet The operating principle of the
hydraulic tappet is based on the
incompressibility of the liquid and on controlled
leakage between the piston and the tappet body. A
constant supply of pressurised oil is provided to
the low pressure chamber. The pressurized oil can
only get the access to the high pressure chamber
through the unidirectional (non-return)
valve. The high pressure chamber is filled when
the rocker arm is on the base radius of the cam
and the spring holds the piston against the valve
stem preventing from system play as well as
vibration and noise. Due to the spring movement,
the tappet extends. This creates a small pressure
decrease in the high pressure chamber to open the
non-return valve. Oil is then transferred from
the low pressure chamber to the high pressure
chamber to restore the proper amount of oil
required to eliminate any play in the
valves. Difficult Operating Conditions For proper
operation of the hydraulic tappets it is
essential that the low pressure chamber of the
piston is always full of oil. In some conditions
this may not occur (due to the fact that oil
leaks away when the engine is switched off, which
can also partially drain the tappets) this
situation will result in play that will occur
with a typical noise similar to ticking, not to
be confused with the normal ticking of the
injectors. When the engine is cold, the tappet
filling time could be very long if the oil used
is not suitable for the specific environmental
conditions. If the engine is very hot or at idle
speed, oil pressure may be low, and small air
bubbles could form in the circuit. Because of
this, the lubricant becomes compressible, thus
compressing the tappet slightly and producing
valve play which is responsible for the ticking
sound. In all cases, the ticking should not last
too long (max 5 minutes) if not, the problem will
surely be due to the poor quality of the oil,
wear or impurities that, transported by the oil,
can infiltrate between the ball valve and its
seat inside the piston This affects the operation
of the tappet itself. In these cases you must
replace the oil or the hydraulic
tappets. Continuous ticking or abnormal sound for
prolonged periods is a symptom of a possible
malfunction, and
15 - 148
15
15 - Engine 42 - Rocker and Fittings 21 - Tappet
Check (Condition)
Calibrate
Tappets and Tappet Housing Check
Tappets Dimensions Use a surface plate and a dial
gauge as shown. Check the perpendicularity of the
plate, making the tappet rotate in the direction
of the arrow. With a gauge, check the length of
the tappet to assess wear. The values measured
must be within tolerances. Refer to PIL
15-42-21. Figure 251.

• Put the tappet on a V-notch surface plate.
• Measure the following dimensions of the tappet
  and tappet housing.
• Perpendicularity of the base with a dial gauge.
• Length of the tappet to assess the wear.
• Diameter of the tappet housing with an internal
  dial gauge.
• Make sure that you measure the housing
  diameter at two locations and the difference
  between the two values should not be more than
  0.02mm.
• Measure the clearance between the tappet and the
  tappet housing from the values derived in step
  2.
• Make sure that all the values are within the
  allowable limits.
• Refer to PIL 15-42-21.

A
C
B

1. Tappet diameter
2. Tappet length
3. Perpendicularity

Clearance between Tappet and Housing Use an
internal dial gauge to measure the diameter of
the tappet housings. Measure quota in two
different points. The difference between the two
values measured must be within tolerance. Refer
to PIL 15-42-21. Figure 252. F D E

1. Quota
2. Tappet
3. Tappet housing

15 - 149
16
15 - Engine 45 - Oil Sump 00 - General
00 - General
Introduction
Introduction .....................................
............. 15-153 Technical Data
.............................................
15-154 Remove and Install ........................
............. 15-154
Figure 253.
A
A Oil Sump
15 - 153
17
15 - Engine 45 - Oil Sump 00 - General
Technical Data
Remove and Install Oil Oil is toxic. If you
swallow any oil, do not induce vomiting, seek
medical advice. Used engine oil contains harmful
contaminants which can cause skin cancer. Do not
handle used engine oil more than necessary.
Always use barrier cream or wear gloves to
prevent skin contact. Wash skin contaminated with
oil thoroughly in warm soapy water. Do not use
petrol, diesel fuel or paraffin to clean your
skin. CAUTION! It is illegal to pollute drains,
sewers or the ground. Clean up all spilt fluids
and/or lubricants. Used fluids and/or lubricants,
filters and contaminated materials must be
disposed of in accordance with local regulations.
Use authorised waste disposal sites. CAUTION! Oil
will gush from the hole when the drain plug is
removed. Keep to one side when you remove the
plug.
Table 80.
Oil sump type Wet
Oil sump capacity 7.5L

• Before Removal
• Get access to the engine.
• Drain the engine oil. Refer to PIL 15-00-00.
• Remove
• Remove the screws that attach the oil sump to
  the bedplate.
• Insert plates in the areas shown by the arrows.
• Figure 254.

E
E
D
E
E

• Oil sump
• Plate insertion areas
• Lift the plates to remove the oil sump.
• Remove the remaining sealant from the oil sump
  and bedplate contact surfaces.
• Remove the screws that attach the oil intake
  pipe.

15 - 154
18
15 - Engine 45 - Oil Sump 00 - General
6. Remove the oil intake pipe and the gasket.
Discard the gasket. Figure 255. F
8. Apply a bead of sealant (Loctite 5660) on the
oil sump contact surface to the specified
thickness. Dimension 2.5mm Figure 257.
M
H
L
K
G
K

• Screw
• Oil intake pipe
• Gasket
• 7. Remove the oil vapour pipes.
• Figure 256.

• Mounting studs
• Screw
• Sealant application surface
• Install the mounting studs to help you to
  position the oil sump.
• Put the oil sump on the bedplate. Make sure that
  the screw holes are aligned.
• Strictly follow the torque tightening sequence.
  Tighten the screws to the correct torque value.
• Figure 258. Torque Sequence

J
4 3 2
20
19
18
5
17
6
J Oil vapour pipes
16
7
Install
8
15

1. Apply Loctite 648 on the threads of the oil
   vapour pipes.
2. Install the oil vapour pipes.
3. Put a new gasket in the seat of the oil intake
   pipe.
4. Attach the oil intake pipe onto the bedplate with
   the screws.
5. Tighten the screws to the correct torque value.
6. Make sure that the oil sump is clean and free
   from contamination.
7. Make sure that the contact faces on the oil sump
   and bedplate are clean.

14
9
1 12 13
10
11

1. After you tighten all of the screws, loosen screw
   no.1 and tighten again to the correct torque
   value.
2. Clean and install the drain plugs with a new O-
   ring. Tighten the plug to the correct torque
   value.
3. Through one of the filler points, fill the engine
   with the recommended oil to the MAX mark on the
   dipstick.
4. Wipe off any spilt oil, install the filler cap
   and make sure it is secure.

15 - 155
19
15 - Engine 45 - Oil Sump 00 - General

• Operate the engine, until the oil pressure low
  warning light has extinguished.
• Check for oil leakage.
• When the oil has cooled, check the oil level
  again, and if necessary top up with clean engine
  oil.
• Table 81. Torque Values

Item Nm
B 35
F 10
L 25
15 - 156
20
15 - Engine 45 - Oil Sump 03 - Drain Plug
03 - Drain Plug Remove and Install Oil Oil is
toxic. If you swallow any oil, do not induce
vomiting, seek medical advice. Used engine oil
contains harmful contaminants which can cause
skin cancer. Do not handle used engine oil more
than necessary. Always use barrier cream or wear
gloves to prevent skin contact. Wash skin
contaminated with oil thoroughly in warm soapy
water. Do not use petrol, diesel fuel or paraffin
to clean your skin. CAUTION! It is illegal to
pollute drains, sewers or the ground. Clean up
all spilt fluids and/or lubricants. Used fluids
and/or lubricants, filters and contaminated
materials must be disposed of in accordance with
local regulations. Use authorised waste disposal
sites.
Figure 260.
C
B

1. Drain plug
2. O-ring

Install

1. Clean and install the drain plug with a new
   O-ring.
2. Tighten the plug to the correct torque value.
3. Through one of the filler points, fill the engine
   with the recommended oil to the MAX mark on the
   dipstick.
4. Wipe off any spilt oil, install the filler cap
   and make sure it is secure.
5. Operate the engine, until the oil pressure low
   warning light has extinguished.
6. Check for oil leakage.
7. When the oil has cooled, check the oil level
   again, and if necessary top up with clean engine
   oil.

Remove Drain the oil when the engine is
warm as contaminants held in suspension will
then be drained with the oil.

• Gain access to the oil sump.
• Place a container of suitable size below the
  drain plug.
• Remove the oil filler cap.
• Figure 259.

Table 82. Torque Values
A
Item Nm
B 35
A Oil filler cap CAUTION! Oil will gush from the
hole when the drain plug is removed. Keep to one
side when you remove the plug. 4. Remove the oil
sump drain plug and O-ring. Let the oil drain out.
15 - 157
21
15 - Engine 45 - Oil Sump 09 - Dipstick

• 09 - Dipstick
• Check (Level)
• Remove the engine oil dipstick.
• Make sure that the oil level is at the MAX mark
  on the dipstick.
• If the oil level is below the required quantity,
  fill the engine with the recommended oil through
  the oil filler point.
• Figure 261.

A
A Oil filler cap Figure 262.

• D
• E
• F
• Dipstick
• Maximum level mark
• Minimum level mark

15 - 158
22
15 - Engine 45 - Oil Sump 10 - Dipstick Pipe
10 - Dipstick Pipe Remove and Install
2. Attach the oil dipstick pipe to the crankcase
with the screw. Figure 265.

• Before removal
• 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.
• Get access to the engine.

• Remove
• Remove the screw.
• Pull out the oil dipstick pipe in the direction
  of the arrow.
• Figure 263.

C
F
B

• B Dipstick pipe
• C Screw
• F Manifold
• Tighten the pipe on the manifold.
• Check the gaskets are correctly installed.
• Figure 266.

A
A
C
G
B
B

1. Dipstick
2. Dipstick pipe
3. Screw

Install 1. Put the new gasket on the seat of the
pipe. Figure 264.
A Dipstick B Dipstick pipe G Gasket 5. Put the
dipstick into the pipe.
After installation 1. Start the engine and check
for any leakage.
B D
E
B B Dipstick pipe D Seat E Gasket
15 - 159
23
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15 - Engine 51 - Timing Gear
51 - Timing Gear
Contents Page No. 15-51-00 General
..................................................
..................................................
..................... 15-161 15-51-21 Front Case
..................................................
..................................................
............... 15-167
15 - 160
25
15 - Engine 51 - Timing Gear 00 - General
00 - General
Introduction
Introduction .....................................
............. 15-161 Component Identification
............................. 15-162 Remove and
Install .....................................
15-164
The timing gears are located inside a casing at
the front end of the engine.
The engine must be timed so that the camshaft
operates the valves at the correct time relative
to the crankshaft position. Valve timing is
achieved by ensuring that the camshaft drive gear
is meshed to the crankshaft gear at their correct
angular positions, Refer to Engine- General,
Operation, The Four Stroke Cycle for more
information about valve timing.
15 - 161
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