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jcb 135 HD User manual

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OPERATOR'S MANUAL
SKIDSTEER LOADER
135 HD, 155 HD
EN - 9831/0450 ISSUE 2 - 11/2014
THIS MANUAL SHOULD ALWAYS STAY WITH THE MACHINE
OPERATOR'S
MANUAL
SKIDSTEER LOADER
135 HD, 155 HD
EN - 9831/0450 - ISSUE 2 - 11/2014
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
Copyright 2014 © 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.
Machine Delivery and Installation
Even if you have operated this type of equipment
before, it is very important that your new machines
operations and functions are explained to you by
a JCB Dealer Representative following delivery of
your new machine.
Following the installation you will know how to gain
maximum productivity and performance from your
new product.
Please contact your local JCB dealer if the
Installation Form (included in this manual) has not
yet been completed with you.
Your local JCB Dealer is
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9831/0450-2
Notes:
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Table of Contents
i 9831/0450-2 i
Contents Page No.
Acronyms Glossary ........................................................................................................................................ vii
Introduction
About this Manual
Model and Serial Number ..................................................................................................................... 1
Using the Manual .................................................................................................................................. 1
Left-Hand Side, Right-Hand Side ......................................................................................................... 1
Cross References ................................................................................................................................. 1
Location of Manual ............................................................................................................................... 2
Safety
Safety - Yours and Others .................................................................................................................... 3
Safety Warnings .................................................................................................................................... 3
General Safety ...................................................................................................................................... 4
Clothing and Personal Protective Equipment (PPE) ............................................................................ 5
About the Product
Introduction
General .................................................................................................................................................. 7
Name and Address of the Manufacturer .............................................................................................. 7
Product Compliance .............................................................................................................................. 7
Description
General .................................................................................................................................................. 8
Intended Use ......................................................................................................................................... 8
Log Moving/Object Handling ................................................................................................................. 8
Optional Equipment and Attachments .................................................................................................. 8
Danger Zone ......................................................................................................................................... 8
Main Component Locations .................................................................................................................. 9
Product and Component Identification
Machine ............................................................................................................................................... 10
Engine ................................................................................................................................................. 10
Operator Protective Structure ............................................................................................................. 11
Safety Labels
General ................................................................................................................................................ 13
Safety Label Identification ................................................................................................................... 14
Operator Station
Component Locations ......................................................................................................................... 16
Interior Switches
Ignition Switch ..................................................................................................................................... 17
Cab Interior Light ................................................................................................................................ 17
Console Switches
General ................................................................................................................................................ 18
Road Lights ......................................................................................................................................... 18
Main Beam .......................................................................................................................................... 18
Hazard Warning Lights ....................................................................................................................... 18
Work Lights ......................................................................................................................................... 19
Park Brake .......................................................................................................................................... 19
Beacon ................................................................................................................................................ 19
Lift Arm Isolation ................................................................................................................................. 19
Window Wipers ................................................................................................................................... 19
Auxiliary Hydraulic Circuit ................................................................................................................... 19
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Table of Contents
ii 9831/0450-2 ii
High Flow Auxiliary ............................................................................................................................. 20
Operation
Introduction
General ................................................................................................................................................ 21
Operating Safety
General ................................................................................................................................................ 22
Worksite Safety ................................................................................................................................... 24
Risk Assessment ................................................................................................................................ 25
Walk-Around Inspection
General ................................................................................................................................................ 27
Entering and Leaving the Operator Station
General ................................................................................................................................................ 28
Emergency Exit ................................................................................................................................... 28
Doors
Operator Door ..................................................................................................................................... 30
Windows
Front Window ...................................................................................................................................... 32
Side Window ....................................................................................................................................... 32
Battery Isolator
General ................................................................................................................................................ 34
Before Starting the Engine
General ................................................................................................................................................ 35
Operator Seat
General ................................................................................................................................................ 36
Basic Seat ........................................................................................................................................... 36
Suspension Seat ................................................................................................................................. 37
Seat Belt
General ................................................................................................................................................ 38
Inertia Reel Seat Belt ......................................................................................................................... 38
Static Seat Belt ................................................................................................................................... 39
Starting the Engine
General ................................................................................................................................................ 41
Stopping and Parking
General ................................................................................................................................................ 43
Preparing for Travel
General ................................................................................................................................................ 44
Preparing for Worksite Travel ............................................................................................................. 44
Beacon ................................................................................................................................................ 44
Safety Equipment
General ................................................................................................................................................ 46
Control Lock ........................................................................................................................................ 46
Drive Controls
General ................................................................................................................................................ 48
Hand Throttle Control ......................................................................................................................... 51
Instruments
General ................................................................................................................................................ 52
Instrument Panel ................................................................................................................................. 53
Getting the Machine Moving
General ................................................................................................................................................ 56
Slopes
General ................................................................................................................................................ 57
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Table of Contents
iii 9831/0450-2 iii
Driving on Slopes ............................................................................................................................... 57
Working on Slopes ............................................................................................................................. 57
Operating Levers/Pedals
General ................................................................................................................................................ 58
Control Layouts ................................................................................................................................... 58
Lift Arm Controls ................................................................................................................................. 58
Auxiliary Circuit Controls ..................................................................................................................... 59
Working with the Lift Arm
General ................................................................................................................................................ 61
Loading a Truck .................................................................................................................................. 61
Heating, Ventilating and Air-Conditioning (HVAC)
General ................................................................................................................................................ 62
Air-Conditioning Controls .................................................................................................................... 62
Power Sockets
Auxiliary Power Socket ....................................................................................................................... 63
Moving a Disabled Machine
General ................................................................................................................................................ 64
Jump-Starting the Engine ................................................................................................................... 64
Retrieval .............................................................................................................................................. 65
Loader Arm (Emergency Operation) .................................................................................................. 65
Lifting the Machine
General ................................................................................................................................................ 67
Transporting the Machine
General ................................................................................................................................................ 68
Operating Environment
General ................................................................................................................................................ 69
Operating in Low Temperatures ......................................................................................................... 69
Operating in High Temperatures ......................................................................................................... 69
Refuelling
General ................................................................................................................................................ 71
Low Fuel Levels .................................................................................................................................. 71
Filling the Tank .................................................................................................................................... 71
Attachments
Working with Attachments
Introduction .......................................................................................................................................... 73
Attachments for your Machine ............................................................................................................ 73
Connecting/Disconnecting Hydraulic Hoses ....................................................................................... 74
Impact Protection ................................................................................................................................ 77
Shovels
General ................................................................................................................................................ 79
Standard Shovel ................................................................................................................................. 79
Grapple Shovel ................................................................................................................................... 80
6-in-1 Shovel ....................................................................................................................................... 82
Forks
Pallet Forks ......................................................................................................................................... 85
Manure Forks ...................................................................................................................................... 86
Snow Blade
General ................................................................................................................................................ 87
Dozer Blade
General ................................................................................................................................................ 91
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Table of Contents
iv 9831/0450-2 iv
Preservation and Storage
Cleaning
General ................................................................................................................................................ 93
Preparation .......................................................................................................................................... 93
Checking For Damage
General ................................................................................................................................................ 95
Storage
General ................................................................................................................................................ 96
Put into Storage .................................................................................................................................. 96
During Storage .................................................................................................................................... 96
Take out of Storage ............................................................................................................................ 97
Security
General ................................................................................................................................................ 98
LiveLink ............................................................................................................................................... 98
Maintenance
Introduction
General ................................................................................................................................................ 99
Owner/Operator Support ..................................................................................................................... 99
Service/Maintenance Agreements .................................................................................................... 100
Obtaining Spare Parts ...................................................................................................................... 100
Maintenance Safety
General .............................................................................................................................................. 101
Fluids and Lubricants ....................................................................................................................... 102
Maintenance Schedules
General .............................................................................................................................................. 106
How to Use the Maintenance Schedules ......................................................................................... 106
Maintenance Intervals ....................................................................................................................... 106
Pre-start Cold Checks, Service Points and Fluid Levels .................................................................. 107
Functional Tests and Final Inspection .............................................................................................. 109
Maintenance Positions
General .............................................................................................................................................. 110
Maintenance Position (Lift Arm Lowered) ........................................................................................ 110
Maintenance Position (Lift Arm Raised) ........................................................................................... 111
Maintenance Position (Lift Arm Raised and Cab Raised) ................................................................ 112
Service Points
General .............................................................................................................................................. 113
Access Apertures
General .............................................................................................................................................. 116
Engine Compartment Cover ............................................................................................................. 116
Rear Cover ........................................................................................................................................ 117
Cab/Canopy ...................................................................................................................................... 118
Tools
General .............................................................................................................................................. 123
Toolbox .............................................................................................................................................. 123
Lubrication
General .............................................................................................................................................. 124
Preparation ........................................................................................................................................ 124
Attachments
General ............................................................................................................................................. 125
Body and Framework
General ............................................................................................................................................. 126
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Table of Contents
v 9831/0450-2 v
Pivot Pins .......................................................................................................................................... 127
Operator Station
General ............................................................................................................................................. 129
Operator Protective Structure ........................................................................................................... 129
Seat ................................................................................................................................................... 130
Seat Belt ........................................................................................................................................... 130
Controls ............................................................................................................................................. 130
Engine
General ............................................................................................................................................. 131
Oil ...................................................................................................................................................... 131
Exhaust ............................................................................................................................................. 133
Air Filter
General ............................................................................................................................................. 135
Fuel System
General ............................................................................................................................................. 136
Fuel Filter .......................................................................................................................................... 136
Water Separator ............................................................................................................................... 137
Cooling System
General ............................................................................................................................................. 140
Coolant .............................................................................................................................................. 140
Cooling Pack .................................................................................................................................... 141
Brakes
Park Brake ........................................................................................................................................ 142
Wheels
General ............................................................................................................................................. 143
Tyres
General ............................................................................................................................................. 145
Tracks
Rubber .............................................................................................................................................. 147
Drive Gearbox
Oil ...................................................................................................................................................... 149
Hydraulic System
General ............................................................................................................................................. 150
Services ............................................................................................................................................ 151
Oil ...................................................................................................................................................... 151
Cylinders / Rams .............................................................................................................................. 151
Electrical System
General ............................................................................................................................................. 152
Battery ............................................................................................................................................... 153
Battery Isolator ................................................................................................................................. 154
Fuses ................................................................................................................................................ 154
Relays ............................................................................................................................................... 155
Technical Data
Static Dimensions
General .............................................................................................................................................. 157
Dimensions ........................................................................................................................................ 157
Weights ............................................................................................................................................. 159
Performance Dimensions
General .............................................................................................................................................. 160
Driving Performance ......................................................................................................................... 160
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Table of Contents
vi 9831/0450-2 vi
Fluids, Lubricants and Capacities
General .............................................................................................................................................. 161
Fuel ................................................................................................................................................... 161
Coolant .............................................................................................................................................. 168
Torque Values
General .............................................................................................................................................. 169
Electrical System
General .............................................................................................................................................. 170
Fuses ................................................................................................................................................. 170
Relays ............................................................................................................................................... 171
Hydraulic System
Auxiliary Circuits ............................................................................................................................... 173
Wheels and Tyres
Tyre Sizes and Pressures ................................................................................................................ 174
Warranty Information
Service Record Sheet ....................................................................................................................... 175
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Table of Contents
vii 9831/0450-2 vii
Acronyms Glossary
DEF Diesel Exhaust Fluid
ECU Electronic Control Unit
ESOS Engine Shut-Off Solenoid
FOPS Falling Object Protective Structure
HVAC Heating Ventilation Air Conditioning
LCD Liquid Crystal Display
LED Light Emitting Diode
PIN Product Identification Number
PPE Personal Protective Equipment
ROPS Roll-Over Protective Structure
RPM Revolutions Per Minute
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