jcb 135 HD User manual
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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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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Notes:
viii 9831/0450-2 viii
Introduction
About this Manual
1 9831/0450-2 1
Introduction
About this Manual
Model and Serial Number
This manual provides information for the following model(s) in the JCB machine range:
Model From: To:
2431601 2432100
2497951 2498450
135 HD
2557052 2557450
2431601 2432100
2497951 2498450
155 HD
2557052 2557450
Using the Manual
This operator's manual is arranged to give you a good understanding of the machine and its safe operation.
It also contains maintenance and technical data.
Read this manual from the front to the back before you use the machine for the first time, even if you have used
machines of a similar/same type before as the technical specification, systems and controls of the machine
may have changed. Particular attention must be given to all the safety aspects of operating and maintaining
the machine.
If there is anything you are not sure about, ask your JCB dealer or employer. Do not guess, you or others could
be killed or seriously injured.
The general and specific warnings in this section are repeated throughout the manual. Read all the safety
statements regularly, so you do not forget them. Remember that the best operators are the safest operators.
The illustrations in this manual are for guidance only. Where the machines are different, the text and or the
illustration will specify.
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 manual.
All of the optional equipment included in this manual may not be available in all territories
Left-Hand Side, Right-Hand Side
In this manual, 'left' and 'right' mean your left and right when you are seated correctly in the machine.
Figure 1.
B
A
ALeft BRight
Cross References
In this manual, cross references are made by presenting the subject title in blue (electronic copy only). The
number of the page upon which the subject begins is indicated within the brackets. For example: Refer to:
Cross References.
Introduction
About this Manual
2 9831/0450-2 2
Location of Manual
The manual is located in the case below the seat. The manual should always be returned to its case after use.
Figure 2.
C
CManual location
Introduction
Safety
3 9831/0450-2 3
Safety
Safety - Yours and Others
All machinery can be hazardous. When a machine is correctly operated and maintained, it is a safe machine
to work with. When it is carelessly operated or poorly maintained it can become a danger to you (the operator)
and others.
In this manual and on the machine you will find warning messages, read and understand them. They inform
you of potential hazards and how to avoid them. If you do not fully understand the warning messages, ask your
employer or JCB dealer to explain them.
Safety is not just a matter of responding to the warnings. All the time you are working on or with the machine
you must be thinking of what hazards there might be and how to avoid them.
Do not work with the machine until you are sure that you can control it.
Do not start any work until you are sure that you and those around you will be safe.
If you are not sure of anything, about the machine or the work, ask someone who knows. Do not assume
anything.
Remember:
• Be careful
• Be alert
• Be safe.
Safety Warnings
In this manual and on the machine, there are safety notices. Each notice starts with a signal word. The signal
word meanings are given below.
The signal word 'DANGER' indicates a hazardous situation which, if not avoided, will result in death or serious
injury.
The signal word 'WARNING' indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
The signal word 'CAUTION' indicates a hazardous situation which, if not avoided, could result in minor or
moderate injury.
The signal word 'Notice' indicates a hazardous situation which, if not avoided, could result in machine damage.
The safety alert system (shown) also helps to identify important safety messages in this manual and on the
machine. When you see this symbol, be alert, your safety is involved, carefully read the message that follows,
and inform other operators.
Figure 3. The safety alert system
Introduction
Safety
4 9831/0450-2 4
General Safety
Training
To operate the machine safely you must know the machine and have the skill to use it. You must abide by
all relevant laws, health and safety regulations that apply to the country you are operating in. The operator's
manual instructs you on the machine, its controls and its safe operation; it is not a training manual. If you are a
new operator, get yourself trained in the skills of using a machine before trying to work with it. If you don't, you
will not do your job well, and you will be a danger to yourself and others. In some markets and for work on certain
jobsites you may be required to have been trained and assessed in accordance with an operator competence
scheme. Make sure that you and your machine comply with relevant local laws and jobsite requirements - it
is your responsibility.
Care and Alertness
All the time you are working with or on the machine, take care and stay alert. Always be careful. Always be
alert for hazards.
Clothing
You can be injured if you do not wear the correct clothing. Loose clothing can get caught in the machinery.
Keep cuffs fastened. Do not wear a necktie or scarf. Keep long hair restrained. Remove rings, watches and
personal jewellery.
Alcohol and Drugs
It is extremely dangerous to operate machinery when under the influence of alcohol or drugs. Do not consume
alcoholic drinks or take drugs before or while operating the machine or attachments. Be aware of medicines
which can cause drowsiness.
Feeling Unwell
Do not attempt to operate the machine if you are feeling unwell. By doing so you could be a danger to yourself
and those you work with.
Mobile Phones
Switch off your mobile phone before entering an area with a potentially explosive atmosphere. Sparks in such
an area could cause an explosion or fire resulting in death or serious injury.
Switch off and do not use your mobile phone when refuelling the machine.
Lifting Equipment
You can be injured if you use incorrect or faulty lifting equipment. You must identify the weight of the item to
be lifted then choose lifting equipment that is strong enough and suitable for the job. Make sure that lifting
equipment is in good condition and complies with all local regulations.
Raised Equipment
Never walk or work under raised equipment unless it is supported by a mechanical device. Equipment which
is supported only by a hydraulic device can drop and injure you if the hydraulic system fails or if the control
is operated (even with the engine stopped).
Make sure that no-one goes near the machine while you install or remove the mechanical device.
Raised Machine
Never position yourself or any part of your body under a raised machine which is not correctly supported. If the
machine moves unexpectedly you could become trapped and suffer serious injury or be killed.
Lightning
Lightning can kill you. Do not use the machine if there is lightning in your area.
Machine Modifications
This machine is manufactured in compliance with prevailing legislative requirements. It must not be altered in
any way which could affect or invalidate its compliance. For advice consult your JCB dealer.
Introduction
Safety
5 9831/0450-2 5
Clothing and Personal Protective Equipment (PPE)
Do not wear loose clothing or jewellery that can get caught on controls or moving parts. Wear protective clothing
and personal safety equipment issued or called for by the job conditions, local regulations or as specified by
your employer.
Notes:
6 9831/0450-2 6
About the Product
Introduction
7 9831/0450-2 7
About the Product
Introduction
General
Before you start using the machine, you must know how the machine operates. Use this part of the manual
to identify each control lever, switch, gauge, button and pedal. Do not guess, if there is anything you do not
understand, ask your JCB dealer.
Name and Address of the Manufacturer
For: Haryana, India .................................................................................................................... Page 7
For: Jaipur, India ........................................................................................................................ Page 7
(For: Haryana, India)
JCB India Limited, 23/7 Mathura Road, Ballabhgarh, Haryana - 121004, India
(For: Jaipur, India)
JCB India Limited, 72, Goner Turn, Agra Road, Jaipur, Rajasthan 302003, India
Product Compliance
Your JCB product was designed to comply with the laws and regulations applicable at the time of its manufacture
for the market in which it was first sold. In many markets, laws and regulations exist that require the owner to
maintain the product at a level of compliance relevant to the product when first produced. Even in the absence
of defined requirements for the product owner, JCB recommend that the product compliance be maintained
to ensure safety of the operator and exposed persons and to ensure the correct environmental performance.
Your product must not be altered in any way which could affect or invalidate any of these requirements. For
advice consult your JCB dealer.
For its compliance as a new product, your JCB and some of its components may bear approval numbers
and marking's, and may have been supplied with a Declaration/Certificate of Conformity. These marking's and
documents are relevant only for the country/region in which the product was first sold to the extent that the
laws and regulations required them.
Re-sales and import/export of products across territories with different laws and regulations can cause new
requirements to become relevant for which the product was not originally designed or specified. In some cases,
pre owned products irrespective of their age are considered new for the purposes of compliance and may be
required to meet the latest requirements which could present an insurmountable barrier to their sale/use.
Despite the presence of any compliance related marking's on the product and components, you should not
assume that compliance in a new market will be possible. In many cases it is the person responsible for import
of a pre owned product into a market that becomes responsible for compliance and who is also considered
the manufacturer.
JCB may be unable to support any product compliance related enquiry for a product which has been moved out
of the legislative country/region where it was first sold, and in particular where a product specification change
or additional certification would have been required in order for the product to be in compliance.
About the Product
Description
8 9831/0450-2 8
Description
General
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.
Intended Use
WARNING Use of the machine in temperatures outside of the intended operating range could cause
component failure or affect control response and result in an instance of uncontrolled machine operation
causing possible injury, death or damage to property.
The machine is intended to be used in normal conditions for the applications and in the environmental conditions
as described in this manual. When used normally with a shovel fitted, the machine loads or excavates through
forward motion of the machine and lifts, transports and discharges material.
Applications include earthmoving, road construction, building and construction, materials depots, landscaping,
arable, livestock and poultry farming and similar applications.
This machine is intended for operation in a temperature range of -12°C to 46°C.
The machine is not intended for use in mining and quarrying applications (other than for light yard clearing
operations), in demolition activities, any use underground, or in any kind of explosive atmosphere.
Use in light forestry application will require the addition of a forestry protection kit to the machine.
If the machine is to be used in applications where there is a high silica concentration, risk due to materials
containing asbestos or similar hazards, additional protective measures such as the use of PPE (Personal
Protective Equipment) may be required. The machine should not be operated by any person who does have
an appropriate level of qualification, training or experience of use of this type of machine. Prior to use of the
machine, its suitability (size, performance, specification etc.) should be considered with regards to the intended
application and any relevant hazards that may exist. Contact your JCB dealer for support in determining the
appropriate JCB machine, attachment and any optional equipment that is suitable for the application and
environment.
Log Moving/Object Handling
Do not use the machine to move or handle logs unless sufficient log protection is installed. You could cause
serious injury to yourself and damage to the machine. For more information, contact your JCB dealer.
Optional Equipment and Attachments
A wide range of optional attachments are available to increase the versatility of your machine. Only the JCB
approved attachments are recommended for use with your machine. Contact your JCB dealer for the full list
of approved attachments available.
Danger Zone
The danger zone is any zone within and/or around the machinery in which a person is subject to a risk to their
health or safety. The danger zone includes the area in immediate proximity to any hazardous moving parts,
areas into which working equipment and attachments can be moved to quickly, the machine normal stopping
distances and also areas into which the machine can quickly turn under normal conditions of use. Depending
on the application at the time, the danger zone could also include the area into which debris, from use of an
attachment or working tool, could be projected and any area into which debris could fall from the machine.
During the operation of the machine, keep all persons out of the danger zone. Persons in the danger zone
could be injured.
Before you do a maintenance task, make the product safe.
About the Product
Description
9 9831/0450-2 9
Main Component Locations
Figure 4.
A
C
D
F
G
H
E
B
ACab BLift arm/boom
CFuel tank DQuickhitch
EHydraulic tank FBattery
GEngine compartment rear door HEngine top cover
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