jcb 135 User manual

OPERATOR'S MANUAL
135, 155, 175, 190, 205
EN - 9831/2350
ISSUE 1 - 03/2016
THIS MANUAL SHOULD ALWAYS STAY WITH THE MACHINE

OPERATOR'S
MANUAL
135, 155, 175, 190, 205
EN - 9831/2350 - ISSUE 1 - 03/2016
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
Copyright 2015 © 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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9831/2350-1
Notes:
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Table of Contents
i 9831/2350-1 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 ................................................................................................................... 13
Operator Station
Component Locations ......................................................................................................................... 16
Console Switches
Window Wipers ................................................................................................................................... 17
Interior Switches
Ignition Switch ..................................................................................................................................... 18
Cab Interior Light ................................................................................................................................ 19
Operation
Introduction
General ................................................................................................................................................ 21
Operating Safety
General ................................................................................................................................................ 22
Worksite Safety ................................................................................................................................... 24
Risk Assessment ................................................................................................................................ 25
Walk-Around Inspection
General ................................................................................................................................................ 27
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Table of Contents
ii 9831/2350-1 ii
Entering and Leaving the Operator Station
General ................................................................................................................................................ 28
Emergency Exit ................................................................................................................................... 28
Doors
Operator Door ..................................................................................................................................... 31
Windows
Front Window ...................................................................................................................................... 33
Side Window ....................................................................................................................................... 33
Before Starting the Engine
General ................................................................................................................................................ 35
Operator Seat
General ................................................................................................................................................ 36
Basic Seat ........................................................................................................................................... 36
Suspension Seat ................................................................................................................................. 37
Seat Belt
General ................................................................................................................................................ 39
Inertia Reel Seat Belt ......................................................................................................................... 39
Static Seat Belt ................................................................................................................................... 40
Mirrors
General ................................................................................................................................................ 42
Starting the Engine
General ................................................................................................................................................ 44
Stopping and Parking
General ................................................................................................................................................ 47
Preparing for Travel
General ................................................................................................................................................ 48
Preparing for Road Travel .................................................................................................................. 48
Preparing for Worksite Travel ............................................................................................................. 49
Smooth Ride System (SRS) ............................................................................................................... 50
Beacon ................................................................................................................................................ 50
Safety Equipment
General ................................................................................................................................................ 52
Control Lock ........................................................................................................................................ 52
Transportation Lock ............................................................................................................................ 53
Drive Controls
General ................................................................................................................................................ 54
Instruments
General ................................................................................................................................................ 62
Instrument Panel ................................................................................................................................. 67
Getting the Machine Moving
General ................................................................................................................................................ 82
Operating Levers/Pedals
General ................................................................................................................................................ 83
Control Layouts ................................................................................................................................... 83
Lift Arm Controls ................................................................................................................................. 83
Auxiliary Circuit Controls ..................................................................................................................... 86
Working with the Lift Arm
General ................................................................................................................................................ 89
Filling the Shovel ................................................................................................................................ 89
Loading a Truck .................................................................................................................................. 90
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Table of Contents
iii 9831/2350-1 iii
Slopes
General ................................................................................................................................................ 91
Driving on Slopes ............................................................................................................................... 91
Working on Slopes ............................................................................................................................. 91
Heating, Ventilating and Air-Conditioning (HVAC)
General ................................................................................................................................................ 92
Air-Conditioning Controls .................................................................................................................... 92
Power Sockets
Auxiliary Power Socket ....................................................................................................................... 93
Radio
General ................................................................................................................................................ 94
Battery Isolator
General ................................................................................................................................................ 97
Fire Extinguisher
General ................................................................................................................................................ 98
Moving a Disabled Machine
General ................................................................................................................................................ 99
Jump-Starting the Engine ................................................................................................................... 99
Retrieval ............................................................................................................................................ 100
Loader Arm (Emergency Operation) ................................................................................................ 100
Lifting the Machine
General .............................................................................................................................................. 102
Transporting the Machine
General .............................................................................................................................................. 105
Loading the Machine onto the Transporting Vehicle/Trailer ............................................................. 105
Operating Environment
General .............................................................................................................................................. 108
Operating in Low Temperatures ....................................................................................................... 108
Operating in High Temperatures ....................................................................................................... 108
Refuelling
General .............................................................................................................................................. 110
Low Fuel Levels ................................................................................................................................ 110
Filling the Tank .................................................................................................................................. 110
Attachments
Working with Attachments
Introduction ........................................................................................................................................ 111
Attachments for your Machine .......................................................................................................... 111
Connecting/Disconnecting Hydraulic Hoses ..................................................................................... 121
Impact Protection .............................................................................................................................. 125
Attachment Frame
General .............................................................................................................................................. 126
Quickhitch
Quickhitch Attachment Bracket ......................................................................................................... 127
Shovels
General .............................................................................................................................................. 133
Standard Shovel ............................................................................................................................... 133
Grapple Shovel ................................................................................................................................. 134
6-in-1 Shovel ..................................................................................................................................... 135
Forks
General .............................................................................................................................................. 138
Pallet Forks ....................................................................................................................................... 138
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Table of Contents
iv 9831/2350-1 iv
Manure Forks .................................................................................................................................... 139
Snow Blade
General .............................................................................................................................................. 141
Preservation and Storage
Cleaning
General .............................................................................................................................................. 145
Preparation ........................................................................................................................................ 145
Checking For Damage
General .............................................................................................................................................. 147
Storage
General .............................................................................................................................................. 148
Put into Storage ................................................................................................................................ 148
During Storage .................................................................................................................................. 148
Take out of Storage .......................................................................................................................... 149
Security
General .............................................................................................................................................. 150
JCB Plantguard ................................................................................................................................. 150
Construction Equipment Security and Registration Scheme (CESAR) ............................................ 150
Maintenance
Introduction
General .............................................................................................................................................. 151
Owner/Operator Support ................................................................................................................... 151
Service/Maintenance Agreements .................................................................................................... 151
Obtaining Spare Parts ...................................................................................................................... 152
Maintenance Safety
General .............................................................................................................................................. 153
Fluids and Lubricants ....................................................................................................................... 154
Maintenance Schedules
General .............................................................................................................................................. 158
How to Use the Maintenance Schedules ......................................................................................... 158
Maintenance Intervals ....................................................................................................................... 158
Pre-start Cold Checks, Service Points and Fluid Levels .................................................................. 158
Functional Tests and Final Inspection .............................................................................................. 161
Maintenance Positions
General .............................................................................................................................................. 162
Maintenance Position (Lift Arm Lowered) ........................................................................................ 162
Maintenance Position (Lift Arm Raised) ........................................................................................... 163
Maintenance Position (Lift Arm Raised and Cab Raised) ................................................................ 164
Service Points
General .............................................................................................................................................. 166
Access Apertures
General .............................................................................................................................................. 169
Engine Compartment Cover ............................................................................................................. 169
Rear Cover ........................................................................................................................................ 170
Cab/Canopy ...................................................................................................................................... 171
Tools
General .............................................................................................................................................. 176
Toolbox .............................................................................................................................................. 176
Lubrication
General .............................................................................................................................................. 177
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Table of Contents
v 9831/2350-1 v
Preparation ........................................................................................................................................ 177
Attachments
General ............................................................................................................................................. 178
Body and Framework
General ............................................................................................................................................. 179
Pivot Pins .......................................................................................................................................... 180
Operator Station
General ............................................................................................................................................. 182
Operator Protective Structure ........................................................................................................... 182
Seat ................................................................................................................................................... 183
Seat Belt ........................................................................................................................................... 183
Controls ............................................................................................................................................. 183
Engine
General ............................................................................................................................................. 184
Oil ...................................................................................................................................................... 184
Drive Belt .......................................................................................................................................... 188
Exhaust ............................................................................................................................................. 190
Air Filter
General ............................................................................................................................................. 191
Outer Element .................................................................................................................................. 191
Fuel System
General ............................................................................................................................................. 193
Fuel Filter .......................................................................................................................................... 193
Water Separator ............................................................................................................................... 194
Cooling System
General ............................................................................................................................................. 196
Coolant .............................................................................................................................................. 196
Cooling Pack .................................................................................................................................... 197
Brakes
Park Brake ........................................................................................................................................ 199
Wheels
General ............................................................................................................................................. 200
Tyres
General ............................................................................................................................................. 202
Drive Gearbox
Oil ...................................................................................................................................................... 204
Hydraulic System
General ............................................................................................................................................. 205
Services ............................................................................................................................................ 206
Oil ...................................................................................................................................................... 206
Cylinder Rams .................................................................................................................................. 206
Electrical System
General ............................................................................................................................................. 208
Battery ............................................................................................................................................... 208
Battery Isolator ................................................................................................................................. 209
Fuses ................................................................................................................................................ 210
Relays ............................................................................................................................................... 211
Window Washer ................................................................................................................................ 212
Miscellaneous
Fire Extinguisher ............................................................................................................................... 214
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Table of Contents
vi 9831/2350-1 vi
Technical Data
Static Dimensions
General .............................................................................................................................................. 215
Dimensions ........................................................................................................................................ 215
Weights ............................................................................................................................................. 217
Performance Dimensions
General .............................................................................................................................................. 219
Driving Performance ......................................................................................................................... 220
Noise Emissions
General .............................................................................................................................................. 221
Noise Data ........................................................................................................................................ 221
Vibration Emissions
General .............................................................................................................................................. 222
Vibration Data ................................................................................................................................... 222
Fluids, Lubricants and Capacities
General .............................................................................................................................................. 224
Fuel ................................................................................................................................................... 225
Coolant .............................................................................................................................................. 231
Torque Values
General .............................................................................................................................................. 233
Electrical System
General .............................................................................................................................................. 234
Fuses ................................................................................................................................................. 234
Relays ............................................................................................................................................... 235
Hydraulic System
Auxiliary Circuits ............................................................................................................................... 238
Wheels and Tyres
Tyre Sizes and Pressures ................................................................................................................ 239
Declaration of Conformity
General .............................................................................................................................................. 240
Data ................................................................................................................................................... 240
Warranty Information
Service Record Sheet ....................................................................................................................... 242
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Table of Contents
vii 9831/2350-1 vii
Acronyms Glossary
CESAR Construction Equipment Security and Registration
DEF Diesel Exhaust Fluid
ECU Electronic Control Unit
ESOS Engine Shut-Off Solenoid
FEAD Front End Accessory Drive
FOPS Falling Object Protective Structure
HVAC Heating Ventilation Air Conditioning
ISO International Organization for Standardization
LCD Liquid Crystal Display
LED Light Emitting Diode
PIN Product Identification Number
PPE Personal Protective Equipment
RMS Root Mean Square
ROPS Roll-Over Protective Structure
SRS Smooth Ride System
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