jcb 135 User manual

OPERATOR'S MANUAL
135, 150T, 155, 175, 190, 190T, 205, 205T
EN - 9811/9500
ISSUE 4 - 01/2016
THIS MANUAL SHOULD ALWAYS STAY WITH THE MACHINE

OPERATOR'S
MANUAL
135, 150T, 155, 175,
190, 190T, 205, 205T
EN - 9811/9500 - ISSUE 4 - 01/2016
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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9811/9500-4
Notes:
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Table of Contents
i 9811/9500-4 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 ................................................................................................................................. 2
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 9811/9500-4 ii
Entering and Leaving the Operator Station
General ................................................................................................................................................ 28
Emergency Exit ................................................................................................................................... 29
Doors
Operator Door ..................................................................................................................................... 32
Windows
Front Window ...................................................................................................................................... 34
Side Window ....................................................................................................................................... 34
Before Starting the Engine
General ................................................................................................................................................ 36
Operator Seat
General ................................................................................................................................................ 37
Basic Seat ........................................................................................................................................... 37
Suspension Seat ................................................................................................................................. 38
Seat Belt
General ................................................................................................................................................ 40
Inertia Reel Seat Belt ......................................................................................................................... 40
Static Seat Belt ................................................................................................................................... 41
Mirrors
General ................................................................................................................................................ 43
Starting the Engine
General ................................................................................................................................................ 45
Stopping and Parking
General ................................................................................................................................................ 48
Preparing for Travel
General ................................................................................................................................................ 49
Preparing for Road Travel .................................................................................................................. 49
Preparing for Worksite Travel ............................................................................................................. 50
Smooth Ride System (SRS) ............................................................................................................... 51
Beacon ................................................................................................................................................ 51
Safety Equipment
General ................................................................................................................................................ 53
Control Lock ........................................................................................................................................ 53
Transportation Lock ............................................................................................................................ 54
Drive Controls
General ................................................................................................................................................ 55
Instruments
General ................................................................................................................................................ 63
Instrument Panel ................................................................................................................................. 68
Getting the Machine Moving
General ................................................................................................................................................ 83
Operating Levers/Pedals
General ................................................................................................................................................ 84
Control Layouts ................................................................................................................................... 84
Lift Arm Controls ................................................................................................................................. 84
Auxiliary Circuit Controls ..................................................................................................................... 87
Working with the Lift Arm
General ................................................................................................................................................ 90
Filling the Shovel ................................................................................................................................ 90
Loading a Truck .................................................................................................................................. 91
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Table of Contents
iii 9811/9500-4 iii
Slopes
General ................................................................................................................................................ 92
Driving on Slopes ............................................................................................................................... 92
Working on Slopes ............................................................................................................................. 92
Heating, Ventilating and Air-Conditioning (HVAC)
General ................................................................................................................................................ 93
Air-Conditioning Controls .................................................................................................................... 93
Power Sockets
Auxiliary Power Socket ....................................................................................................................... 94
Radio
General ................................................................................................................................................ 95
Battery Isolator
General ................................................................................................................................................ 98
Fire Extinguisher
General ................................................................................................................................................ 99
Moving a Disabled Machine
General .............................................................................................................................................. 100
Jump-Starting the Engine ................................................................................................................. 100
Retrieval ............................................................................................................................................ 101
Loader Arm (Emergency Operation) ................................................................................................ 101
Lifting the Machine
General .............................................................................................................................................. 103
Transporting the Machine
General .............................................................................................................................................. 106
Loading the Machine onto the Transporting Vehicle/Trailer ............................................................. 106
Operating Environment
General .............................................................................................................................................. 109
Operating in Low Temperatures ....................................................................................................... 109
Operating in High Temperatures ....................................................................................................... 109
Refuelling
General .............................................................................................................................................. 111
Low Fuel Levels ................................................................................................................................ 111
Filling the Tank .................................................................................................................................. 111
Attachments
Working with Attachments
Introduction ........................................................................................................................................ 113
Attachments for your Machine .......................................................................................................... 113
Connecting/Disconnecting Hydraulic Hoses ..................................................................................... 123
Impact Protection .............................................................................................................................. 127
Attachment Frame
General .............................................................................................................................................. 128
Quickhitch
Quickhitch Attachment Bracket ......................................................................................................... 129
Shovels
General .............................................................................................................................................. 135
Standard Shovel ............................................................................................................................... 135
Grapple Shovel ................................................................................................................................. 136
6-in-1 Shovel ..................................................................................................................................... 137
Forks
General .............................................................................................................................................. 140
Pallet Forks ....................................................................................................................................... 140
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Table of Contents
iv 9811/9500-4 iv
Manure Forks .................................................................................................................................... 141
Snow Blade
General .............................................................................................................................................. 143
Preservation and Storage
Cleaning
General .............................................................................................................................................. 147
Preparation ........................................................................................................................................ 147
Checking For Damage
General .............................................................................................................................................. 149
Storage
General .............................................................................................................................................. 150
Put into Storage ................................................................................................................................ 150
During Storage .................................................................................................................................. 150
Take out of Storage .......................................................................................................................... 151
Security
General .............................................................................................................................................. 152
JCB Plantguard ................................................................................................................................. 152
Construction Equipment Security and Registration Scheme (CESAR) ............................................ 152
LiveLink ............................................................................................................................................. 152
Maintenance
Introduction
General .............................................................................................................................................. 153
Owner/Operator Support ................................................................................................................... 153
Service/Maintenance Agreements .................................................................................................... 153
Obtaining Spare Parts ...................................................................................................................... 154
Maintenance Safety
General .............................................................................................................................................. 155
Fluids and Lubricants ....................................................................................................................... 156
Maintenance Schedules
General .............................................................................................................................................. 160
How to Use the Maintenance Schedules ......................................................................................... 160
Maintenance Intervals ....................................................................................................................... 160
Pre-start Cold Checks, Service Points and Fluid Levels .................................................................. 160
Functional Tests and Final Inspection .............................................................................................. 163
Maintenance Positions
General .............................................................................................................................................. 164
Maintenance Position (Lift Arm Lowered) ........................................................................................ 164
Maintenance Position (Lift Arm Raised) ........................................................................................... 165
Maintenance Position (Lift Arm Raised and Cab Raised) ................................................................ 166
Service Points
General .............................................................................................................................................. 168
Access Apertures
General .............................................................................................................................................. 173
Engine Compartment Cover ............................................................................................................. 173
Rear Cover ........................................................................................................................................ 175
Cab/Canopy ...................................................................................................................................... 176
Tools
General .............................................................................................................................................. 181
Toolbox .............................................................................................................................................. 181
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Table of Contents
v 9811/9500-4 v
Lubrication
General .............................................................................................................................................. 182
Preparation ........................................................................................................................................ 182
Attachments
General ............................................................................................................................................. 183
Body and Framework
General ............................................................................................................................................. 184
Pivot Pins .......................................................................................................................................... 185
Operator Station
General ............................................................................................................................................. 187
Operator Protective Structure ........................................................................................................... 187
Seat ................................................................................................................................................... 188
Seat Belt ........................................................................................................................................... 188
Controls ............................................................................................................................................. 188
Engine
General ............................................................................................................................................. 189
Oil ...................................................................................................................................................... 189
Drive Belt .......................................................................................................................................... 193
Exhaust ............................................................................................................................................. 195
Air Filter
General ............................................................................................................................................. 196
Outer Element .................................................................................................................................. 196
Fuel System
General ............................................................................................................................................. 197
Fuel Filter .......................................................................................................................................... 197
Water Separator ............................................................................................................................... 198
Cooling System
General ............................................................................................................................................. 200
Coolant .............................................................................................................................................. 200
Cooling Pack .................................................................................................................................... 201
Brakes
Park Brake ........................................................................................................................................ 203
Wheels
General ............................................................................................................................................. 204
Tyres
General ............................................................................................................................................. 206
Tracks
Rubber .............................................................................................................................................. 208
Drive Gearbox
Oil ...................................................................................................................................................... 210
Hydraulic System
General ............................................................................................................................................. 211
Services ............................................................................................................................................ 212
Oil ...................................................................................................................................................... 212
Cylinder Rams .................................................................................................................................. 212
Electrical System
General ............................................................................................................................................. 214
Battery ............................................................................................................................................... 214
Battery Isolator ................................................................................................................................. 215
Fuses ................................................................................................................................................ 216
Relays ............................................................................................................................................... 217
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Table of Contents
vi 9811/9500-4 vi
Window Washer ................................................................................................................................ 218
Miscellaneous
Fire Extinguisher ............................................................................................................................... 220
Technical Data
Static Dimensions
General .............................................................................................................................................. 221
Dimensions ........................................................................................................................................ 221
Weights ............................................................................................................................................. 225
Performance Dimensions
General .............................................................................................................................................. 228
Driving Performance ......................................................................................................................... 230
Noise Emissions
General .............................................................................................................................................. 232
Noise Data ........................................................................................................................................ 232
Vibration Emissions
General .............................................................................................................................................. 234
Vibration Data ................................................................................................................................... 235
Fluids, Lubricants and Capacities
General .............................................................................................................................................. 237
Fuel ................................................................................................................................................... 238
Coolant .............................................................................................................................................. 244
Torque Values
General .............................................................................................................................................. 246
Electrical System
General .............................................................................................................................................. 247
Fuses ................................................................................................................................................. 247
Relays ............................................................................................................................................... 248
Hydraulic System
Auxiliary Circuits ............................................................................................................................... 251
Wheels and Tyres
Tyre Sizes and Pressures ................................................................................................................ 252
Tracks
General .............................................................................................................................................. 253
Declaration of Conformity
General .............................................................................................................................................. 254
Data ................................................................................................................................................... 254
Warranty Information
Service Record Sheet ....................................................................................................................... 256
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Table of Contents
vii 9811/9500-4 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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Notes:
viii 9811/9500-4 viii

Introduction
About this Manual
1 9811/9500-4 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:
135 01755000 01764999
150T 01755000 01764999
155 01755000 01764999
175 01755000 01764999
190 01755000 01764999
190T 01755000 01764999
205 02201002 02206002
205T 01755000 01764999
Using the Manual
This operator's manual is arranged to give you a good understanding of the product and its safe operation. It
also contains maintenance and technical data.
Read this manual from the front to the back before you use the product 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 product.
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 product
without notice is reserved. No responsibility will be accepted for discrepancies which may occur between
specifications of the product 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

Introduction
About this Manual
2 9811/9500-4 2
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:
Introduction > About this Manual > Cross References (Page 2).
Location of Manual
The manual is located in the case behind the seat or below the seat. The manual should always be returned
to its case after use.
Figure 2.
C
CManual location
Figure 3.
C
CManual location

Introduction
Safety
3 9811/9500-4 3
Safety
Safety - Yours and Others
All machinery can be hazardous. When a product is correctly operated and maintained, it is a safe product 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 product 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 product
you must be thinking of what hazards there might be and how to avoid them.
Do not work with the product 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 product 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 product, 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 product damage.
The safety alert system (shown) also helps to identify important safety messages in this manual and on the
product. When you see this symbol, be alert, your safety is involved, carefully read the message that follows,
and inform other operators.
Figure 4. The safety alert system

Introduction
Safety
4 9811/9500-4 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 complies 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 9811/9500-4 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 9811/9500-4 6

About the Product
Introduction
7 9811/9500-4 7
About the Product
Introduction
General
Before you start using the product, you must know how the product 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
JCB Manufacturing Inc, 2000 Bamford BLVD, Pooler, Georgia, USA, 31322.
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 9811/9500-4 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 -20°C (-4°F) to 46°C (115°F).
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 9811/9500-4 9
Main Component Locations
The illustration shows a typical machine model. Your machine may look different from the one shown.
Figure 5.
4
3
6
8
7
1
2
5
9
1ROPS/FOPS cab 2Fuel tank filler point
3Lift arm/boom 4Front working lights
5Quickhitch 6Rubber tracks
7Engine top cover 8Wheels/tyres
9Exhaust