jcb TM180 User manual

OPERATOR'S MANUAL
LOADER
TM180, TM220
EN - 9821/9300 ISSUE 4 - 11/2017
THIS MANUAL SHOULD ALWAYS STAY WITH THE MACHINE

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OPERATOR'S
MANUAL
LOADER
TM180, TM220
EN - 9821/9300 - ISSUE 4 - 11/2017
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
Copyright 2017 © 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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9821/9300-4
Notes:
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Table of Contents
i 9821/9300-4 i
Contents Page No.
Acronyms Glossary ....................................................................................................................................... viii
Introduction
About this Manual
Model and Serial Number ..................................................................................................................... 1
Using the Manual .................................................................................................................................. 1
Left-Hand Side, Right-Hand Side ......................................................................................................... 1
Cab/Canopy .......................................................................................................................................... 1
Cross References ................................................................................................................................. 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 .................................................................................................................. 8
Product and Component Identification
Machine ............................................................................................................................................... 10
Engine ................................................................................................................................................. 10
Axle ..................................................................................................................................................... 11
Gearbox ............................................................................................................................................... 11
Operator Protective Structure ............................................................................................................. 12
Safety Labels
General ................................................................................................................................................ 14
Safety Label Identification ................................................................................................................... 15
Operator Station
Component Locations ......................................................................................................................... 16
Interior Switches
Ignition Switch ..................................................................................................................................... 18
Multi-Purpose Switch .......................................................................................................................... 18
Cab Interior Light ................................................................................................................................ 19
Console Switches
General ................................................................................................................................................ 21
Road Lights ......................................................................................................................................... 21
Rear Fog Lights .................................................................................................................................. 21
Hazard Warning Lights ....................................................................................................................... 21
Front Work Lights ............................................................................................................................... 22
Rear Work Lights ................................................................................................................................ 22
Boom Work Light ................................................................................................................................ 22
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Table of Contents
ii 9821/9300-4 ii
Smooth Ride System (SRS) ............................................................................................................... 22
Beacon ................................................................................................................................................ 22
Lift Arm Quickhitch ............................................................................................................................. 22
Controls Isolation ................................................................................................................................ 23
Rear Window Wiper ............................................................................................................................ 23
Roof Window Wiper ............................................................................................................................ 23
Constant Flow ..................................................................................................................................... 23
Two Speed Range .............................................................................................................................. 23
Gear Change ...................................................................................................................................... 24
Operation
Introduction
General ................................................................................................................................................ 25
Operating Safety
General ................................................................................................................................................ 26
Worksite Safety ................................................................................................................................... 28
Risk Assessment ................................................................................................................................ 29
Walk-Around Inspection
General ................................................................................................................................................ 31
Entering and Leaving the Operator Station
General ................................................................................................................................................ 32
Emergency Exit ................................................................................................................................... 32
Doors
Operator Door ..................................................................................................................................... 34
Windows
Side Window ....................................................................................................................................... 35
Battery Isolator
General ................................................................................................................................................ 36
Before Starting the Engine
General ................................................................................................................................................ 37
Operator Seat
General ................................................................................................................................................ 39
Suspension Seat ................................................................................................................................. 39
Seat Belt
General ................................................................................................................................................ 41
Inertia Reel Seat Belt ......................................................................................................................... 41
Mirrors
General ................................................................................................................................................ 43
Starting the Engine
General ................................................................................................................................................ 45
Immobiliser .......................................................................................................................................... 46
Stopping and Parking
General ................................................................................................................................................ 50
Preparing for Travel
General ................................................................................................................................................ 52
Preparing for Road Travel .................................................................................................................. 52
Preparing for Worksite Travel ............................................................................................................. 54
Smooth Ride System (SRS) ............................................................................................................... 55
Beacon ................................................................................................................................................ 55
Safety Equipment
Articulation Lock .................................................................................................................................. 57
Control Lock ........................................................................................................................................ 58
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Table of Contents
iii 9821/9300-4 iii
Drive Controls
Steering Wheel ................................................................................................................................... 60
Steering Column ................................................................................................................................. 60
Accelerator Pedal ................................................................................................................................ 60
Service Brake Pedal ........................................................................................................................... 60
Park Brake .......................................................................................................................................... 60
Transmission Drive Lever ................................................................................................................... 61
Instruments
Instrument Panel ................................................................................................................................. 63
Slopes
General ................................................................................................................................................ 71
Driving on Slopes ............................................................................................................................... 71
Working on Slopes ............................................................................................................................. 72
Driving the Machine
General ................................................................................................................................................ 73
Limited Slip Differential (LSD) ............................................................................................................ 75
Operating Levers/Pedals
General ................................................................................................................................................ 76
Control Layouts ................................................................................................................................... 76
Lift Arm Controls ................................................................................................................................. 76
Auxiliary Circuit Controls ..................................................................................................................... 77
Lifting and Loading
General ................................................................................................................................................ 80
Load Charts ........................................................................................................................................ 80
Longitudinal Load Moment Indicator (LLMI) ....................................................................................... 83
Load Motion Control System .............................................................................................................. 87
Working with the Lift Arm
General ................................................................................................................................................ 95
Fork Ratings ........................................................................................................................................ 98
Working with Pallets ........................................................................................................................... 99
Working with Bales ........................................................................................................................... 101
Working with Irregular Loads ............................................................................................................ 102
Stacking Loads ................................................................................................................................. 103
Filling the Shovel .............................................................................................................................. 104
Loading a Truck ................................................................................................................................ 105
Heating, Ventilating and Air-Conditioning (HVAC)
General .............................................................................................................................................. 106
Air-Conditioning Controls .................................................................................................................. 106
Cab Heater Controls ......................................................................................................................... 106
Power Sockets
Auxiliary Power Socket ..................................................................................................................... 108
Fire Extinguisher
General .............................................................................................................................................. 109
Moving a Disabled Machine
General .............................................................................................................................................. 110
Jump-Starting the Engine ................................................................................................................. 110
Retrieval ............................................................................................................................................ 111
Recovery Hitch .................................................................................................................................. 112
Lifting the Machine
General .............................................................................................................................................. 114
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Table of Contents
iv 9821/9300-4 iv
Transporting the Machine
General .............................................................................................................................................. 117
Operating Environment
General .............................................................................................................................................. 121
Operating in Low Temperatures ....................................................................................................... 121
Operating in High Temperatures ....................................................................................................... 121
Refuelling
General .............................................................................................................................................. 123
Low Fuel Levels ................................................................................................................................ 123
Filling the Tank .................................................................................................................................. 123
Attachments
Working with Attachments
Introduction ........................................................................................................................................ 125
Attachments for your Machine .......................................................................................................... 125
Connecting/Disconnecting Hydraulic Hoses ..................................................................................... 126
Quickhitch
General .............................................................................................................................................. 130
Lift Arm Quickhitch Carriage ............................................................................................................ 130
Tow Hitches
General .............................................................................................................................................. 137
Mechanical Tow Hitch ....................................................................................................................... 137
Work Platforms
General .............................................................................................................................................. 139
Preservation and Storage
Cleaning
General .............................................................................................................................................. 141
Preparation ........................................................................................................................................ 142
Checking For Damage
General .............................................................................................................................................. 143
Storage
General .............................................................................................................................................. 144
Put into Storage ................................................................................................................................ 144
During Storage .................................................................................................................................. 144
Take out of Storage .......................................................................................................................... 145
Security
General .............................................................................................................................................. 146
JCB Plantguard ................................................................................................................................. 146
Construction Equipment Security and Registration Scheme (CESAR) ............................................ 146
LiveLink ............................................................................................................................................. 146
Maintenance
Introduction
General .............................................................................................................................................. 147
Owner/Operator Support ................................................................................................................... 147
Service/Maintenance Agreements .................................................................................................... 148
Initial Service and Inspection ............................................................................................................ 148
Obtaining Spare Parts ...................................................................................................................... 148
Maintenance Safety
General .............................................................................................................................................. 149
Fluids and Lubricants ....................................................................................................................... 150
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Table of Contents
v 9821/9300-4 v
Maintenance Schedules
General .............................................................................................................................................. 154
How to Use the Maintenance Schedules ......................................................................................... 154
Maintenance Intervals ....................................................................................................................... 154
Pre-start Cold Checks, Service Points and Fluid Levels .................................................................. 155
Functional Tests and Final Inspection .............................................................................................. 157
Maintenance Positions
General .............................................................................................................................................. 159
Maintenance Position (Lift Arm Lowered) ........................................................................................ 159
Maintenance Position (Lift Arm Raised) ........................................................................................... 160
Service Points
General .............................................................................................................................................. 161
Access Apertures
General .............................................................................................................................................. 162
Engine Compartment Cover ............................................................................................................. 162
Cab Heater Door .............................................................................................................................. 163
Tools
Toolbox .............................................................................................................................................. 164
Lubrication
General .............................................................................................................................................. 165
Preparation ........................................................................................................................................ 165
Driveshafts ........................................................................................................................................ 165
Attachments
General ............................................................................................................................................. 166
Body and Framework
General ............................................................................................................................................. 167
Pivot Pins .......................................................................................................................................... 167
Articulated Joint ................................................................................................................................ 170
Lift Arm
General ............................................................................................................................................. 171
Wear Pads ........................................................................................................................................ 173
Operator Station
General ............................................................................................................................................. 175
Operator Protective Structure ........................................................................................................... 175
Seat ................................................................................................................................................... 175
Seat Belt ........................................................................................................................................... 175
Controls ............................................................................................................................................. 176
Heating, Ventilating and Air-Conditioning (HVAC)
Recirculation Filter ............................................................................................................................ 177
Fresh Air Filter .................................................................................................................................. 177
Engine
General ............................................................................................................................................. 180
Oil ...................................................................................................................................................... 180
Drive Belt .......................................................................................................................................... 182
Emissions Control System ............................................................................................................... 185
Air Filter
General ............................................................................................................................................. 189
Outer Element .................................................................................................................................. 189
Dust Valve ........................................................................................................................................ 190
Fuel System
General ............................................................................................................................................. 191
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Table of Contents
vi 9821/9300-4 vi
Pre-Filter Element ............................................................................................................................. 191
Fuel Filter .......................................................................................................................................... 192
Water Separator ............................................................................................................................... 193
Cooling System
General ............................................................................................................................................. 194
Coolant .............................................................................................................................................. 194
Cooling Pack .................................................................................................................................... 195
Brakes
General .............................................................................................................................................. 196
Park Brake ........................................................................................................................................ 197
Service Brake ................................................................................................................................... 198
Steering System
General ............................................................................................................................................. 199
Driveshafts
General ............................................................................................................................................. 200
Wheels
General ............................................................................................................................................. 201
Tyres
General ............................................................................................................................................. 202
Hydraulic System
General ............................................................................................................................................. 204
Services ............................................................................................................................................ 205
Oil ...................................................................................................................................................... 205
Hose Burst Check Valves ................................................................................................................. 206
Electrical System
General ............................................................................................................................................. 208
Battery ............................................................................................................................................... 208
Battery Isolator ................................................................................................................................. 210
Fuses ................................................................................................................................................ 210
Relays ............................................................................................................................................... 210
Window Washer ................................................................................................................................ 211
Miscellaneous
Fire Extinguisher ............................................................................................................................... 212
Technical Data
Static Dimensions
Dimensions ........................................................................................................................................ 213
Weights ............................................................................................................................................. 216
Performance Dimensions
Lift Arm Dimensions and Performance ............................................................................................. 218
Driving Performance ......................................................................................................................... 224
Towing Weights ................................................................................................................................. 224
Noise Emissions
General .............................................................................................................................................. 226
Noise Data ........................................................................................................................................ 226
Vibration Emissions
General .............................................................................................................................................. 227
Vibration Data ................................................................................................................................... 228
Fluids, Lubricants and Capacities
General .............................................................................................................................................. 230
Fuel ................................................................................................................................................... 230
Coolant .............................................................................................................................................. 232
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Table of Contents
vii 9821/9300-4 vii
Torque Values
General .............................................................................................................................................. 233
Electrical System
General .............................................................................................................................................. 234
Fuses ................................................................................................................................................. 234
Relays ............................................................................................................................................... 236
Engine
General .............................................................................................................................................. 237
Wheels and Tyres
General .............................................................................................................................................. 238
Tyre Sizes and Pressures ................................................................................................................ 238
Declaration of Conformity
General .............................................................................................................................................. 242
Data ................................................................................................................................................... 243
Warranty Information
Service Record Sheet ....................................................................................................................... 245

Table of Contents
viii 9821/9300-4 viii
Acronyms Glossary
ARV Auxiliary Relief Valve
CESAR Construction Equipment Security and Registration
DEF Diesel Exhaust Fluid
DTC Diagnostic Trouble Code
ECU Electronic Control Unit
ESOS Engine Shut-Off Solenoid
ETRTO European Tyre and Rim Technical Organisation
FEAD Front End Accessory Drive
FOPS Falling Object Protective Structure
HVAC Heating Ventilation Air Conditioning
LCD Liquid Crystal Display
LED Light Emitting Diode
LH Left Hand
LLMC Longitudinal Load Moment Control
LLMI Longitudinal Load Moment Indicator
LSD Limited Slip Differential
PIN Product Identification Number
RMS Root Mean Square
ROPS Roll-Over Protective Structure
SCR Selective Catalytic Reduction
SRS Smooth Ride System
SWL Safe Working Load
VIN Vehicle Identification Number

Introduction
About this Manual
1 9821/9300-4 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:
TM180 2096873
2128886
2679851
TM220
2682926
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.
ALeft BRight
Cab/Canopy
This manual frequently makes references to the cab. For example, 'do not operate the machine without an
operator's manual in the cab'. These statements also apply to canopy build machines.

Introduction
About this Manual
2 9821/9300-4 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:
Cross References (Page 2).

Introduction
Safety
3 9821/9300-4 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, you must 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 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 symbol (shown) also helps to identify important safety messages in this manual. When
you see this symbol your safety is involved, carefully read the message that follows.
Figure 2. The safety alert system symbol

Introduction
Safety
4 9821/9300-4 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 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 9821/9300-4 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 9821/9300-4 6

About the Product
Introduction
7 9821/9300-4 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
JCB Earthmovers Limited, Harewood Estate, Leek Road, Cheadle, Stoke On Trent, Staffordshire, United
Kingdom, ST10 2JX
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 9821/9300-4 8
Description
General
A self-propelled wheeled machine with an integral front mounted shovel-supporting structure and linkage.
The machine can load or excavate through the forward motion of the machine and can lift, transport and
discharge material.
Intended Use
The machine is intended to be used in normal conditions for the applications described in this manual.
If the machine is used for other applications or in dangerous environments, for example in a flammable
atmosphere or in areas with dust containing asbestos, special safety regulations must be obeyed and the
machine must be equipped for use in these environments.
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.
Main Component Locations
The illustration(s) show a typical machine model, your machine may look different to the model shown.