JCB 135, 155, 175, 190, 205 Operator Manual 9831-2350

Description

• Model List:
  • 135, 155, 175, 190, 205

• 1. Acronyms Glossary ………………………………………………………………………………………………………………………. vii
• 2. Introduction
• 3. About this Manual
• 4. Model and Serial Number ……………………………………………………………………………………………………… 1
• 5. Using the Manual …………………………………………………………………………………………………………………. 1
• 6. Left-Hand Side, Right-Hand Side …………………………………………………………………………………………… 1
• 7. Cross References ………………………………………………………………………………………………………………… 1
• 8. Location of Manual ………………………………………………………………………………………………………………. 2
• 9. Safety
• 10. Safety – Yours and Others …………………………………………………………………………………………………….. 3
• 11. Safety Warnings …………………………………………………………………………………………………………………… 3
• 12. General Safety …………………………………………………………………………………………………………………….. 4
• 13. Clothing and Personal Protective Equipment (PPE) …………………………………………………………………. 5
• 14. About the Product
• 15. Introduction
• 16. General ……………………………………………………………………………………………………………………………….. 7
• 17. Name and Address of the Manufacturer …………………………………………………………………………………. 7
• 18. Product Compliance ……………………………………………………………………………………………………………… 7
• 19. Description
• 20. General ……………………………………………………………………………………………………………………………….. 8
• 21. Intended Use ……………………………………………………………………………………………………………………….. 8
• 22. Log Moving-Object Handling ………………………………………………………………………………………………….. 8
• 23. Optional Equipment and Attachments …………………………………………………………………………………….. 8
• 24. Danger Zone ……………………………………………………………………………………………………………………….. 8
• 25. Main Component Locations …………………………………………………………………………………………………… 9
• 26. Product and Component Identification
• 27. Machine …………………………………………………………………………………………………………………………….. 10
• 28. Engine ………………………………………………………………………………………………………………………………. 10
• 29. Operator Protective Structure ………………………………………………………………………………………………. 11
• 30. Safety Labels
• 31. General ……………………………………………………………………………………………………………………………… 13
• 32. Safety Label Identification ……………………………………………………………………………………………………. 13
• 33. Operator Station
• 34. Component Locations …………………………………………………………………………………………………………. 16
• 35. Console Switches
• 36. Window Wipers ………………………………………………………………………………………………………………….. 17
• 37. Interior Switches
• 38. Ignition Switch ……………………………………………………………………………………………………………………. 18
• 39. Cab Interior Light ……………………………………………………………………………………………………………….. 19
• 40. Operation
• 41. Introduction
• 42. General ……………………………………………………………………………………………………………………………… 21
• 43. Operating Safety
• 44. General ……………………………………………………………………………………………………………………………… 22
• 45. Worksite Safety ………………………………………………………………………………………………………………….. 24
• 46. Risk Assessment ……………………………………………………………………………………………………………….. 25
• 47. Walk-Around Inspection
• 48. General ……………………………………………………………………………………………………………………………… 27
• 49. Entering and Leaving the Operator Station
• 50. General ……………………………………………………………………………………………………………………………… 28
• 51. Emergency Exit ………………………………………………………………………………………………………………….. 28
• 52. Doors
• 53. Operator Door ……………………………………………………………………………………………………………………. 31
• 54. Windows
• 55. Front Window …………………………………………………………………………………………………………………….. 33
• 56. Side Window ……………………………………………………………………………………………………………………… 33
• 57. Before Starting the Engine
• 58. General ……………………………………………………………………………………………………………………………… 35
• 59. Operator Seat
• 60. General ……………………………………………………………………………………………………………………………… 36
• 61. Basic Seat …………………………………………………………………………………………………………………………. 36
• 62. Suspension Seat ………………………………………………………………………………………………………………… 37
• 63. Seat Belt
• 64. General ……………………………………………………………………………………………………………………………… 39
• 65. Inertia Reel Seat Belt …………………………………………………………………………………………………………. 39
• 66. Static Seat Belt ………………………………………………………………………………………………………………….. 40
• 67. Mirrors
• 68. General ……………………………………………………………………………………………………………………………… 42
• 69. Starting the Engine
• 70. General ……………………………………………………………………………………………………………………………… 44
• 71. Stopping and Parking
• 72. General ……………………………………………………………………………………………………………………………… 47
• 73. Preparing for Travel
• 74. General ……………………………………………………………………………………………………………………………… 48
• 75. Preparing for Road Travel …………………………………………………………………………………………………… 48
• 76. Preparing for Worksite Travel ………………………………………………………………………………………………. 49
• 77. Smooth Ride System (SRS) ………………………………………………………………………………………………… 50
• 78. Beacon ……………………………………………………………………………………………………………………………… 50
• 79. Safety Equipment
• 80. General ……………………………………………………………………………………………………………………………… 52
• 81. Control Lock ………………………………………………………………………………………………………………………. 52
• 82. Transportation Lock ……………………………………………………………………………………………………………. 53
• 83. Drive Controls
• 84. General ……………………………………………………………………………………………………………………………… 54
• 85. Instruments
• 86. General ……………………………………………………………………………………………………………………………… 62
• 87. Instrument Panel ………………………………………………………………………………………………………………… 67
• 88. Getting the Machine Moving
• 89. General ……………………………………………………………………………………………………………………………… 82
• 90. Operating Levers-Pedals
• 91. General ……………………………………………………………………………………………………………………………… 83
• 92. Control Layouts ………………………………………………………………………………………………………………….. 83
• 93. Lift Arm Controls ………………………………………………………………………………………………………………… 83
• 94. Auxiliary Circuit Controls ……………………………………………………………………………………………………… 86
• 95. Working with the Lift Arm
• 96. General ……………………………………………………………………………………………………………………………… 89
• 97. Filling the Shovel ……………………………………………………………………………………………………………….. 89
• 98. Loading a Truck …………………………………………………………………………………………………………………. 90
• 99. Slopes
• 100. General ……………………………………………………………………………………………………………………………… 91
• 101. Driving on Slopes ………………………………………………………………………………………………………………. 91
• 102. Working on Slopes …………………………………………………………………………………………………………….. 91
• 103. Heating, Ventilating and Air-Conditioning (HVAC)
• 104. General ……………………………………………………………………………………………………………………………… 92
• 105. Air-Conditioning Controls …………………………………………………………………………………………………….. 92
• 106. Power Sockets
• 107. Auxiliary Power Socket ……………………………………………………………………………………………………….. 93
• 108. Radio
• 109. General ……………………………………………………………………………………………………………………………… 94
• 110. Battery Isolator
• 111. General ……………………………………………………………………………………………………………………………… 97
• 112. Fire Extinguisher
• 113. General ……………………………………………………………………………………………………………………………… 98
• 114. Moving a Disabled Machine
• 115. General ……………………………………………………………………………………………………………………………… 99
• 116. Jump-Starting the Engine ……………………………………………………………………………………………………. 99
• 117. Retrieval ………………………………………………………………………………………………………………………….. 100
• 118. Loader Arm (Emergency Operation) …………………………………………………………………………………… 100
• 119. Lifting the Machine
• 120. General ……………………………………………………………………………………………………………………………. 102
• 121. Transporting the Machine
• 122. General ……………………………………………………………………………………………………………………………. 105
• 123. Loading the Machine onto the Transporting Vehicle-Trailer ……………………………………………………. 105
• 124. Operating Environment
• 125. General ……………………………………………………………………………………………………………………………. 108
• 126. Operating in Low Temperatures …………………………………………………………………………………………. 108
• 127. Operating in High Temperatures …………………………………………………………………………………………. 108
• 128. Refuelling
• 129. General ……………………………………………………………………………………………………………………………. 110
• 130. Low Fuel Levels ……………………………………………………………………………………………………………….. 110
• 131. Filling the Tank …………………………………………………………………………………………………………………. 110
• 132. Attachments
• 133. Working with Attachments
• 134. Introduction ………………………………………………………………………………………………………………………. 111
• 135. Attachments for your Machine ……………………………………………………………………………………………. 111
• 136. Connecting-Disconnecting Hydraulic Hoses …………………………………………………………………………. 121
• 137. Impact Protection ……………………………………………………………………………………………………………… 125
• 138. Attachment Frame
• 139. General ……………………………………………………………………………………………………………………………. 126
• 140. Quickhitch
• 141. Quickhitch Attachment Bracket …………………………………………………………………………………………… 127
• 142. Shovels
• 143. General ……………………………………………………………………………………………………………………………. 133
• 144. Standard Shovel ………………………………………………………………………………………………………………. 133
• 145. Grapple Shovel ………………………………………………………………………………………………………………… 134
• 146. 6-in-1 Shovel ……………………………………………………………………………………………………………………. 135
• 147. Forks
• 148. General ……………………………………………………………………………………………………………………………. 138
• 149. Pallet Forks ……………………………………………………………………………………………………………………… 138
• 150. Manure Forks …………………………………………………………………………………………………………………… 139
• 151. Snow Blade
• 152. General ……………………………………………………………………………………………………………………………. 141
• 153. Preservation and Storage
• 154. Cleaning
• 155. General ……………………………………………………………………………………………………………………………. 145
• 156. Preparation ………………………………………………………………………………………………………………………. 145
• 157. Checking For Damage
• 158. General ……………………………………………………………………………………………………………………………. 147
• 159. Storage
• 160. General ……………………………………………………………………………………………………………………………. 148
• 161. Put into Storage ……………………………………………………………………………………………………………….. 148
• 162. During Storage …………………………………………………………………………………………………………………. 148
• 163. Take out of Storage ………………………………………………………………………………………………………….. 149
• 164. Security
• 165. General ……………………………………………………………………………………………………………………………. 150
• 166. JCB Plantguard ………………………………………………………………………………………………………………… 150
• 167. Construction Equipment Security and Registration Scheme (CESAR) …………………………………….. 150
• 168. Maintenance
• 169. Introduction
• 170. General ……………………………………………………………………………………………………………………………. 151
• 171. Owner-Operator Support ……………………………………………………………………………………………………. 151
• 172. Service-Maintenance Agreements ………………………………………………………………………………………. 151
• 173. Obtaining Spare Parts ………………………………………………………………………………………………………. 152
• 174. Maintenance Safety
• 175. General ……………………………………………………………………………………………………………………………. 153
• 176. Fluids and Lubricants ……………………………………………………………………………………………………….. 154
• 177. Maintenance Schedules
• 178. General ……………………………………………………………………………………………………………………………. 158
• 179. How to Use the Maintenance Schedules …………………………………………………………………………….. 158
• 180. Maintenance Intervals ……………………………………………………………………………………………………….. 158
• 181. Pre-start Cold Checks, Service Points and Fluid Levels ………………………………………………………… 158
• 182. Functional Tests and Final Inspection …………………………………………………………………………………. 161
• 183. Maintenance Positions
• 184. General ……………………………………………………………………………………………………………………………. 162
• 185. Maintenance Position (Lift Arm Lowered) ……………………………………………………………………………. 162
• 186. Maintenance Position (Lift Arm Raised) ………………………………………………………………………………. 163
• 187. Maintenance Position (Lift Arm Raised and Cab Raised) ………………………………………………………. 164
• 188. Service Points
• 189. General ……………………………………………………………………………………………………………………………. 166
• 190. Access Apertures
• 191. General ……………………………………………………………………………………………………………………………. 169
• 192. Engine Compartment Cover ………………………………………………………………………………………………. 169
• 193. Rear Cover ………………………………………………………………………………………………………………………. 170
• 194. Cab-Canopy …………………………………………………………………………………………………………………….. 171
• 195. Tools
• 196. General ……………………………………………………………………………………………………………………………. 176
• 197. Toolbox ……………………………………………………………………………………………………………………………. 176
• 198. Lubrication
• 199. General ……………………………………………………………………………………………………………………………. 177
• 200. Preparation ………………………………………………………………………………………………………………………. 177
• 201. Attachments
• 202. General …………………………………………………………………………………………………………………………… 178
• 203. Body and Framework
• 204. General …………………………………………………………………………………………………………………………… 179
• 205. Pivot Pins ………………………………………………………………………………………………………………………… 180
• 206. Operator Station
• 207. General …………………………………………………………………………………………………………………………… 182
• 208. Operator Protective Structure …………………………………………………………………………………………….. 182
• 209. Seat ………………………………………………………………………………………………………………………………… 183
• 210. Seat Belt …………………………………………………………………………………………………………………………. 183
• 211. Controls …………………………………………………………………………………………………………………………… 183
• 212. Engine
• 213. General …………………………………………………………………………………………………………………………… 184
• 214. Oil …………………………………………………………………………………………………………………………………… 184
• 215. Drive Belt ………………………………………………………………………………………………………………………… 188
• 216. Exhaust …………………………………………………………………………………………………………………………… 190
• 217. Air Filter
• 218. General …………………………………………………………………………………………………………………………… 191
• 219. Outer Element …………………………………………………………………………………………………………………. 191
• 220. Fuel System
• 221. General …………………………………………………………………………………………………………………………… 193
• 222. Fuel Filter ………………………………………………………………………………………………………………………… 193
• 223. Water Separator ………………………………………………………………………………………………………………. 194
• 224. Cooling System
• 225. General …………………………………………………………………………………………………………………………… 196
• 226. Coolant ……………………………………………………………………………………………………………………………. 196
• 227. Cooling Pack …………………………………………………………………………………………………………………… 197
• 228. Brakes
• 229. Park Brake ………………………………………………………………………………………………………………………. 199
• 230. Wheels
• 231. General …………………………………………………………………………………………………………………………… 200
• 232. Tyres
• 233. General …………………………………………………………………………………………………………………………… 202
• 234. Drive Gearbox
• 235. Oil …………………………………………………………………………………………………………………………………… 204
• 236. Hydraulic System
• 237. General …………………………………………………………………………………………………………………………… 205
• 238. Services ………………………………………………………………………………………………………………………….. 206
• 239. Oil …………………………………………………………………………………………………………………………………… 206
• 240. Cylinder Rams …………………………………………………………………………………………………………………. 206
• 241. Electrical System
• 242. General …………………………………………………………………………………………………………………………… 208
• 243. Battery …………………………………………………………………………………………………………………………….. 208
• 244. Battery Isolator ………………………………………………………………………………………………………………… 209
• 245. Fuses ……………………………………………………………………………………………………………………………… 210
• 246. Relays …………………………………………………………………………………………………………………………….. 211
• 247. Window Washer ……………………………………………………………………………………………………………….. 212
• 248. Miscellaneous
• 249. Fire Extinguisher ………………………………………………………………………………………………………………. 214
• 250. Technical Data
• 251. Static Dimensions
• 252. General ……………………………………………………………………………………………………………………………. 215
• 253. Dimensions ………………………………………………………………………………………………………………………. 215
• 254. Weights …………………………………………………………………………………………………………………………… 217
• 255. Performance Dimensions
• 256. General ……………………………………………………………………………………………………………………………. 219
• 257. Driving Performance …………………………………………………………………………………………………………. 220
• 258. Noise Emissions
• 259. General ……………………………………………………………………………………………………………………………. 221
• 260. Noise Data ………………………………………………………………………………………………………………………. 221
• 261. Vibration Emissions
• 262. General ……………………………………………………………………………………………………………………………. 222
• 263. Vibration Data ………………………………………………………………………………………………………………….. 222
• 264. Fluids, Lubricants and Capacities
• 265. General ……………………………………………………………………………………………………………………………. 224
• 266. Fuel ………………………………………………………………………..