Name: JCB Robot 135, Robot 155 Operator Manual 9821-7900
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Description

Model List:
- Robot 135, Robot 155

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