JCB ROBOT 190,190HF,1110,1110HF Operator Handbook Manual

Operator Handbook ROBOT 190, 190HF, 1110, 1110HF From serial number 888000 onwards ! THIS HANDBOOK MUST BE KEPT IN THE MACHINE AT ALL TIMES ! Publication Number 9801/4320 January 2002 Issue 4 Purchased from www.WorkshopManuals.co.uk

Purchased from www.WorkshopManuals.co.uk

SAFETY NOTICES ! WARNING Study This Handbook Before Starting The Machine You must understand and follow the instructions in this handbook. You must observe all relevant laws and regulations. If you are unsure about anything, ask your JCB distributor or employer. Do not guess, you or others could be killed or seriously injured. INT-1-1-1 ! CAUTION Do not fit an attachment to this machine which is not JCB approved. Consult your JCB distributor before fitting any non approved attachment. 8-4-1-6 4320-1 In this handbook and on the machine there are safety notices. Each notice starts with a signal word. The meanings of the signal words are given below. ! DANGER Denotes an extreme hazard exists. If proper precautions are not taken, it is highly probable that the operator (or others) could be killed or seriously injured. INT-1-2-1 ! WARNING Denotes a hazard exists. If proper precautions are not taken, the operator (or others) could be killed or seriously injured. INT-1-2-2 ! CAUTION Denotes a reminder of safety practices. Failure to follow these safety practices could result in injury to the operator (or others) and possible damage to the machine. INT-1-2-3 MACHINE SECURITY Vandalism and theft of unattended machines is an ever increasing problem and JCB is doing everything possible to help combat this. JCB PLANTGUARD is a comprehensive package available to help you safeguard your machine. It includes such devices as vandal proof covers, window etching, immobiliser, concealed serial number, battery isolator, Tracker security system and much more. Remember that the fitting of any one of these security devices will help to minimise not only the damage or loss of your machine but also subsequent lost productivity. It could also result in reduced insurance premiums. Your JCB Distributor or Dealer will be pleased to provide information on any of these sensible precautions. ACT NOW! INT-1-2-4 Purchased from www.WorkshopManuals.co.uk

i i CONTENTS INTRODUCTION Page About this Handbook Machine Models ........................................................ 1 Using this Handbook ................................................. 1 Location of Handbook ............................................... 1 Units of Measurement ............................................... 1 Page Numbering ....................................................... 1 Left Side, Right Side ................................................. 1 Using the Machine .................................................... 1 The JCB Skid Steer Loader Machine Description .................................................. 2 Safety First - Yours and Other People's ................ 3 Safety Check List General Safety .......................................................... 3 Operating Safety ....................................................... 4 Maintenance Safety .................................................. 5 Safety Decals .......................................................... 8 Identifying Your Machine Machine Identification Plate ..................................... 9 Typical Vehicle Identification Number (VIN) ................ 9 Unit Identification ...................................................... 9 JCB Immobiliser Option ........................................ 10 OPERATION Introduction ............................................................ 21 Before Entering the Cab ........................................ 21 Entering/Leaving the Cab ........................................ 22 Cab Door and Vents Opening and Closing the Cab Door ......................... 23 Ventilation of Optional Glazed Cab .......................... 23 Emergency Exits .................................................... 24 Seat and Safety Restraint Seat Adjustment .......................................................... 25 Seat Removal and Replacement ................................ 25 Safety Restraint .......................................................... 25 Controls, Switches and Instruments Cab Layout (servo machines) ................................ 26 Cab Layout (manual machines) ............................. 28 Switches ..................................................................... 30 Warning Indicators ................................................... 31 Seat Belt Fastening the Seat Belt ............................................ 32 Releasing the Seat Belt ............................................ 32 Checking Seat Belt Operation .................................. 32 Page Cab Heater Unit (optional) ..................................... 33 Cab Interior Light (optional) .................................. 34 Loader Controls (servo machines) Loader Arm/Shovel Control Lever (single lever drive control) ........................................ 34 Loader ArmControl Lever (dual lever drive control) .... 34A Shovel Control Lever (dual lever drive control) ........... 34A Auxiliary Attachments Control Pedal (optional) ........... 35 Float Control Switch (optional) ................................... 35 Loader Controls (manual machines) Loader Arm Control - Lever Option ............................ 36 Shovel Control - Lever Option .................................... 36 Loader Arm/Shovel Control - Pedal Option ................ 37 Auxiliary Attachments Control (optional) .................... 37 Before Starting the Engine .................................... 38 Starting the Engine ................................................ 39 Jump-Starting the Engine ..................................... 40 Rotating Beacon (optional) ................................... 41 Travelling Position Travelling on Site ..................................................... 41 Travelling on Public Roads ...................................... 41 Travelling on Public Roads (UK only) ......................... 42 Driving the Machine Drive Control Lever (servo single lever control) ........... 43 Drive Control Levers (servo dual lever drive & manual controls) ................ 44 Getting Moving ......................................................... 45 Stopping and Parking ............................................... 45 Operating Practices .................................................. 46 Using the Attachments and Site Safety ............... 47 Quickhitch Control Engaging the Shovel/Attachments ........................... 49 Disengaging the Shovel/Attachments ...................... 50 Working with the Loader Filling the Shovel ...................................................... 51 Loading a Truck ....................................................... 51 Scraping and Cutting ............................................... 51 Operating in Low Temperatures ........................... 52 Operating in High Temperatures .......................... 52 Moving a Disabled Machine Preparation for Towing/Winching ............................... 53 After Towing/Winching ................................................ 53 4320-2 Purchased from www.WorkshopManuals.co.uk

ii ii CONTENTS OPERATION (cont’d) Page Transporting the Machine Using a Trailer ......................................................... 54 Using a Truck .......................................................... 55 Transportation Safety .............................................. 55 Lifting the Machine Safe Lifting Procedure .............................................. 57 Emergency Load Lower Procedure ....................... 56 Testing the Parking Brake ........................................ 57 MAINTENANCE Service Requirements ........................................... 61 Lubricants - Health and Safety Hygiene ................................................................... 62 Storage .................................................................... 62 Waste Disposal ........................................................ 62 Handling ................................................................... 62 First Aid - Oil ............................................................ 62 Spillage .................................................................... 62 Fires ......................................................................... 62 Service Schedules Every 10 Operating Hours or Daily .......................... 63 Every 50 Operating Hours or Weekly ...................... 63 Every 100 Operating Hours or 2 Weekly ................. 63 Every 250 Operating Hours or Monthly ................... 64 Every 500 Operating Hours or 6 Monthly ................ 64 Every 1000 Operating Hours or Yearly .................... 64 Every 2000 Operating Hours or 2 Yearly ................. 64 Cleaning the Cab Floor and Rear Chassis ............. 65 ROPS/FOPS Cab/Canopy Checking the ROPS/FOPS Cab/Canopy ................. 65 Loader Arm Safety Strut Installing the Safety Strut ......................................... 66 Removing the Safety Strut ....................................... 66 Engine Compartment Access Top Cover ................................................................. 67 Rear Panel ................................................................. 67 Radiator and Oil Cooler ............................................... 67 Cleaning the Radiator and Oil Cooler ....................... 67 Seat Belt Checking Seat Belt Condition and Security .............. 68 Greasing (10 Hours) Quickhitch Pivot Points ............................................. 68 Page Greasing (50 Hours) Loader Arm Pivot Point ............................................ 69 Lift Ram Pivots ......................................................... 69 Greasing and Oiling (100 Hours) Safety Restraint mechanism ...................................... 70 Control Linkage (manual machines) ........................... 70 Throttle Pedal (if fitted) ............................................. 70 Engine Air Filter Changing the Elements ........................................... 71 Engine Oil and Filter Checking the Oil Level ............................................. 72 Changing the Oil and Filter ...................................... 72 Engine Cooling System Coolant Mixtures ...................................................... 74 Checking the Coolant Level ..................................... 74 Changing the Coolant .............................................. 75 Cleaning the Coolant Radiator and Oil Cooler ......... 75 Engine Alternator Belt Checking the Alternator Belt Tension ........................ 76 Adjusting the Alternator Belt ..................................... 76 Drive Chain Lubrication Checking the Oil Level ............................................. 77 Changing the Oil ...................................................... 77 Fuel System Types of Fuel ........................................................... 78 Fuel Standards ........................................................ 78 Low Temperature Fuels ........................................... 78 Petrol ....................................................................... 78 Advice ...................................................................... 78 Fatty Acid Methyl Ester Fuels .................................... 78 Filling the Tank ........................................................ 78 Draining the Fuel Sediment Bowl .............................. 79 Changing the Fuel Filter Element .............................. 80 Bleeding the Fuel System .......................................... 80 Hydraulic System Checking the Oil Level ............................................ 81 Changing the Filter .................................................. 81 Changing the High-flow Filter .................................... 82 Battery Safety ...................................................................... 83 Checking the Electrolyte Level ................................ 84 Warning Symbols ..................................................... 84 Electrical System Fuses .......................................................................... 85 Primary Fuses ............................................................ 86 Relays ........................................................................ 86 Light Bulbs ................................................................. 86 4320-4 Purchased from www.WorkshopManuals.co.uk

iii iii CONTENTS MAINTENANCE (cont’d) Page Windscreen Washer ............................................... 87 Tracks Track Adjustment ....................................................... 87 Tyres and Wheels Inflating the Tyres ..................................................... 88 Renewing Segments of Optional Non-Inflatable Tyres 88 Checking the Wheel Nut Torques ............................ 88 Fluids, Capacities and Lubricants ........................ 89 Obtaining Replacement Parts ................................ 89 Storage Storing the Machine ................................................... 90 OPTIONAL ATTACHMENTS Page Introduction ........................................................... 101 Quick Release Couplings ..................................... 102 Connecting/Disconnecting Hydraulic Hoses ..... 103 Attachments Controls ............................................ 104 Shovels .................................................................... 105 6-in-1 Shovel ............................................................ 105 Pallet Forks .............................................................. 108 Manure/Silage Fork with Top Grab ........................ 109 Attachment Frame ................................................... 110 Wheel Mounted Tracks ........................................... 111 SPECIFICATION General Specification ............................................. 131 Tyre Specification ................................................... 131 Static Dimensions - Wheeled Machines ................ 132 Static Dimensions - Tracked Machines ................ 134 Noise and Vibration Data Machines up to serial no. 888055 ............................. 136 Machines from serial no. 888056 .............................. 137 4320-3 Purchased from www.WorkshopManuals.co.uk

1 1 INTRODUCTION ABOUT THIS HANDBOOK Machine Models This handbook provides information for the following models in the JCB Skid Steer Loader range: Robot 190, 190HF, 1110 and 1110HF from serial no. 888000 The handbook covers both servo and manual controls although some illustrations may show only one type. Information also covers both wheeled and tracked machines unless otherwise stated. Using this Handbook The illustrations in this handbook are for guidance only. Where the machines differ, the text and/or the illustration will specify. This handbook is arranged to give you a good understanding of the machine and its safe operation. It also contains maintenance information and specification data. Read this handbook from front to back before using the machine for the first time. Particular attention must be given to all the safety aspects of operating and maintaining the machine. General warnings in this chapter are repeated throughout the book, as well as specific warnings. Read all the safety statements regularly, so you do not forget them. Remember that the best operators are the safest operators. Finally, treat this handbook as part of the machine. Keep it clean and in good condition. Do not operate the machine without a handbook in the cab. If there is anything you are not sure about, ask your JCB distributor or employer. Do not guess, you or others could be killed or seriously injured. 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 publication. INT-1-2-5/1 Location of Handbook The handbook is located in the case provided which is behind the seat, as shown at A. The handbook should always be returned to its correct stowage. Units of Measurement In this handbook, the S.I. system of units is used. For example, liquid capacities are given in litres. The Imperial units follow in parenthesis () eg 28 litres (6 UK gal). Page Numbering The page numbering system in this handbook is not continuous. There is a gap between sections. This allows for the insertion of new pages in later issues of the handbook. Left Side, Right Side In this handbook, 'left' B and 'right' C mean your left and right when you are seated correctly in the machine. Using the Machine To use the Skid Steer Loader efficiently and safely you must know the machine and have the skill to use it. This handbook instructs you on the machine, its controls and its safe operation. It is not a training manual on the art of loading. If you are a new operator, get yourself trained in the skills of using a Skid Steer Loader before trying to work with it. If you do not, you will not do your job well, and you will be a danger to yourself and others. 4320-1 378210 C B 332720 A Purchased from www.WorkshopManuals.co.uk

2 2 INTRODUCTION THE JCB SKIDSTEER LOADER 4320-1 Machine Description The Robot 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. When used normally with a shovel fitted, the machine loads or excavates through forward motion of the machine and lifts, transports and discharges material. ROPS/FOPS CAB LOADER ARM QUICKHITCH FRONT WORKING LIGHTS 378230 378220 ENGINE COMPARTMENT REAR COVER HYDRAULIC SIGHT GLASS HYDRAULIC TANK ENGINE TOP COVER REAR WORKING LIGHT BATTERY FUEL TANK 378240 RUBBER TRACKS Purchased from www.WorkshopManuals.co.uk

3 3 INTRODUCTION SAFETY FIRST - YOURS AND OTHER PEOPLE'S All construction and agricultural equipment can be hazardous. When a Skid Steer Loader is correctly operated and properly maintained, it is a safe machine to work with. But when it is carelessly operated or poorly maintained it can become a danger to you (the operator) and others. In this handbook and on the machine you will find warning messages. Read and understand them. They tell you of potential hazards and how to avoid them. If you do not fully understand the warning messages, ask your employer or JCB distributor to explain them. But 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 what hazards there might be and how to avoid them. General Safety ! WARNING Handbook You and others can be injured if you operate or maintain the machine without first studying this handbook. Read the safety instructions before operating the machine. If you do not understand anything, ask your employer or JCB distributor to explain it. Keep this handbook clean and in good condition. Do not operate the machine without a handbook in the cab, or if there is anything on the machine you do not understand. INT-1-3-2 ! CAUTION Regulations Obey all laws, work site and local regulations which affect you and your machine. INT-1-3-3 ! WARNING Decals You can be injured if you do not obey the decal safety instructions. Keep decals clean. Replace unreadable or missing decals with new ones before operating the machine. Make sure replacement parts include warning decals where necessary. INT-1-3-4 ! WARNING 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. INT-1-3-5 Do not work with the machine until you are sure that you can control it. Do not start any job until you are sure that you and those around you will be safe. If you are unsure of anything, about the machine or the job, ask someone who knows. Do not assume anything. Remember BE CAREFUL BE ALERT BE SAFE INT-1-3-1/1 ! WARNING Raised Attachments Raised attachments can fall and injure you. Do not walk or work under raised attachments unless they are safely blocked. INT-1-3-8 ! WARNING Clothing You can be injured if you do not wear the proper clothing. Loose clothing can get caught in the machinery. Wear protective clothing to suit the job. Examples of protective clothing are: a hard hat, safety shoes, safety glasses, a well fitting overall, ear-protectors and industrial gloves. Keep cuffs fastened. Do not wear a necktie or scarf. Keep long hair restrained. INT-1-3-6 ! WARNING Lifting Equipment You can be injured if you use faulty lifting equipment. Make sure that lifting equipment is in good condition. Make sure that lifting tackle complies with all local regulations and is suitable for the job. Make sure that lifting equipment is strong enough for the job. INT-1-3-7 4230-1 SAFETY CHECK LIST Purchased from www.WorkshopManuals.co.uk

4 4 INTRODUCTION SAFETY CHECK LIST (continued) General Safety (continued) ! WARNING 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 whilst operating the machine or attachments. Be aware of medicines which can cause drowsiness. INT-1-3-9 Operating Safety ! WARNING Practice You or others can be killed or seriously injured if you do unfamiliar operations without first practising them. Practise away from the work site on a clear area. Keep other people away. Do not perform new operations until you are sure you can do them safely. INT-2-1-1 ! WARNING Machine Condition A defective machine can injure you or others. Do not operate a machine which is defective or has missing parts. Make sure the maintenance procedures in this handbook are completed before using the machine. INT-2-1-2 ! WARNING Controls You or others can be killed or seriously injured if you operate the control levers from outside the cab. Operate the controls levers only when you are correctly seated inside the cab. INT-2-1-3 ! WARNING Machine Limits Operating the machine beyond its design limits can damage the machine, it can also be dangerous. Do not operate the machine outside its limits. Do not try to upgrade the machine performance with unapproved modifications. INT-2-1-4 ! WARNING Passengers Passengers in or on the machine can cause accidents. The JCB Skid Steer Loader is a one man machine. Do not carry passengers. INT-2-2-2 ! CAUTION Machine Modifications This machine is manufactured in compliance with legislative and other requirements. It should not be altered in any way which could affect or invalidate any of these requirements. For advice consult your JCB Distributor. Reference should also be made to Optional Attachments section where appropriate. INT-1-3-10 ! WARNING Rollover Should the machine start to roll over, you can be crushed if you try to leave the cab. If the machine starts to roll over, DO NOT TRY TO JUMP FROM THE CAB. STAY IN THE CAB, WITH YOUR SEAT BELT FASTENED. INT-2-1-12 ! WARNING ROPS/FOPS Structure The machine is fitted with a Roll Over Protection Structure (ROPS) and a Falling Objects Protection Structure (FOPS). You could be killed or seriously injured if you operate the machine with a damaged or missing ROPS/FOPS. If the ROPS/FOPS has been in an accident, do not use the machine until the structure has been renewed. Modifications and repairs that are not approved by the manufacturer may be dangerous and will invalidate the ROPS/FOPS certification. INT-2-1-9/3 ! WARNING Seat Belts The ROPS/FOPS cab is designed to give you protection in an accident. If you do not wear your seat belt, you could be thrown around inside the cab or thrown out of the machine and crushed. You must wear a seat belt when using the machine. Fasten the seat belt before starting the engine. 2-2-1-9 ! CAUTION Cold Starting Do not use ether or other starting fluids to assist cold starting. Using these fluids may result in an explosion causing possible injury and/or damage to the engine. 3-2-1-9 4230-1 Purchased from www.WorkshopManuals.co.uk

JCB ROBOT 190,190HF,1110,1110HF Operator Handbook Manual

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