JCB 403 Operator Manual 9821-1000

Description

• Model List:
  • 403

• 1. Safety Notices
• 2. Important Information ……………………………………………………………………….xiii
• 3. The Operator Manual …………………………………………………………………..xiii
• 4. Safety Warnings ………………………………………………………………………….xiv
• 5. Introduction
• 6. About this Manual ………………………………………………………………………………1
• 7. Machine Model and Serial Number ………………………………………………….1
• 8. Using this Manual ………………………………………………………………………….1
• 9. Left Side, Right Side ………………………………………………………………………2
• 10. Cab-Canopy …………………………………………………………………………………3
• 11. Cross References ………………………………………………………………………….3
• 12. Machine Description …………………………………………………………………………..5
• 13. The JCB Wheeled Loader ………………………………………………………………5
• 14. Intended Use ………………………………………………………………………………..5
• 15. Component Location ……………………………………………………………………..6
• 16. Safety Check List ……………………………………………………………………………….8
• 17. Safety – Yours and Others ………………………………………………………………8
• 18. General Safety ……………………………………………………………………………..9
• 19. Operating Safety …………………………………………………………………………12
• 20. Maintenance Safety ……………………………………………………………………..21
• 21. Safety Labels …………………………………………………………………………………..33
• 22. Introduction …………………………………………………………………………………33
• 23. Safety Label Identification …………………………………………………………….34
• 24. Part Numbers and Descriptions …………………………………………………….35
• 25. Identifying Your Machine …………………………………………………………………..38
• 26. Machine Identification Plate ………………………………………………………….38
• 27. Component Identification Plates …………………………………………………….41
• 28. Machine Security ……………………………………………………………………………..46
• 29. Introduction …………………………………………………………………………………46
• 30. JCB Plantguard …………………………………………………………………………..46
• 31. Construction Equipment Security And Registration Scheme (CESAR) .46
• 32. Operation
• 33. Introduction ……………………………………………………………………………………..49
• 34. Before Entering the Cab ……………………………………………………………………50
• 35. Entering and Leaving the Cab ……………………………………………………………52
• 36. Seat Controls …………………………………………………………………………………..53
• 37. Introduction …………………………………………………………………………………53
• 38. Operators Seat – Standard (Inertia Belt) ………………………………………….54
• 39. Seat Belts ……………………………………………………………………………………….55
• 40. Static Seat Belt ……………………………………………………………………………55
• 41. Inertia Reel Seat Belt …………………………………………………………………..58
• 42. Cab Layout ……………………………………………………………………………………..62
• 43. Drive Controls, Switches and Instruments ……………………………………………64
• 44. Drive Controls ……………………………………………………………………………..64
• 45. Switches …………………………………………………………………………………….68
• 46. Instruments …………………………………………………………………………………70
• 47. Operating Levers ……………………………………………………………………………..74
• 48. Introduction …………………………………………………………………………………74
• 49. Loader Controls Lever ………………………………………………………………….75
• 50. Auxiliary Control Lever …………………………………………………………………77
• 51. Safety Equipment …………………………………………………………………………….78
• 52. Fire Extinguishers ………………………………………………………………………..78
• 53. Beacon ………………………………………………………………………………………79
• 54. Before Starting the Engine …………………………………………………………………80
• 55. Starting the Engine …………………………………………………………………………..83
• 56. Preparing The Machine for Travel ………………………………………………………87
• 57. Introduction …………………………………………………………………………………87
• 58. Preparing for Road Travel …………………………………………………………….87
• 59. Preparing for Site Travel ……………………………………………………………….88
• 60. Getting The Machine Moving ……………………………………………………………..90
• 61. Operating Practices ……………………………………………………………………..90
• 62. Operating Procedure ……………………………………………………………………91
• 63. Stopping and Parking the Machine ……………………………………………………..93
• 64. Working With The Machine ……………………………………………………………….96
• 65. Operating Practices and Site Safety ………………………………………………96
• 66. Safety Practices ………………………………………………………………………….97
• 67. Machine Safety ………………………………………………………………………….100
• 68. Clothing and Safety Equipment ……………………………………………………102
• 69. Danger Zone …………………………………………………………………………….102
• 70. Log Moving-Handling ………………………………………………………………….102
• 71. Working with a Shovel ………………………………………………………………..103
• 72. Working on Slopes …………………………………………………………………….106
• 73. Driving Across Slopes ………………………………………………………………..109
• 74. Operating Environment …………………………………………………………………… 111
• 75. Operating in Low Temperatures ………………………………………………….. 111
• 76. Operating in High Temperatures …………………………………………………. 112
• 77. Operating in Dusty or Sandy Areas ……………………………………………… 112
• 78. Operating in Coastal Regions …………………………………………………….. 112
• 79. Operating on Wet or Soft Ground ………………………………………………… 113
• 80. Refuelling the Machine …………………………………………………………………… 114
• 81. Low Fuel Levels ……………………………………………………………………….. 114
• 82. Filling the Tank …………………………………………………………………………. 115
• 83. Moving A Disabled Machine ……………………………………………………………. 117
• 84. Introduction ………………………………………………………………………………. 117
• 85. Lower the Loader Arm in an Emergency ………………………………………. 117
• 86. Preparation for Towing-Winching …………………………………………………. 118
• 87. Towing-Winching ……………………………………………………………………….120
• 88. After Towing-Winching ………………………………………………………………..121
• 89. Transporting The Machine ……………………………………………………………….122
• 90. Moving the Machine Onto the Trailer ……………………………………………122
• 91. Articulation Lock ………………………………………………………………………..125
• 92. Lifting the Machine …………………………………………………………………………127
• 93. Storage of the Machine …………………………………………………………………..130
• 94. Introduction ……………………………………………………………………………….130
• 95. Storage Area …………………………………………………………………………….130
• 96. Prepare the Machine for Storage …………………………………………………130
• 97. Put the Machine into Storage ………………………………………………………131
• 98. During Storage ………………………………………………………………………….131
• 99. Take the Machine Out of Storage …………………………………………………132
• 100. Routine Maintenance
• 101. Service Requirements …………………………………………………………………….133
• 102. Introduction ……………………………………………………………………………….133
• 103. Owner-Operator Support …………………………………………………………….134
• 104. Service-Maintenance Agreements ……………………………………………….135
• 105. Fit for Purpose Tests for Lifting Equipment …………………………………….135
• 106. Obtaining Replacement Parts ………………………………………………………135
• 107. Health and Safety …………………………………………………………………………..136
• 108. Lubricants …………………………………………………………………………………136
• 109. Battery ……………………………………………………………………………………..140
• 110. Service Schedules ………………………………………………………………………….144
• 111. Introduction ……………………………………………………………………………….144
• 112. How to Use the Service Schedules ………………………………………………145
• 113. Calendar Equivalents …………………………………………………………………146
• 114. Pre-Start Cold Checks, Service Points and Fluid Levels ………………….147
• 115. Functional Test and Final Inspection …………………………………………….151
• 116. Fluids, Lubricants and Capacities ……………………………………………………..154
• 117. Specifications ……………………………………………………………………………154
• 118. Coolant Mixtures ……………………………………………………………………….158
• 119. Prepare The Machine For Maintenance …………………………………………….160
• 120. Introduction ……………………………………………………………………………….160
• 121. How to Make the Machine Safe (Loader Arm Lowered) ………………….162
• 122. How to Make the Machine Safe (Loader Arm Raised) …………………….163
• 123. Cleaning the Machine ……………………………………………………………………..167
• 124. Introduction ……………………………………………………………………………….167
• 125. Preparing the Machine for Cleaning ……………………………………………..168
• 126. Cleaning the Machine …………………………………………………………………169
• 127. Checking for Damage ……………………………………………………………………..170
• 128. Check the Machine Body and Structure ………………………………………..170
• 129. Check the Tyres ………………………………………………………………………..170
• 130. Check the Seat and Seat Belt ……………………………………………………..171
• 131. Check the Hydraulic Hoses and Fittings ……………………………………….172
• 132. Checking the ROPS Structure ……………………………………………………..172
• 133. Check the Electrical Circuits ………………………………………………………..173
• 134. Greasing ……………………………………………………………………………………….174
• 135. Introduction ……………………………………………………………………………….174
• 136. Preparing the Machine for Greasing …………………………………………….175
• 137. Grease the Machine …………………………………………………………………..175
• 138. Access Panels ……………………………………………………………………………….177
• 139. Introduction ……………………………………………………………………………….177
• 140. Engine Cover …………………………………………………………………………….177
• 141. Brakes ………………………………………………………………………………………….179
• 142. Park Brake ………………………………………………………………………………..179
• 143. Electrical System ……………………………………………………………………………181
• 144. Battery ……………………………………………………………………………………..181
• 145. Battery Isolator ………………………………………………………………………….184
• 146. Jump Starting the Engine ……………………………………………………………186
• 147. Fuses and Relays ………………………………………………………………………189
• 148. Engine ………………………………………………………………………………………….192
• 149. Oil and Filter ……………………………………………………………………………..192
• 150. Cooling System …………………………………………………………………………197
• 151. Alternator Drive Belt …………………………………………………………………..201
• 152. Air Filter ……………………………………………………………………………………202
• 153. Fuel System …………………………………………………………………………………..206
• 154. Introduction ……………………………………………………………………………….206
• 155. Draining the Filter ………………………………………………………………………208
• 156. Changing the Fuel Filter ……………………………………………………………..209
• 157. Bleeding the Fuel System …………………………………………………………..210
• 158. Hydraulic System ……………………………………………………………………………212
• 159. Introduction ……………………………………………………………………………….212
• 160. Releasing the Hydraulic Pressure ………………………………………………..213
• 161. Checking the Hydraulic Fluid Level ………………………………………………214
• 162. Changing the Filter Element ………………………………………………………..216
• 163. Filling the Hydraulic System ………………………………………………………..217
• 164. Tyres and Wheels …………………………………………………………………………..218
• 165. Tyre Inflation ……………………………………………………………………………..218
• 166. Checking the Wheel Nut Torques …………………………………………………220
• 167. Fire Extinguisher (if fitted) ………………………………………………………………..221
• 168. Checking the Fire Extinguisher ……………………………………………………221
• 169. Optional Attachments
• 170. Introduction ……………………………………………………………………………………223
• 171. Attachments for your Machine ………………………………………………………….226
• 172. Connecting-Disconnecting Hydraulic Hoses ……………………………………….227
• 173. Introduction ……………………………………………………………………………….227
• 174. Connecting the Hydraulic Hoses ………………………………………………….228
• 175. Disconnecting the Hydraulic Hoses ………………………………………………230
• 176. Quick Release Couplings ……………………………………………………………232
• 177. Quickhitch Attachments …………………………………………………………………..236
• 178. Introduction ……………………………………………………………………………….236
• 179. Engage the Shovel-Attachment ……………………………………………………237
• 180. Disengage the Shovel-Attachment ……………………………………………….239
• 181. Specifications
• 182. Working Capacity …………………………………………………………………………..241
• 183. Engine ……………………………………………………………………………………..244
• 184. Static Dimensions …………………………………………………………………………..245
• 185. Noise Data …………………………………………………………………………………….250
• 186. Introduction ……………………………………………………………………………….250
• 187. Machine ……………………………………………………………………………………251
• 188. Vibration Data ………………………………………………………………………………..252
• 189. Introduction ……………………………………………………………………………….252
• 190. Whole Body Vibration Emission …………………………………………………..254
• 191. Wheels and Tyres …………………………………………………………………………..256
• 192. Warranty Information
• 193. Machine Service Record Sheet ………………………………………………………..257
• 194. Registration Information ………………………………………………………………….261
• 195. European Community Standards
• 196. EC Declaration of Conformity …………………………………………………………..263
• 197. Introduction ……………………………………………………………………………….263
• 198. Explanation of the EC Declaration of Conformity ……………………………266