JCB 506-36, 507-42, 509-42, 510-56, 512-56, 514-56 Tier 3 Loadall Operator Manual 9821-3917

Description

• Model List:
  • 506-36, 507-42, 509-42, 510-56, 512-56, 514-56 Tier 3 Loadall

• 1. Safety Notices
• 2. Important Information ………………………………………………………………………..vii
• 3. The Operator Manual ……………………………………………………………………vii
• 4. Safety Warnings …………………………………………………………………………..vii
• 5. Introduction
• 6. About This Manual ……………………………………………………………………………..1
• 7. Machine Model and Serial Number ………………………………………………….1
• 8. Using this Manual ………………………………………………………………………….1
• 9. Left Side, Right Side ………………………………………………………………………1
• 10. Cab-Canopy …………………………………………………………………………………1
• 11. Cross References ………………………………………………………………………….1
• 12. Machine Description …………………………………………………………………………..2
• 13. The JCB Loadall ……………………………………………………………………………2
• 14. Intended Use ………………………………………………………………………………..2
• 15. Component Location ……………………………………………………………………..2
• 16. Safety Check List ……………………………………………………………………………….4
• 17. Safety – Yours and Others ………………………………………………………………4
• 18. General Safety ……………………………………………………………………………..4
• 19. Operating Safety …………………………………………………………………………..6
• 20. Maintenance Safety ……………………………………………………………………..10
• 21. Safety Labels …………………………………………………………………………………..15
• 22. Introduction …………………………………………………………………………………15
• 23. Safety Label Identification …………………………………………………………….16
• 24. Identifying Your Machine …………………………………………………………………..19
• 25. Machine Identification Plate ………………………………………………………….19
• 26. Component Identification Plates …………………………………………………….20
• 27. Machine Security ……………………………………………………………………………..23
• 28. Introduction …………………………………………………………………………………23
• 29. JCB Plantguard …………………………………………………………………………..23
• 30. Operation
• 31. Introduction ……………………………………………………………………………………..25
• 32. Before Entering the Cab ……………………………………………………………………26
• 33. Entering and Leaving the Cab ……………………………………………………………27
• 34. Emergency Exit …………………………………………………………………………..28
• 35. Doors and Windows …………………………………………………………………………29
• 36. Opening and Closing the Door ………………………………………………………29
• 37. Opening and Closing the Upper Door Section …………………………………29
• 38. Seat Controls …………………………………………………………………………………..31
• 39. Introduction …………………………………………………………………………………31
• 40. Suspension Seat (KAB 100 Series – Mechanical) …………………………….32
• 41. Seat Belt …………………………………………………………………………………………33
• 42. Inertia Reel Seat Belt …………………………………………………………………..33
• 43. Cab Layout ……………………………………………………………………………………..34
• 44. Component Key …………………………………………………………………………..35
• 45. Drive Controls, Switches and Instruments ……………………………………………36
• 46. Drive Controls ……………………………………………………………………………..36
• 47. Switches …………………………………………………………………………………….39
• 48. Instrument Panel …………………………………………………………………………42
• 49. Air Conditioning and Cab Heater Controls ………………………………………47
• 50. Operating Levers ……………………………………………………………………………..48
• 51. Introduction …………………………………………………………………………………48
• 52. Boom and Carriage Controls …………………………………………………………49
• 53. Auxiliary Controls ………………………………………………………………………..50
• 54. Chassis Leveling (Sway) Control …………………………………………………..51
• 55. Stabilizer Controls (if fitted) …………………………………………………………..52
• 56. Safety Equipment …………………………………………………………………………….54
• 57. Control Locks ……………………………………………………………………………..54
• 58. Load Charts ………………………………………………………………………………..55
• 59. Boom Indicators ………………………………………………………………………….57
• 60. Inclinometer ………………………………………………………………………………..57
• 61. Beacon ………………………………………………………………………………………58
• 62. Fire Extinguisher (if fitted) …………………………………………………………….59
• 63. Before Starting the Engine …………………………………………………………………60
• 64. Starting the Engine …………………………………………………………………………..62
• 65. Preparing the Machine for Travel ……………………………………………………….63
• 66. Introduction …………………………………………………………………………………63
• 67. Preparing for Road Travel …………………………………………………………….63
• 68. Preparing for Site Travel ……………………………………………………………….64
• 69. Getting the Machine Moving ………………………………………………………………66
• 70. Operating Practices ……………………………………………………………………..66
• 71. Operating Procedure ……………………………………………………………………67
• 72. Stopping and Parking the Machine ……………………………………………………..68
• 73. Working with the Machine …………………………………………………………………69
• 74. Operating Practices and Site Safety ………………………………………………69
• 75. Clothing and Safety Equipment ……………………………………………………..69
• 76. Danger Zone ………………………………………………………………………………69
• 77. Safety Practices ………………………………………………………………………….69
• 78. Working with the Boom ………………………………………………………………..71
• 79. Use of Machines on Gradients or Slopes ………………………………………..80
• 80. RAS (Rear Axle Stabilization) System …………………………………………….83
• 81. Interlock System ………………………………………………………………………….84
• 82. Operating Environment ……………………………………………………………………..85
• 83. Operating in Low Temperatures …………………………………………………….85
• 84. Operating in High Temperatures ……………………………………………………85
• 85. Refuelling the Machine ……………………………………………………………………..86
• 86. Low Fuel Levels ………………………………………………………………………….86
• 87. Filling the Tank ……………………………………………………………………………86
• 88. Moving a Disabled Machine ………………………………………………………………88
• 89. Recovery Hitch ……………………………………………………………………………88
• 90. Transporting the Machine ………………………………………………………………….89
• 91. Lifting a Machine ……………………………………………………………………………..90
• 92. Storage of the Machine …………………………………………………………………….91
• 93. Introduction …………………………………………………………………………………91
• 94. Storage Area ………………………………………………………………………………91
• 95. Prepare the Machine for Storage …………………………………………………..91
• 96. Put the Machine into Storage ………………………………………………………..91
• 97. During Storage ……………………………………………………………………………91
• 98. Take the Machine Out of Storage …………………………………………………..92
• 99. Routine Maintenance
• 100. Service Requirements ………………………………………………………………………93
• 101. Introduction …………………………………………………………………………………93
• 102. Owner-Operator Support ………………………………………………………………93
• 103. Service-Maintenance Agreements …………………………………………………93
• 104. Initial Service and Inspection (100 Hours) ……………………………………….93
• 105. Fit for Purpose Tests for Lifting Equipment ………………………………………94
• 106. Obtaining Replacement Parts ………………………………………………………..94
• 107. Health and Safety …………………………………………………………………………….95
• 108. Lubricants …………………………………………………………………………………..95
• 109. Battery ……………………………………………………………………………………….97
• 110. Service Schedules ……………………………………………………………………………99
• 111. Introduction …………………………………………………………………………………99
• 112. How to Use the Service Schedules ………………………………………………..99
• 113. Calendar Equivalents …………………………………………………………………..99
• 114. Pre-start Cold Checks, Service Points and Fluid Levels ………………….100
• 115. Functional Test and Final Inspection …………………………………………….103
• 116. Fluids, Lubricants and Capacities ……………………………………………………..105
• 117. Coolant Mixtures ……………………………………………………………………….105
• 118. Fuel …………………………………………………………………………………………107
• 119. Prepare the Machine for Maintenance ……………………………………………… 110
• 120. Introduction ………………………………………………………………………………. 110
• 121. How to Make the Machine Safe (Boom Lowered) ………………………….. 111
• 122. How to Make the Machine Safe (Boom Lifted) ………………………………. 112
• 123. Cleaning the Machine …………………………………………………………………….. 115
• 124. Introduction ………………………………………………………………………………. 115
• 125. Preparing the Machine for Cleaning …………………………………………….. 115
• 126. Cleaning the Machine ………………………………………………………………… 116
• 127. Checking for Damage …………………………………………………………………….. 118
• 128. Check the Machine Body and Structure ……………………………………….. 118
• 129. Check the Tires ………………………………………………………………………… 118
• 130. Check the Seat and Seat Belt …………………………………………………….. 118
• 131. Check the Hydraulic Hoses and Fittings ………………………………………. 118
• 132. Check the Electrical Circuits ……………………………………………………….. 119
• 133. Checking the ROPS-FOPS Structure ……………………………………………120
• 134. Greasing ……………………………………………………………………………………….121
• 135. Introduction ……………………………………………………………………………….121
• 136. Preparing the Machine for Greasing …………………………………………….121
• 137. Every 50 Hours ………………………………………………………………………….122
• 138. Every 500 Hours ………………………………………………………………………..124
• 139. Every 1000 Hours ………………………………………………………………………127
• 140. Oiling ……………………………………………………………………………………………128
• 141. Park Brake Cable ………………………………………………………………………128
• 142. Control Levers …………………………………………………………………………..128
• 143. Boom Chains …………………………………………………………………………….129
• 144. Access Panels ……………………………………………………………………………….130
• 145. Battery Cover ……………………………………………………………………………130
• 146. Engine Cover …………………………………………………………………………….131
• 147. Undershield ………………………………………………………………………………132
• 148. Rear Boom Cover ………………………………………………………………………133
• 149. Central Access Panels ……………………………………………………………….134
• 150. Cab Heater and Air Conditioning ………………………………………………………135
• 151. Changing the Air Intake Filter ………………………………………………………135
• 152. Boom ……………………………………………………………………………………………136
• 153. Boom Chains …………………………………………………………………………….136
• 154. Brakes ………………………………………………………………………………………….140
• 155. Park Brake ………………………………………………………………………………..140
• 156. Foot Brake ………………………………………………………………………………..142
• 157. Electrical System ……………………………………………………………………………143
• 158. Battery ……………………………………………………………………………………..143
• 159. Jump Starting the Engine ……………………………………………………………144
• 160. Fuses ……………………………………………………………………………………….145
• 161. Primary Fuses …………………………………………………………………………..147
• 162. Relays ……………………………………………………………………………………..148
• 163. Engine ………………………………………………………………………………………….150
• 164. Oil and Filter ……………………………………………………………………………..150
• 165. Cooling System …………………………………………………………………………152
• 166. Front End Accessory Drive Belt …………………………………………………..154
• 167. Air Filter ……………………………………………………………………………………156
• 168. Fuel System …………………………………………………………………………………..159
• 169. Introduction ……………………………………………………………………………….159
• 170. Water Separator and Engine Fuel Filter ………………………………………..159
• 171. Bleeding the System ………………………………………………………………….164
• 172. Hydraulic System ……………………………………………………………………………165
• 173. Introduction ……………………………………………………………………………….165
• 174. Releasing the Hydraulic Pressure ………………………………………………..166
• 175. Oil and Filter ……………………………………………………………………………..167
• 176. Hose Burst Protection Valves ………………………………………………………170
• 177. Transmission …………………………………………………………………………………172
• 178. Gearbox ……………………………………………………………………………………172
• 179. Axles ………………………………………………………………………………………..174
• 180. Tires and Wheels ……………………………………………………………………………178
• 181. Tire Ballast ………………………………………………………………………………..178
• 182. Tire Inflation ………………………………………………………………………………178
• 183. Wheel Nuts ……………………………………………………………………………….179
• 184. Wheel Alignment ……………………………………………………………………………180
• 185. Introduction ……………………………………………………………………………….180
• 186. Manual Steer Mode Selector ……………………………………………………….180
• 187. Wear Pads …………………………………………………………………………………….181
• 188. Boom Wear Pad Clearance …………………………………………………………181
• 189. Windshield Washer …………………………………………………………………………183
• 190. Checking the Level …………………………………………………………………….183
• 191. Fire Extinguisher (if fitted) ………………………………………………………………..184
• 192. Checking the Fire Extinguisher ……………………………………………………184
• 193. Optional Attachments
• 194. Introduction ……………………………………………………………………………………185
• 195. Attachments for your Machine ………………………………………………………….186
• 196. Connecting-Disconnecting Hydraulic Hoses ……………………………………….187
• 197. Introduction ……………………………………………………………………………….187
• 198. Connecting the Hydraulic Hoses ………………………………………………….187
• 199. Disconnecting the Hydraulic Hoses ………………………………………………188
• 200. Quick Release Couplings ……………………………………………………………189
• 201. Q-Fit Attachments …………………………………………………………………………..191
• 202. Mechanical Pin Locking ………………………………………………………………191
• 203. Specifications
• 204. Static Dimensions …………………………………………………………………………..193
• 205. All Models …………………………………………………………………………………193
• 206. Performance Dimensions ………………………………………………………………..194
• 207. Lift Performance ………………………………………………………………………..194
• 208. Maximum Wading Depth …………………………………………………………….195
• 209. Tire Sizes and Pressures ………………………………………………………………..196
• 210. Introduction ……………………………………………………………………………….196
• 211. Specifications ……………………………………………………………………………196
• 212. Warranty Information
• 213. Machine Service Record Sheet ………………………………………………………..199