JCB 506-36, 507-42, 509-42, 510-56, 512-56, 514-56 Tier 4 Loadall Operator Manual 9821-6717

Description

• Model List:
  • 506-36, 507-42, 509-42, 510-56, 512-56, 514-56 Tier 4 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. Product Compliance ………………………………………………………………………1
• 8. Machine Model and Serial Number ………………………………………………….1
• 9. Using this Manual ………………………………………………………………………….1
• 10. Left Side, Right Side ………………………………………………………………………2
• 11. Cab-Canopy …………………………………………………………………………………2
• 12. Cross References ………………………………………………………………………….2
• 13. Machine Description …………………………………………………………………………..3
• 14. The JCB Loadall ……………………………………………………………………………3
• 15. Intended Use ………………………………………………………………………………..3
• 16. Component Location ……………………………………………………………………..3
• 17. Safety Check List ……………………………………………………………………………….5
• 18. Safety – Yours and Others ………………………………………………………………5
• 19. General Safety ……………………………………………………………………………..5
• 20. Operating Safety …………………………………………………………………………..7
• 21. Maintenance Safety …………………………………………………………………….. 11
• 22. Safety Labels …………………………………………………………………………………..16
• 23. Introduction …………………………………………………………………………………16
• 24. Safety Label Identification …………………………………………………………….17
• 25. Identifying Your Machine …………………………………………………………………..20
• 26. Machine Identification Plate ………………………………………………………….20
• 27. Component Identification Plates …………………………………………………….21
• 28. Machine Security ……………………………………………………………………………..24
• 29. Introduction …………………………………………………………………………………24
• 30. JCB Plantguard …………………………………………………………………………..24
• 31. Operation
• 32. Introduction ……………………………………………………………………………………..27
• 33. Before Entering the Cab ……………………………………………………………………28
• 34. Entering and Leaving the Cab ……………………………………………………………29
• 35. Emergency Exit …………………………………………………………………………..30
• 36. Doors and Windows …………………………………………………………………………31
• 37. Opening and Closing the Door ………………………………………………………31
• 38. Opening and Closing the Upper Door Section …………………………………31
• 39. Seat Controls …………………………………………………………………………………..32
• 40. Introduction …………………………………………………………………………………32
• 41. Suspension Seat (KAB 100 Series – Mechanical) …………………………….33
• 42. Seat Belt …………………………………………………………………………………………34
• 43. Inertia Reel Seat Belt …………………………………………………………………..34
• 44. Cab Layout ……………………………………………………………………………………..35
• 45. Component Key …………………………………………………………………………..36
• 46. Drive Controls, Switches and Instruments ……………………………………………37
• 47. Drive Controls ……………………………………………………………………………..37
• 48. Switches …………………………………………………………………………………….40
• 49. Instrument Panel …………………………………………………………………………43
• 50. Air Conditioning and Cab Heater Controls ………………………………………48
• 51. Operating Levers ……………………………………………………………………………..49
• 52. Introduction …………………………………………………………………………………49
• 53. Boom and Carriage Controls …………………………………………………………50
• 54. Auxiliary Controls ………………………………………………………………………..51
• 55. Chassis Leveling (Sway) Control …………………………………………………..52
• 56. Stabilizer Controls (if fitted) …………………………………………………………..53
• 57. Safety Equipment …………………………………………………………………………….55
• 58. Control Locks ……………………………………………………………………………..55
• 59. Load Charts ………………………………………………………………………………..56
• 60. Boom Indicators ………………………………………………………………………….58
• 61. Inclinometer ………………………………………………………………………………..58
• 62. Beacon ………………………………………………………………………………………59
• 63. Fire Extinguisher (if fitted) …………………………………………………………….60
• 64. Before Starting the Engine …………………………………………………………………61
• 65. Starting the Engine …………………………………………………………………………..63
• 66. Preparing the Machine for Travel ……………………………………………………….65
• 67. Introduction …………………………………………………………………………………65
• 68. Preparing for Road Travel …………………………………………………………….65
• 69. Preparing for Site Travel ……………………………………………………………….66
• 70. Getting the Machine Moving ………………………………………………………………68
• 71. Operating Practices ……………………………………………………………………..68
• 72. Operating Procedure ……………………………………………………………………69
• 73. Stopping and Parking the Machine ……………………………………………………..70
• 74. Working with the Machine …………………………………………………………………71
• 75. Operating Practices and Site Safety ………………………………………………71
• 76. Clothing and Safety Equipment ……………………………………………………..71
• 77. Danger Zone ………………………………………………………………………………71
• 78. Safety Practices ………………………………………………………………………….71
• 79. Working with the Boom ………………………………………………………………..73
• 80. Use of Machines on Gradients or Slopes ………………………………………..82
• 81. RAS (Rear Axle Stabilization) System …………………………………………….84
• 82. Interlock System ………………………………………………………………………….85
• 83. Operating Environment ……………………………………………………………………..86
• 84. Operating in Low Temperatures …………………………………………………….86
• 85. Operating in High Temperatures ……………………………………………………86
• 86. Refuelling the Machine ……………………………………………………………………..87
• 87. Low Fuel Levels ………………………………………………………………………….87
• 88. Filling the Tank ……………………………………………………………………………87
• 89. Moving a Disabled Machine ………………………………………………………………89
• 90. Recovery Hitch ……………………………………………………………………………89
• 91. Transporting the Machine ………………………………………………………………….90
• 92. Lifting a Machine ……………………………………………………………………………..91
• 93. Storage of the Machine …………………………………………………………………….92
• 94. Introduction …………………………………………………………………………………92
• 95. Storage Area ………………………………………………………………………………92
• 96. Prepare the Machine for Storage …………………………………………………..92
• 97. Put the Machine into Storage ………………………………………………………..92
• 98. During Storage ……………………………………………………………………………92
• 99. Take the Machine Out of Storage …………………………………………………..93
• 100. Routine Maintenance
• 101. Service Requirements ………………………………………………………………………95
• 102. Introduction …………………………………………………………………………………95
• 103. Owner-Operator Support ………………………………………………………………95
• 104. Environmental Protection Agency and California Air Resources Board .95
• 105. Service-Maintenance Agreements …………………………………………………96
• 106. Initial Service and Inspection (100 Hours) ……………………………………….96
• 107. Fit for Purpose Tests for Lifting Equipment ………………………………………96
• 108. Obtaining Replacement Parts ………………………………………………………..96
• 109. Health and Safety …………………………………………………………………………….97
• 110. Lubricants …………………………………………………………………………………..97
• 111. Battery ……………………………………………………………………………………….99
• 112. Service Schedules ………………………………………………………………………….101
• 113. Introduction ……………………………………………………………………………….101
• 114. How to Use the Service Schedules ………………………………………………101
• 115. Calendar Equivalents …………………………………………………………………101
• 116. Pre-start Cold Checks, Service Points and Fluid Levels ………………….102
• 117. Functional Test and Final Inspection …………………………………………….105
• 118. Fluids, Lubricants and Capacities ……………………………………………………..107
• 119. Coolant Mixtures ……………………………………………………………………….108
• 120. Fuel ……………………………………………………………………………………………..109
• 121. Fuels ………………………………………………………………………………………..109
• 122. Prepare the Machine for Maintenance ……………………………………………… 114
• 123. Introduction ………………………………………………………………………………. 114
• 124. How to Make the Machine Safe (Boom Lowered) ………………………….. 115
• 125. How to Make the Machine Safe (Boom Lifted) ………………………………. 116
• 126. Cleaning the Machine …………………………………………………………………….. 119
• 127. Introduction ………………………………………………………………………………. 119
• 128. Preparing the Machine for Cleaning …………………………………………….. 119
• 129. Cleaning the Machine …………………………………………………………………120
• 130. Checking for Damage ……………………………………………………………………..123
• 131. Check the Machine Body and Structure ………………………………………..123
• 132. Check the Tires …………………………………………………………………………123
• 133. Check the Seat and Seat Belt ……………………………………………………..123
• 134. Check the Hydraulic Hoses and Fittings ……………………………………….123
• 135. Check the Electrical Circuits ………………………………………………………..124
• 136. Checking the ROPS-FOPS Structure ……………………………………………124
• 137. Greasing ……………………………………………………………………………………….126
• 138. Introduction ……………………………………………………………………………….126
• 139. Preparing the Machine for Greasing …………………………………………….126
• 140. Every 50 Hours ………………………………………………………………………….127
• 141. Every 500 Hours ………………………………………………………………………..130
• 142. Every 1000 Hours ………………………………………………………………………133
• 143. Oiling ……………………………………………………………………………………………134
• 144. Park Brake Cable ………………………………………………………………………134
• 145. Control Levers …………………………………………………………………………..134
• 146. Boom Chains …………………………………………………………………………….135
• 147. Access Panels ……………………………………………………………………………….136
• 148. Battery Cover ……………………………………………………………………………136
• 149. Engine Cover …………………………………………………………………………….137
• 150. Undershield ………………………………………………………………………………138
• 151. Rear Boom Cover ………………………………………………………………………139
• 152. Central Access Panels ……………………………………………………………….140
• 153. Cab Heater and Air Conditioning ………………………………………………………141
• 154. Changing the Air Intake Filter ………………………………………………………141
• 155. Boom ……………………………………………………………………………………………142
• 156. Boom Chains …………………………………………………………………………….142
• 157. Brakes ………………………………………………………………………………………….146
• 158. Park Brake ………………………………………………………………………………..146
• 159. Foot Brake ………………………………………………………………………………..148
• 160. Electrical System ……………………………………………………………………………149
• 161. Battery ……………………………………………………………………………………..149
• 162. Jump Starting the Engine ……………………………………………………………150
• 163. Fuses ……………………………………………………………………………………….151
• 164. Primary Fuses …………………………………………………………………………..153
• 165. Relays ……………………………………………………………………………………..154
• 166. Engine Compartment Fuse and Relay Box ……………………………………156
• 167. Engine ………………………………………………………………………………………….157
• 168. Oil and Filter ……………………………………………………………………………..157
• 169. Cooling System …………………………………………………………………………160
• 170. Crankcase Ventilation …………………………………………………………………162
• 171. Front End Accessory Drive Belt …………………………………………………..163
• 172. Air Filter ……………………………………………………………………………………165
• 173. Fuel System …………………………………………………………………………………..167
• 174. Introduction ……………………………………………………………………………….167
• 175. Water Separator and Engine Fuel Filter ………………………………………..168
• 176. Bleeding the System ………………………………………………………………….172
• 177. Hydraulic System ……………………………………………………………………………173
• 178. Introduction ……………………………………………………………………………….173
• 179. Releasing the Hydraulic Pressure ………………………………………………..174
• 180. Oil and Filter ……………………………………………………………………………..175
• 181. Hose Burst Protection Valves ………………………………………………………178
• 182. Transmission …………………………………………………………………………………180
• 183. Gearbox ……………………………………………………………………………………180
• 184. Axles ………………………………………………………………………………………..182
• 185. Tires and Wheels ……………………………………………………………………………186
• 186. Tire Ballast ………………………………………………………………………………..186
• 187. Semi Solid Tires ………………………………………………………………………..186
• 188. Tire Inflation ………………………………………………………………………………187
• 189. Wheel Nuts ……………………………………………………………………………….188
• 190. Wheel Alignment ……………………………………………………………………………189
• 191. Introduction ……………………………………………………………………………….189
• 192. Manual Steer Mode Selector ……………………………………………………….189
• 193. Wear Pads …………………………………………………………………………………….190
• 194. Boom Wear Pad Clearance …………………………………………………………190
• 195. Windshield Washer …………………………………………………………………………192
• 196. Checking the Level …………………………………………………………………….192
• 197. Fire Extinguisher (if fitted) ………………………………………………………………..193
• 198. Checking the Fire Extinguisher ……………………………………………………193
• 199. Optional Attachments
• 200. Introduction ……………………………………………………………………………………195
• 201. Attachments for your Machine ………………………………………………………….196
• 202. Connecting-Disconnecting Hydraulic Hoses ……………………………………….197
• 203. Introduction ……………………………………………………………………………….197
• 204. Connecting the Hydraulic Hoses ………………………………………………….197
• 205. Disconnecting the Hydraulic Hoses ………………………………………………198
• 206. Quick Release Couplings ……………………………………………………………199
• 207. Q-Fit Attachments …………………………………………………………………………..201
• 208. Mechanical Pin Locking ………………………………………………………………201
• 209. Specifications
• 210. Static Dimensions …………………………………………………………………………..203
• 211. All Models …………………………………………………………………………………203
• 212. Performance Dimensions ………………………………………………………………..204
• 213. Lift Performance ………………………………………………………………………..204
• 214. Maximum Wading Depth …………………………………………………………….205
• 215. Tire Sizes and Pressures ………………………………………………………………..206
• 216. Introduction ……………………………………………………………………………….206
• 217. Specifications ……………………………………………………………………………206
• 218. Warranty Information
• 219. Machine Service Record Sheet ………………………………………………………..209
• 220. Emission Control System Maintenance and Warranty Statement (all EPA and
• 221. CARB Regulated Territories) …………………………………………………………… 211
• 222. Emissions Control System Warranty ……………………………………………. 211
• 223. Maintenance, Replacement And Repair Of Emission Control System Warrantied Components ………………………………………………………………….. 211
• 224. Terms Of Emission Control System Warranty ……………………………….. 211
• 225. Emission Control System Maintenance and Warranty Statement (EPA Regulated Territories Only) ……………………………………………………………………..213
• 226. Items Covered By Emissions System Warranty ……………………………..213
• 227. Emission Control System Maintenance And Warranty Statement (CARB) 214
• 228. California Emission Control Warranty Statement ……………………………214