JCB 516-40 AND, 516-40 AGRI Tier 3 Loadall Operator Manual 9821-9750-2

Description

• Model List:
  • 516-40 AND, 516-40 AGRI Tier 3 Loadall

• 1. Safety Notices
• 2. Important Information …………………………………………………………………………1
• 3. The Operator Manual …………………………………………………………………….1
• 4. Safety Warnings ……………………………………………………………………………1
• 5. Introduction
• 6. About This Manual ……………………………………………………………………………..3
• 7. Name and Address of Manufacturer ………………………………………………..3
• 8. Product Compliance ………………………………………………………………………3
• 9. Machine Model and Serial Number ………………………………………………….3
• 10. Using this Manual ………………………………………………………………………….3
• 11. Left Side, Right Side ………………………………………………………………………4
• 12. Cab-Canopy …………………………………………………………………………………4
• 13. Cross References ………………………………………………………………………….4
• 14. Machine Description …………………………………………………………………………..5
• 15. The JCB 516-40 ……………………………………………………………………………5
• 16. Intended Use ………………………………………………………………………………..5
• 17. Component Location ……………………………………………………………………..5
• 18. Safety Check List ……………………………………………………………………………….6
• 19. Safety – Yours and Others ………………………………………………………………6
• 20. General Safety ……………………………………………………………………………..6
• 21. Operating Safety …………………………………………………………………………..8
• 22. Maintenance Safety ……………………………………………………………………..12
• 23. Safety Labels …………………………………………………………………………………..17
• 24. Introduction …………………………………………………………………………………17
• 25. Safety Label Identification …………………………………………………………….18
• 26. Part Numbers and Descriptions …………………………………………………….18
• 27. Identifying Your Machine …………………………………………………………………..21
• 28. Machine Identification Plate ………………………………………………………….21
• 29. Typical Product Identification Number ………………………………………….21
• 30. Component Identification Plates …………………………………………………….22
• 31. Typical Engine Identification Number …………………………………………..22
• 32. Emission Control Information ………………………………………………………22
• 33. ROPS Data Plate ………………………………………………………………………22
• 34. FOPS Data Plate ………………………………………………………………………24
• 35. Machine Security ……………………………………………………………………………..25
• 36. Introduction …………………………………………………………………………………25
• 37. JCB Plantguard …………………………………………………………………………..25
• 38. Construction Equipment Security And Registration Scheme (CESAR) .25
• 39. Operation
• 40. Introduction ……………………………………………………………………………………..27
• 41. Before Entering the Cab ……………………………………………………………………28
• 42. Entering and Leaving the Cab ……………………………………………………………29
• 43. Emergency Exit …………………………………………………………………………..30
• 44. Doors and Windows …………………………………………………………………………31
• 45. Opening and Closing the Doors …………………………………………………….31
• 46. Opening and Closing the Door Upper Section …………………………………32
• 47. Door Catch ……………………………………………………………………………….32
• 48. Visibility Aids ……………………………………………………………………………………33
• 49. Mirrors and Adjustment ………………………………………………………………..33
• 50. Introduction ………………………………………………………………………………33
• 51. Mirrors ……………………………………………………………………………………..34
• 52. Visibility Diagrams ……………………………………………………………………..35
• 53. Seat Controls …………………………………………………………………………………..39
• 54. Introduction …………………………………………………………………………………39
• 55. Operators Seat ……………………………………………………………………………39
• 56. Seat Belt …………………………………………………………………………………………40
• 57. Inertia Reel Seat Belt …………………………………………………………………..40
• 58. Fasten the Seat Belt ………………………………………………………………….40
• 59. Check the Seat Belt is Operating Correctly …………………………………..40
• 60. Release the Seat Belt ………………………………………………………………..40
• 61. Cab Layouts ……………………………………………………………………………………41
• 62. Three Lever Control …………………………………………………………………….41
• 63. Component Key ………………………………………………………………………..41
• 64. Single Lever Control (Optional) ……………………………………………………..42
• 65. Component Key ………………………………………………………………………..42
• 66. Drive Controls, Switches and Instrument Panel ……………………………………43
• 67. Drive Controls – Manual Lever machines ………………………………………..43
• 68. Steering Wheel …………………………………………………………………………43
• 69. Accelerator Pedal ……………………………………………………………………..43
• 70. Brake-Inching Pedal …………………………………………………………………..43
• 71. Forward-Reverse Switch …………………………………………………………….43
• 72. Park Brake Lever ………………………………………………………………………44
• 73. Park brake Warning …………………………………………………………………..44
• 74. Horn ………………………………………………………………………………………..45
• 75. Drive Controls – Single Lever Machines (Optional) …………………………..46
• 76. Steering Wheel …………………………………………………………………………46
• 77. Accelerator Pedal ……………………………………………………………………..46
• 78. Brake-Inching Pedal …………………………………………………………………..46
• 79. Forward-Reverse Switch …………………………………………………………….46
• 80. Park Brake Lever ………………………………………………………………………46
• 81. Varispeed Control (Option) …………………………………………………………47
• 82. Horn ………………………………………………………………………………………..47
• 83. Switches …………………………………………………………………………………….48
• 84. Console Panel Switches …………………………………………………………….48
• 85. Column Switches ………………………………………………………………………51
• 86. Starter Switch ……………………………………………………………………………51
• 87. Cab Interior Light ………………………………………………………………………52
• 88. Roof-Mounted Wiper ………………………………………………………………….52
• 89. Instrument Panel …………………………………………………………………………53
• 90. Digital LCD Fuel Gauge ……………………………………………………………..54
• 91. Indicator Lights …………………………………………………………………………54
• 92. Blink Codes – Boom Extend – Retract …………………………………………..55
• 93. Blink Codes – Auxiliary Warning Light …………………………………………..55
• 94. Warning Lights ………………………………………………………………………….56
• 95. Heater Controls …………………………………………………………………………..58
• 96. Heater ……………………………………………………………………………………..58
• 97. Operating Levers ……………………………………………………………………………..59
• 98. Introduction …………………………………………………………………………………59
• 99. Boom and Carriage Controls – Manual Lever Machines (Option) ……….60
• 100. Introduction ………………………………………………………………………………60
• 101. Raise Boom-Lower Boom …………………………………………………………..60
• 102. Tilt Carriage Back-Forward (Crowd-Dump) ……………………………………60
• 103. Extend Boom-Retract Boom ……………………………………………………….61
• 104. Boom and Carriage Controls – Single Lever Machines (Option) …………62
• 105. Overview ………………………………………………………………………………….62
• 106. Auxiliary Controls – Manual Lever Machines (If fitted) ……………………….63
• 107. Auxiliary Controls – Single Lever Machines ……………………………………..63
• 108. Introduction ………………………………………………………………………………63
• 109. Auxiliary (Constant Flow Mode) …………………………………………………..63
• 110. Safety Equipment …………………………………………………………………………….65
• 111. Load Charts ………………………………………………………………………………..65
• 112. Introduction to Load Charts ………………………………………………………..65
• 113. Using the Load Charts ……………………………………………………………….65
• 114. Longitudinal Load Moment Indicator (LLMI) …………………………………….67
• 115. Introduction ………………………………………………………………………………67
• 116. Checking the Indicator ……………………………………………………………….68
• 117. Setting the Volume and Brightness ………………………………………………69
• 118. Diagnostic Fault Codes ………………………………………………………………70
• 119. LLMI with Longitudinal Load Moment Control ………………………………….71
• 120. Introduction ………………………………………………………………………………71
• 121. Load Control Mode ……………………………………………………………………73
• 122. Emergency Override Function …………………………………………………….74
• 123. Warm Up Procedure ………………………………………………………………….74
• 124. Daily Functional Check ………………………………………………………………75
• 125. Inclinometer ………………………………………………………………………………..76
• 126. Fire Extinguisher (if fitted) …………………………………………………………….76
• 127. Operation …………………………………………………………………………………76
• 128. Beacon ………………………………………………………………………………………77
• 129. Before Starting the Engine …………………………………………………………………78
• 130. Starting the Engine …………………………………………………………………………..80
• 131. Preparing the Machine for Travel ……………………………………………………….82
• 132. Introduction …………………………………………………………………………………82
• 133. Preparing for Road Travel …………………………………………………………….82
• 134. Preparing for Site Travel ……………………………………………………………….84
• 135. Getting the Machine Moving ………………………………………………………………85
• 136. Operating Practices ……………………………………………………………………..85
• 137. Operating Procedure ……………………………………………………………………86
• 138. Stopping and Parking the Machine ……………………………………………………..87
• 139. Working with the Machine …………………………………………………………………89
• 140. Operating Practices and Site Safety ………………………………………………89
• 141. Clothing and Safety Equipment ……………………………………………………..89
• 142. Danger Zone ………………………………………………………………………………89
• 143. Working with the Boom ………………………………………………………………..90
• 144. Introduction ………………………………………………………………………………90
• 145. Risk Assessment ………………………………………………………………………91
• 146. Lifting and Loading Operations ……………………………………………………92
• 147. Fork Ratings …………………………………………………………………………….93
• 148. Handling Palleted Loads …………………………………………………………….94
• 149. Handling Bales ………………………………………………………………………….95
• 150. Handling Uneven Loads …………………………………………………………….96
• 151. Stacking Loads …………………………………………………………………………97
• 152. Filling a Shovel …………………………………………………………………………98
• 153. Loading a Truck ………………………………………………………………………..99
• 154. Use of Machines on Gradients or Slopes ………………………………………..99
• 155. Driving Up and Down Gradients ………………………………………………….99
• 156. Driving Across Gradients ………………………………………………………….100
• 157. Lifting Operations on Gradients …………………………………………………101
• 158. Operating Environment ……………………………………………………………………102
• 159. Operating in Low Temperatures …………………………………………………..102
• 160. Operating in High Temperatures ………………………………………………….102
• 161. Refuelling the Machine ……………………………………………………………………103
• 162. Low Fuel Levels ………………………………………………………………………..103
• 163. Filling the Tank ………………………………………………………………………….103
• 164. Moving a Disabled Machine …………………………………………………………….105
• 165. Transporting the Machine ………………………………………………………………..106
• 166. Lifting the Machine …………………………………………………………………………108
• 167. Introduction ……………………………………………………………………………….108
• 168. Preparing the Machine ……………………………………………………………….108
• 169. Lifting the Machine …………………………………………………………………….109
• 170. Storage of the Machine ………………………………………………………………….. 110
• 171. Introduction ………………………………………………………………………………. 110
• 172. Storage Area ……………………………………………………………………………. 110
• 173. Prepare the Machine for Storage ………………………………………………… 110
• 174. Put the Machine into Storage ……………………………………………………… 110
• 175. During Storage …………………………………………………………………………. 110
• 176. Take the Machine Out of Storage ………………………………………………… 111
• 177. Routine Maintenance
• 178. Service Requirements ……………………………………………………………………. 113
• 179. Fit for Purpose Tests for Lifting Equipment ……………………………………. 113
• 180. Obtaining Replacement Parts ……………………………………………………… 113
• 181. Health and Safety ………………………………………………………………………….. 114
• 182. Lubricants ………………………………………………………………………………… 114
• 183. Introduction ……………………………………………………………………………. 114
• 184. Hygiene …………………………………………………………………………………. 114
• 185. Storage …………………………………………………………………………………. 114
• 186. Waste Disposal ………………………………………………………………………. 114
• 187. Handling ………………………………………………………………………………… 114
• 188. First Aid – Oil ………………………………………………………………………….. 115
• 189. Spillage …………………………………………………………………………………. 115
• 190. Fires ……………………………………………………………………………………… 115
• 191. Battery …………………………………………………………………………………….. 116
• 192. Warning Symbols ……………………………………………………………………. 117
• 193. First Aid – Electrolyte ……………………………………………………………….. 117
• 194. Service Schedules …………………………………………………………………………. 118
• 195. Introduction ………………………………………………………………………………. 118
• 196. How to Use the Service Schedules ……………………………………………… 118
• 197. Calendar Equivalents ………………………………………………………………… 118
• 198. Pre-start Cold Checks, Service Points and Fluid Levels …………………. 119
• 199. Functional Test and Final Inspection …………………………………………….122
• 200. Fluids, Lubricants and Capacities ……………………………………………………..124
• 201. Specifications ……………………………………………………………………………124
• 202. Fuels ………………………………………………………………………………………..125
• 203. Acceptable and Unacceptable Fuels ………………………………………….125
• 204. Fuels for Low Temperatures ……………………………………………………..125
• 205. Biodiesel Fuel …………………………………………………………………………125
• 206. Coolant Mixtures ……………………………………………………………………….127
• 207. Tools …………………………………………………………………………………………….128
• 208. Toolbox …………………………………………………………………………………….128
• 209. Carrying Tools onto the Machine ………………………………………………….128
• 210. Prepare the Machine for Maintenance ………………………………………………129
• 211. Introduction ……………………………………………………………………………….129
• 212. How to Make the Machine Safe (Boom Lowered) …………………………..129
• 213. How to Make the Machine Safe (Boom Lifted) ……………………………….130
• 214. Installing the Maintenance Strut …………………………………………………130
• 215. Removing the Maintenance Strut ……………………………………………….131
• 216. Using a Jack to Lift the Machine ………………………………………………….131
• 217. Cleaning the Machine ……………………………………………………………………..134
• 218. Introduction ……………………………………………………………………………….134
• 219. Detergents ……………………………………………………………………………..134
• 220. Pressure Washing and Steam Cleaning ……………………………………..134
• 221. Preparing the Machine for Cleaning ……………………………………………..135
• 222. Cleaning the Machine …………………………………………………………………135
• 223. Fan Reverse (if fitted) …………………………………………………………………138
• 224. Checking For Damage …………………………………………………………………….139
• 225. Checking the ROPS-FOPS …………………………………………………………139
• 226. Greasing ……………………………………………………………………………………….141
• 227. Preparing the Machine for Greasing …………………………………………….142
• 228. Greasing Sequence ……………………………………………………………………142
• 229. Grease Points ……………………………………………………………………………143
• 230. Boom Pivot Grease Points ………………………………………………………..143
• 231. Front Steering Linkage Grease Points ………………………………………..144
• 232. Rear Steering Linkage Grease Points ………………………………………..144
• 233. Rear Axle Pivot Grease Point ……………………………………………………145
• 234. Wear Pad Runways and Bonnet Hinge Points …………………………….145
• 235. Extension Ram Pivot ……………………………………………………………….146
• 236. Oiling ……………………………………………………………………………………………147
• 237. Access Panels ……………………………………………………………………………….148
• 238. Introduction ……………………………………………………………………………….148
• 239. Engine Cover …………………………………………………………………………….149
• 240. Maintenance Position ………………………………………………………………149
• 241. Operation Position …………………………………………………………………..149
• 242. Engine Side Panel ……………………………………………………………………..149
• 243. Maintenance Position ………………………………………………………………149
• 244. Operation Position …………………………………………………………………..150
• 245. Rear Engine Guard ……………………………………………………………………151
• 246. Maintenance Position ………………………………………………………………151
• 247. Operation Position …………………………………………………………………..151
• 248. Underfloor Cover ……………………………………………………………………….152
• 249. Maintenance Position ………………………………………………………………152
• 250. Operation Position …………………………………………………………………..152
• 251. Hydraulic Tank Cover …………………………………………………………………152
• 252. Maintenance Position ………………………………………………………………152
• 253. Operation Position …………………………………………………………………..153
• 254. Operators Seat Base ………………………………………………………………….154
• 255. Maintenance Position ………………………………………………………………154
• 256. Operation Position …………………………………………………………………..154
• 257. Rear Wheel Arch Panels …………………………………………………………….155
• 258. Maintenance Position ………………………………………………………………155
• 259. Operation Position …………………………………………………………………..155
• 260. Left Instrument Panel …………………………………………………………………155
• 261. Maintenance Position ………………………………………………………………155
• 262. Operation Position …………………………………………………………………..155
• 263. Right Cab Panel ………………………………………………………………………..156
• 264. Maintenance Position ………………………………………………………………156
• 265. Operation Position …………………………………………………………………..156
• 266. Air Conditioning (If Fitted) ………………………………………………………………..157
• 267. Service Checks …………………………………………………………………………157
• 268. Off-Season Operation ………………………………………………………………157
• 269. Cab Heater Filter ……………………………………………………………………………158
• 270. Replacing the Cab Heater Filter …………………………………………………..158
• 271. Brakes ………………………………………………………………………………………….159
• 272. Park Brake ………………………………………………………………………………..159
• 273. Introduction …………………………………………………………………………….159
• 274. Testing the Park Brake ……………………………………………………………..159
• 275. Park Brake Adjustment up to sn 1769015 …………………………………..161
• 276. Park Brake Adjustment from sn 1769016 ……………………………………162
• 277. Foot Brake ………………………………………………………………………………..162
• 278. Checking the Foot Brake Fluid Level ………………………………………….162
• 279. Checking the Brake Shoe Condition …………………………………………..164
• 280. Electrical System ……………………………………………………………………………165
• 281. Introduction ……………………………………………………………………………….165
• 282. Battery ……………………………………………………………………………………..165
• 283. Battery Disconnection-Connection ……………………………………………..165
• 284. Checking the Electrolyte Level ………………………………………………….165
• 285. Battery Isolator ………………………………………………………………………..166
• 286. Jump Starting the Engine ……………………………………………………………167
• 287. Fuses ……………………………………………………………………………………….169