JCB 520-40, 524-50, 527-55 Loadall Operator Manual 9811-6000

Description

• Model List:
  • 520-40, 524-50, 527-55 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. Units of Measurement ……………………………………………………………………1
• 10. Left Side, Right Side ………………………………………………………………………1
• 11. Cab-Canopy …………………………………………………………………………………1
• 12. Cross References ………………………………………………………………………….1
• 13. Machine Description …………………………………………………………………………..2
• 14. The JCB Loadall ……………………………………………………………………………2
• 15. Intended Use ………………………………………………………………………………..2
• 16. Component Location ……………………………………………………………………..2
• 17. Safety Check List ……………………………………………………………………………….4
• 18. Safety – Yours and Others ………………………………………………………………4
• 19. General Safety ……………………………………………………………………………..4
• 20. Operating Safety …………………………………………………………………………..6
• 21. Maintenance Safety ……………………………………………………………………..10
• 22. Safety Labels …………………………………………………………………………………..15
• 23. Introduction …………………………………………………………………………………15
• 24. Safety Label Identification (Machines built before January 2010) ……….16
• 25. Safety Label Identification (Machines built after January 2010) ………….18
• 26. Identifying Your Machine …………………………………………………………………..20
• 27. Machine Identification Plate ………………………………………………………….20
• 28. Component Identification Plates …………………………………………………….22
• 29. Machine Security ……………………………………………………………………………..25
• 30. Introduction …………………………………………………………………………………25
• 31. JCB Plantguard …………………………………………………………………………..25
• 32. Construction Equipment Security And Registration Scheme (CESAR) .25
• 33. Operation
• 34. Introduction ……………………………………………………………………………………..27
• 35. Before Entering the Cab ……………………………………………………………………28
• 36. Entering and Leaving the Cab ……………………………………………………………29
• 37. Emergency Exit …………………………………………………………………………..30
• 38. Doors and Windows …………………………………………………………………………31
• 39. Opening and Closing the Doors …………………………………………………….31
• 40. Opening and Closing the Upper Door Section …………………………………32
• 41. Seat Controls …………………………………………………………………………………..33
• 42. Introduction …………………………………………………………………………………33
• 43. Basic Seat ………………………………………………………………………………….33
• 44. Seat Belt …………………………………………………………………………………………34
• 45. Inertia Reel Seat Belt …………………………………………………………………..34
• 46. Static Seat Belt ……………………………………………………………………………35
• 47. Cab Layout ……………………………………………………………………………………..36
• 48. 520-40 Machines …………………………………………………………………………36
• 49. 524-50, 527-55 Machines ……………………………………………………………..38
• 50. Drive Controls, Switches and Instruments ……………………………………………40
• 51. Drive Controls ……………………………………………………………………………..40
• 52. Switches …………………………………………………………………………………….43
• 53. Instrument Panel …………………………………………………………………………46
• 54. Cab Heater Controls …………………………………………………………………….50
• 55. Operating Levers ……………………………………………………………………………..51
• 56. Introduction …………………………………………………………………………………51
• 57. Control Layouts …………………………………………………………………………..51
• 58. Boom and Carriage Controls …………………………………………………………52
• 59. Auxiliary Controls ………………………………………………………………………..57
• 60. Float Control ……………………………………………………………………………….59
• 61. Safety Equipment …………………………………………………………………………….60
• 62. Control Locks ……………………………………………………………………………..60
• 63. Load Charts ………………………………………………………………………………..61
• 64. Boom Indicators ………………………………………………………………………….63
• 65. Load Moment Indicator (LMI) ………………………………………………………..64
• 66. Inclinometer ………………………………………………………………………………..68
• 67. Beacon ………………………………………………………………………………………68
• 68. Fire Extinguisher (if fitted) …………………………………………………………….69
• 69. Before Starting the Engine …………………………………………………………………70
• 70. Starting the Engine …………………………………………………………………………..72
• 71. Preparing the Machine for Travel ……………………………………………………….73
• 72. Introduction …………………………………………………………………………………73
• 73. Preparing for Road Travel …………………………………………………………….73
• 74. Preparing for Site Travel ……………………………………………………………….74
• 75. Getting the Machine Moving ………………………………………………………………75
• 76. Operating Practices ……………………………………………………………………..75
• 77. Operating Procedure ……………………………………………………………………76
• 78. Stopping and Parking the Machine ……………………………………………………..77
• 79. Working with the Machine …………………………………………………………………78
• 80. Operating Practices and Site Safety ………………………………………………78
• 81. Clothing and Safety Equipment ……………………………………………………..78
• 82. Danger Zone ………………………………………………………………………………78
• 83. Working with the Boom ………………………………………………………………..79
• 84. Use of Machines on Gradients or Slopes ………………………………………..88
• 85. Operating Environment ……………………………………………………………………..91
• 86. Introduction …………………………………………………………………………………91
• 87. Operating in Low Temperatures …………………………………………………….91
• 88. Operating in High Temperatures ……………………………………………………91
• 89. Tow Hitch Option ……………………………………………………………………………..92
• 90. Introduction …………………………………………………………………………………92
• 91. Connecting the Trailer ………………………………………………………………….93
• 92. Prepare the Trailer For Towing ………………………………………………………94
• 93. Refuelling the Machine ……………………………………………………………………..95
• 94. Low Fuel Levels ………………………………………………………………………….95
• 95. Filling the Tank ……………………………………………………………………………95
• 96. Moving a Disabled Machine ………………………………………………………………97
• 97. Transporting the Machine ………………………………………………………………….98
• 98. Storage of the Machine …………………………………………………………………..100
• 99. Introduction ……………………………………………………………………………….100
• 100. Storage Area …………………………………………………………………………….100
• 101. Prepare the Machine for Storage …………………………………………………100
• 102. Put the Machine into Storage ………………………………………………………100
• 103. During Storage ………………………………………………………………………….100
• 104. Take the Machine Out of Storage …………………………………………………101
• 105. Routine Maintenance
• 106. Service Requirements …………………………………………………………………….103
• 107. Introduction ……………………………………………………………………………….103
• 108. Owner-Operator Support …………………………………………………………….103
• 109. Service-Maintenance Agreements ……………………………………………….103
• 110. Initial Service and Inspection (100 Hours) ……………………………………..103
• 111. Fit for Purpose Tests for Lifting Equipment …………………………………….104
• 112. Obtaining Replacement Parts ………………………………………………………104
• 113. Health and Safety …………………………………………………………………………..105
• 114. Lubricants …………………………………………………………………………………105
• 115. Battery ……………………………………………………………………………………..107
• 116. Service Schedules ………………………………………………………………………….109
• 117. Introduction ……………………………………………………………………………….109
• 118. How to Use the Service Schedules ………………………………………………109
• 119. Calendar Equivalents …………………………………………………………………109
• 120. Pre-start Cold Checks, Service Points and Fluid Levels …………………. 110
• 121. Functional Test and Final Inspection ……………………………………………. 113
• 122. Fluids, Lubricants and Capacities …………………………………………………….. 115
• 123. Coolant Mixtures ………………………………………………………………………. 116
• 124. Fuels ……………………………………………………………………………………….. 117
• 125. Prepare the Machine for Maintenance ………………………………………………120
• 126. Introduction ……………………………………………………………………………….120
• 127. How to Make the Machine Safe (Boom Lowered) …………………………..121
• 128. How to Make the Machine Safe
• 129. (Boom Lifted) …………………………………………………………………………….122
• 130. Cleaning the Machine ……………………………………………………………………..124
• 131. Introduction ……………………………………………………………………………….124
• 132. Preparing the Machine for Cleaning ……………………………………………..124
• 133. Cleaning the Machine …………………………………………………………………125
• 134. Checking for Damage ……………………………………………………………………..127
• 135. Check the Machine Body and Structure ………………………………………..127
• 136. Check the Tyres ………………………………………………………………………..127
• 137. Check the Seat and Seat Belt ……………………………………………………..127
• 138. Check the Hydraulic Hoses and Fittings ……………………………………….127
• 139. Checking the ROPS-FOPS Structure ……………………………………………128
• 140. Greasing ……………………………………………………………………………………….129
• 141. Introduction ……………………………………………………………………………….129
• 142. Preparing the Machine for Greasing …………………………………………….129
• 143. Every 50 Hours ………………………………………………………………………….130
• 144. Every 500 Hours ………………………………………………………………………..133
• 145. Every 1000 Hours ………………………………………………………………………134
• 146. Oiling ……………………………………………………………………………………………135
• 147. Access Panels ……………………………………………………………………………….136
• 148. Engine Cover …………………………………………………………………………….136
• 149. Battery Cover ……………………………………………………………………………136
• 150. Rear Grille ………………………………………………………………………………..136
• 151. Undershields …………………………………………………………………………….137
• 152. Seat Base …………………………………………………………………………………138
• 153. Cab Heater Filter ……………………………………………………………………………139
• 154. Cleaning the Cab Heater Filter …………………………………………………….139
• 155. Brakes ………………………………………………………………………………………….140
• 156. Park Brake ………………………………………………………………………………..140
• 157. Foot Brake ………………………………………………………………………………..142
• 158. Electrical System ……………………………………………………………………………143
• 159. Battery ……………………………………………………………………………………..143
• 160. Jump Starting the Engine ……………………………………………………………145
• 161. Fuses ……………………………………………………………………………………….146
• 162. Primary Fuses …………………………………………………………………………..148
• 163. Relays ……………………………………………………………………………………..149
• 164. Engine ………………………………………………………………………………………….150
• 165. Oil and Filter ……………………………………………………………………………..150
• 166. Cooling System …………………………………………………………………………153
• 167. Alternator Drive Belt …………………………………………………………………..155
• 168. Air Filter ……………………………………………………………………………………156
• 169. Fuel System …………………………………………………………………………………..159
• 170. Introduction ……………………………………………………………………………….159
• 171. Cleaning the Lift Pump Gauze (520-40 Machines) …………………………160
• 172. Fuel Filter …………………………………………………………………………………161
• 173. Bleeding the System ………………………………………………………………….164
• 174. Hydraulic System ……………………………………………………………………………166
• 175. Introduction ……………………………………………………………………………….166
• 176. Releasing the Hydraulic Pressure ………………………………………………..167
• 177. Oil and Filter ……………………………………………………………………………..168
• 178. Changing the Hydraulic Tank Filler Cap ………………………………………..170
• 179. Hose Burst Protection Valves ………………………………………………………171
• 180. Transmission …………………………………………………………………………………173
• 181. Gearbox ……………………………………………………………………………………173
• 182. Axles ………………………………………………………………………………………..174
• 183. Tyres and Wheels …………………………………………………………………………..176
• 184. Tyre Inflation ……………………………………………………………………………..176
• 185. Wheel Alignment ……………………………………………………………………………178
• 186. Introduction ……………………………………………………………………………….178
• 187. Permanent 4-Wheel Steer …………………………………………………………..178
• 188. Electronic Steer Mode Selector ……………………………………………………179
• 189. Wear Pads …………………………………………………………………………………….180
• 190. Boom Wear Pad Clearance …………………………………………………………180
• 191. Windscreen Washer ……………………………………………………………………….181
• 192. Checking the Level …………………………………………………………………….181
• 193. Fire Extinguisher (if fitted) ………………………………………………………………..182
• 194. Checking the Fire Extinguisher ……………………………………………………182
• 195. Optional Attachments
• 196. Introduction ……………………………………………………………………………………183
• 197. Attachments for your Machine ………………………………………………………….184
• 198. Connecting-Disconnecting Hydraulic Hoses ……………………………………….185
• 199. Introduction ……………………………………………………………………………….185
• 200. Connecting the Hydraulic Hoses ………………………………………………….185
• 201. Disconnecting the Hydraulic Hoses ………………………………………………186
• 202. Quick Release Couplings ……………………………………………………………187
• 203. Q-Fit Attachments …………………………………………………………………………..189
• 204. Compact Tool Carrier …………………………………………………………………189
• 205. Skid Steer Hitch …………………………………………………………………………193
• 206. Fork Mounted Hook ………………………………………………………………………..195
• 207. Safety ………………………………………………………………………………………195
• 208. Installing …………………………………………………………………………………..195
• 209. Removing …………………………………………………………………………………195
• 210. Operation ………………………………………………………………………………….196
• 211. Maintenance ……………………………………………………………………………..196
• 212. 6-in-1 Shovel …………………………………………………………………………………197
• 213. Safety ………………………………………………………………………………………197
• 214. Preparing for Travel ……………………………………………………………………197
• 215. Control ……………………………………………………………………………………..197
• 216. Operation ………………………………………………………………………………….197
• 217. Daily Maintenance ……………………………………………………………………..199
• 218. Manure-Silage Fork with Top Grab ……………………………………………………200
• 219. Safety ………………………………………………………………………………………200
• 220. Control ……………………………………………………………………………………..200
• 221. Preparing for Travel ……………………………………………………………………200
• 222. Installing and Removing ……………………………………………………………..200
• 223. Operation ………………………………………………………………………………….200
• 224. Daily Maintenance ……………………………………………………………………..200
• 225. Specifications
• 226. Static Dimensions …………………………………………………………………………..201
• 227. 520-40 ……………………………………………………………………………………..201
• 228. 524-50, 527-55 ………………………………………………………………………….202
• 229. Performance Dimensions ………………………………………………………………..203
• 230. Lift Performance ………………………………………………………………………..203
• 231. Loader Performance …………………………………………………………………..205
• 232. Noise Data …………………………………………………………………………………….206
• 233. Introduction ……………………………………………………………………………….206
• 234. 520-40 ……………………………………………………………………………………..206
• 235. 524-50, 527-55 ………………………………………………………………………….206
• 236. Vibration Data ………………………………………………………………………………..207
• 237. Introduction ……………………………………………………………………………….207
• 238. 520-40, 524-50, 527-55 ………………………………………………………………208
• 239. Tyre Sizes and Pressures ………………………………………………………………..209
• 240. Introduction ……………………………………………………………………………….209
• 241. Specifications ……………………………………………………………………………209
• 242. Trailer Towing ………………………………………………………………………………..210
• 243. Towing Limitations ……………………………………………………………………..210
• 244. Load Charts ………………………………………………………………………………….. 211
• 245. Introduction ………………………………………………………………………………. 211
• 246. Warranty Information
• 247. Machine Service Record Sheet ………………………………………………………..213
• 248. Registration Information ………………………………………………………………….215
• 249. European Community Standards
• 250. EC Declaration of Conformity …………………………………………………………..217
• 251. Introduction ……………………………………………………………………………….217
• 252. Explanation of the EC Declaration of Conformity ……………………………219