JCB 520-40 Loadall Operator Manual 9801-9094

Description

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