JCB 520-40 Loadall Operator Manual 9821-0400

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