JCB 520-50, 525-50, 525-50S Loadall Operator Manual 9811-9200

Description

• Model List:
  • 520-50, 525-50, 525-50S 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 Locations ……………………………………………………………………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 …………………………………………………………….16
• 25. Identifying Your Machine …………………………………………………………………..18
• 26. Machine Identification Plate ………………………………………………………….18
• 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 Rear Window ………………………………………….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 …………………………………………………………………………………….40
• 51. Instrument Panel …………………………………………………………………………43
• 52. Air Conditioning and Heater Controls ……………………………………………..46
• 53. Operating Levers ……………………………………………………………………………..47
• 54. Introduction …………………………………………………………………………………47
• 55. Control Layouts …………………………………………………………………………..47
• 56. Boom and Carriage Controls …………………………………………………………48
• 57. Auxiliary Controls ………………………………………………………………………..49
• 58. Safety Equipment …………………………………………………………………………….50
• 59. Control Lever Locks …………………………………………………………………….50
• 60. Load Charts ………………………………………………………………………………..51
• 61. Boom Indicators ………………………………………………………………………….53
• 62. Load Moment Indicator (LMI) ………………………………………………………..54
• 63. Inclinometer ………………………………………………………………………………..58
• 64. Beacon ………………………………………………………………………………………58
• 65. Fire Extinguisher (if fitted) …………………………………………………………….59
• 66. Before Starting the Engine …………………………………………………………………60
• 67. Starting the Engine …………………………………………………………………………..62
• 68. Preparing the Machine for Travel ……………………………………………………….64
• 69. Preparing for Road Travel …………………………………………………………….64
• 70. Preparing for Site Travel ……………………………………………………………….65
• 71. Getting the Machine Moving ………………………………………………………………66
• 72. Operating Practices ……………………………………………………………………..66
• 73. Operating Procedure ……………………………………………………………………67
• 74. Stopping and Parking the Machine ……………………………………………………..68
• 75. Testing the Park Brake …………………………………………………………………69
• 76. Working with the Machine …………………………………………………………………70
• 77. Operating Practices and Site Safety ………………………………………………70
• 78. Clothing and Safety Equipment ……………………………………………………..70
• 79. Danger Zone ………………………………………………………………………………70
• 80. Working with the Boom ………………………………………………………………..71
• 81. Use of Machines on Gradients or Slopes ………………………………………..80
• 82. Operating Environment ……………………………………………………………………..83
• 83. Introduction …………………………………………………………………………………83
• 84. Operating in Low Temperatures …………………………………………………….83
• 85. Operating in High Temperatures ……………………………………………………83
• 86. Tow Hitch Options …………………………………………………………………………….84
• 87. Introduction …………………………………………………………………………………84
• 88. Mechanical Tow Hitch Option ………………………………………………………..85
• 89. Hydraulic Tow Hitch Option …………………………………………………………..86
• 90. Refuelling the Machine ……………………………………………………………………..88
• 91. Low Fuel Levels ………………………………………………………………………….88
• 92. Filling the Tank ……………………………………………………………………………88
• 93. Moving a Disabled Machine ………………………………………………………………90
• 94. Recovery Hitch ……………………………………………………………………………90
• 95. Transporting the Machine ………………………………………………………………….91
• 96. Storage of the Machine …………………………………………………………………….93
• 97. Introduction …………………………………………………………………………………93
• 98. Storage Area ………………………………………………………………………………93
• 99. Prepare the Machine for Storage …………………………………………………..93
• 100. Put the Machine into Storage ………………………………………………………..93
• 101. During Storage ……………………………………………………………………………93
• 102. Take the Machine Out of Storage …………………………………………………..94
• 103. Routine Maintenance
• 104. Service Requirements ………………………………………………………………………95
• 105. Introduction …………………………………………………………………………………95
• 106. Owner-Operator Support ………………………………………………………………95
• 107. Service-Maintenance Agreements …………………………………………………95
• 108. Fit for Purpose Tests for Lifting Equipment ………………………………………96
• 109. Obtaining Replacement Parts ………………………………………………………..96
• 110. Health and Safety …………………………………………………………………………….97
• 111. Lubricants …………………………………………………………………………………..97
• 112. Battery ……………………………………………………………………………………….99
• 113. Service Schedules ………………………………………………………………………….101
• 114. Introduction ……………………………………………………………………………….101
• 115. How to Use the Service Schedules ………………………………………………101
• 116. Calendar Equivalents …………………………………………………………………101
• 117. Pre-start Cold Checks, Service Points and Fluid Levels ………………….102
• 118. Functional Test and Final Inspection …………………………………………….105
• 119. Fluids, Lubricants and Capacities ……………………………………………………..107
• 120. Coolant Mixtures ……………………………………………………………………….108
• 121. Fuels ………………………………………………………………………………………..109
• 122. Prepare the Machine for Maintenance ……………………………………………… 112
• 123. Introduction ………………………………………………………………………………. 112
• 124. How to Make the Machine Safe (Boom Lowered) ………………………….. 113
• 125. How to Make the Machine Safe (Boom Lifted) ………………………………. 114
• 126. Cleaning the Machine …………………………………………………………………….. 116
• 127. Introduction ………………………………………………………………………………. 116
• 128. Preparing the Machine for Cleaning …………………………………………….. 116
• 129. Cleaning the Machine ………………………………………………………………… 117
• 130. Checking for Damage …………………………………………………………………….. 119
• 131. Check the Machine Body and Structure ……………………………………….. 119
• 132. Check the Tyres ……………………………………………………………………….. 119
• 133. Check the Seat and Seat Belt …………………………………………………….. 119
• 134. Check the Hydraulic Hoses and Fittings ………………………………………. 119
• 135. Checking the ROPS-FOPS Structure ……………………………………………120
• 136. Greasing ……………………………………………………………………………………….121
• 137. Introduction ……………………………………………………………………………….121
• 138. Preparing the Machine for Greasing …………………………………………….121
• 139. Every 50 Hours ………………………………………………………………………….122
• 140. Every 500 Hours ………………………………………………………………………..123
• 141. Every 1000 Hours ………………………………………………………………………124
• 142. Oiling ……………………………………………………………………………………………125
• 143. Every 50 Hours ………………………………………………………………………….125
• 144. Access Panels ……………………………………………………………………………….126
• 145. Engine Cover …………………………………………………………………………….126
• 146. Rear Grille ………………………………………………………………………………..126
• 147. Cab Heater Filter ……………………………………………………………………………127
• 148. Cleaning the Cab Heater Filter …………………………………………………….127
• 149. Brakes ………………………………………………………………………………………….128
• 150. Electrical System ……………………………………………………………………………129
• 151. Battery ……………………………………………………………………………………..129
• 152. Jump Starting the Engine ……………………………………………………………131
• 153. Fuses ……………………………………………………………………………………….132
• 154. Primary Fuses …………………………………………………………………………..136
• 155. Relays ……………………………………………………………………………………..137
• 156. Engine ………………………………………………………………………………………….140
• 157. Oil and Filter ……………………………………………………………………………..140
• 158. Cooling System …………………………………………………………………………143
• 159. Alternator Drive Belt …………………………………………………………………..145
• 160. Air Filter ……………………………………………………………………………………146
• 161. Fuel System …………………………………………………………………………………..148
• 162. Introduction ……………………………………………………………………………….148
• 163. Water Sediment Bowl and Engine Fuel Filter …………………………………149
• 164. Bleeding the System ………………………………………………………………….152
• 165. Hydraulic System ……………………………………………………………………………155
• 166. Introduction ……………………………………………………………………………….155
• 167. Venting Hydraulic Pressure …………………………………………………………155
• 168. Oil and Filter ……………………………………………………………………………..156
• 169. Hydraulic Tank Filler Cap ……………………………………………………………158
• 170. Hose Burst Protection Valves ………………………………………………………159
• 171. Transmission …………………………………………………………………………………160
• 172. Gearbox ……………………………………………………………………………………160
• 173. Axles ………………………………………………………………………………………..162
• 174. Tyres and Wheels …………………………………………………………………………..164
• 175. Tyre Inflation ……………………………………………………………………………..164
• 176. Wheel Alignment ……………………………………………………………………………166
• 177. Introduction ……………………………………………………………………………….166
• 178. Permanent 4-Wheel Steer …………………………………………………………..166
• 179. Electronic Steer Mode Selector ……………………………………………………167
• 180. Wear Pads …………………………………………………………………………………….168
• 181. Boom Wear Pad Clearance …………………………………………………………168
• 182. Windscreen Washer ……………………………………………………………………….169
• 183. Fire Extinguisher (if fitted) ………………………………………………………………..170
• 184. Checking the Fire Extinguisher ……………………………………………………170
• 185. Optional Attachments
• 186. Introduction ……………………………………………………………………………………171
• 187. Attachments for your Machine ………………………………………………………….172
• 188. Connecting-Disconnecting Hydraulic Hoses ……………………………………….173
• 189. Introduction ……………………………………………………………………………….173
• 190. Connecting the Hydraulic Hoses ………………………………………………….173
• 191. Disconnecting the Hydraulic Hoses ………………………………………………174
• 192. Quick Release Couplings ……………………………………………………………175
• 193. Q-Fit Attachments …………………………………………………………………………..177
• 194. Compact Tool Carrier …………………………………………………………………177
• 195. Fork Mounted Hook ………………………………………………………………………..181
• 196. Safety ………………………………………………………………………………………181
• 197. Installing …………………………………………………………………………………..181
• 198. Removing …………………………………………………………………………………181
• 199. Operation ………………………………………………………………………………….182
• 200. Maintenance ……………………………………………………………………………..182
• 201. Work Platforms ………………………………………………………………………………183
• 202. Specifications
• 203. Static Dimensions …………………………………………………………………………..185
• 204. 520-50, 525-50, 525-50S ……………………………………………………………185
• 205. Performance Dimensions ………………………………………………………………..186
• 206. 520-50, 525-50, 525-50S ……………………………………………………………186
• 207. Noise Data …………………………………………………………………………………….187
• 208. Introduction ……………………………………………………………………………….187
• 209. All Machines ……………………………………………………………………………..187
• 210. Vibration Data ………………………………………………………………………………..188
• 211. Introduction ……………………………………………………………………………….188
• 212. 520-50, 525-50, 525-50S ……………………………………………………………189
• 213. Tyre Sizes and Pressures ………………………………………………………………..190
• 214. Introduction ……………………………………………………………………………….190
• 215. Specifications ……………………………………………………………………………190
• 216. Trailer Towing ………………………………………………………………………………..191
• 217. Towing Limitations ……………………………………………………………………..191
• 218. Load Charts …………………………………………………………………………………..192
• 219. Introduction ……………………………………………………………………………….192
• 220. Warranty Information
• 221. Machine Service Record Sheet ………………………………………………………..193
• 222. Registration Information ………………………………………………………………….195
• 223. European Community Standards
• 224. EC Declaration of Conformity …………………………………………………………..197
• 225. Introduction ……………………………………………………………………………….197
• 226. Explanation of the EC Declaration of Conformity ……………………………199