JCB 526-56 (T4i) to 560-80 (T4i) Operator Manual 9821-9050

Description

• Model List:
  • 526-56 (T4i), 531-70 (T4i), 533-105 (T4i), 535-95 (T4i), 535-v125 (T4i), 535-v140 (T4i), 536-60 (T4i), 536-70 (T4i), 536-70LP (T4i), 540-140 (T4i), 540-170 (T4i), 540-200 (T4i), 540-v140 (T4i), 541-70 (T4i), 550-80 (T4i), 560-80 (T4i)

• 1. Acronyms Glossary ……………………………………………………………………………………………………………………… viii
• 2. Introduction
• 3. About this Manual
• 4. Model and Serial Number ……………………………………………………………………………………………………… 1
• 5. Using the Manual …………………………………………………………………………………………………………………. 1
• 6. Left-Hand Side, Right-Hand Side …………………………………………………………………………………………… 1
• 7. Cab-Canopy ………………………………………………………………………………………………………………………… 2
• 8. Cross References ………………………………………………………………………………………………………………… 2
• 9. Safety
• 10. Safety – Yours and Others …………………………………………………………………………………………………….. 3
• 11. Safety Warnings …………………………………………………………………………………………………………………… 3
• 12. General Safety …………………………………………………………………………………………………………………….. 4
• 13. Clothing and Personal Protective Equipment (PPE) …………………………………………………………………. 5
• 14. About the Product
• 15. Introduction
• 16. General ……………………………………………………………………………………………………………………………….. 7
• 17. Name and Address of the Manufacturer …………………………………………………………………………………. 7
• 18. Product Compliance ……………………………………………………………………………………………………………… 7
• 19. Description
• 20. General ……………………………………………………………………………………………………………………………….. 8
• 21. Intended Use ……………………………………………………………………………………………………………………….. 8
• 22. Log Moving-Object Handling ………………………………………………………………………………………………….. 8
• 23. Optional Equipment and Attachments …………………………………………………………………………………….. 8
• 24. Danger Zone ……………………………………………………………………………………………………………………….. 8
• 25. Main Component Locations …………………………………………………………………………………………………… 9
• 26. Product and Component Identification
• 27. Machine …………………………………………………………………………………………………………………………….. 10
• 28. Engine ………………………………………………………………………………………………………………………………. 13
• 29. Axle ………………………………………………………………………………………………………………………………….. 14
• 30. Gearbox …………………………………………………………………………………………………………………………….. 16
• 31. Operator Protective Structure ………………………………………………………………………………………………. 17
• 32. Safety Labels
• 33. General ……………………………………………………………………………………………………………………………… 19
• 34. Safety Label Identification ……………………………………………………………………………………………………. 19
• 35. Operator Station
• 36. Component Locations …………………………………………………………………………………………………………. 21
• 37. Interior Switches
• 38. Ignition Switch ……………………………………………………………………………………………………………………. 24
• 39. Multi-Purpose Switch ………………………………………………………………………………………………………….. 24
• 40. Cab Interior Light ……………………………………………………………………………………………………………….. 25
• 41. Console Switches
• 42. General ……………………………………………………………………………………………………………………………… 27
• 43. Road Lights ……………………………………………………………………………………………………………………….. 27
• 44. Rear Fog Lights …………………………………………………………………………………………………………………. 27
• 45. Hazard Warning Lights ……………………………………………………………………………………………………….. 27
• 46. Work Lights ……………………………………………………………………………………………………………………….. 28
• 47. Transmission Mode …………………………………………………………………………………………………………….. 28
• 48. Transmission Disconnect …………………………………………………………………………………………………….. 28
• 49. Tilt Lock …………………………………………………………………………………………………………………………….. 28
• 50. Automatic Smooth Ride System …………………………………………………………………………………………… 28
• 51. Heater ……………………………………………………………………………………………………………………………….. 28
• 52. Air-Conditioning ………………………………………………………………………………………………………………….. 29
• 53. Window Heater ………………………………………………………………………………………………………………….. 29
• 54. Inner Boom Extend-Retract …………………………………………………………………………………………………. 29
• 55. Controls Isolation ……………………………………………………………………………………………………………….. 29
• 56. Stabiliser Isolation ………………………………………………………………………………………………………………. 29
• 57. Chassis Levelling ……………………………………………………………………………………………………………….. 30
• 58. Hydraulic Function ……………………………………………………………………………………………………………… 30
• 59. Hydraulic Mode ………………………………………………………………………………………………………………….. 30
• 60. Hydraulic Venting ……………………………………………………………………………………………………………….. 30
• 61. Hydraulic Tow Hitch ……………………………………………………………………………………………………………. 30
• 62. Reverse Fan ……………………………………………………………………………………………………………………… 31
• 63. Rear Window Wiper ……………………………………………………………………………………………………………. 31
• 64. Roof Window Wiper ……………………………………………………………………………………………………………. 31
• 65. Operation
• 66. Introduction
• 67. General ……………………………………………………………………………………………………………………………… 33
• 68. Operating Safety
• 69. General ……………………………………………………………………………………………………………………………… 34
• 70. Worksite Safety ………………………………………………………………………………………………………………….. 36
• 71. Risk Assessment ……………………………………………………………………………………………………………….. 37
• 72. Walk-Around Inspection
• 73. General ……………………………………………………………………………………………………………………………… 39
• 74. Entering and Leaving the Operator Station
• 75. General ……………………………………………………………………………………………………………………………… 40
• 76. Emergency Exit ………………………………………………………………………………………………………………….. 40
• 77. Doors
• 78. Operator Door ……………………………………………………………………………………………………………………. 43
• 79. Windows
• 80. Rear Window …………………………………………………………………………………………………………………….. 47
• 81. Battery Isolator
• 82. General ……………………………………………………………………………………………………………………………… 49
• 83. Before Starting the Engine
• 84. General ……………………………………………………………………………………………………………………………… 50
• 85. Operator Seat
• 86. General ……………………………………………………………………………………………………………………………… 51
• 87. Basic Seat …………………………………………………………………………………………………………………………. 51
• 88. Suspension Seat ………………………………………………………………………………………………………………… 52
• 89. Heated Seat Controls …………………………………………………………………………………………………………. 55
• 90. Seat Belt
• 91. General ……………………………………………………………………………………………………………………………… 56
• 92. Inertia Reel Seat Belt …………………………………………………………………………………………………………. 56
• 93. Static Seat Belt ………………………………………………………………………………………………………………….. 57
• 94. Mirrors
• 95. General ……………………………………………………………………………………………………………………………… 59
• 96. Starting the Engine
• 97. General ……………………………………………………………………………………………………………………………… 60
• 98. Immobiliser ………………………………………………………………………………………………………………………… 62
• 99. Stopping and Parking
• 100. General ……………………………………………………………………………………………………………………………… 66
• 101. Preparing for Travel
• 102. General ……………………………………………………………………………………………………………………………… 67
• 103. Preparing for Road Travel …………………………………………………………………………………………………… 67
• 104. Preparing for Worksite Travel ………………………………………………………………………………………………. 70
• 105. Smooth Ride System (SRS) ………………………………………………………………………………………………… 72
• 106. Beacon ……………………………………………………………………………………………………………………………… 73
• 107. Safety Equipment
• 108. Control Lock ………………………………………………………………………………………………………………………. 75
• 109. Drive Controls
• 110. Steering Wheel ………………………………………………………………………………………………………………….. 80
• 111. Steering Column ………………………………………………………………………………………………………………… 80
• 112. Accelerator Pedal ……………………………………………………………………………………………………………….. 80
• 113. Service Brake Pedal …………………………………………………………………………………………………………… 80
• 114. Park Brake ………………………………………………………………………………………………………………………… 81
• 115. Transmission Drive Lever ……………………………………………………………………………………………………. 81
• 116. Gear Lever ………………………………………………………………………………………………………………………… 83
• 117. Steer Mode Control ……………………………………………………………………………………………………………. 87
• 118. Instruments
• 119. Instrument Panel ………………………………………………………………………………………………………………… 88
• 120. Getting the Machine Moving
• 121. General ……………………………………………………………………………………………………………………………. 108
• 122. Slopes
• 123. General ……………………………………………………………………………………………………………………………. 110
• 124. Driving on Slopes …………………………………………………………………………………………………………….. 110
• 125. Working on Slopes …………………………………………………………………………………………………………… 111
• 126. Driving the Machine
• 127. Steer Modes …………………………………………………………………………………………………………………….. 113
• 128. Limited Slip Differential (LSD) ……………………………………………………………………………………………. 114
• 129. Towing Other Equipment …………………………………………………………………………………………………… 115
• 130. Operating Levers-Pedals
• 131. General ……………………………………………………………………………………………………………………………. 147
• 132. Control Layouts ………………………………………………………………………………………………………………… 147
• 133. Boom Controls …………………………………………………………………………………………………………………. 148
• 134. Chassis Levelling Controls ………………………………………………………………………………………………… 153
• 135. Stabiliser Controls …………………………………………………………………………………………………………….. 154
• 136. Auxiliary Circuit Controls ……………………………………………………………………………………………………. 157
• 137. Lifting and Loading
• 138. General ……………………………………………………………………………………………………………………………. 166
• 139. Load Charts …………………………………………………………………………………………………………………….. 166
• 140. Boom Indicators ……………………………………………………………………………………………………………….. 169
• 141. Inclinometers ……………………………………………………………………………………………………………………. 169
• 142. Interlocks …………………………………………………………………………………………………………………………. 170
• 143. Longitudinal Load Moment Indicator (LLMI) …………………………………………………………………………. 176
• 144. Load Motion Control System ……………………………………………………………………………………………… 178
• 145. Working with the Boom
• 146. General ……………………………………………………………………………………………………………………………. 186
• 147. Fork Ratings …………………………………………………………………………………………………………………….. 187
• 148. Repositioning the Forks …………………………………………………………………………………………………….. 187
• 149. Working with Pallets …………………………………………………………………………………………………………. 188
• 150. Working with Bales …………………………………………………………………………………………………………… 190
• 151. Working with Irregular Loads ……………………………………………………………………………………………… 191
• 152. Stacking Loads ………………………………………………………………………………………………………………… 192
• 153. Filling the Shovel ……………………………………………………………………………………………………………… 193
• 154. Loading a Truck ……………………………………………………………………………………………………………….. 194
• 155. Adjusting the Boom ………………………………………………………………………………………………………….. 194
• 156. Heating, Ventilating and Air-Conditioning (HVAC)
• 157. General ……………………………………………………………………………………………………………………………. 196
• 158. Air-Conditioning Controls …………………………………………………………………………………………………… 196
• 159. Face Level Fan ………………………………………………………………………………………………………………… 197
• 160. Fire Extinguisher
• 161. General ……………………………………………………………………………………………………………………………. 198
• 162. Moving a Disabled Machine
• 163. Jump-Starting the Engine ………………………………………………………………………………………………….. 199
• 164. Recovery Hitch …………………………………………………………………………………………………………………. 199
• 165. Lifting the Machine
• 166. General ……………………………………………………………………………………………………………………………. 201
• 167. Transporting the Machine
• 168. General ……………………………………………………………………………………………………………………………. 205
• 169. Loading the Machine onto the Transporting Vehicle-Trailer ……………………………………………………. 205
• 170. Operating Environment
• 171. General ……………………………………………………………………………………………………………………………. 211
• 172. Operating in Low Temperatures …………………………………………………………………………………………. 211
• 173. Operating in High Temperatures …………………………………………………………………………………………. 212
• 174. Refuelling
• 175. General ……………………………………………………………………………………………………………………………. 213
• 176. Low Fuel Levels ……………………………………………………………………………………………………………….. 213
• 177. Filling the Tank …………………………………………………………………………………………………………………. 213
• 178. Attachments
• 179. Working with Attachments
• 180. Introduction ………………………………………………………………………………………………………………………. 215
• 181. Attachments for your Machine ……………………………………………………………………………………………. 215
• 182. Connecting-Disconnecting Hydraulic Hoses …………………………………………………………………………. 216
• 183. Tool Carrier
• 184. General ……………………………………………………………………………………………………………………………. 224
• 185. Quick-fit Carriage
• 186. General ……………………………………………………………………………………………………………………………. 229
• 187. Tow Hitches
• 188. General ……………………………………………………………………………………………………………………………. 233
• 189. Ladder Hitch …………………………………………………………………………………………………………………….. 236
• 190. Hydraulic Tow Hitch ………………………………………………………………………………………………………….. 240
• 191. Mechanical Tow Hitch ……………………………………………………………………………………………………….. 242
• 192. Side-Shift Carriage
• 193. General ……………………………………………………………………………………………………………………………. 245
• 194. Jibs
• 195. General ……………………………………………………………………………………………………………………………. 250
• 196. Extension Jib ……………………………………………………………………………………………………………………. 250
• 197. Roof Truss Jib ………………………………………………………………………………………………………………….. 251
• 198. Hooks
• 199. Fork-Mounted Hook ………………………………………………………………………………………………………….. 254
• 200. Work Platforms
• 201. General ……………………………………………………………………………………………………………………………. 256
• 202. Preservation and Storage
• 203. Cleaning
• 204. General ……………………………………………………………………………………………………………………………. 257
• 205. Preparation ………………………………………………………………………………………………………………………. 257
• 206. Checking For Damage
• 207. General ……………………………………………………………………………………………………………………………. 259
• 208. Storage
• 209. General ……………………………………………………………………………………………………………………………. 260
• 210. Put into Storage ……………………………………………………………………………………………………………….. 260
• 211. During Storage …………………………………………………………………………………………………………………. 260
• 212. Take out of Storage ………………………………………………………………………………………………………….. 261
• 213. Security
• 214. General ……………………………………………………………………………………………………………………………. 262
• 215. JCB Plantguard ………………………………………………………………………………………………………………… 262
• 216. Construction Equipment Security and Registration Scheme (CESAR) …………………………………….. 262
• 217. LiveLink …………………………………………………………………………………………………………………………… 262
• 218. Maintenance
• 219. Introduction
• 220. General ……………………………………………………………………………………………………………………………. 263
• 221. Owner-Operator Support ……………………………………………………………………………………………………. 263
• 222. Service-Maintenance Agreements ………………………………………………………………………………………. 264
• 223. Initial Service and Inspection ……………………………………………………………………………………………… 264
• 224. Obtaining Spare Parts ………………………………………………………………………………………………………. 264
• 225. Maintenance Safety
• 226. General ……………………………………………………………………………………………………………………………. 265
• 227. Fluids and Lubricants ……………………………………………………………………………………………………….. 266
• 228. Maintenance Schedules
• 229. General ……………………………………………………………………………………………………………………………. 270
• 230. How to Use the Maintenance Schedules …………………………………………………………………………….. 270
• 231. Maintenance Intervals ……………………………………………………………………………………………………….. 270
• 232. Pre-start Cold Checks, Service Points and Fluid Levels ………………………………………………………… 271
• 233. Functional Tests and Final Inspection …………………………………………………………………………………. 273
• 234. Maintenance Positions
• 235. General ……………………………………………………………………………………………………………………………. 276
• 236. Maintenance Position – Boom Lowered ……………………………………………………………………………….. 276
• 237. Maintenance Position – Boom Raised …………………………………………………………………………………. 277
• 238. Service Points
• 239. General ……………………………………………………………………………………………………………………………. 283
• 240. Access Apertures
• 241. General ……………………………………………………………………………………………………………………………. 292
• 242. Battery Cover …………………………………………………………………………………………………………………… 292
• 243. Engine Compartment Cover ………………………………………………………………………………………………. 293
• 244. Rear Cover ………………………………………………………………………………………………………………………. 294
• 245. Undershield ……………………………………………………………………………………………………………………… 296
• 246. Tools
• 247. General ……………………………………………………………………………………………………………………………. 298
• 248. Toolbox ……………………………………………………………………………………………………………………………. 298
• 249. Lubrication
• 250. General ……………………………………………………………………………………………………………………………. 299
• 251. Preparation ……………………………………………………………………………………..