JCB 527-58 Tier 4I Operator Manual 9821-7000

Description

• Model List:
  • 527-58 Tier 4I

• 1. Safety Notices
• 2. Important Information …………………………………………………………………………1
• 3. The Operator Manual …………………………………………………………………….1
• 4. Safety Warnings ……………………………………………………………………………1
• 5. Introduction
• 6. About This Manual ……………………………………………………………………………..3
• 7. Product Compliance ………………………………………………………………………3
• 8. Machine Model and Serial Number ………………………………………………….3
• 9. Using this Manual ………………………………………………………………………….3
• 10. Left Side, Right Side ………………………………………………………………………3
• 11. Cab-Canopy …………………………………………………………………………………4
• 12. Cross References ………………………………………………………………………….4
• 13. Machine Description …………………………………………………………………………..5
• 14. The JCB Loadall ……………………………………………………………………………5
• 15. Intended Use ………………………………………………………………………………..5
• 16. Component Location ……………………………………………………………………..5
• 17. Safety Check List ……………………………………………………………………………….7
• 18. Safety – Yours and Others ………………………………………………………………7
• 19. General Safety ……………………………………………………………………………..7
• 20. Operating Safety …………………………………………………………………………..9
• 21. Maintenance Safety ……………………………………………………………………..13
• 22. Safety Labels …………………………………………………………………………………..18
• 23. Introduction …………………………………………………………………………………18
• 24. Safety Label Identification …………………………………………………………….19
• 25. Identifying Your Machine …………………………………………………………………..22
• 26. Machine Identification Plate ………………………………………………………….22
• 27. Component Identification Plates …………………………………………………….24
• 28. Machine Security ……………………………………………………………………………..28
• 29. Introduction …………………………………………………………………………………28
• 30. JCB Plantguard …………………………………………………………………………..28
• 31. LiveLink ……………………………………………………………………………………..28
• 32. Construction Equipment Security And Registration Scheme (CESAR) .28
• 33. Immobiliser …………………………………………………………………………………28
• 34. Operation
• 35. Introduction ……………………………………………………………………………………..31
• 36. Before Entering the Cab ……………………………………………………………………32
• 37. Entering and Leaving the Cab ……………………………………………………………33
• 38. Emergency Exit …………………………………………………………………………..34
• 39. Doors and Windows …………………………………………………………………………35
• 40. Opening and Closing the Door ………………………………………………………35
• 41. Opening and Closing the Upper Door Section …………………………………35
• 42. Opening and Closing the Rear Window ………………………………………….36
• 43. Visibility Aids ……………………………………………………………………………………37
• 44. Mirrors and Adjustment ………………………………………………………………..37
• 45. Seat Controls …………………………………………………………………………………..41
• 46. Introduction …………………………………………………………………………………41
• 47. Operator Present Switch ………………………………………………………………41
• 48. Seat Options ……………………………………………………………………………….41
• 49. Suspension Seat (KAB 100 Series – Mechanical) …………………………….42
• 50. Suspension Seat (KAB 100 Series – Air) …………………………………………43
• 51. Seat Belt …………………………………………………………………………………………44
• 52. Inertia Reel Seat Belt …………………………………………………………………..44
• 53. Static Seat Belt ……………………………………………………………………………45
• 54. Cab Layout ……………………………………………………………………………………..46
• 55. Component Key …………………………………………………………………………..47
• 56. Drive Controls, Switches and Instruments ……………………………………………48
• 57. Drive Controls ……………………………………………………………………………..48
• 58. Switches …………………………………………………………………………………….55
• 59. Instrument Panel …………………………………………………………………………61
• 60. LCD Screen ………………………………………………………………………………..63
• 61. Warning Lights …………………………………………………………………………….79
• 62. Air Conditioning and Cab Heater Controls ………………………………………81
• 63. Operating Lever ……………………………………………………………………………….82
• 64. Introduction …………………………………………………………………………………82
• 65. Boom and Carriage Controls …………………………………………………………83
• 66. Auxiliary Controls ………………………………………………………………………..84
• 67. Safety Equipment …………………………………………………………………………….86
• 68. Control Locks ……………………………………………………………………………..86
• 69. Load Charts ………………………………………………………………………………..87
• 70. Boom Indicators ………………………………………………………………………….89
• 71. Longitudinal Load Moment Indicator (LLMI) …………………………………….90
• 72. Longitudinal Load Moment Control (LLMC) System …………………………94
• 73. Inclinometer ………………………………………………………………………………..97
• 74. Beacon (if fitted) ………………………………………………………………………….98
• 75. Fire Extinguisher (if fitted) …………………………………………………………….99
• 76. Before Starting the Engine ……………………………………………………………….100
• 77. Starting the Engine …………………………………………………………………………102
• 78. Immobiliser (if fitted) …………………………………………………………………..104
• 79. Preparing the Machine for Travel ……………………………………………………..107
• 80. Introduction ……………………………………………………………………………….107
• 81. Preparing for Road Travel …………………………………………………………..107
• 82. Preparing for Site Travel ……………………………………………………………..109
• 83. Smooth Ride System (SRS) ……………………………………………………….. 110
• 84. Getting the Machine Moving ……………………………………………………………. 111
• 85. Operating Practices …………………………………………………………………… 111
• 86. Operating Procedure …………………………………………………………………. 112
• 87. Stopping and Parking the Machine …………………………………………………… 113
• 88. Working with the Machine ………………………………………………………………. 114
• 89. Operating Practices and Site Safety ……………………………………………. 114
• 90. Clothing and Safety Equipment …………………………………………………… 114
• 91. Danger Zone ……………………………………………………………………………. 114
• 92. Safety Practices ……………………………………………………………………….. 114
• 93. Working with the Boom ……………………………………………………………… 116
• 94. Use of Machines on Gradients or Slopes ………………………………………125
• 95. Operating Environment ……………………………………………………………………128
• 96. Operating in Low Temperatures …………………………………………………..128
• 97. Operating in High Temperatures ………………………………………………….128
• 98. Protection offered by the Cab ………………………………………………………129
• 99. Tow Hitch Options …………………………………………………………………………..130
• 100. Introduction ……………………………………………………………………………….130
• 101. Connecting the Trailer ………………………………………………………………..131
• 102. Prepare the Trailer for Towing ……………………………………………………..137
• 103. Refuelling the Machine ……………………………………………………………………139
• 104. Low Fuel Levels ………………………………………………………………………..139
• 105. Filling the Tank ………………………………………………………………………….139
• 106. Moving A Disabled Machine …………………………………………………………….141
• 107. Towing ……………………………………………………………………………………..141
• 108. Recovery Hitch ………………………………………………………………………….143
• 109. Transporting the Machine ………………………………………………………………..144
• 110. Lifting a Machine ……………………………………………………………………………145
• 111. Storage of the Machine …………………………………………………………………..146
• 112. Introduction ……………………………………………………………………………….146
• 113. Storage Area …………………………………………………………………………….146
• 114. Prepare the Machine for Storage …………………………………………………146
• 115. Put the Machine into Storage ………………………………………………………146
• 116. During Storage ………………………………………………………………………….146
• 117. Take the Machine Out of Storage …………………………………………………147
• 118. Routine Maintenance
• 119. Service Requirements …………………………………………………………………….149
• 120. Introduction ……………………………………………………………………………….149
• 121. Owner-Operator Support …………………………………………………………….149
• 122. Service-Maintenance Agreements ……………………………………………….149
• 123. Initial Service and Inspection (100 Hours) ……………………………………..149
• 124. Fit for Purpose Tests for Lifting Equipment …………………………………….150
• 125. Obtaining Replacement Parts ………………………………………………………150
• 126. Health and Safety …………………………………………………………………………..151
• 127. Lubricants …………………………………………………………………………………151
• 128. Battery ……………………………………………………………………………………..153
• 129. Service Schedules ………………………………………………………………………….155
• 130. Introduction ……………………………………………………………………………….155
• 131. How to Use the Service Schedules ………………………………………………155
• 132. Calendar Equivalents …………………………………………………………………155
• 133. Pre-start Cold Checks, Service Points and Fluid Levels ………………….156
• 134. Functional Test and Final Inspection …………………………………………….160
• 135. Fluids, Lubricants and Capacities ……………………………………………………..162
• 136. Coolant Mixtures ……………………………………………………………………….164
• 137. Fuels ………………………………………………………………………………………..164
• 138. Prepare the Machine for Maintenance ………………………………………………169
• 139. Introduction ……………………………………………………………………………….169
• 140. How to Make the Machine Safe (Boom Lowered) …………………………..170
• 141. How to Make the Machine Safe (Boom Lifted) ……………………………….171
• 142. Cleaning the Machine ……………………………………………………………………..173
• 143. Introduction ……………………………………………………………………………….173
• 144. Preparing the Machine for Cleaning ……………………………………………..173
• 145. Cleaning the Machine …………………………………………………………………174
• 146. Auto Fan Reverse (if fitted) …………………………………………………………176
• 147. Checking for Damage ……………………………………………………………………..177
• 148. Check the Machine Body and Structure ………………………………………..177
• 149. Check the Tyres ………………………………………………………………………..177
• 150. Check the Seat and Seat Belt ……………………………………………………..177
• 151. Check the Hydraulic Hoses and Fittings ……………………………………….177
• 152. Check the Electrical Circuits ………………………………………………………..178
• 153. Checking the ROPS-FOPS Structure ……………………………………………179
• 154. Greasing ……………………………………………………………………………………….180
• 155. Introduction ……………………………………………………………………………….180
• 156. Preparing the Machine for Greasing …………………………………………….180
• 157. Every 50 Hours ………………………………………………………………………….181
• 158. Every 500 Hours ………………………………………………………………………..183
• 159. Every 1000 Hours ………………………………………………………………………185
• 160. Oiling ……………………………………………………………………………………………186
• 161. Park Brake Cable ………………………………………………………………………186
• 162. Access Panels ……………………………………………………………………………….187
• 163. Introduction ……………………………………………………………………………….187
• 164. Battery Covers …………………………………………………………………………..187
• 165. Engine Cover …………………………………………………………………………….188
• 166. Rear Cover ……………………………………………………………………………….189
• 167. Deck Plate ………………………………………………………………………………..190
• 168. Engine Compartment Undershield ……………………………………………….191
• 169. Front Undershield ………………………………………………………………………192
• 170. Centre Undershield ……………………………………………………………………192
• 171. Rear Undershield ………………………………………………………………………193
• 172. Cab Undershield ………………………………………………………………………..194
• 173. Cab Heater and Air Conditioning ………………………………………………………195
• 174. Changing the Air Intake Filter ………………………………………………………195
• 175. Boom ……………………………………………………………………………………………196
• 176. Re-phasing of 3-Stage Booms …………………………………………………….196
• 177. Brakes ………………………………………………………………………………………….197
• 178. Park Brake ………………………………………………………………………………..197
• 179. Foot Brake ………………………………………………………………………………..199
• 180. Electrical System ……………………………………………………………………………200
• 181. Battery ……………………………………………………………………………………..200
• 182. Jump Starting the Engine ……………………………………………………………202
• 183. Secondary Fuses ………………………………………………………………………203
• 184. Primary Fuses …………………………………………………………………………..206
• 185. Relays ……………………………………………………………………………………..208
• 186. Engine ………………………………………………………………………………………….210
• 187. Oil and Filter ……………………………………………………………………………..210
• 188. Cooling System …………………………………………………………………………213
• 189. Crankcase Ventilation (if fitted) …………………………………………………….215
• 190. Front End Accessory Drive Belt …………………………………………………..216
• 191. Air Filter ……………………………………………………………………………………219
• 192. Fuel System …………………………………………………………………………………..220
• 193. Introduction ……………………………………………………………………………….220
• 194. Water Separator and Engine Fuel Filter ………………………………………..221
• 195. Bleeding the System ………………………………………………………………….225
• 196. Hydraulic System ……………………………………………………………………………226
• 197. Introduction ……………………………………………………………………………….226
• 198. Releasing the Hydraulic Pressure ………………………………………………..227
• 199. Oil and Filter ……………………………………………………………………………..228
• 200. Hose Burst Protection Valves ………………………………………………………231
• 201. Transmission …………………………………………………………………………………232
• 202. Axles ………………………………………………………………………………………..232
• 203. Transmission Motor Gear Train ……………………………………………………236
• 204. Tyres and Wheels …………………………………………………………………………..237
• 205. Tyre Inflation ……………………………………………………………………………..237
• 206. Checking the Wheel Nut Torques …………………………………………………238
• 207. Wheel Alignment ……………………………………………………………………………239
• 208. Introduction ……………………………………………………………………………….239
• 209. Electronic Steer Mode Selector ……………………………………………………240
• 210. Wear Pads …………………………………………………………………………………….241
• 211. Boom Wear Pad Clearance …………………………………………………………241
• 212. Windscreen Washer ……………………………………………………………………….242
• 213. Checking the Level …………………………………………………………………….242
• 214. Fire Extinguisher (if fitted) ………………………………………………………………..243
• 215. Checking the Fire Extinguisher ……………………………………………………243
• 216. Optional Attachments
• 217. Introduction ……………………………………………………………………………………245
• 218. Attachments for your Machine ………………………………………………………….246
• 219. Connecting-Disconnecting Hydraulic Hoses ……………………………………….247
• 220. Introduction ……………………………………………………………………………….247
• 221. Connecting the Hydraulic Hoses ………………………………………………….247
• 222. Disconnecting the Hydraulic Hoses ………………………………………………248
• 223. Quick Release Couplings ……………………………………………………………249
• 224. Tool Carrier Attachments …………………………………………………………………251
• 225. Mechanical Pin Locking Option ……………………………………………………251
• 226. Hydraulic Pin Locking Option ………………………………………………………253
• 227. Q-Fit Attachments …………………………………………………………………………..257
• 228. Mechanical Pin Locking Option ……………………………………………………257
• 229. Hydraulic Pin Locking Option ………………………………………………………259
• 230. Extension Jib …………………………………………………………………………………263
• 231. Safety ………………………………………………………………………………………263
• 232. Installing-Removing ……………………………………………………………………263
• 233. Operation ………………………………………………………………………………….263
• 234. Maintenance ……………………………………………………………………………..264
• 235. Fork Mounted Hook ………………………………………………………………………..265
• 236. Safety ………………………………………………………………………………………265
• 237. Installing …………………………………………………………………………………..265
• 238. Removing …………………………………………………………………………………265
• 239. Operation ………………………………………………………………………………….266
• 240. Maintenance ……………………………………………………………………………..266
• 241. Sideshift Carriage …………………………………………………………………………..267
• 242. Operation ………………………………………………………………………………….267
• 243. Installing the Sideshift Carriage ……………………………………………………268
• 244. Removing the Sideshift Carriage ………………………………………………….269
• 245. Maintenance ……………………………………………………………………………..270
• 246. Roof Truss Jib ……………………………………………………………………………….271
• 247. Safety ………………………………………………………………………………………271
• 248. Installing-Removing ……………………………………………………………………271
• 249. Operation ………………………………………………………………………………….271
• 250. Extending the Jib ……………………………………………………………………….272
• 251. Changing the Jib Angle ………………………………………………………………273
• 252. Maintenance ……………………………………………………………………………..273
• 253. Work Platforms ………………………………………………………………………………274
• 254. Specifications
• 255. Static Dimensions …………………………………………………………………………..275
• 256. Performance Dimensions ………………………………………………………………..277
• 257. Lift Performance ………………………………………………………………………..277
• 258. Maximum Wading Depth …………………………………………………………….278
• 259. Axle Weight Distribution ………………………………………………………………….279
• 260. Trailer Towing ………………………………………………………………………………..280
• 261. Towing Limitations ……………………………………………………………………..280
• 262. Tyre Sizes and Pressures ………………………………………………………………..281
• 263. Introduction ……………………………………………………………………………….281
• 264. Specifications ……………………………………………………………………………281
• 265. Noise Data …………………………………………………………………………………….282
• 266. Introduction ……………………………………………………………………………….282
• 267. 527-58 ……………………………………………………………………………………..282
• 268. Vibration Data ………………………………………………………………………………..283
• 269. Introduction ……………………………………………………………………………….283
• 270. 527-58 ……………………………………………………………………………………..284
• 271. Warranty Information
• 272. Machine Service Record Sheet ………………………………………………………..285
• 273. Registration Information ………………………………………………………………….287
• 274. European Community Standards
• 275. EC Declaration of Conformity …………………………………………………………..289
• 276. Introduction ……………………………………………………………………………….289
• 277. Explanation of the EC Declaration of Conformity ……………………………291