JCB 528-70, 528S, 530-60 Operator Manual

Description

• Model List:
  • 528-70, 528S, 530-60

• 1. About this Handbook
• 2. Machine Model and Serial Number ………………….. 1
• 3. Using this Handbook . …………………………………….. 1
• 4. Units of Measurement …………………………………….. 1
• 5. Page Numbering ……………………………………………. 1
• 6. Left Side, Right Side . ……………………………………… 1
• 7. Using the Machine …………………………………………. 1
• 8. Page Cross References ………………………………….. 1
• 9. The JCB Loadall
• 10. Machine Description ………………………………………. 2
• 11. Safety – Yours and Other People's ………………… 3
• 12. Safety Check List
• 13. General Safety ………………………………………………. 3
• 14. Operating Safety ……………………………………………. 4
• 15. Maintenance Safety ……………………………………….. 5
• 16. Safety Decals ……………………………………………….. 8
• 17. Identifying Your Machine
• 18. Machine Identification …………………………………….. 10
• 19. Typical Machine Identification Number …………….. 10
• 20. Engine Identification . ……………………………………… 10
• 21. Typical Engine Identification Number ……………….. 10
• 22. Transmission And Axle Identification………………….. 11
• 23. OPERATION
• 24. Introduction …………………………………………………. 33
• 25. Before Entering the Cab
• 26. Check for Cleanliness ……………………………………… 33
• 27. Check for Damage ………………………………………….. 33
• 28. Check the Tyres ……………………………………………… 34
• 29. Opening-Closing the Battery Cover …………………… 34
• 30. Check the Battery Cover, Hydraulic Oil Filler Cap
• 31. and Fuel Filler Cap ………………………………………….. 34
• 32. Entering and Leaving the Cab, Doors and Windows
• 33. Entering and Leaving the Cab ……………………………… 35
• 34. Opening and Closing the Door ………………………… 36
• 35. Open and Closing the Upper Door Section ……….. 36
• 36. Open and Closing the Rear Window ………………….. 37
• 37. Emergency Exit ……………………………………………… 37
• 38. Fire Extinguisher ………………………………………….. 38
• 39. Seat Controls
• 40. Adjusting the Seat ………………………………………….. 39
• 41. Seat Belt
• 42. Fasten the Seat Belt ……………………………………….. 40
• 43. Release the Seat Belt ……………………………………… 40
• 44. Adjust the Seat Belt . ………………………………………. 40
• 45. Cab Layout and Controls ……………………………… 41
• 46. Steer Mode Selection ……………………………………. 43
• 47. Cab Switches and Instruments
• 48. Switches ………………………………………………………. 44
• 49. Steering Column Switches ………………………………. 45
• 50. Instrument Panel Switches ……………………………… 46
• 51. Side Panel Switches ……………………………………….. 46
• 52. Instruments …………………………………………………… 47
• 53. Warnings (Visual only) ……………………………………. 48
• 54. Warnings (Audible-Visual) ………………………………… 48
• 55. Warning Beacon . …………………………………………… 49
• 56. Cab Light . …………………………………………………….. 49
• 57. Heater (cab versions only) …………………………….. 50
• 58. Air Conditioning Option …………………………………. 51
• 59. Boom and Carriage Controls
• 60. Introduction ……………………………………………………. 52
• 61. Dual Lever Control:
• 62. Raise Boom-Lower Boom ……………………………….. 53
• 63. Extend Boom-Retract Boom ……………………………. 54
• 64. Tilt Carriage Forward-Back ……………………………… 55
• 65. Single Lever Control:
• 66. Raise Boom-Lower Boom ……………………………….. 56
• 67. Extend Boom-Retract Boom ……………………………. 57
• 68. Tilt Carriage Forward-Back ……………………………… 58
• 69. Auxiliary Control …………………………………………… 59
• 70. Control Lever Lock Options
• 71. Tilt Lever Lock ……………………………………………….. 60
• 72. All Lever Lock ……………………………………………….. 60
• 73. Before Starting the Engine
• 74. Pre-Start Inspection ……………………………………….. 61
• 75. Starting the Engine ………………………………………. 62
• 76. Preparing for Road Travel …………………………….. 63
• 77. Preparing for Site Travel ………………………………. 65
• 78. Testing the Parking Brake …………………………….. 66
• 79. Parking Brake Adjustment …………………………….. 67
• 80. Getting the Machine Moving
• 81. Operating Practices ……………………………………….. 68
• 82. Limited Slip Differential (LSD) …………………………… 68
• 83. Stopping and Parking the Machine ……………….. 70
• 84. Using the Load Charts and Boom Indicators …. 71
• 85. Safe Load Indicator
• 86. Checking the Indicator ……………………………………. 73
• 87. Load Moment Indicator
• 88. Checking the Indicator …………………………………….. 74
• 89. Setting the Volume and Brightness …………………… 75
• 90. Diagnostic Fault Codes ……………………………………. 75
• 91. Smooth Ride System ……………………………………… 75A
• 92. Working with the Machine
• 93. Introduction…………………………………………………….. 76
• 94. Safety Practices………………………………………………. 76
• 95. Risk Assessment……………………………………………… 77
• 96. Lifting and Loading Operations …………………………. 78
• 97. Safety Warnings………………………………………………. 78A
• 98. Fork Ratings……………………………………………………. 78B
• 99. Handling Palleted Loads …………………………………. 79
• 100. Uneven Loads ……………………………………………….. 80
• 101. Lifting Bales ………………………………………………….. 81
• 102. Placing Bales ………………………………………………… 81
• 103. Working With a Shovel……………………………………… 81A
• 104. Use of Machine on Gradients or Slopes……………… 81C
• 105. Operating in Low Temperatures …………………….. 82
• 106. Operating in High Temperatures …………………… 82
• 107. Towing a Machine
• 108. Preparing for Towing ……………………………………… 83
• 109. Transporting the Machine …………………………….. 83
• 110. Light Mechanical Tow Hitch Option ………………. 85
• 111. Hydraulic Tow Hitch Option …………………………… 86
• 112. Mechanical Tow Hitch Option ………………………. 88
• 113. Re-aligning the Road Wheels
• 114. 528-70 Machines With All Wheel Steering Only ….. 90
• 115. 528-70 Machines With Optional Steer Mode
• 116. Selector …………………………………………………………. 91
• 117. 528S, 536-60 Machines …………………………………… 91
• 118. Lifting a Machine ………………………………………….. 92
• 119. MAINTENANCE
• 120. Lubricants – Health and Safety
• 121. Hygiene ………………………………………………………… 93
• 122. Storage ………………………………………………………… 93
• 123. Waste Disposal ……………………………………………… 93
• 124. Handling ……………………………………………………….. 93
• 125. First Aid – Oil …………………………………………………. 93
• 126. Spillage ………………………………………………………… 93
• 127. Fires …………………………………………………………….. 93
• 128. Boom Safety Strut
• 129. Installing ……………………………………………………….. 94
• 130. Removing ……………………………………………………… 95
• 131. Tools
• 132. Wheel Brace and Bar ………………………………………. 95
• 133. Engine Cover
• 134. Opening-Closing the Engine Cover . …………………. 96
• 135. Checking for Damage …………………………………… 97
• 136. Seat Belt
• 137. Checking the Seat Belt Condition and Security …. 97
• 138. Storage
• 139. Storing the Machine ………………………………………… 97
• 140. Cleaning the Machine …………………………………… 98
• 141. Service Requirements
• 142. Introduction …………………………………………………… 100
• 143. Maintenance …………………………………………………. 100
• 144. Owner-Operator Support ………………………………… 100
• 145. Service-Maintenance Agreements ……………………. 100
• 146. Service Schedules ………………………………………… 100
• 147. Daily Checks – Every 10 Hours
• 148. Cleaning the Pre-Cleaner (if fitted) ……………………. 104
• 149. Checking the Engine Oil Level …………………………. 104
• 150. Checking the Coolant Level …………………………….. 105
• 151. Checking the Transmission Oil Level ………………… 106
• 152. Checking the Fire Extinguisher (if fitted) ……………. 106
• 153. Tyres And Wheels ………………………………………….. 107
• 154. Checking the ROPS-FOPS Structure ……………….. 108
• 155. Checking The Windscreen Washer Fluid…………….. 109
• 156. Weekly Checks – Every 50 Hours
• 157. Draining the Fuel Filter . …………………………………… 109
• 158. Draining the Fuel Sediment Bowl ……………………… 110
• 159. Cleaning the Fuel Sediment Bowl …………………….. 110
• 160. Checking the Axle Oil Level …………………………….. 111
• 161. Checking-Filling the Hub Oil Levels ………………….. 112
• 162. Checking the Hydraulic Fluid Level …………………… 113
• 163. Greasing…………………………………………………………. 114
• 164. Greasing – Q-Fit Carriage Pivot Pins and
• 165. Ram Pivot Pins – 528S, 530-60 ………………………… 114
• 166. Greasing – Pivot Pins ……………………………………… 115
• 167. Greasing – Fork Pivot Pins ……………………………… 116
• 168. 6 Monthly Checks – Every 500 Hours
• 169. Greasing – Drive Shafts ………………………………….. 116
• 170. Changing the Engine Oil and Filter …………………… 117
• 171. Checking The Air Cleaner Dust Valve ……………….. 118
• 172. Battery Terminals – Tightness……………………………. 118
• 173. 6 Monthly Checks – Every 500 Hours – continued
• 174. Changing the Air Filter Outer Element ………………. 119
• 175. Draining the Fuel Filter ……………………………………. 120
• 176. Changing the Fuel Filter Element ……………………… 120
• 177. Adjusting the Alternator Drive Belt ……………………. 121
• 178. Checking the Foot Brake Fluid Level ………………… 121
• 179. Changing The Transmission Oil Filter …………………. 122
• 180. Changing the Axle Oil …………………………………….. 123
• 181. Changing the Hub Oil ……………………………………… 124
• 182. Oil Immersed Brakes ……………………………………….. 124
• 183. Changing the Hydraulic Filter Element ……………… 125
• 184. Lubricating The Boom Wear Pad Runways…………. 126
• 185. Oiling……………………………………………………………… 127
• 186. Cleaning the Cab Heater Filter …………………………. 128
• 187. Checking The Front Axle Breather …………………….. 128
• 188. Yearly Checks – Every 1000 Hours
• 189. Changing The Transmission Oil and Filter …………. 129
• 190. Lubricating The Extension Ram Pivot Pin ………….. 130
• 191. 2 Yearly Checks – Every 2000 Hours
• 192. Changing The Air Filter Inner Element ………………. 131
• 193. Changing the Engine Coolant ………………………….. 132
• 194. Coolant Mixtures ……………………………………………. 133
• 195. Fuel System
• 196. Types of Fuel . ……………………………………………….. 134
• 197. Fuel Standards ………………………………………………. 134
• 198. Low Temperature Fuels . …………………………………. 134
• 199. Filling the Tank ………………………………………………. 135
• 200. Prime the System …………………………………………… 135
• 201. Hose Burst Protection Valves
• 202. Checking the Hose Burst Protection Valves ………. 136
• 203. Battery
• 204. Warning Symbols …………………………………………… 138
• 205. Checking the Electrolyte Level ………………………… 139
• 206. Battery Isolator ………………………………………………. 140
• 207. Jump-Starting the Engine ……………………………….. 141
• 208. Electrical System
• 209. Fuse Identification – 528-70 Machines ……………… 142
• 210. Relay Identification – 528-70 Machines ………………. 142
• 211. Fuse Identification – 528S, 530-60 Machines ……… 143
• 212. Relay Identification – 528S, 530-60 Machines …….. 144
• 213. Fuse Links ……………………………………………………… 145
• 214. Bulbs ……………………………………………………………. 146
• 215. Obtaining Replacement Parts ……………………….. 146
• 216. Fluids, Lubricants, Capacities and Specifications
• 217. 528-70, 528S and 530-60 …………………………………… 147
• 218. OPTIONAL ATTACHMENTS
• 219. Introduction …………………………………………………. 161
• 220. Quick Release Couplings
• 221. Quick Release Couplings – Do’s and Don’ts . …….. 162
• 222. Remove Pressure from Service Lines ……………….. 162
• 223. Connecting Quick Release Couplings ………………. 162
• 224. Disconnecting Quick Release Couplings…………….. 162
• 225. Installing and Removing Q-Fit Attachments
• 226. Installing Attachments ……………………………………. 163
• 227. Removing Attachments …………………………………… 165
• 228. Hydraulic Pin Locking Option
• 229. Installing Attachments ……………………………………. 166
• 230. Removing Attachments …………………………………… 167
• 231. Extension Jib
• 232. Safety …………………………………………………………… 168
• 233. Installing-Removing …………………………………………. 168
• 234. Operation ………………………………………………………. 168
• 235. Maintenance ………………………………………………….. 168A
• 236. Fork Mounted Hook
• 237. Safety …………………………………………………………… 169
• 238. Installing ……………………………………………………….. 169
• 239. Removing ……………………………………………………… 169
• 240. Operation ……………………………………………………… 170
• 241. Maintenance …………………………………………………. 170
• 242. Work Platforms ……………………………………………… 171
• 243. SPECIFICATIONS
• 244. Static Dimensions
• 245. 528-70 ………………………………………………………….. 191
• 246. 528S ……………………………………………………………… 191
• 247. 530-60……………………………………………………………. 191
• 248. Performance Dimensions
• 249. 528-70 ………………………………………………………….. 192
• 250. 528S ……………………………………………………………… 192
• 251. 530-60 …………………………………………………………… 192
• 252. Tyres and Pressures
• 253. 528-70 ………………………………………………………….. 192
• 254. 528S ……………………………………………………………… 192
• 255. 530-60 …………………………………………………………… 192
• 256. Noise and Vibration Data ……………………………… 193
• 257. Load Charts ………………………………………………….. 194