JCB 530, 530FS Plus. 530FS Super, 532, 533-105, 535, 537, 540-70, 540-170, 540FS Plus, 540FS Super Owner Manual

Description

• Model List:
  • 530, 530FS Plus. 530FS Super, 532, 533-105, 535, 537, 540-70, 540-170, 540FS Plus, 540FS Super

• 1. INTRODUCTION
• 2. About this Handbook
• 3. Machine Model and Serial Number ………………….. 1
• 4. Using this Handbook . …………………………………….. 1
• 5. Units of Measurement …………………………………….. 1
• 6. Page Numbering ……………………………………………. 1
• 7. Left Side, Right Side . ……………………………………… 1
• 8. Using the Machine …………………………………………. 1
• 9. Page Cross References ………………………………….. 1
• 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. Identification Plate. ………………………………………….. 9
• 19. Typical Machine Identification Number …………….. 9
• 20. Unit Identification…………………………………………….. 9
• 21. JCB Immobiliser Option …………………………………. 10
• 22. OPERATION
• 23. Introduction …………………………………………………. 21
• 24. Before Entering the Cab ……………………………….. 21
• 25. Entering and Leaving the Cab, Doors and Windows 22
• 26. Opening and Closing the Door ………………………… 23
• 27. Open and Closing the Rear Window ………………….. 23
• 28. Open and Closing the Upper Door Section ……….. 24
• 29. Emergency Exit ……………………………………………… 24
• 30. Seat Controls
• 31. Type 1 . …………………………………………………………. 24A
• 32. Type 2 . …………………………………………………………. 24A
• 33. Type 3 (Air Suspension) . …………………………………. 24B
• 34. Seat Belt
• 35. Fasten the Seat Belt ……………………………………….. 25
• 36. Release the Seat Belt ……………………………………… 25
• 37. Adjust the Seat Belt . ………………………………………. 25
• 38. Cab Layout and Controls ……………………………… 26
• 39. Cab Switches and Instruments
• 40. Starter Switch ……………………………………………….. 29
• 41. Steering Column Switches ………………………………. 30
• 42. Instrument Panel Switches ……………………………… 31
• 43. Steer Mode Selector ……………………………………….. 32
• 44. Phasing 4 Wheel Steer …………………………………….. 32
• 45. Four Wheel Drive Disconnect Switch Option ………. 32
• 46. Manual Steer Mode Selection …………………………… 32A
• 47. Warning Beacon ……………………………………………. 33
• 48. Cab Light ……………………………………………………… 33
• 49. Instruments …………………………………………………… 34
• 50. Warnings (Visual only) ……………………………………. 35
• 51. Warnings (Audible-Visual) ………………………………… 35
• 52. Heater and Air Conditioning
• 53. Heater ……………………………………………………………. 36
• 54. Air Conditioning Option ………………………………….. 36
• 55. Boom and Carriage Controls
• 56. Introduction ……………………………………………………. 37
• 57. Single Lever Control
• 58. Raise Boom-Lower Boom ……………………………….. 38
• 59. Extend Boom-Retract Boom ……………………………. 39
• 60. Tilt Carriage Forward-Back ……………………………… 40
• 61. Auxiliary Operation …………………………………………. 41
• 62. Control Locks …………………………………………………. 42
• 63. All Lever Locks ……………………………………………….. 42
• 64. Tilt Lever Lock ………………………………………………… 42
• 65. Dual Lever Control
• 66. Raise Boom-Lower Boom ……………………………….. 43
• 67. Extend Boom-Retract Boom ……………………………. 44
• 68. Tilt Carriage Forward-Back ……………………………… 45
• 69. Auxiliary Operation …………………………………………. 46
• 70. Control Locks …………………………………………………. 47
• 71. All Lever Locks ……………………………………………….. 47
• 72. Tilt Lever Lock ………………………………………………… 47
• 73. Manual Auxiliary Control
• 74. Raise Boom-Lower Boom ……………………………….. 48
• 75. Extend Boom-Retract Boom ……………………………. 49
• 76. Tilt Carriage Forward-Back ……………………………… 50
• 77. Auxiliary Operation …………………………………………. 51
• 78. Control Locks …………………………………………………. 52
• 79. All Lever Locks ……………………………………………….. 52
• 80. Tilt Lever Lock ………………………………………………… 52
• 81. Auxiliary Lever Lock ………………………………………… 52
• 82. Servo Control
• 83. Raise Boom-Lower Boom ……………………………….. 53
• 84. Extend Boom-Retract Boom ……………………………. 54
• 85. Extend-Retract Inner Boom ……………………………… 54
• 86. Tilt Carriage Forward-Back ……………………………… 55
• 87. Auxiliary Operation …………………………………………. 56
• 88. Control Locks …………………………………………………. 57
• 89. All Lever Locks ……………………………………………….. 57
• 90. Tilt Lever Lock ………………………………………………… 57
• 91. Chassis Levelling (Sway) Option …………………… 58
• 92. Stabiliser Control Option
• 93. Using the Stabilisers ……………………………………….. 59
• 94. Lower and Raise Stabilisers………………………………. 59
• 95. Before Starting the Engine ……………………………. 60
• 96. Starting the Engine ………………………………………. 61
• 97. Preparing for Road Travel …………………………….. 62
• 98. Preparing for Site Travel ………………………………. 64
• 99. Smooth Ride System …………………………………….. 65
• 100. Testing the Parking Brake …………………………….. 66
• 101. Getting the Machine Moving
• 102. Operating Practices ……………………………………….. 67
• 103. Limited Slip Differential (LSD) ……………………………. 67
• 104. Operation of Five Speed Transmission ………………. 68A
• 105. Stopping and Parking the Machine ……………….. 69
• 106. Using the Load Charts and Boom Indicators …. 70
• 107. Safe Load Indicator
• 108. Checking the Indicator …………………………………….. 72
• 109. Load Moment Indicator (LMI)
• 110. Checking the Indicator …………………………………….. 73
• 111. Setting the Volume and Brightness …………………… 74
• 112. Diagnostic Fault Codes ……………………………………. 74
• 113. Working with the Machine
• 114. Introduction ……………………………………………………. 75
• 115. Safety Practices ……………………………………………… 75
• 116. Risk Assessment……………………………………………… 76
• 117. Lifting and Loading Operations ………………………… 77
• 118. Safety Warnings ……………………………………………… 78
• 119. Fork Ratings …………………………………………………… 79
• 120. Handling Palleted Loads ………………………………….. 80
• 121. Uneven Loads ……………………………………………….. 81
• 122. Lifting Bales ………………………………………………….. 82
• 123. Placing Bales ………………………………………………… 82
• 124. Working With a Shovel……………………………………… 82A
• 125. Use of Machines on Gradients or Slopes ……………. 83
• 126. Operating in Low Temperatures ……………………. 86
• 127. Operating in High Temperatures …………………… 86
• 128. Towing a Machine ………………………………………… 87
• 129. Recovery Hitch …………………………………………….. 87
• 130. Mechanical Tow Hitch Option ………………………. 88
• 131. Hydraulic Tow Hitch Option ………………………….. 90
• 132. Transporting the Machine …………………………….. 92
• 133. Lifting a Machine ………………………………………….. 93
• 134. MAINTENANCE
• 135. Lubricants – Health and Safety
• 136. Hygiene ………………………………………………………… 94
• 137. Storage ………………………………………………………… 94
• 138. Waste Disposal ……………………………………………… 94
• 139. Handling ……………………………………………………….. 94
• 140. First Aid – Oil …………………………………………………. 94
• 141. Spillage ………………………………………………………… 94
• 142. Fires …………………………………………………………….. 94
• 143. Service Requirements
• 144. Introduction …………………………………………………… 95
• 145. Maintenance …………………………………………………. 95
• 146. Owner-Operator Support ………………………………… 95
• 147. Service-Maintenance Agreements ……………………. 95
• 148. Service Schedules ………………………………………… 95
• 149. Boom Safety Strut
• 150. Installing ……………………………………………………….. 99
• 151. Removing ……………………………………………………… 99
• 152. Engine Cover
• 153. Opening-Closing the Cover . ……………………………. 100
• 154. Cleaning the Machine …………………………………… 101
• 155. Checking for Damage …………………………………… 102
• 156. Seat Belt
• 157. Checking the Seat Belt Condition and Security …. 102
• 158. Greasing ………………………………………………………. 102
• 159. Greasing (Every 50 Hours) 530, 540-70 ……………… 103
• 160. Greasing (Every 50 Hours) 535 …………………………. 104
• 161. Greasing (Every 50 Hours) 532, 537, 540-170 …….. 105
• 162. Greasing the Optional Sideshift Carriage …………… 106
• 163. Greasing (Every 500 Hours) ……………………………… 106
• 164. Greasing the Hydraulic Tow Hitch ……………………… 107
• 165. Oiling …………………………………………………………… 107
• 166. Brakes
• 167. Checking the Footbrake Fluid Level ………………….. 107A
• 168. Parking Brake Adjustment –
• 169. 530, 535 and 540 Machines to 772032 ………………….. 108
• 170. 532 and 537 Machines to778686 ………………………… 108
• 171. Parking Brake Adjustment –
• 172. 530, 535 and 540 Machines from 772033………………. 109
• 173. 532 and 537 Machines from 778687…………………….. 109
• 174. 533-105 Machines …………………………………………… 109
• 175. 540-170 Machines …………………………………………… 109
• 176. 530FS Plus and 540FS Plus Machines…………………… 109
• 177. 530FS Super (530SXL France)…………………………… 109
• 178. 540FS Super (540SXL France)…………………………… 109
• 179. Tyres And Wheels
• 180. Tyre Inflation …………………………………………………. 110
• 181. Checking The Roadwheel Tightness ………………… 110
• 182. Engine Air Filter
• 183. Changing the Elements …………………………………… 111
• 184. Engine Oil And Filter
• 185. Checking the Oil Level ……………………………………. 112
• 186. Changing the Oil And Filter ……………………………… 112
• 187. Engine Cooling System
• 188. Checking the Coolant Level …………………………….. 113
• 189. Coolant Mixtures ……………………………………………. 114
• 190. Changing the Coolant …………………………………….. 114
• 191. Cab Heater Filter
• 192. Cleaning the Cab Heater Filter …………………………. 115
• 193. Fuel System
• 194. Types of Fuel ………………………………………………… 116
• 195. Fuel Standards ………………………………………………. 116
• 196. Low Temperature Fuels ………………………………….. 116
• 197. Filling the Tank ………………………………………………. 117
• 198. Prime the System …………………………………………… 117
• 199. Draining the Filter …………………………………………… 118
• 200. Changing the Filter Element …………………………….. 118
• 201. Draining the Sediment Bowl ……………………………. 119
• 202. Cleaning the Sediment Bowl ……………………………. 119
• 203. Transmission
• 204. Check Transmission Oil Level ………………………….. 120
• 205. Changing the Oil and Filter ……………………………….. 121
• 206. Front And Rear Axle
• 207. Checking the Axle Oil Level …………………………….. 122
• 208. Changing the Axle Oil …………………………………….. 122
• 209. Front And Rear Hub
• 210. Checking the Hub Oil Levels ……………………………. 123
• 211. Oil Immersed Brakes ………………………………………. 123
• 212. Changing the Hub Oil ……………………………………… 123
• 213. Hydraulic System
• 214. Checking The Fluid Level ………………………………… 124
• 215. Changing The Pilot Filter Element …………………….. 124A
• 216. Changing The Filter Element ……………………………. 125
• 217. Hose Burst Protection Valves
• 218. Checking The Hose Burst Protection Valves ……… 127
• 219. Battery
• 220. Warning Symbols …………………………………………… 129
• 221. Checking the Electrolyte Level ………………………… 130
• 222. Battery Isolator ………………………………………………. 131
• 223. Jump-Starting the Engine . ……………………………. 132
• 224. Electrical System
• 225. Fuse Identification ………………………………………….. 133
• 226. Fuse Links………………………………………………………. 134
• 227. Bulbs ……………………………………………………………. 135
• 228. Adjusting The Alternator Drive Belt …………………… 135
• 229. Air Conditioning Option
• 230. Adjusting The Air Conditioning Compressor
• 231. Drive Belt ………………………………………………………. 136
• 232. Cleaning The Air Conditioning Filter …………………. 136
• 233. Windscreen Washer ……………………………………… 137
• 234. Obtaining Replacement Parts ……………………….. 137
• 235. Fluids, Lubricants, Capacities and Specifications
• 236. 530, 533, 535 and 540-70 Machines …………………….. 138
• 237. 532, 537 and 540-170 Machines ………………………….. 139
• 238. Boom Wear Pad Clearance
• 239. Wear Limits ……………………………………………………. 140
• 240. OPTIONAL ATTACHMENTS
• 241. Introduction …………………………………………………. 141
• 242. Quick Release Couplings
• 243. Quick Release Couplings – Do’s and Don’ts . …….. 142
• 244. Remove Pressure from Service Lines ……………….. 142
• 245. Connecting Quick Release Couplings ………………. 142
• 246. Disconnecting Quick Release Couplings …………… 142
• 247. Installing and Removing Q-Fit Attachments
• 248. Installing Attachments ……………………………………. 143
• 249. Removing Attachments …………………………………… 145
• 250. Hydraulic Pin Locking Option
• 251. Installing Attachments ……………………………………. 146
• 252. Removing Attachments …………………………………… 148
• 253. Extension Jib
• 254. Safety …………………………………………………………… 150
• 255. Installing-Removing …………………………………………. 150
• 256. Operation ……………………………………………………… 150
• 257. Maintenance …………………………………………………. 151
• 258. Fork Mounted Hook
• 259. Safety …………………………………………………………… 152
• 260. Installing ……………………………………………………….. 152
• 261. Removing ……………………………………………………… 152
• 262. Operation ……………………………………………………… 153
• 263. Maintenance …………………………………………………. 153
• 264. Sideshift Carriage ………………………………………….. 154
• 265. Operation ………………………………………………………. 155
• 266. Installing the Sideshift Carriage ………………………… 156
• 267. Removing the Sideshift Carriage ………………………. 157
• 268. Roof Truss Jib
• 269. Safety …………………………………………………………… 158
• 270. Installing-Removing …………………………………………. 158
• 271. Operation ……………………………………………………… 158
• 272. Maintenance …………………………………………………. 159A
• 273. Work Platforms ……………………………………………… 159B
• 274. SPECIFICATIONS
• 275. Static Dimensions
• 276. 530, 540-70 …………………………………………………… 160
• 277. 535 ……………………………………………………………….. 161
• 278. 533 ……………………………………………………………….. 161A
• 279. 532, 537 and 540-170 ……………………………………….. 162
• 280. Performance Dimensions ……………………………… 163
• 281. Axle Weight Distribution ……………………………….. 164
• 282. Engine Emissions ………………………………………….. 164
• 283. Tyres and Pressures …………………………………….. 165
• 284. Noise and Vibration Data ……………………………… 166
• 285. Load Charts
• 286. Introduction ……………………………………………………. 167
• 287. 530Machines ………………………………………………….. 168
• 288. 532 Non Sway Machines …………………………………. 170
• 289. 532 Sway Machines ………………………………………… 175
• 290. 535 Machines …………………………………………………. 180
• 291. 537 Non Sway Machines …………………………………. 182
• 292. 537 Sway Machines ………………………………………… 187
• 293. 540 Machines – Not 540-170…………………………….. 192
• 294. 540-170 Machines ………………………………………….. 194
• 295. 533-105 Machines ………………………………………….. 199