Name: JCB 540-v140, 540-v180 Loadall Operator Manual 9831-4000
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Description

Model List:
- 540-v140, 540-v180 Loadall

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