JCB 800D Workmax Operator Manual 9811-5150

Description

• Model List:
  • 800D Workmax

• 1. Safety Notices
• 2. Important Information ……………………………………………………………………….xiii
• 3. The Operator Manual …………………………………………………………………..xiii
• 4. Safety Warnings ………………………………………………………………………….xiv
• 5. Introduction
• 6. About this Manual ………………………………………………………………………………1
• 7. Machine Model and Serial Number ………………………………………………….1
• 8. Using this Manual ………………………………………………………………………….1
• 9. Left Side, Right Side ………………………………………………………………………2
• 10. Cab-Canopy …………………………………………………………………………………2
• 11. Cross References ………………………………………………………………………….2
• 12. Machine Description …………………………………………………………………………..3
• 13. The JCB Workmax 800D ………………………………………………………………..3
• 14. Intended Use ………………………………………………………………………………..3
• 15. Component Location ……………………………………………………………………..4
• 16. Safety Check List ……………………………………………………………………………….6
• 17. Safety – Yours and Others ………………………………………………………………6
• 18. General Safety ……………………………………………………………………………..7
• 19. Operating Safety …………………………………………………………………………10
• 20. Maintenance Safety ……………………………………………………………………..18
• 21. Safety Labels …………………………………………………………………………………..28
• 22. Introduction …………………………………………………………………………………28
• 23. Safety Label Identification …………………………………………………………….29
• 24. Part Numbers and Description ………………………………………………………31
• 25. Identifying Your Machine …………………………………………………………………..34
• 26. Machine Identification Plate ………………………………………………………….34
• 27. Typical Product Identification Number Data Plate …………………………….36
• 28. Component Identification Plates …………………………………………………….36
• 29. Operation
• 30. Introduction ……………………………………………………………………………………..39
• 31. Before Entering the Cab ……………………………………………………………………40
• 32. Entering and Leaving the Cab ……………………………………………………………43
• 33. Introduction …………………………………………………………………………………43.
• 34. Seat Controls …………………………………………………………………………………..44
• 35. Introduction …………………………………………………………………………………44
• 36. Operator and Passenger Seat Usage …………………………………………….44
• 37. Adjustment …………………………………………………………………………………45
• 38. Seat Belts ……………………………………………………………………………………….46
• 39. Inertia Reel Seat Belt …………………………………………………………………..46
• 40. Visibility Aids ……………………………………………………………………………………49
• 41. Mirrors ……………………………………………………………………………………….49
• 42. Cab Layout ……………………………………………………………………………………..52
• 43. Component Key …………………………………………………………………………..52
• 44. Drive Controls, Switches and Instruments ……………………………………………54
• 45. Drive Controls ……………………………………………………………………………..54
• 46. Switches …………………………………………………………………………………….58
• 47. Instruments …………………………………………………………………………………64
• 48. Safety Equipment …………………………………………………………………………….67
• 49. Beacon ………………………………………………………………………………………67
• 50. Before Starting the Engine …………………………………………………………………68
• 51. Starting the Engine …………………………………………………………………………..71
• 52. Preparing the Machine for Travel ……………………………………………………….73
• 53. Introduction …………………………………………………………………………………73
• 54. Preparing for Road Travel …………………………………………………………….73
• 55. Preparing for Site Travel ……………………………………………………………….74
• 56. Getting the Machine Moving ………………………………………………………………75
• 57. Operating Practices ……………………………………………………………………..75
• 58. Operating Procedure ……………………………………………………………………77
• 59. 2-4 Wheel Drive …………………………………………………………………………..78
• 60. Stopping and Parking the Machine ……………………………………………………..79
• 61. Working with your Machine ……………………………………………………………….81
• 62. Operating Practices and Site Safety ………………………………………………81
• 63. Danger Zone ………………………………………………………………………………82
• 64. Clothing and Safety Equipment ……………………………………………………..82
• 65. Safety Practices ………………………………………………………………………….83
• 66. Operating on Slopes or Rough Terrain ……………………………………………85
• 67. Working with the Loadbay …………………………………………………………….86
• 68. Operating Environment ……………………………………………………………………..91
• 69. Operating in Low Temperatures …………………………………………………….91
• 70. Operating in High Temperatures ……………………………………………………91
• 71. Tow Hitch Options …………………………………………………………………………….93
• 72. Introduction …………………………………………………………………………………93
• 73. Connecting the Trailer ………………………………………………………………….94
• 74. Disconnecting the Trailer ………………………………………………………………96
• 75. Refuelling the Machine ……………………………………………………………………..97
• 76. Low Fuel Levels ………………………………………………………………………….97
• 77. Filling the Tank ……………………………………………………………………………97
• 78. Moving a Disabled Machine …………………………………………………………….100
• 79. Transporting the Machine ………………………………………………………………..101
• 80. Prepare for Road Travel ……………………………………………………………..101
• 81. Before Using the Trailer-Transporter …………………………………………….102
• 82. Loading a Machine onto the Transporting Vehicle-Trailer ………………..103
• 83. Secure the Machine in Position ……………………………………………………104
• 84. Lifting the Machine …………………………………………………………………….105
• 85. Storage of the Machine …………………………………………………………………..107
• 86. Introduction ……………………………………………………………………………….107
• 87. Storage Area …………………………………………………………………………….107
• 88. Prepare the Machine for Storage …………………………………………………107
• 89. Put the Machine into Storage ………………………………………………………108
• 90. During Storage ………………………………………………………………………….109
• 91. Take the Machine Out of Storage …………………………………………………109
• 92. Routine Maintenance
• 93. Service Requirements ……………………………………………………………………. 111
• 94. Introduction ………………………………………………………………………………. 111
• 95. Owner-Operator Support ……………………………………………………………. 112
• 96. Service-Maintenance Agreements ………………………………………………. 113
• 97. Initial Service and Inspection ………………………………………………………. 113
• 98. Obtaining Replacement Parts ……………………………………………………… 113
• 99. Health and Safety ………………………………………………………………………….. 114
• 100. Lubricants ………………………………………………………………………………… 114
• 101. Battery …………………………………………………………………………………….. 118
• 102. Service Schedules ………………………………………………………………………….122
• 103. Introduction ……………………………………………………………………………….122
• 104. How to Use the Service Schedules ………………………………………………123
• 105. Hours and Distance Equivalents ………………………………………………….124
• 106. Pre-start Cold Checks, Service Points and Fluid Levels ………………….125
• 107. Functional Tests and Final Inspection …………………………………………..131
• 108. Fluids, Lubricants and Capacities ……………………………………………………..134
• 109. Types of Fuel …………………………………………………………………………….135
• 110. Coolant Mixtures ……………………………………………………………………….138
• 111. Prepare the Machine for Maintenance ………………………………………………140
• 112. Introduction ……………………………………………………………………………….140
• 113. Make the Machine Safe ………………………………………………………………140
• 114. Cleaning the Machine ……………………………………………………………………..141
• 115. Introduction ……………………………………………………………………………….141
• 116. Prepare the Machine for Cleaning ………………………………………………..142
• 117. Cleaning …………………………………………………………………………………..143
• 118. Checking for Damage ……………………………………………………………………..146
• 119. Check the Machine Body and Structure ………………………………………..146
• 120. Check the Tyres ………………………………………………………………………..146
• 121. Check the Seat and Seat Belt ……………………………………………………..147
• 122. Checking the ROPS …………………………………………………………………..148
• 123. Greasing ……………………………………………………………………………………….150
• 124. Introduction ……………………………………………………………………………….150
• 125. Prepare the Machine for Greasing ……………………………………………….151
• 126. Access Panels ……………………………………………………………………………….154
• 127. Introduction ……………………………………………………………………………….154
• 128. Front Access Panel ……………………………………………………………………154
• 129. Brakes ………………………………………………………………………………………….156
• 130. Park Brake ………………………………………………………………………………..156
• 131. Foot Brake ………………………………………………………………………………..161
• 132. Electrical System ……………………………………………………………………………165
• 133. Battery ……………………………………………………………………………………..165
• 134. Fuses ……………………………………………………………………………………….172
• 135. Relays ……………………………………………………………………………………..174
• 136. Engine ………………………………………………………………………………………….175
• 137. Oil and Filter ……………………………………………………………………………..175
• 138. Cooling System …………………………………………………………………………180
• 139. Alternator Drive Belt …………………………………………………………………..188
• 140. Air Filter ……………………………………………………………………………………190
• 141. Fuel System …………………………………………………………………………………..194
• 142. Introduction ……………………………………………………………………………….194
• 143. Draining and Cleaning the Fuel Filter-Water Separator ……………………195
• 144. Changing the Fuel Filter ……………………………………………………………..197
• 145. Bleeding the Fuel System …………………………………………………………..198
• 146. Accelerator Free Travel ………………………………………………………………200
• 147. Speed Control and Governor ……………………………………………………….200
• 148. Transmission …………………………………………………………………………………202
• 149. Gearbox ……………………………………………………………………………………202
• 150. Rear Axle ………………………………………………………………………………….204
• 151. Front Axle (4WD only) ………………………………………………………………..206
• 152. Checking the Driveshaft CV Joint Gaiters ……………………………………..208
• 153. Checking the CVT Belt ……………………………………………………………….209
• 154. Steering and Suspension ………………………………………………………………..210
• 155. Wheel Alignment ……………………………………………………………………….210
• 156. Tyres and Wheels ………………………………………………………………………….. 211
• 157. Tyre Inflation …………………………………………………………………………….. 211
• 158. Tyre Replacement ……………………………………………………………………..213
• 159. Checking the Wheel Nut Torques …………………………………………………214
• 160. Replace a Wheel ……………………………………………………………………….214
• 161. Specifications
• 162. Static Dimensions …………………………………………………………………………..217
• 163. Tyre Sizes and Pressures ………………………………………………………………..220
• 164. Performance Dimensions ………………………………………………………………..221
• 165. Main Specifications …………………………………………………………………….221
• 166. Speeds …………………………………………………………………………………….222
• 167. Electrical Equipment ……………………………………………………………………….223
• 168. Trailer Towing ………………………………………………………………………………..224
• 169. Towing Limitations ……………………………………………………………………..224
• 170. Noise Data …………………………………………………………………………………….225
• 171. Vibration Data ………………………………………………………………………………..226
• 172. Introduction ……………………………………………………………………………….226
• 173. Workmax 800D ………………………………………………………………………….228
• 174. Warranty Information
• 175. Machine Service Record Sheet ………………………………………………………..231
• 176. Registration Information ………………………………………………………………….239
• 177. European Community Standards
• 178. EC Declaration of Conformity …………………………………………………………..241
• 179. Introduction ……………………………………………………………………………….241