JCB Loadalls – Side Engine (SA, SB And SC Engine) Operator Manual 9811-3100

Description

• Model List:
  • Loadalls – Side Engine (SA, SB And SC Engine)

• 1. Safety Notices
• 2. Important Information ………………………………………………………………………..vii
• 3. The Operator Manual ……………………………………………………………………vii
• 4. Safety Warnings …………………………………………………………………………..vii
• 5. Introduction
• 6. About This Manual ……………………………………………………………………………..1
• 7. Machine Model and Serial Number ………………………………………………….1
• 8. Using this Manual ………………………………………………………………………….1
• 9. Units of Measurement ……………………………………………………………………1
• 10. Left Side, Right Side ………………………………………………………………………1
• 11. Using the Machine …………………………………………………………………………1
• 12. Cab-Canopy …………………………………………………………………………………2
• 13. Cross References ………………………………………………………………………….2
• 14. Machine Description …………………………………………………………………………..3
• 15. The JCB Loadall ……………………………………………………………………………3
• 16. Intended Use ………………………………………………………………………………..3
• 17. Component Location ……………………………………………………………………..3
• 18. Safety Check List ……………………………………………………………………………….5
• 19. Safety – Yours and Others ………………………………………………………………5
• 20. General Safety ……………………………………………………………………………..5
• 21. Operating Safety …………………………………………………………………………..7
• 22. Maintenance Safety …………………………………………………………………….. 11
• 23. Safety Decals ………………………………………………………………………………….17
• 24. Introduction …………………………………………………………………………………17
• 25. Safety Decal Recognition ……………………………………………………………..18
• 26. Identifying Your Machine …………………………………………………………………..20
• 27. Machine Identification Plate ………………………………………………………….20
• 28. Component Identification Plates …………………………………………………….23
• 29. Machine Security ……………………………………………………………………………..26
• 30. Introduction …………………………………………………………………………………26
• 31. JCB Plantguard …………………………………………………………………………..26
• 32. Construction Equipment Security And Registration Scheme (CESAR) .26
• 33. Operation
• 34. Introduction ……………………………………………………………………………………..27
• 35. Before Entering the Cab ……………………………………………………………………28
• 36. Entering and Leaving the Cab ……………………………………………………………29
• 37. Emergency Exit …………………………………………………………………………..30
• 38. Doors and Windows …………………………………………………………………………32
• 39. Opening and Closing the Door ………………………………………………………32
• 40. Opening and Closing the Upper Door Section …………………………………32
• 41. Opening and Closing the Rear Window ………………………………………….33
• 42. Seat Controls …………………………………………………………………………………..34
• 43. Introduction …………………………………………………………………………………34
• 44. Seat Options ……………………………………………………………………………….34
• 45. Suspension Seat (Type 1) …………………………………………………………….35
• 46. Suspension Seat (Type 2) …………………………………………………………….36
• 47. Suspension Seat (Type 3) …………………………………………………………….37
• 48. Seat Belt …………………………………………………………………………………………38
• 49. Inertia Reel Seat Belt …………………………………………………………………..38
• 50. Static Seat Belt ……………………………………………………………………………39
• 51. Cab Layout ……………………………………………………………………………………..40
• 52. Component Key …………………………………………………………………………..42
• 53. Drive Controls, Switches and Instruments ……………………………………………43
• 54. Drive Controls ……………………………………………………………………………..43
• 55. Switches …………………………………………………………………………………….50
• 56. Instruments …………………………………………………………………………………57
• 57. Instrument Panel …………………………………………………………………………58
• 58. Torque Lock (6-Speed Transmission) ……………………………………………..64
• 59. Air Conditioning and Heater Controls ……………………………………………..65
• 60. Operating Levers ……………………………………………………………………………..66
• 61. Introduction …………………………………………………………………………………66
• 62. Control Layouts …………………………………………………………………………..66
• 63. Boom and Carriage Controls …………………………………………………………67
• 64. Auxiliary Controls ………………………………………………………………………..77
• 65. Chassis Levelling (Sway) Option ……………………………………………………82
• 66. Stabiliser Control Option ……………………………………………………………….84
• 67. Safety Equipment …………………………………………………………………………….86
• 68. Control Lever Locks …………………………………………………………………….86
• 69. Load Charts ………………………………………………………………………………..89
• 70. Boom Indicators ………………………………………………………………………….92
• 71. Load Moment Indicator (LMI) ………………………………………………………..93
• 72. LC1 and LC4 Load Control Systems ………………………………………………97
• 73. LC2 and LC3 Load Control System ………………………………………………105
• 74. Inclinometer ……………………………………………………………………………… 110
• 75. Beacon ……………………………………………………………………………………. 111
• 76. Fire Extinguisher (if fitted) ………………………………………………………….. 111
• 77. Before Starting the Engine ………………………………………………………………. 112
• 78. Starting the Engine ………………………………………………………………………… 114
• 79. Preparing the Machine for Travel …………………………………………………….. 116
• 80. Preparing for Road Travel ………………………………………………………….. 116
• 81. Preparing for Site Travel …………………………………………………………….. 118
• 82. Smooth Ride System (SRS) ………………………………………………………..120
• 83. Getting the Machine Moving …………………………………………………………….121
• 84. Operating Practices ……………………………………………………………………121
• 85. Operating Procedure ………………………………………………………………….122
• 86. Stopping and Parking the Machine ……………………………………………………123
• 87. Working with the Machine ……………………………………………………………….125
• 88. Operating Practices and Site Safety …………………………………………….125
• 89. Safety Practices ………………………………………………………………………..125
• 90. Danger Zone …………………………………………………………………………….126
• 91. Risk Assessment ……………………………………………………………………….126
• 92. Lifting and Loading Operations ……………………………………………………127
• 93. Safety Warnings ………………………………………………………………………..128
• 94. Fork Ratings ……………………………………………………………………………..130
• 95. Handling Palleted Loads …………………………………………………………….131
• 96. Uneven Loads …………………………………………………………………………..132
• 97. Handling Bales ………………………………………………………………………….133
• 98. Working with a Shovel ………………………………………………………………..134
• 99. Use of Machines on Gradients or Slopes ………………………………………135
• 100. Interlock System ………………………………………………………………………..138
• 101. Operating Environment ……………………………………………………………………139
• 102. Introduction ……………………………………………………………………………….139
• 103. Operating in Low Temperatures …………………………………………………..139
• 104. Operating in High Temperatures ………………………………………………….139
• 105. Tow Hitch Options …………………………………………………………………………..140
• 106. Introduction ……………………………………………………………………………….140
• 107. Connecting the Trailer ………………………………………………………………..141
• 108. Preparing the Trailer for Towing …………………………………………………..144
• 109. Refuelling the Machine ……………………………………………………………………146
• 110. Low Fuel Levels ………………………………………………………………………..146
• 111. Filling the Tank ………………………………………………………………………….146
• 112. Moving a Disabled Machine …………………………………………………………….148
• 113. Recovery Hitch ………………………………………………………………………….148
• 114. Transporting the Machine ………………………………………………………………..149
• 115. Lifting a Machine ……………………………………………………………………………150
• 116. Storage of the Machine …………………………………………………………………..151
• 117. Introduction ……………………………………………………………………………….151
• 118. Storage Area …………………………………………………………………………….151
• 119. Prepare the Machine for Storage …………………………………………………151
• 120. Put the Machine into Storage ………………………………………………………151
• 121. During Storage ………………………………………………………………………….151
• 122. Take the Machine Out of Storage …………………………………………………152
• 123. Routine Maintenance
• 124. Service Requirements …………………………………………………………………….153
• 125. Introduction ……………………………………………………………………………….153
• 126. Owner-Operator Support …………………………………………………………….153
• 127. Service-Maintenance Agreements ……………………………………………….153
• 128. Initial Service and Inspection (100 Hours) ……………………………………..153
• 129. Lifting Regulations – Inspections and Tests ……………………………………154
• 130. Obtaining Replacement Parts ………………………………………………………154
• 131. Health and Safety …………………………………………………………………………..155
• 132. Lubricants …………………………………………………………………………………155
• 133. Battery ……………………………………………………………………………………..157
• 134. Service Schedules ………………………………………………………………………….159
• 135. Introduction ……………………………………………………………………………….159
• 136. How to Use the Service Schedules ………………………………………………159
• 137. Calendar Equivalents …………………………………………………………………159
• 138. Pre-start Cold Checks, Service Points and Fluid Levels ………………….160
• 139. Functional Test and Final Inspection …………………………………………….163
• 140. Fluids, Lubricants and Capacities ……………………………………………………..165
• 141. Coolant Mixtures ……………………………………………………………………….167
• 142. Fuels ………………………………………………………………………………………..168
• 143. Prepare the Machine for Maintenance ………………………………………………171
• 144. Introduction ……………………………………………………………………………….171
• 145. How to Make the Machine Safe (Boom Lowered) …………………………..172
• 146. How to Make the Machine Safe (Boom Lifted) ………………………………173
• 147. Cleaning the Machine ……………………………………………………………………..176
• 148. Introduction ……………………………………………………………………………….176
• 149. Preparing the Machine for Cleaning ……………………………………………..176
• 150. Cleaning the Machine …………………………………………………………………177
• 151. Fan Reverse (if fitted) …………………………………………………………………179
• 152. Checking for Damage ……………………………………………………………………..180
• 153. Check the Machine Body and Structure ………………………………………..180
• 154. Check the Tyres ………………………………………………………………………..180
• 155. Check the Seat and Seat Belt ……………………………………………………..180
• 156. Check the Hydraulic Hoses and Fittings ……………………………………….180
• 157. Checking the ROPS-FOPS Structure ……………………………………………181
• 158. Greasing ……………………………………………………………………………………….182
• 159. Introduction ……………………………………………………………………………….182
• 160. Preparing the Machine for Greasing …………………………………………….182
• 161. Every 50 Hours ………………………………………………………………………….183
• 162. Every 500 Hours ………………………………………………………………………..189
• 163. Every 1000 Hours ………………………………………………………………………190
• 164. Access Panels ……………………………………………………………………………….191
• 165. Battery Cover ……………………………………………………………………………191
• 166. Engine Cover …………………………………………………………………………….192
• 167. Rear Cover (if fitted) …………………………………………………………………..193
• 168. Undershield ………………………………………………………………………………194
• 169. Heater and Air Conditioning …………………………………………………………….195
• 170. Changing the Air Intake Filter ………………………………………………………195
• 171. Boom ……………………………………………………………………………………………196
• 172. Re-phasing of 3-Stage Booms …………………………………………………….196
• 173. Brakes ………………………………………………………………………………………….197
• 174. Park Brake ………………………………………………………………………………..197
• 175. Foot Brake ………………………………………………………………………………..199
• 176. Electrical System ……………………………………………………………………………200
• 177. Battery ……………………………………………………………………………………..200
• 178. Jump Starting the Engine ……………………………………………………………202
• 179. Fuses ……………………………………………………………………………………….203
• 180. Link Box Fuses …………………………………………………………………………. 211
• 181. Relays ……………………………………………………………………………………..212
• 182. Engine ………………………………………………………………………………………….220
• 183. Oil and Filter ……………………………………………………………………………..220
• 184. Cooling System …………………………………………………………………………222
• 185. Front End Accessory Drive Belt …………………………………………………..224
• 186. Air Filter ……………………………………………………………………………………226
• 187. Fuel System …………………………………………………………………………………..228
• 188. Introduction ……………………………………………………………………………….228
• 189. Water Separator and Engine Fuel Filter ………………………………………..228
• 190. Bleeding the System ………………………………………………………………….233
• 191. Hydraulic System ……………………………………………………………………………234
• 192. Introduction ……………………………………………………………………………….234
• 193. Releasing the Hydraulic Pressure ………………………………………………..235
• 194. Oil and FIlters ……………………………………………………………………………236
• 195. Hose Burst Protection Valves ………………………………………………………241
• 196. Transmission …………………………………………………………………………………244
• 197. Gearbox ……………………………………………………………………………………244
• 198. Front and Rear Axle …………………………………………………………………..247
• 199. Tyres and Wheels …………………………………………………………………………..250
• 200. Tyre Inflation ……………………………………………………………………………..250
• 201. Checking the Wheel Nut Torques …………………………………………………251
• 202. Wheel Nut Torque Indicators (if fitted) …………………………………………..251
• 203. Wheel Alignment ……………………………………………………………………………252
• 204. Introduction ……………………………………………………………………………….252
• 205. Manual Steer Mode Selector ……………………………………………………….252
• 206. Electronic Steer Mode Selector ……………………………………………………253
• 207. Wear Pads …………………………………………………………………………………….254
• 208. Boom Wear Pad Clearance …………………………………………………………254
• 209. Windscreen Washer ……………………………………………………………………….256
• 210. Checking the Level …………………………………………………………………….256
• 211. Fire Extinguisher (if fitted) ………………………………………………………………..257
• 212. Checking the Fire Extinguisher ……………………………………………………257
• 213. Optional Attachments
• 214. Introduction ……………………………………………………………………………………259
• 215. Attachments for your Machine ………………………………………………………….260
• 216. Connecting-Disconnecting Hydraulic Hoses ……………………………………….261
• 217. Introduction ……………………………………………………………………………….261
• 218. Connecting the Hydraulic Hoses ………………………………………………….261
• 219. Disconnecting the Hydraulic Hoses ………………………………………………262
• 220. Quick Release Couplings ……………………………………………………………263
• 221. Q-Fit Attachments …………………………………………………………………………..265
• 222. Mechanical Pin Locking Option ……………………………………………………265
• 223. Hydraulic Pin Locking Option ………………………………………………………267
• 224. Extension Jib …………………………………………………………………………………269
• 225. Safety ………………………………………………………………………………………269
• 226. Installing-Removing ……………………………………………………………………269
• 227. Operation ………………………………………………………………………………….269
• 228. Maintenance ……………………………………………………………………………..270
• 229. Fork Mounted Hook ………………………………………………………………………..271
• 230. Safety ………………………………………………………………………………………271
• 231. Installing …………………………………………………………………………………..271
• 232. Removing …………………………………………………………………………………271
• 233. Operation ………………………………………………………………………………….272
• 234. Maintenance ……………………………………………………………………………..272
• 235. Sideshift Carriage …………………………………………………………………………..273
• 236. Operation ………………………………………………………………………………….273
• 237. Installing the Sideshift Carriage ……………………………………………………274
• 238. Removing the Sideshift Carriage ………………………………………………….275
• 239. Maintenance ……………………………………………………………………………..276
• 240. Roof Truss Jib ……………………………………………………………………………….277
• 241. Safety ………………………………………………………………………………………277
• 242. Installing-Removing ……………………………………………………………………277
• 243. Operation ………………………………………………………………………………….277
• 244. Extending the Jib ……………………………………………………………………….278
• 245. Changing the Jib Angle ………………………………………………………………279
• 246. Maintenance ……………………………………………………………………………..279
• 247. Work Platforms ………………………………………………………………………………280
• 248. Specifications
• 249. Static Dimensions …………………………………………………………………………..281
• 250. 531-70, 541-70 ………………………………………………………………………….281
• 251. 533-105 ……………………………………………………………………………………282
• 252. 535-95 ……………………………………………………………………………………..284
• 253. 536-60 ……………………………………………………………………………………..286
• 254. 536-70 ……………………………………………………………………………………..289
• 255. 535-125, 535-140 ………………………………………………………………………290
• 256. 535-125 HiViz, 535-140 HiViz ……………………………………………………..292
• 257. 540-140 ……………………………………………………………………………………294
• 258. 540-170 ……………………………………………………………………………………296
• 259. Performance Dimensions ………………………………………………………………..298
• 260. Lift Performance ………………………………………………………………………..298
• 261. Maximum Wading Depth …………………………………………………………….300
• 262. Axle Weight Distribution ………………………………………………………………….301
• 263. Machines Without Stabilisers ………………………………………………………301
• 264. Machines With Stabilisers …………………………………………………………..302
• 265. Noise Data …………………………………………………………………………………….303
• 266. Vibration Data ………………………………………………………………………………..304
• 267. Introduction ……………………………………………………………………………….304
• 268. 531-70, 533-105, 535-95, 536-60, 536-70, 541-70 …………………………305
• 269. 535-125, 535-140, 540-140 …………………………………………………………306
• 270. 535-125 HiViz, 535-140 HiViz ……………………………………………………..307
• 271. 540-170 ……………………………………………………………………………………308
• 272. Tyre Sizes and Pressures ………………………………………………………………..309
• 273. Introduction ……………………………………………………………………………….309
• 274. Specifications ……………………………………………………………………………309
• 275. Trailer Towing ………………………………………………………………………………..314
• 276. Towing Limitations ……………………………………………………………………..314
• 277. Load Charts …………………………………………………………………………………..315
• 278. Introduction ……………………………………………………………………………….315
• 279. Warranty Information
• 280. Machine Service Record Sheet ………………………………………………………..317
• 281. Registration Information ………………………………………………………………….319