JCB Series II Loadall Operator Manual 9801-8980

Description

• Model List:
  • 530-70, 532-120, 533-105, 535-60, 535-95, 535-125, 535-140, 537-135, 540-70, 540-140, 540-170 Series II Loadall

• 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. ………………………………………….. 10
• 19. Unit Identification…………………………………………….. 10
• 20. JCB Immobiliser Option …………………………………. 12
• 21. OPERATION
• 22. Introduction …………………………………………………. 21
• 23. Before Entering the Cab ……………………………….. 21
• 24. Entering and Leaving the Cab, Doors and Windows 22
• 25. Opening and Closing the Door ………………………… 23
• 26. Open and Closing the Rear Window ………………….. 23
• 27. Open and Closing the Upper Door Section ……….. 24
• 28. Emergency Exit ……………………………………………… 24
• 29. Seat Controls
• 30. Adjusting the Seat …………………………………………… 25
• 31. Seat Belt
• 32. Fasten the Seat Belt ……………………………………….. 27
• 33. Release the Seat Belt ……………………………………… 27
• 34. Adjust the Seat Belt . ………………………………………. 27
• 35. Cab Layout and Controls ……………………………… 28
• 36. Cab Switches and Instruments
• 37. Starter Switch ……………………………………………….. 30
• 38. Steering Column Switches ………………………………. 31
• 39. Instrument Panel Switches (Left Hand Group) …… 32
• 40. Instrument Panel Switches (Right Hand Group) …. 32
• 41. Steer Mode Selector ……………………………………….. 33
• 42. Phasing 4 Wheel Steer …………………………………….. 33
• 43. Four Wheel Drive Disconnect Switch Option ………. 33
• 44. Manual Steer Mode Selection (if fitted) ………………. 33A
• 45. Warning Beacon ……………………………………………. 34
• 46. Cab Light ……………………………………………………… 34
• 47. Instruments …………………………………………………… 35
• 48. Warnings – On Instrument Panel (Visual only) ……. 35
• 49. Warnings – On Warning Cluster (Visual only) …….. 36
• 50. Warnings – On Warning Cluster (Audible-Visual) …. 36
• 51. Heater and Air Conditioning
• 52. Heater ……………………………………………………………. 37
• 53. Air Conditioning Option ………………………………….. 37
• 54. Face-Level Fan (optional…………………………………… 37
• 55. Boom and Carriage Controls
• 56. Introduction ……………………………………………………. 38
• 57. Single Lever Control
• 58. Raise Boom-Lower Boom ……………………………….. 39
• 59. Extend Boom-Retract Boom ……………………………. 40
• 60. Re-phasing of 3 Stage Booms…………………………… 40
• 61. Tilt Carriage Forward-Back ……………………………… 41
• 62. Auxiliary Operation …………………………………………. 42
• 63. Control Locks …………………………………………………. 42A
• 64. Manual Auxiliary Control
• 65. Raise Boom-Lower Boom ……………………………….. 43
• 66. Extend Boom-Retract Boom ……………………………. 44
• 67. Tilt Carriage Forward-Back ……………………………… 45
• 68. Auxiliary Operation …………………………………………. 46
• 69. Control Locks …………………………………………………. 47
• 70. Servo Control
• 71. Raise Boom-Lower Boom ……………………………….. 48
• 72. Extend Boom-Retract Boom ……………………………. 49
• 73. Extend-Retract Inner Boom ……………………………… 49
• 74. Tilt Carriage Forward-Back ……………………………… 50
• 75. Auxiliary Operation …………………………………………. 51
• 76. Control Locks …………………………………………………. 52
• 77. Chassis Levelling (Sway) Option …………………… 53
• 78. Stabiliser Control Option
• 79. Using the Stabilisers ……………………………………….. 54
• 80. Stabiliser Indicator Lights …………………………………. 54
• 81. Lower and Raise Stabilisers………………………………. 54A
• 82. Before Starting the Engine ……………………………. 55
• 83. Starting the Engine ………………………………………. 56
• 84. Preparing for Road Travel …………………………….. 57
• 85. Preparing for Site Travel ………………………………. 59
• 86. Smooth Ride System …………………………………….. 60
• 87. Testing the Parking Brake …………………………….. 61
• 88. Getting the Machine Moving
• 89. Operating Practices ……………………………………….. 62
• 90. Limited Slip Differential (LSD) ……………………………. 62
• 91. Operation of Five Speed Transmission ………………. 64
• 92. Stopping and Parking the Machine ……………….. 65
• 93. Using the Load Charts and Boom Indicators …. 66
• 94. Load Moment Indicator (LMI)
• 95. Checking the Indicator …………………………………….. 68
• 96. Setting the Volume and Brightness …………………… 69
• 97. Diagnostic Fault Codes ……………………………………. 69
• 98. LC1 Load Control System
• 99. Introduction ……………………………………………………. 70
• 100. Machine Model and Serial Number ……………………. 70
• 101. General Information …………………………………………. 70
• 102. The LC1 Indicator Display…………………………………. 71
• 103. Load Control Mode………………………………………….. 72
• 104. Ground Work Mode …………………………………………. 74
• 105. Emergency Override ………………………………………… 75
• 106. Daily Functional Check …………………………………….. 76
• 107. Setting the Volume and Brightness ……………………. 77
• 108. Diagnostic Fault Codes…………………………………….. 78
• 109. LC2 Load Control System
• 110. Introduction ……………………………………………………. 79
• 111. Machine Model and Serial Number ……………………. 79
• 112. General Information …………………………………………. 79
• 113. The LC2 Indicator Display…………………………………. 80
• 114. Load Control Mode………………………………………….. 81
• 115. Ground Work Mode …………………………………………. 82
• 116. Emergency Override ………………………………………… 83
• 117. Daily Functional Check …………………………………….. 84
• 118. Setting the Volume and Brightness ……………………. 85
• 119. Diagnostic Fault Codes…………………………………….. 86
• 120. Working with the Machine
• 121. Introduction ……………………………………………………. 87
• 122. Safety Practices ……………………………………………… 87
• 123. Risk Assessment……………………………………………… 88
• 124. Lifting and Loading Operations ………………………… 89
• 125. Safety Warnings ……………………………………………… 90
• 126. Fork Ratings …………………………………………………… 91
• 127. Handling Palleted Loads ………………………………….. 92
• 128. Uneven Loads ……………………………………………….. 93
• 129. Lifting Bales ………………………………………………….. 94
• 130. Placing Bales ………………………………………………… 94
• 131. Working With a Shovel……………………………………… 95
• 132. Use of Machines on Gradients or Slopes ……………. 97
• 133. Operating in Low Temperatures ……………………. 100
• 134. Operating in High Temperatures …………………… 100
• 135. Towing a Machine ………………………………………… 101
• 136. Recovery Hitch …………………………………………….. 101
• 137. Mechanical Tow Hitch Option ………………………. 102
• 138. Hydraulic Tow Hitch Option ………………………….. 104
• 139. Transporting the Machine …………………………….. 106
• 140. Lifting a Machine …………………………………………… 107
• 141. MAINTENANCE
• 142. Lubricants – Health and Safety
• 143. Hygiene ………………………………………………………… 110
• 144. Storage ………………………………………………………… 110
• 145. Waste Disposal ……………………………………………… 110
• 146. Handling ……………………………………………………….. 110
• 147. First Aid – Oil …………………………………………………. 110
• 148. Spillage ………………………………………………………… 110
• 149. Fires …………………………………………………………….. 110
• 150. Service Requirements
• 151. Introduction …………………………………………………… 111
• 152. Maintenance …………………………………………………. 111
• 153. Owner-Operator Support ………………………………… 111
• 154. Service-Maintenance Agreements ……………………. 111
• 155. Service Schedules ………………………………………… 111
• 156. Boom Safety Strut
• 157. Installing ……………………………………………………….. 115
• 158. Removing ……………………………………………………… 115
• 159. Engine Cover
• 160. Opening-Closing the Cover . ……………………………. 116
• 161. Cleaning the Machine …………………………………… 116
• 162. Undershield Removal and Replacement …………….. 116
• 163. Checking for Damage …………………………………… 118
• 164. Seat Belt
• 165. Checking the Seat Belt Condition and Security …. 118
• 166. Greasing (General) ……………………………………….. 118
• 167. Greasing (Every 50 Hours) 530-70, 540-70 …………. 119
• 168. Greasing (Every 50 Hours) 533-105, 535-95 ……….. 120
• 169. Greasing (Every 50 Hours) 535-60……………………… 121
• 170. Greasing (Every 50 Hours) 532-120, 535-125, 535-140
• 171. 537-135, 540-140, 540-170………………………………. 122
• 172. Greasing the Optional Sideshift Carriage …………… 123
• 173. Greasing (Every 500 Hours) ……………………………… 123
• 174. Greasing the Hydraulic Tow Hitch ……………………… 124
• 175. Greasing (Every 1000 Hours) ……………………………. 124
• 176. Oiling …………………………………………………………… 125
• 177. Brakes
• 178. Checking the Footbrake Fluid Level ………………….. 125
• 179. Parking Brake Adjustment ………………………………… 125A
• 180. Tyres And Wheels
• 181. Tyre Inflation …………………………………………………. 126
• 182. Checking The Roadwheel Tightness ………………… 126
• 183. Engine Air Filter
• 184. Changing the Elements …………………………………… 126A
• 185. Engine Oil And Filter
• 186. Checking the Oil Level ……………………………………. 127
• 187. Changing the Oil And Filter ……………………………… 127
• 188. Engine Cooling System
• 189. Checking the Coolant Level …………………………….. 128
• 190. Coolant Mixtures ……………………………………………. 129
• 191. Changing the Coolant …………………………………….. 130
• 192. Fuel System
• 193. Types of Fuel ………………………………………………… 131
• 194. Low Temperature Fuels ………………………………….. 131
• 195. Filling the Tank ………………………………………………. 132
• 196. Priming the System ………………………………………… 132
• 197. Draining the Filter (A Series Engine) ………………….. 134
• 198. Changing the Filter Element (A Series Engine) …… 134
• 199. Draining the Filter (R Series Engine) …………………. 135
• 200. Changing the Filter Element (R Series Engine) …… 135
• 201. Draining the Sediment Bowl ……………………………. 136
• 202. Cleaning the Sediment Bowl ……………………………. 136
• 203. Transmission
• 204. Check Transmission Oil Level ………………………….. 137
• 205. Changing the Oil and Filter ……………………………….. 138
• 206. Front And Rear Axle
• 207. Checking the Axle Oil Level …………………………….. 140
• 208. Changing the Axle Oil …………………………………….. 140
• 209. Front And Rear Hub
• 210. Checking the Hub Oil Levels ……………………………. 141
• 211. Oil Immersed Brakes ………………………………………. 141
• 212. Changing the Hub Oil ……………………………………… 141
• 213. Hydraulic System
• 214. Checking The Fluid Level ………………………………… 142
• 215. Changing The Pilot Filter Element …………………….. 143
• 216. Changing The Filter Element ……………………………. 144
• 217. Hose Burst Protection Valves
• 218. Checking The Hose Burst Protection Valves ……… 146
• 219. Battery
• 220. Warning Symbols …………………………………………… 148
• 221. Checking the Electrolyte Level ………………………… 149
• 222. Battery Isolator ………………………………………………. 150
• 223. Jump-Starting the Engine . ……………………………. 151
• 224. Electrical System
• 225. Fuse Identification ………………………………………….. 152
• 226. Fuse Links………………………………………………………. 152
• 227. Bulbs ……………………………………………………………. 153
• 228. Adjusting the Alternator Drive Belt ……………………. 153
• 229. Heater and Air Conditioning Options
• 230. Adjusting the Air Conditioning Compressor
• 231. Drive Belt ………………………………………………………. 154
• 232. Changing the Air Intake Filter …………………………… 154
• 233. Windscreen Washer ……………………………………… 155
• 234. Obtaining Replacement Parts ……………………….. 155
• 235. Fluids, Lubricants, Capacities and Specifications
• 236. 530-70, 533-105, 535-60, 535-95 and 540-70 ………. 156
• 237. 532-120, 535-125, 535-140, 537-135 540-140
• 238. and 540-170 ……………………………………………………… 157
• 239. Boom Wear Pad Clearance
• 240. Wear Limits ……………………………………………………. 158
• 241. OPTIONAL ATTACHMENTS
• 242. Introduction …………………………………………………. 161
• 243. Quick Release Couplings
• 244. Quick Release Couplings – Do’s and Don’ts . …….. 163
• 245. Remove Pressure from Service Lines ……………….. 163A
• 246. Connecting Quick Release Couplings ………………. 163A
• 247. Disconnecting Quick Release Couplings …………… 163A
• 248. Installing and Removing Q-Fit Attachments
• 249. Installing Attachments ……………………………………. 164
• 250. Removing Attachments …………………………………… 166
• 251. Hydraulic Pin Locking Option
• 252. Installing Attachments ……………………………………. 167
• 253. Removing Attachments …………………………………… 169
• 254. Extension Jib
• 255. Safety …………………………………………………………… 171
• 256. Installing-Removing …………………………………………. 171
• 257. Operation ……………………………………………………… 171
• 258. Maintenance …………………………………………………. 172
• 259. Fork Mounted Hook
• 260. Safety …………………………………………………………… 173
• 261. Installing ……………………………………………………….. 173
• 262. Removing ……………………………………………………… 173
• 263. Operation ……………………………………………………… 174
• 264. Maintenance …………………………………………………. 174
• 265. Sideshift Carriage ………………………………………….. 175
• 266. Operation ………………………………………………………. 176
• 267. Installing the Sideshift Carriage ………………………… 177
• 268. Removing the Sideshift Carriage ………………………. 178
• 269. Roof Truss Jib
• 270. Safety…………………………………………………………….. 179
• 271. Installing-Removing …………………………………………. 179
• 272. Operation ………………………………………………………. 179
• 273. Maintenance ………………………………………………….. 181
• 274. Work Platforms ……………………………………………… 182
• 275. SPECIFICATIONS
• 276. Static Dimensions ………………………………………….. 191
• 277. Performance Dimensions ……………………………… 195
• 278. Axle Weight Distribution ……………………………….. 196
• 279. Engine Emissions ………………………………………….. 197
• 280. Tyres and Pressures …………………………………….. 198
• 281. Trailer Towing Limitations………………………………. 199B
• 282. Noise and Vibration Data ……………………………… 200
• 283. Load Charts ………………………………………………….. 201