JCB Side Engine (MC05, LLMI-LLMC) Loadalls Operator Manual 9811-0434

Description

• Model List:
  • Side Engine (MC05, LLMI-LLMC) Loadalls

• 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. Left Side, Right Side ………………………………………………………………………1
• 10. Cab-Canopy …………………………………………………………………………………1
• 11. Cross References ………………………………………………………………………….1
• 12. Machine Description …………………………………………………………………………..2
• 13. The JCB Loadall ……………………………………………………………………………2
• 14. Intended Use ………………………………………………………………………………..2
• 15. Component Location ……………………………………………………………………..2
• 16. Safety Check List ……………………………………………………………………………….4
• 17. Safety – Yours and Others ………………………………………………………………4
• 18. General Safety ……………………………………………………………………………..4
• 19. Operating Safety …………………………………………………………………………..6
• 20. Maintenance Safety ……………………………………………………………………..10
• 21. Safety Labels …………………………………………………………………………………..15
• 22. Introduction …………………………………………………………………………………15
• 23. Safety Label Identification …………………………………………………………….16
• 24. Identifying Your Machine …………………………………………………………………..19
• 25. Machine Identification Plate ………………………………………………………….19
• 26. Component Identification Plates …………………………………………………….21
• 27. Machine Security ……………………………………………………………………………..25
• 28. Introduction …………………………………………………………………………………25
• 29. JCB Plantguard …………………………………………………………………………..25
• 30. Operation
• 31. Introduction ……………………………………………………………………………………..27
• 32. Before Entering the Cab ……………………………………………………………………28
• 33. Entering and Leaving the Cab ……………………………………………………………29
• 34. Emergency Exit …………………………………………………………………………..30
• 35. Doors and Windows …………………………………………………………………………32
• 36. Opening and Closing the Door ………………………………………………………32
• 37. Opening and Closing the Upper Door Section …………………………………32
• 38. Opening and Closing the Rear Window ………………………………………….33
• 39. Seat Controls …………………………………………………………………………………..34
• 40. Introduction …………………………………………………………………………………34
• 41. Seat Options ……………………………………………………………………………….34
• 42. Suspension Seat (KAB 100 Series – Mechanical) …………………………….35
• 43. Suspension Seat (KAB 100 Series – Air) …………………………………………36
• 44. Suspension Seat (KAB 800 Series – Air) …………………………………………37
• 45. Suspension Seat (Grammer – Air) ………………………………………………….38
• 46. Seat Belt …………………………………………………………………………………………40
• 47. Inertia Reel Seat Belt …………………………………………………………………..40
• 48. Static Seat Belt ……………………………………………………………………………41
• 49. Cab Layout ……………………………………………………………………………………..42
• 50. Operating Levers …………………………………………………………………………43
• 51. Component Key …………………………………………………………………………..44
• 52. Drive Controls, Switches and Instruments ……………………………………………45
• 53. Drive Controls ……………………………………………………………………………..45
• 54. Switches …………………………………………………………………………………….52
• 55. Instrument Panel (SD and SF Engines) ………………………………………….60
• 56. Instrument Panel (SE Engine) ……………………………………………………….66
• 57. Torque Lock (6-Speed Transmission) ……………………………………………..78
• 58. Air Conditioning and Cab Heater Controls ………………………………………79
• 59. Operating Levers ……………………………………………………………………………..80
• 60. Introduction …………………………………………………………………………………80
• 61. Control Layouts …………………………………………………………………………..80
• 62. Boom and Carriage Controls …………………………………………………………81
• 63. Auxiliary Controls ………………………………………………………………………..86
• 64. Chassis Levelling (Sway) Option ……………………………………………………91
• 65. Stabiliser Control Option ……………………………………………………………….93
• 66. Safety Equipment …………………………………………………………………………….95
• 67. Control Locks ……………………………………………………………………………..95
• 68. Load Charts ………………………………………………………………………………..99
• 69. Boom Indicators ………………………………………………………………………..102
• 70. Longitudinal Load Moment Indicator (LLMI) …………………………………..103
• 71. Longitudinal Load Moment Control (LLMC) System ……………………….107
• 72. MC05 Load Control System ……………………………………………………….. 112
• 73. Inclinometer ……………………………………………………………………………… 119
• 74. Beacon …………………………………………………………………………………….120
• 75. Fire Extinguisher (if fitted) …………………………………………………………..120
• 76. Before Starting the Engine ……………………………………………………………….122
• 77. Starting the Engine …………………………………………………………………………124
• 78. Preparing the Machine for Travel ……………………………………………………..126
• 79. Introduction ……………………………………………………………………………….126
• 80. Preparing for Road Travel …………………………………………………………..126
• 81. Preparing for Site Travel ……………………………………………………………..128
• 82. Smooth Ride System (SRS) ………………………………………………………..130
• 83. Getting the Machine Moving …………………………………………………………….131
• 84. Operating Practices ……………………………………………………………………131
• 85. Operating Procedure ………………………………………………………………….132
• 86. Stopping and Parking the Machine ……………………………………………………134
• 87. Working with the Machine ……………………………………………………………….135
• 88. Operating Practices and Site Safety …………………………………………….135
• 89. Clothing and Safety Equipment ……………………………………………………135
• 90. Danger Zone …………………………………………………………………………….135
• 91. Working with the Boom ………………………………………………………………136
• 92. Use of Machines on Gradients or Slopes ………………………………………146
• 93. Interlock System ………………………………………………………………………..149
• 94. Operating Environment ……………………………………………………………………150
• 95. Operating in Low Temperatures …………………………………………………..150
• 96. Operating in High Temperatures ………………………………………………….150
• 97. Tow Hitch Options …………………………………………………………………………..151
• 98. Introduction ……………………………………………………………………………….151
• 99. Connecting the Trailer ………………………………………………………………..152
• 100. Preparing the Trailer for Towing …………………………………………………..159
• 101. Refuelling the Machine ……………………………………………………………………163
• 102. Low Fuel Levels ………………………………………………………………………..163
• 103. Filling the Tank ………………………………………………………………………….163
• 104. Moving a Disabled Machine …………………………………………………………….165
• 105. Recovery Hitch ………………………………………………………………………….165
• 106. Transporting the Machine ………………………………………………………………..166
• 107. Lifting a Machine ……………………………………………………………………………167
• 108. Storage of the Machine …………………………………………………………………..169
• 109. Introduction ……………………………………………………………………………….169
• 110. Storage Area …………………………………………………………………………….169
• 111. Prepare the Machine for Storage …………………………………………………169
• 112. Put the Machine into Storage ………………………………………………………169
• 113. During Storage ………………………………………………………………………….169
• 114. Take the Machine Out of Storage …………………………………………………170
• 115. Routine Maintenance
• 116. Service Requirements …………………………………………………………………….171
• 117. Introduction ……………………………………………………………………………….171
• 118. Owner-Operator Support …………………………………………………………….171
• 119. Service-Maintenance Agreements ……………………………………………….171
• 120. Initial Service and Inspection ……………………………………………………….171
• 121. Fit for Purpose Tests for Lifting Equipment …………………………………….172
• 122. Obtaining Replacement Parts ………………………………………………………172
• 123. Health and Safety …………………………………………………………………………..173
• 124. Lubricants …………………………………………………………………………………173
• 125. Battery ……………………………………………………………………………………..175
• 126. Service Schedules ………………………………………………………………………….177
• 127. Introduction ……………………………………………………………………………….177
• 128. How to Use the Service Schedules ………………………………………………177
• 129. Calendar Equivalents …………………………………………………………………177
• 130. Pre-start Cold Checks, Service Points and Fluid Levels ………………….178
• 131. Functional Test and Final Inspection …………………………………………….182
• 132. Fluids, Lubricants and Capacities ……………………………………………………..184
• 133. Coolant Mixtures ……………………………………………………………………….186
• 134. Fuels ………………………………………………………………………………………..187
• 135. Prepare the Machine for Maintenance ………………………………………………190
• 136. Introduction ……………………………………………………………………………….190
• 137. How to Make the Machine Safe (Boom Lowered) …………………………..191
• 138. How to Make the Machine Safe (Boom Lifted) ……………………………….192
• 139. Cleaning the Machine ……………………………………………………………………..195
• 140. Introduction ……………………………………………………………………………….195
• 141. Preparing the Machine for Cleaning ……………………………………………..195
• 142. Cleaning the Machine …………………………………………………………………196
• 143. Fan Reverse (if fitted) …………………………………………………………………198
• 144. Checking for Damage ……………………………………………………………………..199
• 145. Check the Machine Body and Structure ………………………………………..199
• 146. Check the Tyres ………………………………………………………………………..199
• 147. Check the Seat and Seat Belt ……………………………………………………..199
• 148. Check the Hydraulic Hoses and Fittings ……………………………………….199
• 149. Check the Electrical Circuits ………………………………………………………..199
• 150. Checking the ROPS-FOPS Structure ……………………………………………201
• 151. Greasing ……………………………………………………………………………………….202
• 152. Introduction ……………………………………………………………………………….202
• 153. Preparing the Machine for Greasing …………………………………………….202
• 154. Every 50 Hours ………………………………………………………………………….203
• 155. Every 500 Hours ……………………………………………………………………….. 211
• 156. Every 1000 Hours ………………………………………………………………………213
• 157. Access Panels ……………………………………………………………………………….214
• 158. Introduction ……………………………………………………………………………….214
• 159. Battery Cover ……………………………………………………………………………214
• 160. Engine Cover …………………………………………………………………………….215
• 161. Rear Cover (if fitted) …………………………………………………………………..216
• 162. Undershield ………………………………………………………………………………217
• 163. Cab Heater and Air Conditioning ………………………………………………………218
• 164. Changing the Air Intake Filter ………………………………………………………218
• 165. Boom ……………………………………………………………………………………………219
• 166. Re-phasing of 3-Stage Booms …………………………………………………….219
• 167. Brakes ………………………………………………………………………………………….220
• 168. Park Brake ………………………………………………………………………………..220
• 169. Foot Brake (Excluding 550-80 Machines) ……………………………………..222
• 170. Footbrake (550-80 Machines) ……………………………………………………..222
• 171. Electrical System ……………………………………………………………………………223
• 172. Battery ……………………………………………………………………………………..223
• 173. Jump Starting the Engine ……………………………………………………………225
• 174. Fuses ……………………………………………………………………………………….226
• 175. Primary Fuses …………………………………………………………………………..239
• 176. Relays ……………………………………………………………………………………..240
• 177. Engine ………………………………………………………………………………………….250
• 178. Oil and Filter ……………………………………………………………………………..250
• 179. Cooling System …………………………………………………………………………252
• 180. Crankcase Ventilation (if fitted) …………………………………………………….254
• 181. Front End Accessory Drive Belt …………………………………………………..255
• 182. Air Filter ……………………………………………………………………………………257
• 183. Fuel System …………………………………………………………………………………..259
• 184. Introduction ……………………………………………………………………………….259
• 185. Water Separator and Engine Fuel Filter ………………………………………..259
• 186. Bleeding the System ………………………………………………………………….265
• 187. Hydraulic System ……………………………………………………………………………267
• 188. Introduction ……………………………………………………………………………….267
• 189. Releasing the Hydraulic Pressure ………………………………………………..268
• 190. Oil and FIlters ……………………………………………………………………………269
• 191. Hose Burst Protection Valves ………………………………………………………275
• 192. Transmission …………………………………………………………………………………277
• 193. Gearbox ……………………………………………………………………………………277
• 194. Front and Rear Axle …………………………………………………………………..280
• 195. Tyres and Wheels …………………………………………………………………………..284
• 196. Tyre Inflation ……………………………………………………………………………..284
• 197. Wheel Nuts ……………………………………………………………………………….285
• 198. Wheel Alignment ……………………………………………………………………………286
• 199. Introduction ……………………………………………………………………………….286
• 200. Manual Steer Mode Selector ……………………………………………………….286
• 201. Electronic Steer Mode Selector ……………………………………………………287
• 202. Wear Pads …………………………………………………………………………………….288
• 203. Boom Wear Pad Clearance …………………………………………………………288
• 204. Windscreen Washer ……………………………………………………………………….291
• 205. Checking the Level …………………………………………………………………….291
• 206. Fire Extinguisher (if fitted) ………………………………………………………………..292
• 207. Checking the Fire Extinguisher ……………………………………………………292
• 208. Optional Attachments
• 209. Introduction ……………………………………………………………………………………293
• 210. Attachments for your Machine ………………………………………………………….294
• 211. Connecting-Disconnecting Hydraulic Hoses ……………………………………….295
• 212. Introduction ……………………………………………………………………………….295
• 213. Connecting the Hydraulic Hoses ………………………………………………….295
• 214. Disconnecting the Hydraulic Hoses ………………………………………………296
• 215. Quick Release Couplings ……………………………………………………………297
• 216. Q-Fit Attachments …………………………………………………………………………..299
• 217. Mechanical Pin Locking Option ……………………………………………………299
• 218. Hydraulic Pin Locking Option ………………………………………………………301
• 219. Extension Jibs, Hooks and Suspended Loads ……………………………………303
• 220. Sideshift Carriage …………………………………………………………………………..304
• 221. Operation ………………………………………………………………………………….304
• 222. Installing the Sideshift Carriage ……………………………………………………305
• 223. Removing the Sideshift Carriage ………………………………………………….306
• 224. Maintenance ……………………………………………………………………………..307
• 225. Attachments with Hydraulic Clamping of Loads ………………………………….308
• 226. Work Platforms ………………………………………………………………………………309
• 227. Specifications
• 228. Static Dimensions ………………………………………………………………………….. 311
• 229. 531-70, 541-70 …………………………………………………………………………. 311
• 230. 533-105 ……………………………………………………………………………………312
• 231. 535-95 ……………………………………………………………………………………..314
• 232. 536-60 ……………………………………………………………………………………..316
• 233. 536-70 ……………………………………………………………………………………..318
• 234. 535-125 HiViz, 535-140 HiViz ……………………………………………………..319
• 235. 540-140, 550-140 ………………………………………………………………………321
• 236. 540-170 ……………………………………………………………………………………323
• 237. 550-80 ……………………………………………………………………………………..325
• 238. Performance Dimensions ………………………………………………………………..326
• 239. Lift Performance ………………………………………………………………………..326
• 240. Maximum Wading Depth …………………………………………………………….328
• 241. Wind Loads ………………………………………………………………………………328
• 242. Axle Weight Distribution ………………………………………………………………….329
• 243. Machines Without Stabilisers ………………………………………………………329
• 244. Machines With Stabilisers …………………………………………………………..330
• 245. Noise Data …………………………………………………………………………………….331
• 246. Introduction ……………………………………………………………………………….331
• 247. 531-70, 533-105, 535-95, 536-60, 536-70, 541-70 …………………………331
• 248. 535-125 HiViz, 535-140 HiViz ……………………………………………………..331
• 249. 540-140, 550-140, 540-170 …………………………………………………………331
• 250. 550-80 ……………………………………………………………………………………..331
• 251. Vibration Data ………………………………………………………………………………..332
• 252. Introduction ……………………………………………………………………………….332
• 253. 531-70, 533-105, 535-95, 536-60, 536-70, 541-70 …………………………333
• 254. 535-125 HiViz, 535-140 HiViz ……………………………………………………..334
• 255. 540-140, 550-140 ………………………………………………………………………335
• 256. 540-170 ……………………………………………………………………………………336
• 257. 550-80 ……………………………………………………………………………………..337
• 258. Tyre Sizes and Pressures ………………………………………………………………..338
• 259. Introduction ……………………………………………………………………………….338
• 260. Specifications ……………………………………………………………………………338
• 261. Trailer Towing ………………………………………………………………………………..343
• 262. Towing Limitations ……………………………………………………………………..343
• 263. Warranty Information
• 264. Machine Service Record Sheet ………………………………………………………..344