JCB Side Engine (Tier 2 Engine) Loadalls Operator Manual 9811-5800

Description

• Model List:
  • Side Engine (Tier 2 Engine) 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. Construction Equipment Security And Registration Scheme (CESAR) .25
• 31. LiveLink ……………………………………………………………………………………..25
• 32. Operation
• 33. Introduction ……………………………………………………………………………………..27
• 34. Before Entering the Cab ……………………………………………………………………28
• 35. Entering and Leaving the Cab ……………………………………………………………29
• 36. Emergency Exit …………………………………………………………………………..30
• 37. Doors and Windows …………………………………………………………………………31
• 38. Opening and Closing the Door ………………………………………………………31
• 39. Opening and Closing the Upper Door Section …………………………………31
• 40. Opening and Closing the Rear Window ………………………………………….32
• 41. Seat Controls …………………………………………………………………………………..33
• 42. Introduction …………………………………………………………………………………33
• 43. Seat Options ……………………………………………………………………………….33
• 44. Suspension Seat (KAB 100 Series – Mechanical) …………………………….34
• 45. Suspension Seat (KAB 100 Series – Air) …………………………………………35
• 46. Suspension Seat (KAB 800 Series – Air) …………………………………………36
• 47. Suspension Seat (Grammer – Air) ………………………………………………….37
• 48. Seat Belt …………………………………………………………………………………………39
• 49. Inertia Reel Seat Belt …………………………………………………………………..39
• 50. Static Seat Belt ……………………………………………………………………………40
• 51. Cab Layout ……………………………………………………………………………………..41
• 52. Component Key …………………………………………………………………………..43
• 53. Drive Controls, Switches and Instruments ……………………………………………44
• 54. Drive Controls ……………………………………………………………………………..44
• 55. Switches …………………………………………………………………………………….48
• 56. Instrument Panel …………………………………………………………………………54
• 57. Air Conditioning and Cab Heater Controls ………………………………………60
• 58. Operating Levers ……………………………………………………………………………..61
• 59. Introduction …………………………………………………………………………………61
• 60. Control Layouts …………………………………………………………………………..61
• 61. Boom and Carriage Controls …………………………………………………………62
• 62. Auxiliary Controls ………………………………………………………………………..66
• 63. Chassis Levelling (Sway) Option ……………………………………………………69
• 64. Stabiliser Control Option ……………………………………………………………….71
• 65. Safety Equipment …………………………………………………………………………….73
• 66. Control Locks ……………………………………………………………………………..73
• 67. Load Charts ………………………………………………………………………………..76
• 68. Boom Indicators ………………………………………………………………………….78
• 69. Load Moment Indicator (LMI) ………………………………………………………..78
• 70. LC1 and LC4 Load Control Systems ………………………………………………83
• 71. LC2, LC3 and LC5 Load Control System ………………………………………..91
• 72. Inclinometer ………………………………………………………………………………..96
• 73. Beacon ………………………………………………………………………………………97
• 74. Fire Extinguisher (if fitted) …………………………………………………………….97
• 75. Before Starting the Engine …………………………………………………………………98
• 76. Starting the Engine …………………………………………………………………………100
• 77. Immobiliser (if fitted) …………………………………………………………………..101
• 78. Preparing the Machine for Travel ……………………………………………………..103
• 79. Introduction ……………………………………………………………………………….103
• 80. Preparing for Road Travel …………………………………………………………..103
• 81. Preparing for Site Travel ……………………………………………………………..105
• 82. Smooth Ride System (SRS) ………………………………………………………..107
• 83. Getting the Machine Moving …………………………………………………………….108
• 84. Operating Practices ……………………………………………………………………108
• 85. Operating Procedure ………………………………………………………………….109
• 86. Stopping and Parking the Machine …………………………………………………… 110
• 87. Working with the Machine ………………………………………………………………. 111
• 88. Operating Practices and Site Safety ……………………………………………. 111
• 89. Clothing and Safety Equipment …………………………………………………… 111
• 90. Danger Zone ……………………………………………………………………………. 111
• 91. Safety Practices ……………………………………………………………………….. 111
• 92. Working with the Boom ……………………………………………………………… 113
• 93. Use of Machines on Gradients or Slopes ………………………………………122
• 94. Interlock System ………………………………………………………………………..125
• 95. Operating Environment ……………………………………………………………………126
• 96. Operating in Low Temperatures …………………………………………………..126
• 97. Operating in High Temperatures ………………………………………………….126
• 98. Tow Hitch Options …………………………………………………………………………..127
• 99. Introduction ……………………………………………………………………………….127
• 100. Connecting the Trailer ………………………………………………………………..128
• 101. Preparing the Trailer for Towing …………………………………………………..131
• 102. Refuelling the Machine ……………………………………………………………………133
• 103. Low Fuel Levels ………………………………………………………………………..133
• 104. Filling the Tank ………………………………………………………………………….133
• 105. Moving a Disabled Machine …………………………………………………………….135
• 106. Recovery Hitch ………………………………………………………………………….135
• 107. Transporting the Machine ………………………………………………………………..136
• 108. Lifting a Machine ……………………………………………………………………………137
• 109. Storage of the Machine …………………………………………………………………..138
• 110. Introduction ……………………………………………………………………………….138
• 111. Storage Area …………………………………………………………………………….138
• 112. Prepare the Machine for Storage …………………………………………………138
• 113. Put the Machine into Storage ………………………………………………………138
• 114. During Storage ………………………………………………………………………….138
• 115. Take the Machine Out of Storage …………………………………………………139
• 116. Routine Maintenance
• 117. Service Requirements …………………………………………………………………….141
• 118. Introduction ……………………………………………………………………………….141
• 119. Owner-Operator Support …………………………………………………………….141
• 120. Service-Maintenance Agreements ……………………………………………….141
• 121. Initial Service and Inspection (100 Hours) ……………………………………..141
• 122. Fit for Purpose Tests for Lifting Equipment …………………………………….142
• 123. Obtaining Replacement Parts ………………………………………………………142
• 124. Health and Safety …………………………………………………………………………..143
• 125. Lubricants …………………………………………………………………………………143
• 126. Battery ……………………………………………………………………………………..145
• 127. Service Schedules ………………………………………………………………………….147
• 128. Introduction ……………………………………………………………………………….147
• 129. How to Use the Service Schedules ………………………………………………147
• 130. Calendar Equivalents …………………………………………………………………147
• 131. Pre-start Cold Checks, Service Points and Fluid Levels ………………….148
• 132. Functional Test and Final Inspection …………………………………………….151
• 133. Fluids, Lubricants and Capacities ……………………………………………………..153
• 134. Coolant Mixtures ……………………………………………………………………….155
• 135. Fuels ………………………………………………………………………………………..156
• 136. Prepare the Machine for Maintenance ………………………………………………159
• 137. Introduction ……………………………………………………………………………….159
• 138. How to Make the Machine Safe (Boom Lowered) …………………………..160
• 139. How to Make the Machine Safe (Boom Lifted) ……………………………….161
• 140. Cleaning the Machine ……………………………………………………………………..164
• 141. Introduction ……………………………………………………………………………….164
• 142. Preparing the Machine for Cleaning ……………………………………………..164
• 143. Cleaning the Machine …………………………………………………………………165
• 144. Fan Reverse (if fitted) …………………………………………………………………167
• 145. Checking for Damage ……………………………………………………………………..168
• 146. Check the Machine Body and Structure ………………………………………..168
• 147. Check the Tyres ………………………………………………………………………..168
• 148. Check the Seat and Seat Belt ……………………………………………………..168
• 149. Check the Hydraulic Hoses and Fittings ……………………………………….168
• 150. Check the Electrical Circuits ………………………………………………………..169
• 151. Checking the ROPS-FOPS Structure ……………………………………………170
• 152. Greasing ……………………………………………………………………………………….171
• 153. Introduction ……………………………………………………………………………….171
• 154. Preparing the Machine for Greasing …………………………………………….171
• 155. Every 50 Hours ………………………………………………………………………….172
• 156. Every 500 Hours ………………………………………………………………………..178
• 157. Every 1000 Hours ………………………………………………………………………180
• 158. Access Panels ……………………………………………………………………………….181
• 159. Battery Cover ……………………………………………………………………………181
• 160. Engine Cover …………………………………………………………………………….182
• 161. Rear Cover (if fitted) …………………………………………………………………..183
• 162. Undershield ………………………………………………………………………………184
• 163. Cab Heater and Air Conditioning ………………………………………………………185
• 164. Changing the Air Intake Filter ………………………………………………………185
• 165. Boom ……………………………………………………………………………………………186
• 166. Re-phasing of 3-Stage Booms …………………………………………………….186
• 167. Brakes ………………………………………………………………………………………….187
• 168. Park Brake ………………………………………………………………………………..187
• 169. Foot Brake ………………………………………………………………………………..189
• 170. Electrical System ……………………………………………………………………………190
• 171. Battery ……………………………………………………………………………………..190
• 172. Jump Starting the Engine ……………………………………………………………192
• 173. Fuses ……………………………………………………………………………………….193
• 174. Primary Fuses …………………………………………………………………………..198
• 175. Relays ……………………………………………………………………………………..199
• 176. Engine ………………………………………………………………………………………….204
• 177. Oil and Filter ……………………………………………………………………………..204
• 178. Cooling System …………………………………………………………………………206
• 179. Front End Accessory Drive Belt …………………………………………………..208
• 180. Air Filter ……………………………………………………………………………………210
• 181. Fuel System …………………………………………………………………………………..212
• 182. Introduction ……………………………………………………………………………….212
• 183. Water Separator and Engine Fuel Filter ………………………………………..212
• 184. Bleeding the System ………………………………………………………………….217
• 185. Hydraulic System ……………………………………………………………………………218
• 186. Introduction ……………………………………………………………………………….218
• 187. Releasing the Hydraulic Pressure ………………………………………………..219
• 188. Oil and FIlters ……………………………………………………………………………220
• 189. Changing the Pilot Filter Element …………………………………………………222
• 190. Hose Burst Protection Valves ………………………………………………………224
• 191. Transmission …………………………………………………………………………………226
• 192. Gearbox ……………………………………………………………………………………226
• 193. Front and Rear Axle …………………………………………………………………..228
• 194. Tyres and Wheels …………………………………………………………………………..231
• 195. Tyre Inflation ……………………………………………………………………………..231
• 196. Wheel Nuts ……………………………………………………………………………….232
• 197. Wheel Alignment ……………………………………………………………………………233
• 198. Introduction ……………………………………………………………………………….233
• 199. Manual Steer Mode Selector ……………………………………………………….233
• 200. Electronic Steer Mode Selector ……………………………………………………234
• 201. Wear Pads …………………………………………………………………………………….235
• 202. Boom Wear Pad Clearance …………………………………………………………235
• 203. Windscreen Washer ……………………………………………………………………….237
• 204. Checking the Level …………………………………………………………………….237
• 205. Fire Extinguisher (if fitted) ………………………………………………………………..238
• 206. Checking the Fire Extinguisher ……………………………………………………238
• 207. Optional Attachments
• 208. Introduction ……………………………………………………………………………………239
• 209. Attachments for your Machine ………………………………………………………….240
• 210. Connecting-Disconnecting Hydraulic Hoses ……………………………………….241
• 211. Introduction ……………………………………………………………………………….241
• 212. Connecting the Hydraulic Hoses ………………………………………………….241
• 213. Disconnecting the Hydraulic Hoses ………………………………………………242
• 214. Quick Release Couplings ……………………………………………………………243
• 215. Q-Fit Attachments …………………………………………………………………………..245
• 216. Mechanical Pin Locking Option ……………………………………………………245
• 217. Hydraulic Pin Locking Option ………………………………………………………247
• 218. Extension Jib …………………………………………………………………………………249
• 219. Safety ………………………………………………………………………………………249
• 220. Installing-Removing ……………………………………………………………………249
• 221. Operation ………………………………………………………………………………….249
• 222. Maintenance ……………………………………………………………………………..250
• 223. Fork Mounted Hook ………………………………………………………………………..251
• 224. Safety ………………………………………………………………………………………251
• 225. Installing …………………………………………………………………………………..251
• 226. Removing …………………………………………………………………………………251
• 227. Operation ………………………………………………………………………………….252
• 228. Maintenance ……………………………………………………………………………..252
• 229. Sideshift Carriage …………………………………………………………………………..253
• 230. Operation ………………………………………………………………………………….253
• 231. Installing the Sideshift Carriage ……………………………………………………254
• 232. Removing the Sideshift Carriage ………………………………………………….255
• 233. Maintenance ……………………………………………………………………………..256
• 234. Roof Truss Jib ……………………………………………………………………………….257
• 235. Safety ………………………………………………………………………………………257
• 236. Installing-Removing ……………………………………………………………………257
• 237. Operation ………………………………………………………………………………….257
• 238. Extending the Jib ……………………………………………………………………….258
• 239. Changing the Jib Angle ………………………………………………………………259
• 240. Maintenance ……………………………………………………………………………..259
• 241. Work Platforms ………………………………………………………………………………260
• 242. Specifications
• 243. Static Dimensions …………………………………………………………………………..261
• 244. 531-70, 541-70 ………………………………………………………………………….261
• 245. 533-105 ……………………………………………………………………………………262
• 246. 535-95 ……………………………………………………………………………………..264
• 247. 536-60 ……………………………………………………………………………………..266
• 248. 536-70 ……………………………………………………………………………………..268
• 249. 535-125 HiViz, 535-140 HiViz ……………………………………………………..269
• 250. 540-140 ……………………………………………………………………………………271
• 251. 550-140 ……………………………………………………………………………………273
• 252. 540-170 ……………………………………………………………………………………275
• 253. 550-170 ……………………………………………………………………………………277
• 254. Performance Dimensions ………………………………………………………………..279
• 255. Lift Performance ………………………………………………………………………..279
• 256. Maximum Wading Depth …………………………………………………………….280
• 257. Axle Weight Distribution ………………………………………………………………….281
• 258. Machines Without Stabilisers ………………………………………………………281
• 259. Machines With Stabilisers …………………………………………………………..282
• 260. Trailer Towing ………………………………………………………………………………..283
• 261. Towing Limitations ……………………………………………………………………..283
• 262. Tyre Sizes and Pressures ………………………………………………………………..284
• 263. Introduction ……………………………………………………………………………….284
• 264. Specifications ……………………………………………………………………………284
• 265. Noise Data …………………………………………………………………………………….289
• 266. Introduction ……………………………………………………………………………….289
• 267. 531-70, 533-105, 535-95, 536-60, 536-70, 541-70 …………………………289
• 268. 535-125 HiViz, 535-140 HiViz, 540-140, 550-140, 540-170, 550-170 ..289
• 269. Vibration Data ………………………………………………………………………………..290
• 270. Introduction ……………………………………………………………………………….290
• 271. 531-70, 533-105, 535-95, 536-60, 536-70, 541-70 …………………………291
• 272. 540-140, 550-140 ………………………………………………………………………292
• 273. 535-125 HiViz, 535-140 HiViz ……………………………………………………..293
• 274. 540-170, 550-170 ………………………………………………………………………294
• 275. Warranty Information
• 276. Machine Service Record Sheet ………………………………………………………..295
• 277. Registration Information ………………………………………………………………….297