JCB Side Engine Tier 2, Tier 3 Loadalls Operator Manual 9831-6800-3

Description

• Model List:
  • Side Engine Tier 2, Tier 3 Loadalls

• 1. Safety Notices
• 2. Important Information …………………………………………………………………………1
• 3. The Operator Manual …………………………………………………………………….1
• 4. Safety Warnings ……………………………………………………………………………1
• 5. Introduction
• 6. About This Manual ……………………………………………………………………………..3
• 7. Machine Model and Serial Number ………………………………………………….3
• 8. Using this Manual ………………………………………………………………………….3
• 9. Left Side, Right Side ………………………………………………………………………3
• 10. Cab-Canopy …………………………………………………………………………………3
• 11. Cross References ………………………………………………………………………….3
• 12. Machine Description …………………………………………………………………………..4
• 13. The JCB Loadall ……………………………………………………………………………4
• 14. Intended Use ………………………………………………………………………………..4
• 15. Component Location ……………………………………………………………………..4
• 16. Safety Check List ……………………………………………………………………………….6
• 17. Safety – Yours and Others ………………………………………………………………6
• 18. General Safety ……………………………………………………………………………..6
• 19. Operating Safety …………………………………………………………………………..8
• 20. Maintenance Safety ……………………………………………………………………..12
• 21. Safety Labels …………………………………………………………………………………..17
• 22. Introduction …………………………………………………………………………………17
• 23. Safety Label Identification …………………………………………………………….18
• 24. Identifying Your Machine …………………………………………………………………..21
• 25. Machine Identification Plate ………………………………………………………….21
• 26. Component Identification Plates …………………………………………………….23
• 27. Machine Security ……………………………………………………………………………..28
• 28. Introduction …………………………………………………………………………………28
• 29. JCB Plantguard …………………………………………………………………………..28
• 30. Construction Equipment Security And Registration Scheme (CESAR) .28
• 31. Operation
• 32. Introduction ……………………………………………………………………………………..29
• 33. Before Entering the Cab ……………………………………………………………………30
• 34. Entering and Leaving the Cab ……………………………………………………………31
• 35. Emergency Exit …………………………………………………………………………..32
• 36. Doors and Windows …………………………………………………………………………34
• 37. Opening and Closing the Door ………………………………………………………34
• 38. Opening and Closing the Upper Door Section …………………………………34
• 39. Opening and Closing the Rear Window ………………………………………….35
• 40. Visibility Aids ……………………………………………………………………………………36
• 41. Mirrors and Adjustment ………………………………………………………………..36
• 42. Seat Controls …………………………………………………………………………………..40
• 43. Introduction …………………………………………………………………………………40
• 44. Operator Present Switch ………………………………………………………………40
• 45. Seat Options ……………………………………………………………………………….40
• 46. Suspension Seat (KAB 100 Series – Mechanical) …………………………….41
• 47. Suspension Seat (KAB 100 Series – Air) …………………………………………42
• 48. Suspension Seat (KAB 800 Series – Air) …………………………………………43
• 49. Suspension Seat (Grammer – Air) ………………………………………………….44
• 50. Seat Belt …………………………………………………………………………………………46
• 51. Inertia Reel Seat Belt …………………………………………………………………..46
• 52. Static Seat Belt ……………………………………………………………………………47
• 53. Cab Layout ……………………………………………………………………………………..48
• 54. Operating Levers …………………………………………………………………………49
• 55. Component Key …………………………………………………………………………..50
• 56. Drive Controls, Switches and Instruments ……………………………………………51
• 57. Drive Controls ……………………………………………………………………………..51
• 58. Switches …………………………………………………………………………………….58
• 59. Instrument Panel (SD and SF Engine) ……………………………………………66
• 60. Instrument Panel (SE Engine) ……………………………………………………….72
• 61. Torque Lock (6-Speed Transmission) ……………………………………………..84
• 62. Air Conditioning and Cab Heater Controls ………………………………………85
• 63. Operating Levers ……………………………………………………………………………..86
• 64. Introduction …………………………………………………………………………………86
• 65. Control Layouts …………………………………………………………………………..86
• 66. Boom and Carriage Controls …………………………………………………………87
• 67. Auxiliary Controls ………………………………………………………………………..93
• 68. Chassis Levelling (Sway) Option ……………………………………………………98
• 69. Stabiliser Control Option ……………………………………………………………..100
• 70. Safety Equipment …………………………………………………………………………..102
• 71. Control Locks ……………………………………………………………………………102
• 72. Load Charts ………………………………………………………………………………106
• 73. Boom Indicators ………………………………………………………………………..108
• 74. Longitudinal Load Moment Indicator (LLMI) …………………………………..109
• 75. Longitudinal Load Moment Control (LLMC) System ………………………. 113
• 76. LC4 Load Control System ………………………………………………………….. 117
• 77. Inclinometer ………………………………………………………………………………125
• 78. Beacon …………………………………………………………………………………….125
• 79. Fire Extinguisher (if fitted) …………………………………………………………..126
• 80. Before Starting the Engine ……………………………………………………………….127
• 81. Starting the Engine …………………………………………………………………………129
• 82. Immobiliser (if fitted) …………………………………………………………………..131
• 83. Preparing the Machine for Travel ……………………………………………………..134
• 84. Introduction ……………………………………………………………………………….134
• 85. Preparing for Road Travel …………………………………………………………..134
• 86. Preparing for Site Travel ……………………………………………………………..136
• 87. Smooth Ride System (SRS) ………………………………………………………..138
• 88. Getting the Machine Moving …………………………………………………………….139
• 89. Operating Practices ……………………………………………………………………139
• 90. Operating Procedure ………………………………………………………………….140
• 91. Stopping and Parking the Machine ……………………………………………………142
• 92. Working with the Machine ……………………………………………………………….143
• 93. Operating Practices and Site Safety …………………………………………….143
• 94. Clothing and Safety Equipment ……………………………………………………143
• 95. Danger Zone …………………………………………………………………………….143
• 96. Safety Practices ………………………………………………………………………..143
• 97. Working with the Boom ………………………………………………………………145
• 98. Use of Machines on Gradients or Slopes ………………………………………154
• 99. Interlock System ………………………………………………………………………..157
• 100. Operating Environment ……………………………………………………………………159
• 101. Operating in Low Temperatures …………………………………………………..159
• 102. Operating in High Temperatures ………………………………………………….159
• 103. Tow Hitch Options …………………………………………………………………………..160
• 104. Introduction ……………………………………………………………………………….160
• 105. Connecting the Trailer ………………………………………………………………..161
• 106. Preparing the Trailer for Towing …………………………………………………..168
• 107. Refuelling the Machine ……………………………………………………………………172
• 108. Low Fuel Levels ………………………………………………………………………..172
• 109. Filling the Tank ………………………………………………………………………….172
• 110. Moving a Disabled Machine …………………………………………………………….174
• 111. Recovery Hitch ………………………………………………………………………….174
• 112. Transporting the Machine ………………………………………………………………..175
• 113. Lifting a Machine ……………………………………………………………………………176
• 114. Storage of the Machine …………………………………………………………………..178
• 115. Introduction ……………………………………………………………………………….178
• 116. Storage Area …………………………………………………………………………….178
• 117. Prepare the Machine for Storage …………………………………………………178
• 118. Put the Machine into Storage ………………………………………………………178
• 119. During Storage ………………………………………………………………………….178
• 120. Take the Machine Out of Storage …………………………………………………179
• 121. Routine Maintenance
• 122. Service Requirements …………………………………………………………………….181
• 123. Introduction ……………………………………………………………………………….181
• 124. Owner-Operator Support …………………………………………………………….181
• 125. Service-Maintenance Agreements ……………………………………………….181
• 126. Initial Service and Inspection ……………………………………………………….181
• 127. Fit for Purpose Tests for Lifting Equipment …………………………………….182
• 128. Obtaining Replacement Parts ………………………………………………………182
• 129. Health and Safety …………………………………………………………………………..183
• 130. Lubricants …………………………………………………………………………………183
• 131. Battery ……………………………………………………………………………………..185
• 132. Service Schedules ………………………………………………………………………….187
• 133. Introduction ……………………………………………………………………………….187
• 134. How to Use the Service Schedules ………………………………………………187
• 135. Calendar Equivalents …………………………………………………………………187
• 136. Pre-start Cold Checks, Service Points and Fluid Levels ………………….188
• 137. Functional Test and Final Inspection …………………………………………….192
• 138. Fluids, Lubricants and Capacities ……………………………………………………..195
• 139. Coolant Mixtures ……………………………………………………………………….197
• 140. Fuels ………………………………………………………………………………………..198
• 141. Prepare the Machine for Maintenance ………………………………………………201
• 142. Introduction ……………………………………………………………………………….201
• 143. How to Make the Machine Safe (Boom Lowered) …………………………..201
• 144. How to Make the Machine Safe (Boom Lifted) ……………………………….202
• 145. Cleaning the Machine ……………………………………………………………………..206
• 146. Introduction ……………………………………………………………………………….206
• 147. Preparing the Machine for Cleaning ……………………………………………..206
• 148. Cleaning the Machine …………………………………………………………………207
• 149. Fan Reverse (if fitted) …………………………………………………………………209
• 150. Checking for Damage ……………………………………………………………………..210
• 151. Check the Machine Body and Structure ………………………………………..210
• 152. Check the Tyres ………………………………………………………………………..210
• 153. Check the Seat and Seat Belt ……………………………………………………..210
• 154. Check the Hydraulic Hoses and Fittings ……………………………………….210
• 155. Check the Electrical Circuits ……………………………………………………….. 211
• 156. Checking the ROPS-FOPS Structure ……………………………………………212
• 157. Greasing ……………………………………………………………………………………….213
• 158. Introduction ……………………………………………………………………………….213
• 159. Preparing the Machine for Greasing …………………………………………….213
• 160. Every 50 Hours ………………………………………………………………………….214
• 161. Every 500 Hours ………………………………………………………………………..223
• 162. Every 1000 Hours ………………………………………………………………………226
• 163. Oiling ……………………………………………………………………………………………227
• 164. Boom Chains …………………………………………………………………………….228
• 165. Access Panels ……………………………………………………………………………….229
• 166. Introduction ……………………………………………………………………………….229
• 167. Battery Cover ……………………………………………………………………………229
• 168. Engine Cover …………………………………………………………………………….230
• 169. Rear Cover (if fitted) …………………………………………………………………..231
• 170. Undershield ………………………………………………………………………………232
• 171. Cab Heater and Air Conditioning ………………………………………………………233
• 172. Changing the Air Intake Filter ………………………………………………………233
• 173. Boom ……………………………………………………………………………………………234
• 174. Re-phasing of 3-Stage Booms …………………………………………………….234
• 175. Boom Chains …………………………………………………………………………….234
• 176. Brakes ………………………………………………………………………………………….238
• 177. Park Brake ………………………………………………………………………………..238
• 178. Foot Brake (Excluding 550-80 Machines) ……………………………………..240
• 179. Footbrake (550-80 Machines) ……………………………………………………..240
• 180. Electrical System ……………………………………………………………………………241
• 181. Battery ……………………………………………………………………………………..241
• 182. Jump Starting the Engine ……………………………………………………………244
• 183. Fuses ……………………………………………………………………………………….245
• 184. Primary Fuses …………………………………………………………………………..275
• 185. Relays ……………………………………………………………………………………..276
• 186. Engine ………………………………………………………………………………………….300
• 187. Oil and Filter ……………………………………………………………………………..300
• 188. Cooling System …………………………………………………………………………302
• 189. Crankcase Ventilation (if fitted) …………………………………………………….304
• 190. Front End Accessory Drive Belt …………………………………………………..305
• 191. Air Filter ……………………………………………………………………………………307
• 192. Fuel System …………………………………………………………………………………..309
• 193. Introduction ……………………………………………………………………………….309
• 194. Water Separator and Engine Fuel Filter ………………………………………..309
• 195. Bleeding the System ………………………………………………………………….315
• 196. Hydraulic System ……………………………………………………………………………317
• 197. Introduction ……………………………………………………………………………….317
• 198. Releasing the Hydraulic Pressure ………………………………………………..318
• 199. Oil and FIlters ……………………………………………………………………………319
• 200. Hose Burst Protection Valves ………………………………………………………325
• 201. Transmission …………………………………………………………………………………327
• 202. Gearbox ……………………………………………………………………………………327
• 203. Front and Rear Axle …………………………………………………………………..330
• 204. Tyres and Wheels …………………………………………………………………………..334
• 205. Tyre Inflation ……………………………………………………………………………..334
• 206. Wheel Nuts ……………………………………………………………………………….335
• 207. Wheel Alignment ……………………………………………………………………………336
• 208. Introduction ……………………………………………………………………………….336
• 209. Manual Steer Mode Selector ……………………………………………………….336
• 210. Electronic Steer Mode Selector ……………………………………………………337
• 211. Wear Pads …………………………………………………………………………………….338
• 212. Boom Wear Pad Clearance …………………………………………………………338
• 213. Windscreen Washer ……………………………………………………………………….342
• 214. Checking the Level …………………………………………………………………….342
• 215. Fire Extinguisher (if fitted) ………………………………………………………………..343
• 216. Checking the Fire Extinguisher ……………………………………………………343
• 217. Optional Attachments
• 218. Introduction ……………………………………………………………………………………345
• 219. Attachments for your Machine ………………………………………………………….346
• 220. Connecting-Disconnecting Hydraulic Hoses ……………………………………….347
• 221. Introduction ……………………………………………………………………………….347
• 222. Connecting the Hydraulic Hoses ………………………………………………….347
• 223. Disconnecting the Hydraulic Hoses ………………………………………………348
• 224. Quick Release Couplings ……………………………………………………………349
• 225. Q-Fit Attachments …………………………………………………………………………..351
• 226. Mechanical Pin Locking Option ……………………………………………………351
• 227. Hydraulic Pin Locking Option ………………………………………………………353
• 228. Extension Jib …………………………………………………………………………………355
• 229. Safety ………………………………………………………………………………………355
• 230. Installing-Removing ……………………………………………………………………355
• 231. Operation ………………………………………………………………………………….355
• 232. Maintenance ……………………………………………………………………………..356
• 233. Fork Mounted Hook ………………………………………………………………………..357
• 234. Safety ………………………………………………………………………………………357
• 235. Installing …………………………………………………………………………………..357
• 236. Removing …………………………………………………………………………………357
• 237. Operation ………………………………………………………………………………….358
• 238. Maintenance ……………………………………………………………………………..358
• 239. Sideshift Carriage …………………………………………………………………………..359
• 240. Operation ………………………………………………………………………………….359
• 241. Installing the Sideshift Carriage ……………………………………………………360
• 242. Removing the Sideshift Carriage ………………………………………………….361
• 243. Maintenance ……………………………………………………………………………..362
• 244. Roof Truss Jib ……………………………………………………………………………….363
• 245. Safety ………………………………………………………………………………………363
• 246. Installing-Removing ……………………………………………………………………363
• 247. Operation ………………………………………………………………………………….363
• 248. Extending the Jib ……………………………………………………………………….364
• 249. Changing the Jib Angle ………………………………………………………………365
• 250. Maintenance ……………………………………………………………………………..365
• 251. Work Platforms ………………………………………………………………………………366
• 252. Specifications
• 253. Static Dimensions …………………………………………………………………………..367
• 254. 531-70, 541-70 ………………………………………………………………………….367
• 255. 533-105 ……………………………………………………………………………………368
• 256. 535-95 ……………………………………………………………………………………..370
• 257. 536-60 ……………………………………………………………………………………..372
• 258. 536-70 ……………………………………………………………………………………..374
• 259. 535-125 HiViz, 535-140 HiViz ……………………………………………………..375
• 260. 540-140 ……………………………………………………………………………………377
• 261. 540-170 ……………………………………………………………………………………379
• 262. 540-200 ……………………………………………………………………………………381
• 263. 550-80 ……………………………………………………………………………………..383
• 264. Performance Dimensions ………………………………………………………………..384
• 265. Lift Performance ………………………………………………………………………..384
• 266. Maximum Wading Depth …………………………………………………………….385
• 267. Axle Weight Distribution ………………………………………………………………….386
• 268. Machines Without Stabilisers ………………………………………………………386
• 269. Machines With Stabilisers …………………………………………………………..387
• 270. Noise Data …………………………………………………………………………………….388
• 271. Introduction ……………………………………………………………………………….388
• 272. 531-70, 533-105, 535-95, 536-60, 536-70, 541-70 …………………………388
• 273. 535-125 HiViz, 535-140 HiViz, 540-140 HiViz ………………………………..388
• 274. 540-140, 540-170, 540-200 …………………………………………………………388
• 275. 550-80 ……………………………………………………………………………………..388
• 276. Vibration Data ………………………………………………………………………………..389
• 277. Introduction ……………………………………………………………………………….389
• 278. 531-70, 533-105, 535-95, 536-60, 536-70, 541-70 …………………………390
• 279. 540-140 ……………………………………………………………………………………391
• 280. 535-125 HiViz, 535-140 HiViz, 540-140 HiViz ………………………………..392
• 281. 540-170, 540-200 ………………………………………………………………………393
• 282. 550-80 ……………………………………………………………………………………..394
• 283. Tyre Sizes and Pressures ………………………………………………………………..395
• 284. Introduction ……………………………………………………………………………….395
• 285. Specifica