JCB Side Engine Tier 3 Loadalls Operator Manual 9811-3150

Description

• Model List:
  • Side Engine Tier 3 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. Units of Measurement ……………………………………………………………………1
• 10. Left Side, Right Side ………………………………………………………………………1
• 11. Using the Machine …………………………………………………………………………2
• 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. Instrument Panel (SD and SF Engine) ……………………………………………56
• 57. Instrument Panel (SE Engine) ……………………………………………………….62
• 58. Torque Lock (6-Speed Transmission) ……………………………………………..73
• 59. Air Conditioning and Heater Controls ……………………………………………..74
• 60. Operating Levers ……………………………………………………………………………..75
• 61. Introduction …………………………………………………………………………………75
• 62. Control Layouts …………………………………………………………………………..75
• 63. Boom and Carriage Controls …………………………………………………………76
• 64. Auxiliary Controls ………………………………………………………………………..86
• 65. Chassis Levelling (Sway) Option ……………………………………………………91
• 66. Stabiliser Control Option ……………………………………………………………….93
• 67. Safety Equipment …………………………………………………………………………….95
• 68. Control Lever Locks …………………………………………………………………….95
• 69. Load Charts ………………………………………………………………………………..99
• 70. Boom Indicators ………………………………………………………………………..102
• 71. Load Moment Indicator (LMI) ………………………………………………………103
• 72. LC1 and LC4 Load Control Systems …………………………………………….107
• 73. LC2 and LC3 Load Control System ……………………………………………… 115
• 74. Inclinometer ………………………………………………………………………………120
• 75. Beacon …………………………………………………………………………………….121
• 76. Fire Extinguisher (if fitted) …………………………………………………………..121
• 77. Before Starting the Engine ……………………………………………………………….122
• 78. Starting the Engine …………………………………………………………………………124
• 79. Preparing the Machine for Travel ……………………………………………………..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 ……………………………………………………133
• 87. Working with the Machine ……………………………………………………………….135
• 88. Operating Practices and Site Safety …………………………………………….135
• 89. Safety Practices ………………………………………………………………………..135
• 90. Danger Zone …………………………………………………………………………….136
• 91. Risk Assessment ……………………………………………………………………….136
• 92. Lifting and Loading Operations ……………………………………………………137
• 93. Safety Warnings ………………………………………………………………………..138
• 94. Fork Ratings ……………………………………………………………………………..140
• 95. Handling Palleted Loads …………………………………………………………….141
• 96. Uneven Loads …………………………………………………………………………..142
• 97. Handling Bales ………………………………………………………………………….143
• 98. Working with a Shovel ………………………………………………………………..144
• 99. Use of Machines on Gradients or Slopes ………………………………………145
• 100. Interlock System ………………………………………………………………………..148
• 101. Operating Environment ……………………………………………………………………149
• 102. Introduction ……………………………………………………………………………….149
• 103. Operating in Low Temperatures …………………………………………………..149
• 104. Operating in High Temperatures ………………………………………………….149
• 105. Tow Hitch Options …………………………………………………………………………..150
• 106. Introduction ……………………………………………………………………………….150
• 107. Connecting the Trailer ………………………………………………………………..151
• 108. Preparing the Trailer for Towing …………………………………………………..154
• 109. Refuelling the Machine ……………………………………………………………………156
• 110. Low Fuel Levels ………………………………………………………………………..156
• 111. Filling the Tank ………………………………………………………………………….156
• 112. Moving a Disabled Machine …………………………………………………………….158
• 113. Recovery Hitch ………………………………………………………………………….158
• 114. Transporting the Machine ………………………………………………………………..159
• 115. Lifting a Machine ……………………………………………………………………………160
• 116. Storage of the Machine …………………………………………………………………..161
• 117. Introduction ……………………………………………………………………………….161
• 118. Storage Area …………………………………………………………………………….161
• 119. Prepare the Machine for Storage …………………………………………………161
• 120. Put the Machine into Storage ………………………………………………………161
• 121. During Storage ………………………………………………………………………….161
• 122. Take the Machine Out of Storage …………………………………………………162
• 123. Routine Maintenance
• 124. Service Requirements …………………………………………………………………….163
• 125. Introduction ……………………………………………………………………………….163
• 126. Owner-Operator Support …………………………………………………………….163
• 127. Service-Maintenance Agreements ……………………………………………….163
• 128. Initial Service and Inspection (100 Hours) ……………………………………..163
• 129. Lifting Regulations – Inspections and Tests ……………………………………164
• 130. Obtaining Replacement Parts ………………………………………………………164
• 131. Health and Safety …………………………………………………………………………..165
• 132. Lubricants …………………………………………………………………………………165
• 133. Battery ……………………………………………………………………………………..167
• 134. Service Schedules ………………………………………………………………………….169
• 135. Introduction ……………………………………………………………………………….169
• 136. How to Use the Service Schedules ………………………………………………169
• 137. Calendar Equivalents …………………………………………………………………169
• 138. Pre-start Cold Checks, Service Points and Fluid Levels ………………….170
• 139. Functional Test and Final Inspection …………………………………………….173
• 140. Fluids, Lubricants and Capacities ……………………………………………………..175
• 141. Coolant Mixtures ……………………………………………………………………….177
• 142. Fuels ………………………………………………………………………………………..178
• 143. Prepare the Machine for Maintenance ………………………………………………181
• 144. Introduction ……………………………………………………………………………….181
• 145. How to Make the Machine Safe (Boom Lowered) …………………………..182
• 146. How to Make the Machine Safe (Boom Lifted) ………………………………183
• 147. Cleaning the Machine ……………………………………………………………………..186
• 148. Introduction ……………………………………………………………………………….186
• 149. Preparing the Machine for Cleaning ……………………………………………..186
• 150. Cleaning the Machine …………………………………………………………………187
• 151. Fan Reverse (if fitted) …………………………………………………………………189
• 152. Checking for Damage ……………………………………………………………………..190
• 153. Check the Machine Body and Structure ………………………………………..190
• 154. Check the Tyres ………………………………………………………………………..190
• 155. Check the Seat and Seat Belt ……………………………………………………..190
• 156. Check the Hydraulic Hoses and Fittings ……………………………………….190
• 157. Checking the ROPS-FOPS Structure ……………………………………………191
• 158. Greasing ……………………………………………………………………………………….192
• 159. Introduction ……………………………………………………………………………….192
• 160. Preparing the Machine for Greasing …………………………………………….192
• 161. Every 50 Hours ………………………………………………………………………….193
• 162. Every 500 Hours ………………………………………………………………………..199
• 163. Every 1000 Hours ………………………………………………………………………200
• 164. Access Panels ……………………………………………………………………………….201
• 165. Battery Cover ……………………………………………………………………………201
• 166. Engine Cover …………………………………………………………………………….202
• 167. Rear Cover (if fitted) …………………………………………………………………..203
• 168. Undershield ………………………………………………………………………………204
• 169. Heater and Air Conditioning …………………………………………………………….205
• 170. Changing the Air Intake Filter ………………………………………………………205
• 171. Boom ……………………………………………………………………………………………206
• 172. Re-phasing of 3-Stage Booms …………………………………………………….206
• 173. Brakes ………………………………………………………………………………………….207
• 174. Park Brake ………………………………………………………………………………..207
• 175. Foot Brake ………………………………………………………………………………..209
• 176. Electrical System ……………………………………………………………………………210
• 177. Battery ……………………………………………………………………………………..210
• 178. Jump Starting the Engine ……………………………………………………………212
• 179. Fuses ……………………………………………………………………………………….213
• 180. Link Box Fuses ………………………………………………………………………….221
• 181. Relays ……………………………………………………………………………………..222
• 182. Engine ………………………………………………………………………………………….231
• 183. Oil and Filter ……………………………………………………………………………..231
• 184. Cooling System …………………………………………………………………………233
• 185. Crankcase Ventilation (if fitted) …………………………………………………….235
• 186. Front End Accessory Drive Belt …………………………………………………..236
• 187. Air Filter ……………………………………………………………………………………238
• 188. Fuel System …………………………………………………………………………………..240
• 189. Introduction ……………………………………………………………………………….240
• 190. Water Separator and Engine Fuel Filter ………………………………………..240
• 191. Bleeding the System ………………………………………………………………….246
• 192. Hydraulic System ……………………………………………………………………………248
• 193. Introduction ……………………………………………………………………………….248
• 194. Releasing the Hydraulic Pressure ………………………………………………..249
• 195. Oil and FIlters ……………………………………………………………………………250
• 196. Hose Burst Protection Valves ………………………………………………………255
• 197. Transmission …………………………………………………………………………………258
• 198. Gearbox ……………………………………………………………………………………258
• 199. Front and Rear Axle …………………………………………………………………..261
• 200. Tyres and Wheels …………………………………………………………………………..264
• 201. Tyre Inflation ……………………………………………………………………………..264
• 202. Checking the Wheel Nut Torques …………………………………………………265
• 203. Wheel Nut Torque Indicators (if fitted) …………………………………………..265
• 204. Wheel Alignment ……………………………………………………………………………266
• 205. Introduction ……………………………………………………………………………….266
• 206. Manual Steer Mode Selector ……………………………………………………….266
• 207. Electronic Steer Mode Selector ……………………………………………………267
• 208. Wear Pads …………………………………………………………………………………….268
• 209. Boom Wear Pad Clearance …………………………………………………………268
• 210. Windscreen Washer ……………………………………………………………………….270
• 211. Checking the Level …………………………………………………………………….270
• 212. Fire Extinguisher (if fitted) ………………………………………………………………..271
• 213. Checking the Fire Extinguisher ……………………………………………………271
• 214. Optional Attachments
• 215. Introduction ……………………………………………………………………………………273
• 216. Attachments for your Machine ………………………………………………………….274
• 217. Connecting-Disconnecting Hydraulic Hoses ……………………………………….275
• 218. Introduction ……………………………………………………………………………….275
• 219. Connecting the Hydraulic Hoses ………………………………………………….275
• 220. Disconnecting the Hydraulic Hoses ………………………………………………276
• 221. Quick Release Couplings ……………………………………………………………277
• 222. Q-Fit Attachments …………………………………………………………………………..279
• 223. Mechanical Pin Locking Option ……………………………………………………279
• 224. Hydraulic Pin Locking Option ………………………………………………………281
• 225. Extension Jib …………………………………………………………………………………283
• 226. Safety ………………………………………………………………………………………283
• 227. Installing-Removing ……………………………………………………………………283
• 228. Operation ………………………………………………………………………………….283
• 229. Maintenance ……………………………………………………………………………..284
• 230. Fork Mounted Hook ………………………………………………………………………..285
• 231. Safety ………………………………………………………………………………………285
• 232. Installing …………………………………………………………………………………..285
• 233. Removing …………………………………………………………………………………285
• 234. Operation ………………………………………………………………………………….286
• 235. Maintenance ……………………………………………………………………………..286
• 236. Sideshift Carriage …………………………………………………………………………..287
• 237. Operation ………………………………………………………………………………….287
• 238. Installing the Sideshift Carriage ……………………………………………………288
• 239. Removing the Sideshift Carriage ………………………………………………….289
• 240. Maintenance ……………………………………………………………………………..290
• 241. Roof Truss Jib ……………………………………………………………………………….291
• 242. Safety ………………………………………………………………………………………291
• 243. Installing-Removing ……………………………………………………………………291
• 244. Operation ………………………………………………………………………………….291
• 245. Extending the Jib ……………………………………………………………………….292
• 246. Changing the Jib Angle ………………………………………………………………293
• 247. Maintenance ……………………………………………………………………………..293
• 248. Work Platforms ………………………………………………………………………………294
• 249. Specifications
• 250. Static Dimensions …………………………………………………………………………..295
• 251. 531-70, 541-70 ………………………………………………………………………….295
• 252. 533-105 ……………………………………………………………………………………296
• 253. 535-95 ……………………………………………………………………………………..298
• 254. 536-60 ……………………………………………………………………………………..300
• 255. 536-70 ……………………………………………………………………………………..303
• 256. 535-125, 535-140 ………………………………………………………………………304
• 257. 535-125 HiViz, 535-140 HiViz ……………………………………………………..306
• 258. 540-140 ……………………………………………………………………………………308
• 259. 540-170 ……………………………………………………………………………………310
• 260. Performance Dimensions ………………………………………………………………..312
• 261. Lift Performance ………………………………………………………………………..312
• 262. Maximum Wading Depth …………………………………………………………….314
• 263. Axle Weight Distribution ………………………………………………………………….315
• 264. Machines Without Stabilisers ………………………………………………………315
• 265. Machines With Stabilisers …………………………………………………………..316
• 266. Noise Data …………………………………………………………………………………….317
• 267. Vibration Data ………………………………………………………………………………..318
• 268. Introduction ……………………………………………………………………………….318
• 269. 531-70, 533-105, 535-95, 536-60, 536-70, 541-70 …………………………319
• 270. 535-125, 535-140, 540-140 …………………………………………………………320
• 271. 535-125 HiViz, 535-140 HiViz ……………………………………………………..321
• 272. 540-170 ……………………………………………………………………………………322
• 273. Tyre Sizes and Pressures ………………………………………………………………..323
• 274. Introduction ……………………………………………………………………………….323
• 275. Specifications ……………………………………………………………………………323
• 276. Trailer Towing ………………………………………………………………………………..328
• 277. Towing Limitations ……………………………………………………………………..328
• 278. Load Charts …………………………………………………………………………………..329
• 279. Introduction ……………………………………………………………………………….329
• 280. Warranty Information
• 281. Machine Service Record Sheet ………………………………………………………..331
• 282. Registration Information ………………………………………………………………….333