JCB Side Engine Tier 3 Loadalls Operator Manual 9821-0300

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. 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 ……………………………………………………………………………..26
• 28. Introduction …………………………………………………………………………………26
• 29. JCB Plantguard …………………………………………………………………………..26
• 30. Construction Equipment Security And Registration Scheme (CESAR) .26
• 31. LiveLink ……………………………………………………………………………………..26
• 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 …………………………………………………………………………32
• 38. Opening and Closing the Door ………………………………………………………32
• 39. Opening and Closing the Upper Door Section …………………………………32
• 40. Opening and Closing the Rear Window ………………………………………….33
• 41. Seat Controls …………………………………………………………………………………..34
• 42. Introduction …………………………………………………………………………………34
• 43. Seat Options ……………………………………………………………………………….34
• 44. Suspension Seat (KAB 100 Series – Mechanical) …………………………….35
• 45. Suspension Seat (KAB 100 Series – Air) …………………………………………36
• 46. Suspension Seat (KAB 800 Series – Air) …………………………………………37
• 47. Suspension Seat (Grammer – Air) ………………………………………………….38
• 48. Seat Belt …………………………………………………………………………………………40
• 49. Inertia Reel Seat Belt …………………………………………………………………..40
• 50. Static Seat Belt ……………………………………………………………………………41
• 51. Cab Layout ……………………………………………………………………………………..42
• 52. Operating Levers …………………………………………………………………………43
• 53. Component Key …………………………………………………………………………..44
• 54. Drive Controls, Switches and Instruments ……………………………………………45
• 55. Drive Controls ……………………………………………………………………………..45
• 56. Switches …………………………………………………………………………………….52
• 57. Instrument Panel (SD and SF Engine) ……………………………………………60
• 58. Instrument Panel (SE Engine) ……………………………………………………….66
• 59. Torque Lock (6-Speed Transmission) ……………………………………………..78
• 60. Air Conditioning and Cab Heater Controls ………………………………………79
• 61. Operating Levers ……………………………………………………………………………..80
• 62. Introduction …………………………………………………………………………………80
• 63. Control Layouts …………………………………………………………………………..80
• 64. Boom and Carriage Controls …………………………………………………………81
• 65. Auxiliary Controls ………………………………………………………………………..86
• 66. Chassis Levelling (Sway) Option ……………………………………………………91
• 67. Stabiliser Control Option ……………………………………………………………….93
• 68. Safety Equipment …………………………………………………………………………….95
• 69. Control Locks ……………………………………………………………………………..95
• 70. Load Charts ………………………………………………………………………………..99
• 71. Boom Indicators ………………………………………………………………………..101
• 72. Longitudinal Load Moment Indicator (LLMI) …………………………………..102
• 73. Longitudinal Load Moment Control (LLMC) System ……………………….106
• 74. LC4 Load Control System ………………………………………………………….. 110
• 75. Inclinometer ……………………………………………………………………………… 118
• 76. Beacon ……………………………………………………………………………………. 118
• 77. Fire Extinguisher (if fitted) ………………………………………………………….. 119
• 78. Before Starting the Engine ……………………………………………………………….120
• 79. Starting the Engine …………………………………………………………………………122
• 80. Immobiliser (if fitted) …………………………………………………………………..124
• 81. Preparing the Machine for Travel ……………………………………………………..126
• 82. Introduction ……………………………………………………………………………….126
• 83. Preparing for Road Travel …………………………………………………………..126
• 84. Preparing for Site Travel ……………………………………………………………..128
• 85. Smooth Ride System (SRS) ………………………………………………………..130
• 86. Getting the Machine Moving …………………………………………………………….131
• 87. Operating Practices ……………………………………………………………………131
• 88. Operating Procedure ………………………………………………………………….132
• 89. Stopping and Parking the Machine ……………………………………………………134
• 90. Working with the Machine ……………………………………………………………….135
• 91. Operating Practices and Site Safety …………………………………………….135
• 92. Clothing and Safety Equipment ……………………………………………………135
• 93. Danger Zone …………………………………………………………………………….135
• 94. Safety Practices ………………………………………………………………………..135
• 95. Working with the Boom ………………………………………………………………137
• 96. Use of Machines on Gradients or Slopes ………………………………………146
• 97. Interlock System ………………………………………………………………………..149
• 98. Operating Environment ……………………………………………………………………150
• 99. Operating in Low Temperatures …………………………………………………..150
• 100. Operating in High Temperatures ………………………………………………….150
• 101. Tow Hitch Options …………………………………………………………………………..151
• 102. Introduction ……………………………………………………………………………….151
• 103. Connecting the Trailer ………………………………………………………………..152
• 104. Preparing the Trailer for Towing …………………………………………………..159
• 105. Refuelling the Machine ……………………………………………………………………163
• 106. Low Fuel Levels ………………………………………………………………………..163
• 107. Filling the Tank ………………………………………………………………………….163
• 108. Moving a Disabled Machine …………………………………………………………….165
• 109. Recovery Hitch ………………………………………………………………………….165
• 110. Transporting the Machine ………………………………………………………………..166
• 111. Lifting a Machine ……………………………………………………………………………167
• 112. Storage of the Machine …………………………………………………………………..169
• 113. Introduction ……………………………………………………………………………….169
• 114. Storage Area …………………………………………………………………………….169
• 115. Prepare the Machine for Storage …………………………………………………169
• 116. Put the Machine into Storage ………………………………………………………169
• 117. During Storage ………………………………………………………………………….169
• 118. Take the Machine Out of Storage …………………………………………………170
• 119. Routine Maintenance
• 120. Service Requirements …………………………………………………………………….171
• 121. Introduction ……………………………………………………………………………….171
• 122. Owner-Operator Support …………………………………………………………….171
• 123. Service-Maintenance Agreements ……………………………………………….171
• 124. Initial Service and Inspection (100 Hours) ……………………………………..171
• 125. Fit for Purpose Tests for Lifting Equipment …………………………………….172
• 126. Obtaining Replacement Parts ………………………………………………………172
• 127. Health and Safety …………………………………………………………………………..173
• 128. Lubricants …………………………………………………………………………………173
• 129. Battery ……………………………………………………………………………………..175
• 130. Service Schedules ………………………………………………………………………….177
• 131. Introduction ……………………………………………………………………………….177
• 132. How to Use the Service Schedules ………………………………………………177
• 133. Calendar Equivalents …………………………………………………………………177
• 134. Pre-start Cold Checks, Service Points and Fluid Levels ………………….178
• 135. Functional Test and Final Inspection …………………………………………….182
• 136. Fluids, Lubricants and Capacities ……………………………………………………..184
• 137. Coolant Mixtures ……………………………………………………………………….186
• 138. Fuels ………………………………………………………………………………………..187
• 139. Prepare the Machine for Maintenance ………………………………………………190
• 140. Introduction ……………………………………………………………………………….190
• 141. How to Make the Machine Safe (Boom Lowered) …………………………..191
• 142. How to Make the Machine Safe (Boom Lifted) ……………………………….192
• 143. Cleaning the Machine ……………………………………………………………………..195
• 144. Introduction ……………………………………………………………………………….195
• 145. Preparing the Machine for Cleaning ……………………………………………..195
• 146. Cleaning the Machine …………………………………………………………………196
• 147. Fan Reverse (if fitted) …………………………………………………………………198
• 148. Checking for Damage ……………………………………………………………………..199
• 149. Check the Machine Body and Structure ………………………………………..199
• 150. Check the Tyres ………………………………………………………………………..199
• 151. Check the Seat and Seat Belt ……………………………………………………..199
• 152. Check the Hydraulic Hoses and Fittings ……………………………………….199
• 153. Check the Electrical Circuits ………………………………………………………..199
• 154. Checking the ROPS-FOPS Structure ……………………………………………201
• 155. Greasing ……………………………………………………………………………………….202
• 156. Introduction ……………………………………………………………………………….202
• 157. Preparing the Machine for Greasing …………………………………………….202
• 158. Every 50 Hours ………………………………………………………………………….203
• 159. Every 500 Hours ……………………………………………………………………….. 211
• 160. Every 1000 Hours ………………………………………………………………………213
• 161. Access Panels ……………………………………………………………………………….214
• 162. Introduction ……………………………………………………………………………….214
• 163. Battery Cover ……………………………………………………………………………214
• 164. Engine Cover …………………………………………………………………………….215
• 165. Rear Cover (if fitted) …………………………………………………………………..216
• 166. Undershield ………………………………………………………………………………217
• 167. Cab Heater and Air Conditioning ………………………………………………………218
• 168. Changing the Air Intake Filter ………………………………………………………218
• 169. Boom ……………………………………………………………………………………………219
• 170. Re-phasing of 3-Stage Booms …………………………………………………….219
• 171. Brakes ………………………………………………………………………………………….220
• 172. Park Brake ………………………………………………………………………………..220
• 173. Foot Brake (Excluding 550-80 Machines) ……………………………………..222
• 174. Footbrake (550-80 Machines) ……………………………………………………..222
• 175. Electrical System ……………………………………………………………………………223
• 176. Battery ……………………………………………………………………………………..223
• 177. Jump Starting the Engine ……………………………………………………………225
• 178. Fuses ……………………………………………………………………………………….226
• 179. Primary Fuses …………………………………………………………………………..254
• 180. Relays ……………………………………………………………………………………..255
• 181. Engine ………………………………………………………………………………………….278
• 182. Oil and Filter ……………………………………………………………………………..278
• 183. Cooling System …………………………………………………………………………280
• 184. Crankcase Ventilation (if fitted) …………………………………………………….282
• 185. Front End Accessory Drive Belt …………………………………………………..283
• 186. Air Filter ……………………………………………………………………………………285
• 187. Fuel System …………………………………………………………………………………..287
• 188. Introduction ……………………………………………………………………………….287
• 189. Water Separator and Engine Fuel Filter ………………………………………..287
• 190. Bleeding the System ………………………………………………………………….293
• 191. Hydraulic System ……………………………………………………………………………295
• 192. Introduction ……………………………………………………………………………….295
• 193. Releasing the Hydraulic Pressure ………………………………………………..296
• 194. Oil and FIlters ……………………………………………………………………………297
• 195. Hose Burst Protection Valves ………………………………………………………303
• 196. Transmission …………………………………………………………………………………305
• 197. Gearbox ……………………………………………………………………………………305
• 198. Front and Rear Axle …………………………………………………………………..308
• 199. Tyres and Wheels …………………………………………………………………………..312
• 200. Tyre Inflation ……………………………………………………………………………..312
• 201. Wheel Nuts ……………………………………………………………………………….313
• 202. Wheel Alignment ……………………………………………………………………………314
• 203. Introduction ……………………………………………………………………………….314
• 204. Manual Steer Mode Selector ……………………………………………………….314
• 205. Electronic Steer Mode Selector ……………………………………………………315
• 206. Wear Pads …………………………………………………………………………………….316
• 207. Boom Wear Pad Clearance …………………………………………………………316
• 208. Windscreen Washer ……………………………………………………………………….319
• 209. Checking the Level …………………………………………………………………….319
• 210. Fire Extinguisher (if fitted) ………………………………………………………………..320
• 211. Checking the Fire Extinguisher ……………………………………………………320
• 212. Optional Attachments
• 213. Introduction ……………………………………………………………………………………321
• 214. Attachments for your Machine ………………………………………………………….322
• 215. Connecting-Disconnecting Hydraulic Hoses ……………………………………….323
• 216. Introduction ……………………………………………………………………………….323
• 217. Connecting the Hydraulic Hoses ………………………………………………….323
• 218. Disconnecting the Hydraulic Hoses ………………………………………………324
• 219. Quick Release Couplings ……………………………………………………………325
• 220. Q-Fit Attachments …………………………………………………………………………..327
• 221. Mechanical Pin Locking Option ……………………………………………………327
• 222. Hydraulic Pin Locking Option ………………………………………………………329
• 223. Extension Jib …………………………………………………………………………………331
• 224. Safety ………………………………………………………………………………………331
• 225. Installing-Removing ……………………………………………………………………331
• 226. Operation ………………………………………………………………………………….331
• 227. Maintenance ……………………………………………………………………………..332
• 228. Fork Mounted Hook ………………………………………………………………………..333
• 229. Safety ………………………………………………………………………………………333
• 230. Installing …………………………………………………………………………………..333
• 231. Removing …………………………………………………………………………………333
• 232. Operation ………………………………………………………………………………….334
• 233. Maintenance ……………………………………………………………………………..334
• 234. Sideshift Carriage …………………………………………………………………………..335
• 235. Operation ………………………………………………………………………………….335
• 236. Installing the Sideshift Carriage ……………………………………………………336
• 237. Removing the Sideshift Carriage ………………………………………………….337
• 238. Maintenance ……………………………………………………………………………..338
• 239. Roof Truss Jib ……………………………………………………………………………….339
• 240. Safety ………………………………………………………………………………………339
• 241. Installing-Removing ……………………………………………………………………339
• 242. Operation ………………………………………………………………………………….339
• 243. Extending the Jib ……………………………………………………………………….340
• 244. Changing the Jib Angle ………………………………………………………………341
• 245. Maintenance ……………………………………………………………………………..341
• 246. Work Platforms ………………………………………………………………………………342
• 247. Specifications
• 248. Static Dimensions …………………………………………………………………………..343
• 249. 531-70, 541-70 ………………………………………………………………………….343
• 250. 533-105 ……………………………………………………………………………………344
• 251. 535-95 ……………………………………………………………………………………..346
• 252. 536-60 ……………………………………………………………………………………..348
• 253. 536-70 ……………………………………………………………………………………..350
• 254. 535-125 HiViz, 535-140 HiViz ……………………………………………………..351
• 255. 540-140 ……………………………………………………………………………………353
• 256. 540-170 ……………………………………………………………………………………355
• 257. 550-80 ……………………………………………………………………………………..357
• 258. Performance Dimensions ………………………………………………………………..358
• 259. Lift Performance ………………………………………………………………………..358
• 260. Maximum Wading Depth …………………………………………………………….359
• 261. Axle Weight Distribution ………………………………………………………………….360
• 262. Machines Without Stabilisers ………………………………………………………360
• 263. Machines With Stabilisers …………………………………………………………..361
• 264. Noise Data …………………………………………………………………………………….362
• 265. Introduction ……………………………………………………………………………….362
• 266. 531-70, 533-105, 535-95, 536-60, 536-70, 541-70 …………………………362
• 267. 535-125 HiViz, 535-140 HiViz ……………………………………………………..362
• 268. 540-140, 540-170 ………………………………………………………………………362
• 269. 550-80 ……………………………………………………………………………………..362
• 270. Vibration Data ………………………………………………………………………………..363
• 271. Introduction ……………………………………………………………………………….363
• 272. 531-70, 533-105, 535-95, 536-60, 536-70, 541-70 …………………………364
• 273. 540-140 ……………………………………………………………………………………365
• 274. 535-125 HiViz, 535-140 HiViz ……………………………………………………..366
• 275. 540-170 ……………………………………………………………………………………367
• 276. 550-80 ……………………………………………………………………………………..368
• 277. Tyre Sizes and Pressures ………………………………………………………………..369
• 278. Introduction ……………………………………………………………………………….369
• 279. Specifications ……………………………………………………………………………369
• 280. Trailer Towing ………………………………………………………………………………..374
• 281. Towing Limitations ……………………………………………………………………..374
• 282. Warranty Information
• 283. Machine Service Record Sheet ………………………………………………………..375
• 284. Registration Information ………………………………………………………………….377
• 285. European Community Standards
• 286. EC Declaration of Conformity …..