JCB Side Engine ( Tier 4I) Loadalls Operator Manual 9821-2350

Description

• Model List:
  • Side Engine ( Tier 4I) 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. Product Compliance ………………………………………………………………………1
• 8. Machine Model and Serial Number ………………………………………………….1
• 9. Using this Manual ………………………………………………………………………….1
• 10. Left Side, Right Side ………………………………………………………………………2
• 11. Cab-Canopy …………………………………………………………………………………2
• 12. Cross References ………………………………………………………………………….2
• 13. Machine Description …………………………………………………………………………..3
• 14. The JCB Loadall ……………………………………………………………………………3
• 15. Intended Use ………………………………………………………………………………..3
• 16. Component Location ……………………………………………………………………..4
• 17. Safety Check List ……………………………………………………………………………….8
• 18. Safety – Yours and Others ………………………………………………………………8
• 19. General Safety ……………………………………………………………………………..8
• 20. Operating Safety …………………………………………………………………………10
• 21. Maintenance Safety ……………………………………………………………………..14
• 22. Safety Labels …………………………………………………………………………………..19
• 23. Introduction …………………………………………………………………………………19
• 24. Safety Label Identification …………………………………………………………….20
• 25. Identifying Your Machine …………………………………………………………………..23
• 26. Machine Identification Plate ………………………………………………………….23
• 27. Component Identification Plates …………………………………………………….25
• 28. Machine Security ……………………………………………………………………………..30
• 29. Introduction …………………………………………………………………………………30
• 30. JCB Plantguard …………………………………………………………………………..30
• 31. LiveLink ……………………………………………………………………………………..30
• 32. Construction Equipment Security And Registration Scheme (CESAR) .30
• 33. Immobiliser …………………………………………………………………………………30
• 34. Operation
• 35. Introduction ……………………………………………………………………………………..33
• 36. Before Entering the Cab ……………………………………………………………………34
• 37. Entering and Leaving the Cab ……………………………………………………………35
• 38. Emergency Exit …………………………………………………………………………..36
• 39. Doors and Windows …………………………………………………………………………39
• 40. Opening and Closing the Door ………………………………………………………39
• 41. Opening and Closing the Upper Door Section …………………………………39
• 42. Opening and Closing the Rear Window – All Machines Except …………..41
• 43. Visibility Aids ……………………………………………………………………………………42
• 44. Mirrors and Adjustment ………………………………………………………………..42
• 45. Seat Controls …………………………………………………………………………………..72
• 46. Introduction …………………………………………………………………………………72
• 47. Operator Present Switch ………………………………………………………………72
• 48. Seat Options ……………………………………………………………………………….72
• 49. Basic Seat ………………………………………………………………………………….73
• 50. Suspension Seat (KAB 100 Series – Mechanical) …………………………….74
• 51. Suspension Seat (KAB 100 Series – Air) …………………………………………75
• 52. Suspension Seat (KAB 800 Series – Air) …………………………………………76
• 53. Seat Belt …………………………………………………………………………………………77
• 54. Inertia Reel Seat Belt …………………………………………………………………..77
• 55. Static Seat Belt ……………………………………………………………………………78
• 56. Cab Layout ……………………………………………………………………………………..79
• 57. (Excludes 525-56 Machines) …………………………………………………………79
• 58. (526-56 Machines) ………………………………………………………………………83
• 59. Drive Controls, Switches and Instruments ……………………………………………85
• 60. Drive Controls ……………………………………………………………………………..85
• 61. Switches …………………………………………………………………………………….97
• 62. Instrument Panel ……………………………………………………………………….104
• 63. LCD Screen ………………………………………………………………………………106
• 64. Warning Lights …………………………………………………………………………..122
• 65. Torque Lock (6-Speed Transmission) ……………………………………………124
• 66. Air Conditioning and Cab Heater Controls …………………………………….125
• 67. Operating Levers ……………………………………………………………………………127
• 68. Introduction ……………………………………………………………………………….127
• 69. Control Layouts …………………………………………………………………………127
• 70. Boom and Carriage Controls ……………………………………………………….128
• 71. Auxiliary Controls ………………………………………………………………………136
• 72. Chassis Levelling (Sway) Option ………………………………………………….142
• 73. Stabiliser Control Option ……………………………………………………………..144
• 74. Safety Equipment …………………………………………………………………………..146
• 75. Control Locks (Excludes 525-56 Machines) …………………………………..146
• 76. Control Locks (526-56 Machines) ………………………………………………..149
• 77. Load Charts ………………………………………………………………………………151
• 78. Boom Indicators ………………………………………………………………………..153
• 79. Longitudinal Load Moment Indicator (LLMI) …………………………………..154
• 80. Longitudinal Load Moment Control All Machines (Excluding 540-170)
• 81. (LLMC) System …………………………………………………………………………158
• 82. LC4 Load Control System (540-170 only) ……………………………………..162
• 83. Inclinometer ………………………………………………………………………………170
• 84. Beacon …………………………………………………………………………………….170
• 85. Fire Extinguisher (if fitted) …………………………………………………………..171
• 86. Before Starting the Engine ……………………………………………………………….172
• 87. Starting the Engine …………………………………………………………………………174
• 88. Immobiliser (if fitted) …………………………………………………………………..176
• 89. Preparing the Machine for Travel ……………………………………………………..179
• 90. Introduction ……………………………………………………………………………….179
• 91. Preparing for Road Travel …………………………………………………………..179
• 92. Preparing for Site Travel ……………………………………………………………..182
• 93. Smooth Ride System (SRS) ………………………………………………………..183
• 94. Getting the Machine Moving …………………………………………………………….184
• 95. Operating Practices ……………………………………………………………………184
• 96. Operating Procedure ………………………………………………………………….185
• 97. Stopping and Parking the Machine ……………………………………………………186
• 98. Working with the Machine ……………………………………………………………….187
• 99. Operating Practices and Site Safety …………………………………………….187
• 100. Clothing and Safety Equipment ……………………………………………………187
• 101. Danger Zone …………………………………………………………………………….187
• 102. Safety Practices ………………………………………………………………………..187
• 103. Working with the Boom ………………………………………………………………189
• 104. Use of Machines on Gradients or Slopes ………………………………………198
• 105. Interlock System ………………………………………………………………………..201
• 106. Operating Environment ……………………………………………………………………202
• 107. Operating in Low Temperatures …………………………………………………..202
• 108. Operating in High Temperatures ………………………………………………….202
• 109. Protection offered by the Cab ………………………………………………………203
• 110. Tow Hitch Options …………………………………………………………………………..204
• 111. Introduction ……………………………………………………………………………….204
• 112. Connecting the Trailer ………………………………………………………………..205
• 113. Preparing the Trailer for Towing …………………………………………………..214
• 114. Refuelling the Machine ……………………………………………………………………220
• 115. Low Fuel Levels ………………………………………………………………………..220
• 116. Filling the Tank ………………………………………………………………………….221
• 117. Moving a Disabled Machine …………………………………………………………….223
• 118. Recovery Hitch ………………………………………………………………………….223
• 119. Transporting the Machine ………………………………………………………………..224
• 120. Lifting a Machine ……………………………………………………………………………225
• 121. Storage of the Machine …………………………………………………………………..227
• 122. Introduction ……………………………………………………………………………….227
• 123. Storage Area …………………………………………………………………………….227
• 124. Prepare the Machine for Storage …………………………………………………227
• 125. Put the Machine into Storage ………………………………………………………227
• 126. During Storage ………………………………………………………………………….227
• 127. Take the Machine Out of Storage …………………………………………………228
• 128. Routine Maintenance
• 129. Service Requirements …………………………………………………………………….229
• 130. Introduction ……………………………………………………………………………….229
• 131. Owner-Operator Support …………………………………………………………….229
• 132. Service-Maintenance Agreements ……………………………………………….229
• 133. Initial Service and Inspection (100 Hours) ……………………………………..229
• 134. Fit for Purpose Tests for Lifting Equipment …………………………………….230
• 135. Obtaining Replacement Parts ………………………………………………………230
• 136. Health and Safety …………………………………………………………………………..231
• 137. Lubricants …………………………………………………………………………………231
• 138. Battery ……………………………………………………………………………………..233
• 139. Service Schedules ………………………………………………………………………….235
• 140. Introduction ……………………………………………………………………………….235
• 141. How to Use the Service Schedules ………………………………………………235
• 142. Calendar Equivalents …………………………………………………………………235
• 143. Pre-start Cold Checks, Service Points and Fluid Levels ………………….236
• 144. Functional Test and Final Inspection …………………………………………….240
• 145. Fluids, Lubricants and Capacities ……………………………………………………..242
• 146. Coolant Mixtures ……………………………………………………………………….245
• 147. Fuels ………………………………………………………………………………………..245
• 148. Prepare the Machine for Maintenance ………………………………………………250
• 149. Introduction ……………………………………………………………………………….250
• 150. How to Make the Machine Safe (Boom Lowered) …………………………..251
• 151. How to Make the Machine Safe (Boom Lifted) ……………………………….252
• 152. Cleaning the Machine ……………………………………………………………………..255
• 153. Introduction ……………………………………………………………………………….255
• 154. Preparing the Machine for Cleaning ……………………………………………..255
• 155. Cleaning the Machine …………………………………………………………………256
• 156. Auto Fan Reverse (if fitted) …………………………………………………………259
• 157. Checking for Damage ……………………………………………………………………..260
• 158. Check the Machine Body and Structure ………………………………………..260
• 159. Check the Tyres ………………………………………………………………………..260
• 160. Check the Seat and Seat Belt ……………………………………………………..260
• 161. Check the Hydraulic Hoses and Fittings ……………………………………….260
• 162. Check the Electrical Circuits ………………………………………………………..260
• 163. Checking the ROPS-FOPS Structure ……………………………………………262
• 164. Greasing ……………………………………………………………………………………….264
• 165. Introduction ……………………………………………………………………………….264
• 166. Preparing the Machine for Greasing …………………………………………….264
• 167. Every 50 Hours ………………………………………………………………………….265
• 168. Every 500 Hours ………………………………………………………………………..274
• 169. Every 1000 Hours ………………………………………………………………………276
• 170. Oiling ……………………………………………………………………………………………277
• 171. Park Brake Cable ………………………………………………………………………277
• 172. Control Levers …………………………………………………………………………..277
• 173. Access Panels ……………………………………………………………………………….278
• 174. Introduction ……………………………………………………………………………….278
• 175. Battery Cover ……………………………………………………………………………278
• 176. Engine Cover …………………………………………………………………………….279
• 177. Rear Cover ……………………………………………………………………………….280
• 178. Undershield ………………………………………………………………………………282
• 179. Cab Heater and Air Conditioning ………………………………………………………283
• 180. Changing the Air Intake Filter ………………………………………………………283
• 181. Changing the Cab Recirculation Air Filter (Excludes 526-56) …………..284
• 182. Boom ……………………………………………………………………………………………285
• 183. Re-phasing of 3-Stage Booms …………………………………………………….285
• 184. Brakes ………………………………………………………………………………………….286
• 185. Park Brake ………………………………………………………………………………..286
• 186. Foot Brake (Excluding 550-80 Machines) ……………………………………..288
• 187. Footbrake (550-80 Machines) ……………………………………………………..288
• 188. Electrical System ……………………………………………………………………………289
• 189. Battery ……………………………………………………………………………………..289
• 190. Jump Starting the Engine ……………………………………………………………291
• 191. Fuses (Excludes 526-56 Machines) ……………………………………………..292
• 192. Fuses (526-56 Machines) ……………………………………………………………296
• 193. Primary Fuses …………………………………………………………………………..298
• 194. Relays (Excludes 526-56 Machines) …………………………………………….299
• 195. Relays (526-56 Machines) ………………………………………………………….303
• 196. Engine Compartment Fuse and Relay Box ……………………………………305
• 197. Engine ………………………………………………………………………………………….306
• 198. Oil and Filter ……………………………………………………………………………..306
• 199. Cooling System …………………………………………………………………………309
• 200. Crankcase Ventilation (if fitted) ……………………………………………………. 311
• 201. Front End Accessory Drive Belt …………………………………………………..312
• 202. Air Filter ……………………………………………………………………………………314
• 203. Fuel System …………………………………………………………………………………..315
• 204. Introduction ……………………………………………………………………………….315
• 205. Water Separator and Engine Fuel Filter ………………………………………..316
• 206. Bleeding the System ………………………………………………………………….320
• 207. Hydraulic System ……………………………………………………………………………321
• 208. Introduction ……………………………………………………………………………….321
• 209. Releasing the Hydraulic Pressure ………………………………………………..322
• 210. Oil and FIlters (Excludes 525-56 Machines) ………………………………….323
• 211. Oil and Filter (526-56 Machines) ………………………………………………….328
• 212. Hose Burst Protection Valves ………………………………………………………331
• 213. Transmission …………………………………………………………………………………333
• 214. Gearbox (Excludes 525-56 Machines) ………………………………………….333
• 215. Gearbox (526-56 Machines) ………………………………………………………..335
• 216. Front and Rear Axle …………………………………………………………………..339
• 217. Tyres and Wheels …………………………………………………………………………..343
• 218. Tyre Inflation ……………………………………………………………………………..343
• 219. Wheel Nuts ……………………………………………………………………………….344
• 220. Wheel Alignment ……………………………………………………………………………345
• 221. Introduction ……………………………………………………………………………….345
• 222. Manual Steer Mode Selector ……………………………………………………….345
• 223. Electronic Steer Mode Selector ……………………………………………………346
• 224. Wear Pads …………………………………………………………………………………….347
• 225. Boom Wear Pad Clearance …………………………………………………………347
• 226. Windscreen Washer ……………………………………………………………………….350
• 227. Checking the Level …………………………………………………………………….350
• 228. Fire Extinguisher (if fitted) ………………………………………………………………..352
• 229. Checking the Fire Extinguisher ……………………………………………………352
• 230. Optional Attachments
• 231. Introduction ……………………………………………………………………………………353
• 232. Attachments for your Machine ………………………………………………………….354
• 233. Connecting-Disconnecting Hydraulic Hoses ……………………………………….355
• 234. Introduction ……………………………………………………………………………….355
• 235. Connecting the Hydraulic Hoses ………………………………………………….355
• 236. Disconnecting the Hydraulic Hoses ………………………………………………356
• 237. Quick Release Couplings ……………………………………………………………357
• 238. Tool Carrier Attachments (526-56 Machines) ……………………………………..359
• 239. Mechanical Pin Locking Option ……………………………………………………359
• 240. Hydraulic Pin Locking Option ………………………………………………………361
• 241. Q-Fit Attachments …………………………………………………………………………..365
• 242. Mechanical Pin Locking Option ……………………………………………………365
• 243. Hydraulic Pin Locking Option ………………………………………………………367
• 244. Extension Jib …………………………………………………………………………………369
• 245. Safety ………………………………………………………………………………………369
• 246. Installing-Removing ……………………………………………………………………369
• 247. Operation ………………………………………………………………………………….369
• 248. Maintenance ……………………………………………………………………………..370
• 249. Fork Mounted Hook ………………………………………………………………………..371
• 250. Safety ………………………………………………………………………………………371
• 251. Installing …………………………………………………………………………………..371
• 252. Removing …………………………………………………………………………………371
• 253. Operation ………………………………………………………………………………….372
• 254. Maintenance ……………………………………………………………………………..372
• 255. Sideshift Carriage …………………………………………………………………………..373
• 256. Operation ………………………………………………………………………………….373
• 257. Installing the Sideshift Carriage ……………………………………………………374
• 258. Removing the Sideshift Carriage ………………………………………………….375
• 259. Maintenance ……………………………………………………………………………..376
• 260. Roof Truss Jib ……………………………………………………………………………….377
• 261. Safety ………………………………………………………………………………………377
• 262. Installing-Removing ……………………………………………………………………377
• 263. Operation ………………………………………………………………………………….377
• 264. Extending the Jib ……………………………………………………………………….378
• 265. Changing the Jib Angle ………………………………………………………………379
• 266. Maintenance ……………………………………………………………………………..379
• 267. Work Platforms ………………………………………………………………………………380
• 268. Specifications
• 269. Static Dimensions …………………………………………………………………………..381
• 270. 526-56 ……………………………………………………………………………………..381
• 271. 531-70, 541-70 ………………………………………………………………………….382
• 272. 533-105 ……………………………………………………………………………………384
• 273. 535-95 ……………………………………………………………………………………..386
• 274. 536-60 ……………………………………………………………………………………..388
• 275. 536-70 ……………………………………………………………………………………..390
• 276. 535-125 HiViz, 535-140 HiViz ……………………………………………………..391
• 277. 540-140 ……………………………………………………………………………………393
• 278. 540-170 ……………………………………………………………………………………395
• 279. 550-80 ……………………………………………………………………………………..397
• 280. Performance Dimensions ………………………………………………………………..398
• 281. Lift Performance ………………………………………………………………………..398
• 282. Maximum Wading Depth …………………………………………………………….400
• 283. Axle Weight Distribution ………………………………………………………………….401
• 284. Machines Without Stabilisers ………………………………………………………401
• 285. Machines With Stabilisers …………………………………………………………..402
• 286. Noise Data ……………………………………………………………………