Name: JCB TM320, TM420 Loader Operator Manual 9831-2500
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Description

Model List:
- TM320, TM420 Loader

1. Acronyms Glossary ……………………………………………………………………………………………………………………… viii
2. Introduction
3. About this Manual
4. Model and Serial Number ……………………………………………………………………………………………………… 1
5. Using the Manual …………………………………………………………………………………………………………………. 1
6. Left-Hand Side, Right-Hand Side …………………………………………………………………………………………… 1
7. Cross References ………………………………………………………………………………………………………………… 1
8. Safety
9. Safety – Yours and Others …………………………………………………………………………………………………….. 2
10. Safety Warnings …………………………………………………………………………………………………………………… 2
11. General Safety …………………………………………………………………………………………………………………….. 3
12. Clothing and Personal Protective Equipment (PPE) …………………………………………………………………. 4
13. About the Product
14. Introduction
15. General ……………………………………………………………………………………………………………………………….. 5
16. Name and Address of the Manufacturer …………………………………………………………………………………. 5
17. Product Compliance ……………………………………………………………………………………………………………… 5
18. Description
19. General ……………………………………………………………………………………………………………………………….. 6
20. Intended Use ……………………………………………………………………………………………………………………….. 6
21. Log Moving-Object Handling ………………………………………………………………………………………………….. 6
22. Optional Equipment and Attachments …………………………………………………………………………………….. 6
23. Danger Zone ……………………………………………………………………………………………………………………….. 6
24. Main Component Locations …………………………………………………………………………………………………… 6
25. Product and Component Identification
26. Machine ………………………………………………………………………………………………………………………………. 9
27. Engine ………………………………………………………………………………………………………………………………. 10
28. Axle ………………………………………………………………………………………………………………………………….. 11
29. Gearbox …………………………………………………………………………………………………………………………….. 12
30. Operator Protective Structure ………………………………………………………………………………………………. 13
31. Safety Labels
32. General ……………………………………………………………………………………………………………………………… 15
33. Safety Label Identification ……………………………………………………………………………………………………. 15
34. Operator Station
35. Component Locations …………………………………………………………………………………………………………. 18
36. Interior Switches
37. Ignition Switch ……………………………………………………………………………………………………………………. 19
38. Multi-Purpose Switch ………………………………………………………………………………………………………….. 19
39. Cab Interior Light ……………………………………………………………………………………………………………….. 20
40. Console Switches
41. General ……………………………………………………………………………………………………………………………… 21
42. Road Lights ……………………………………………………………………………………………………………………….. 21
43. Rear Fog Lights …………………………………………………………………………………………………………………. 21
44. Hazard Warning Lights ……………………………………………………………………………………………………….. 21
45. Front Work Lights ………………………………………………………………………………………………………………. 21
46. Rear Work Lights ……………………………………………………………………………………………………………….. 22
47. Boom Work Light ……………………………………………………………………………………………………………….. 22
48. Transmission Mode …………………………………………………………………………………………………………….. 22
49. Transmission Disconnect …………………………………………………………………………………………………….. 22
50. Smooth Ride System (SRS) ………………………………………………………………………………………………… 22
51. Beacon ……………………………………………………………………………………………………………………………… 22
52. Lift Arm Quickhitch …………………………………………………………………………………………………………….. 23
53. Controls Isolation ……………………………………………………………………………………………………………….. 23
54. Hydraulic Tow Hitch ……………………………………………………………………………………………………………. 23
55. Reverse Fan ……………………………………………………………………………………………………………………… 23
56. Rear Window Wiper ……………………………………………………………………………………………………………. 23
57. Constant Flow ……………………………………………………………………………………………………………………. 23
58. Auxiliary Pressure Dump …………………………………………………………………………………………………….. 23
59. Operation
60. Introduction
61. General ……………………………………………………………………………………………………………………………… 25
62. Operating Safety
63. General ……………………………………………………………………………………………………………………………… 26
64. Worksite Safety ………………………………………………………………………………………………………………….. 28
65. Risk Assessment ……………………………………………………………………………………………………………….. 29
66. Walk-Around Inspection
67. General ……………………………………………………………………………………………………………………………… 31
68. Entering and Leaving the Operator Station
69. General ……………………………………………………………………………………………………………………………… 32
70. Emergency Exit ………………………………………………………………………………………………………………….. 32
71. Doors
72. Operator Door ……………………………………………………………………………………………………………………. 33
73. Battery Isolator
74. General ……………………………………………………………………………………………………………………………… 34
75. Before Starting the Engine
76. General ……………………………………………………………………………………………………………………………… 35
77. Operator Seat
78. General ……………………………………………………………………………………………………………………………… 37
79. Basic Seat …………………………………………………………………………………………………………………………. 37
80. Suspension Seat ………………………………………………………………………………………………………………… 38
81. Seat Belt
82. General ……………………………………………………………………………………………………………………………… 40
83. Inertia Reel Seat Belt …………………………………………………………………………………………………………. 40
84. Mirrors
85. General ……………………………………………………………………………………………………………………………… 42
86. Starting the Engine
87. General ……………………………………………………………………………………………………………………………… 45
88. Warming Up ………………………………………………………………………………………………………………………. 46
89. Immobiliser ………………………………………………………………………………………………………………………… 46
90. Stopping and Parking
91. General ……………………………………………………………………………………………………………………………… 48
92. Preparing for Travel
93. General ……………………………………………………………………………………………………………………………… 50
94. Preparing for Road Travel …………………………………………………………………………………………………… 50
95. Preparing for Worksite Travel ………………………………………………………………………………………………. 52
96. Smooth Ride System (SRS) ………………………………………………………………………………………………… 52
97. Beacon ……………………………………………………………………………………………………………………………… 53
98. Safety Equipment
99. Articulation Lock …………………………………………………………………………………………………………………. 54
100. Control Lock ………………………………………………………………………………………………………………………. 55
101. Drive Controls
102. Steering Wheel ………………………………………………………………………………………………………………….. 56
103. Steering Column ………………………………………………………………………………………………………………… 56
104. Accelerator Pedal ……………………………………………………………………………………………………………….. 56
105. Service Brake Pedal …………………………………………………………………………………………………………… 56
106. Park Brake ………………………………………………………………………………………………………………………… 57
107. Transmission Drive Lever ……………………………………………………………………………………………………. 57
108. Instruments
109. Instrument Panel ………………………………………………………………………………………………………………… 61
110. Slopes
111. General ……………………………………………………………………………………………………………………………… 68
112. Driving on Slopes ………………………………………………………………………………………………………………. 68
113. Working on Slopes …………………………………………………………………………………………………………….. 69
114. Driving the Machine
115. General ……………………………………………………………………………………………………………………………… 70
116. Limited Slip Differential (LSD) ……………………………………………………………………………………………… 71
117. Operating Levers-Pedals
118. General ……………………………………………………………………………………………………………………………… 72
119. Control Layouts ………………………………………………………………………………………………………………….. 72
120. Lift Arm Controls ………………………………………………………………………………………………………………… 72
121. Auxiliary Circuit Controls ……………………………………………………………………………………………………… 75
122. Lifting and Loading
123. General ……………………………………………………………………………………………………………………………… 77
124. Load Charts ………………………………………………………………………………………………………………………. 77
125. Longitudinal Load Moment Indicator (LLMI) …………………………………………………………………………… 80
126. Longitudinal Load Moment Control (LLMC) …………………………………………………………………………… 84
127. Working with the Lift Arm
128. General ……………………………………………………………………………………………………………………………… 89
129. Fork Ratings ………………………………………………………………………………………………………………………. 90
130. Working with Pallets …………………………………………………………………………………………………………… 92
131. Working with Bales …………………………………………………………………………………………………………….. 94
132. Working with Irregular Loads ……………………………………………………………………………………………….. 95
133. Stacking Loads ………………………………………………………………………………………………………………….. 96
134. Filling the Shovel ……………………………………………………………………………………………………………….. 97
135. Loading a Truck …………………………………………………………………………………………………………………. 98
136. Heating, Ventilating and Air-Conditioning (HVAC)
137. General ……………………………………………………………………………………………………………………………… 99
138. Air-Conditioning Controls …………………………………………………………………………………………………….. 99
139. Cab Heater Controls …………………………………………………………………………………………………………… 99
140. Fire Extinguisher
141. General ……………………………………………………………………………………………………………………………. 100
142. Moving a Disabled Machine
143. Getting the Machine Unstuck …………………………………………………………………………………………….. 102
144. Jump-Starting the Engine ………………………………………………………………………………………………….. 102
145. Retrieval ………………………………………………………………………………………………………………………….. 103
146. Recovery Hitch …………………………………………………………………………………………………………………. 104
147. Lift Arm (Emergency Operation) …………………………………………………………………………………………. 105
148. Lifting the Machine
149. General ……………………………………………………………………………………………………………………………. 106
150. Transporting the Machine
151. General ……………………………………………………………………………………………………………………………. 108
152. Operating Environment
153. General ……………………………………………………………………………………………………………………………. 115
154. Operating in Low Temperatures …………………………………………………………………………………………. 115
155. Operating in High Temperatures …………………………………………………………………………………………. 115
156. Cab Filters ……………………………………………………………………………………………………………………….. 116
157. Refuelling
158. General ……………………………………………………………………………………………………………………………. 117
159. Low Fuel Levels ……………………………………………………………………………………………………………….. 117
160. Filling the Tank …………………………………………………………………………………………………………………. 117
161. Attachments
162. Working with Attachments
163. Introduction ………………………………………………………………………………………………………………………. 119
164. Attachments for your Machine ……………………………………………………………………………………………. 119
165. Connecting-Disconnecting Hydraulic Hoses …………………………………………………………………………. 120
166. Quickhitch
167. General ……………………………………………………………………………………………………………………………. 124
168. Lift Arm Quickhitch Carriage ……………………………………………………………………………………………… 124
169. Tow Hitches
170. General ……………………………………………………………………………………………………………………………. 128
171. Hydraulic Tow Hitch ………………………………………………………………………………………………………….. 128
172. Mechanical Tow Hitch ……………………………………………………………………………………………………….. 131
173. Work Platforms
174. General ……………………………………………………………………………………………………………………………. 133
175. Preservation and Storage
176. Cleaning
177. General ……………………………………………………………………………………………………………………………. 135
178. Preparation ………………………………………………………………………………………………………………………. 136
179. Checking For Damage
180. General ……………………………………………………………………………………………………………………………. 137
181. Storage
182. General ……………………………………………………………………………………………………………………………. 138
183. Put into Storage ……………………………………………………………………………………………………………….. 138
184. During Storage …………………………………………………………………………………………………………………. 138
185. Take out of Storage ………………………………………………………………………………………………………….. 139
186. Security
187. General ……………………………………………………………………………………………………………………………. 140
188. JCB Plantguard ………………………………………………………………………………………………………………… 140
189. Construction Equipment Security and Registration Scheme (CESAR) …………………………………….. 140
190. LiveLink …………………………………………………………………………………………………………………………… 140
191. Maintenance
192. Introduction
193. General ……………………………………………………………………………………………………………………………. 141
194. Service-Maintenance Agreements ………………………………………………………………………………………. 141
195. Obtaining Spare Parts ………………………………………………………………………………………………………. 141
196. Maintenance Safety
197. General ……………………………………………………………………………………………………………………………. 142
198. Fluids and Lubricants ……………………………………………………………………………………………………….. 143
199. Maintenance Schedules
200. General ……………………………………………………………………………………………………………………………. 147
201. How to Use the Maintenance Schedules …………………………………………………………………………….. 147
202. Maintenance Intervals ……………………………………………………………………………………………………….. 147
203. Pre-start Cold Checks, Service Points and Fluid Levels ………………………………………………………… 148
204. Functional Tests and Final Inspection …………………………………………………………………………………. 151
205. Maintenance Positions
206. General ……………………………………………………………………………………………………………………………. 153
207. Maintenance Position (Lift Arm Lowered) ……………………………………………………………………………. 153
208. Maintenance Position (Lift Arm Raised) ………………………………………………………………………………. 153
209. Service Points
210. General ……………………………………………………………………………………………………………………………. 155
211. Access Apertures
212. General ……………………………………………………………………………………………………………………………. 157
213. Engine Compartment Cover ………………………………………………………………………………………………. 157
214. Cab Heater Door ……………………………………………………………………………………………………………… 158
215. Tools
216. General ……………………………………………………………………………………………………………………………. 159
217. Toolbox ……………………………………………………………………………………………………………………………. 159
218. Lubrication
219. General ……………………………………………………………………………………………………………………………. 160
220. Preparation ………………………………………………………………………………………………………………………. 160
221. Attachments
222. General …………………………………………………………………………………………………………………………… 161
223. Body and Framework
224. General …………………………………………………………………………………………………………………………… 162
225. Pivot Pins ………………………………………………………………………………………………………………………… 162
226. Lift Arm
227. Wear Pads ………………………………………………………………………………………………………………………. 166
228. Operator Station
229. General …………………………………………………………………………………………………………………………… 167
230. Operator Protective Structure …………………………………………………………………………………………….. 167
231. Seat ………………………………………………………………………………………………………………………………… 167
232. Seat Belt …………………………………………………………………………………………………………………………. 167
233. Controls …………………………………………………………………………………………………………………………… 168
234. Heating, Ventilating and Air-Conditioning (HVAC)
235. Air-Conditioning ……………………………………………………………………………………………………………….. 169
236. Heater …………………………………………………………………………………………………………………………….. 169
237. Engine
238. General …………………………………………………………………………………………………………………………… 171
239. Oil …………………………………………………………………………………………………………………………………… 171
240. Drive Belt ………………………………………………………………………………………………………………………… 173
241. Emissions Control System ………………………………………………………………………………………………… 174
242. Fuel System
243. General …………………………………………………………………………………………………………………………… 179
244. Pre-Filter Element …………………………………………………………………………………………………………….. 180
245. Water Separator ………………………………………………………………………………………………………………. 181
246. Cooling System
247. General …………………………………………………………………………………………………………………………… 182
248. Coolant ……………………………………………………………………………………………………………………………. 182
249. Cooling Pack …………………………………………………………………………………………………………………… 183
250. Brakes
251. General ……………………………………………………………………………………………………………………………. 184
252. Park Brake ………………………………………………………………………………………………………………………. 184
253. Steering System
254. General …………………………………………………………………………………………………………………………… 186
255. Driveshafts
256. General …………………………………………………………..