JCB 520-40 Loadall Operator Manual 9821-0400

JCB 520-40 Loadall Operator Manual 9821-0400 - Image 2

JCB 520-40 Loadall Operator Manual 9821-0400 - Image 3

JCB 520-40 Loadall Operator Manual 9821-0400 - Image 4

JCB 520-40 Loadall Operator Manual 9821-0400 - Image 5

jcb 520 40 loadall operator manual 9821 0400 2

jcb 520 40 loadall operator manual 9821 0400 3

JCB 520-40 Loadall Operator Manual 9821-0400

$20.00

Type Of Manual: Operator Manual
ManualID: 9821-0400
Number of Pages: 224
Size: 13.8MB
Format: PDF

Category: JCB Operator Manual PDF

Model List:
- 520-40 Loadall

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 ……………………………………………………………………..3
17. Safety Check List ……………………………………………………………………………….5
18. Safety – Yours and Others ………………………………………………………………5
19. General Safety ……………………………………………………………………………..5
20. Operating Safety …………………………………………………………………………..7
21. Maintenance Safety …………………………………………………………………….. 11
22. Safety Labels …………………………………………………………………………………..16
23. Introduction …………………………………………………………………………………16
24. Safety Label Identification …………………………………………………………….17
25. Identifying Your Machine …………………………………………………………………..19
26. Machine Identification Plate ………………………………………………………….19
27. Component Identification Plates …………………………………………………….20
28. Machine Security ……………………………………………………………………………..23
29. Introduction …………………………………………………………………………………23
30. JCB Plantguard …………………………………………………………………………..23
31. Construction Equipment Security And Registration Scheme (CESAR) .23
32. Operation
33. Introduction ……………………………………………………………………………………..25
34. Before Entering the Cab ……………………………………………………………………26
35. Entering and Leaving the Cab ……………………………………………………………27
36. Emergency Exit …………………………………………………………………………..28
37. Doors and Windows …………………………………………………………………………29
38. Opening and Closing the Doors …………………………………………………….29
39. Opening and Closing the Upper Door Section …………………………………30
40. Seat Controls …………………………………………………………………………………..31
41. Introduction …………………………………………………………………………………31
42. Basic Seat ………………………………………………………………………………….31
43. Seat Belt …………………………………………………………………………………………32
44. Inertia Reel Seat Belt …………………………………………………………………..32
45. Static Seat Belt ……………………………………………………………………………33
46. Cab Layout ……………………………………………………………………………………..34
47. Component Key …………………………………………………………………………..35
48. Drive Controls, Switches and Instruments ……………………………………………36
49. Drive Controls ……………………………………………………………………………..36
50. Switches …………………………………………………………………………………….38
51. Instrument Panel …………………………………………………………………………41
52. Cab Heater Controls …………………………………………………………………….44
53. Operating Levers ……………………………………………………………………………..45
54. Introduction …………………………………………………………………………………45
55. Boom and Carriage Controls …………………………………………………………46
56. Auxiliary Controls ………………………………………………………………………..47
57. Float Control ……………………………………………………………………………….48
58. Safety Equipment …………………………………………………………………………….49
59. Control Locks ……………………………………………………………………………..49
60. Load Charts ………………………………………………………………………………..50
61. Boom Indicators ………………………………………………………………………….52
62. Longitudinal Load Moment Indicator (LLMI) …………………………………….53
63. Longitudinal Load Moment Indicator (LLMI) with Longitudinal Load Motion
64. Control (LLMC) System ………………………………………………………………..57
65. Inclinometer ………………………………………………………………………………..63
66. Beacon ………………………………………………………………………………………63
67. Fire Extinguisher (if fitted) …………………………………………………………….64
68. Before Starting the Engine …………………………………………………………………65
69. Starting the Engine …………………………………………………………………………..67
70. Immobiliser (if fitted) …………………………………………………………………….68
71. Preparing the Machine for Travel ……………………………………………………….71
72. Introduction …………………………………………………………………………………71
73. Preparing for Road Travel …………………………………………………………….71
74. Preparing for Site Travel ……………………………………………………………….72
75. Getting the Machine Moving ………………………………………………………………73
76. Operating Practices ……………………………………………………………………..73
77. Operating Procedure ……………………………………………………………………74
78. Stopping and Parking the Machine ……………………………………………………..75
79. Working with the Machine …………………………………………………………………76
80. Operating Practices and Site Safety ………………………………………………76
81. Clothing and Safety Equipment ……………………………………………………..76
82. Danger Zone ………………………………………………………………………………76
83. Working with the Boom ………………………………………………………………..77
84. Use of Machines on Gradients or Slopes ………………………………………..86
85. Operating Environment ……………………………………………………………………..89
86. Operating in Low Temperatures …………………………………………………….89
87. Operating in High Temperatures ……………………………………………………89
88. Refuelling the Machine ……………………………………………………………………..90
89. Low Fuel Levels ………………………………………………………………………….90
90. Filling the Tank ……………………………………………………………………………90
91. Moving a Disabled Machine ………………………………………………………………92
92. Recovery Hitch ……………………………………………………………………………93
93. Transporting the Machine ………………………………………………………………….94
94. Storage of the Machine …………………………………………………………………….96
95. Introduction …………………………………………………………………………………96
96. Storage Area ………………………………………………………………………………96
97. Prepare the Machine for Storage …………………………………………………..96
98. Put the Machine into Storage ………………………………………………………..96
99. During Storage ……………………………………………………………………………96
100. Take the Machine Out of Storage …………………………………………………..97
101. Routine Maintenance
102. Service Requirements ………………………………………………………………………99
103. Introduction …………………………………………………………………………………99
104. Owner-Operator Support ………………………………………………………………99
105. Service-Maintenance Agreements …………………………………………………99
106. Initial Service and Inspection …………………………………………………………99
107. Fit for Purpose Tests for Lifting Equipment …………………………………….100
108. Obtaining Replacement Parts ………………………………………………………100
109. Health and Safety …………………………………………………………………………..101
110. Lubricants …………………………………………………………………………………101
111. Battery ……………………………………………………………………………………..103
112. Service Schedules ………………………………………………………………………….105
113. Introduction ……………………………………………………………………………….105
114. How to Use the Service Schedules ………………………………………………105
115. Calendar Equivalents …………………………………………………………………105
116. Pre-start Cold Checks, Service Points and Fluid Levels ………………….106
117. Functional Test and Final Inspection …………………………………………….109
118. Fluids, Lubricants and Capacities …………………………………………………….. 111
119. Coolant Mixtures ………………………………………………………………………. 112
120. Fluid Recommendations (Fuel Specification) ………………………………… 112
121. Diesel Fuel Characteristics – Perkins Recommendation …………………. 114
122. Prepare the Machine for Maintenance ………………………………………………120
123. Introduction ……………………………………………………………………………….120
124. How to Make the Machine Safe (Boom Lowered) …………………………..121
125. How to Make the Machine Safe
126. (Boom Lifted) …………………………………………………………………………….122
127. Cleaning the Machine ……………………………………………………………………..124
128. Introduction ……………………………………………………………………………….124
129. Preparing the Machine for Cleaning ……………………………………………..124
130. Cleaning the Machine …………………………………………………………………125
131. Checking for Damage ……………………………………………………………………..127
132. Check the Machine Body and Structure ………………………………………..127
133. Check the Tyres ………………………………………………………………………..127
134. Check the Seat and Seat Belt ……………………………………………………..127
135. Check the Hydraulic Hoses and Fittings ……………………………………….127
136. Check the Electrical Circuits ………………………………………………………..127
137. Checking the ROPS-FOPS Structure ……………………………………………128
138. Greasing ……………………………………………………………………………………….129
139. Introduction ……………………………………………………………………………….129
140. Preparing the Machine for Greasing …………………………………………….129
141. Every 50 Hours ………………………………………………………………………….130
142. Every 500 Hours ………………………………………………………………………..131
143. Every 1000 Hours ………………………………………………………………………132
144. Oiling ……………………………………………………………………………………………133
145. Access Panels ……………………………………………………………………………….134
146. Engine Cover …………………………………………………………………………….134
147. Battery Cover ……………………………………………………………………………134
148. Rear Grille ………………………………………………………………………………..134
149. Undershields …………………………………………………………………………….135
150. Seat Base …………………………………………………………………………………136
151. Cab Heater Filter ……………………………………………………………………………137
152. Cleaning the Cab Heater Filter …………………………………………………….137
153. Brakes ………………………………………………………………………………………….138
154. Park Brake ………………………………………………………………………………..138
155. Foot Brake ………………………………………………………………………………..140
156. Electrical System ……………………………………………………………………………141
157. Battery ……………………………………………………………………………………..141
158. Jump Starting the Engine ……………………………………………………………143
159. Fuses ……………………………………………………………………………………….144
160. Primary Fuses …………………………………………………………………………..145
161. Relays ……………………………………………………………………………………..146
162. Engine ………………………………………………………………………………………….147
163. Oil and Filter ……………………………………………………………………………..147
164. Cooling System …………………………………………………………………………150
165. Alternator Drive Belt …………………………………………………………………..152
166. Air Filter ……………………………………………………………………………………153
167. Fuel System …………………………………………………………………………………..155
168. Introduction ……………………………………………………………………………….155
169. Cleaning the Lift Pump Gauze …………………………………………………….156
170. Fuel Filter …………………………………………………………………………………157
171. Bleeding the System ………………………………………………………………….159
172. Hydraulic System ……………………………………………………………………………160
173. Introduction ……………………………………………………………………………….160
174. Releasing the Hydraulic Pressure ………………………………………………..161
175. Oil and Filter ……………………………………………………………………………..162
176. Changing the Hydraulic Tank Filler Cap ………………………………………..164
177. Hose Burst Protection Valves ………………………………………………………165
178. Transmission …………………………………………………………………………………167
179. Gearbox ……………………………………………………………………………………167
180. Axles ………………………………………………………………………………………..168
181. Tyres and Wheels …………………………………………………………………………..170
182. Tyre Inflation ……………………………………………………………………………..170
183. Wheel Alignment ……………………………………………………………………………172
184. Introduction ……………………………………………………………………………….172
185. Procedure …………………………………………………………………………………172
186. Wear Pads …………………………………………………………………………………….173
187. Boom Wear Pad Clearance …………………………………………………………173
188. Windscreen Washer ……………………………………………………………………….174
189. Checking the Level …………………………………………………………………….174
190. Fire Extinguisher (if fitted) ………………………………………………………………..175
191. Checking the Fire Extinguisher ……………………………………………………175
192. Optional Attachments
193. Introduction ……………………………………………………………………………………177
194. Attachments for your Machine ………………………………………………………….178
195. Connecting-Disconnecting Hydraulic Hoses ……………………………………….179
196. Introduction ……………………………………………………………………………….179
197. Connecting the Hydraulic Hoses ………………………………………………….179
198. Disconnecting the Hydraulic Hoses ………………………………………………180
199. Quick Release Couplings ……………………………………………………………181
200. Q-Fit Attachments …………………………………………………………………………..183
201. Compact Tool Carrier …………………………………………………………………183
202. Skid Steer Hitch …………………………………………………………………………187
203. Fork Mounted Hook ………………………………………………………………………..189
204. Safety ………………………………………………………………………………………189
205. Installing …………………………………………………………………………………..189
206. Removing …………………………………………………………………………………189
207. Operation ………………………………………………………………………………….190
208. Maintenance ……………………………………………………………………………..190
209. 6-in-1 Shovel …………………………………………………………………………………191
210. Safety ………………………………………………………………………………………191
211. Preparing for Travel ……………………………………………………………………191
212. Control ……………………………………………………………………………………..191
213. Operation ………………………………………………………………………………….191
214. Daily Maintenance ……………………………………………………………………..193
215. Manure-Silage Fork with Top Grab ……………………………………………………194
216. Safety ………………………………………………………………………………………194
217. Control ……………………………………………………………………………………..194
218. Preparing for Travel ……………………………………………………………………194
219. Installing and Removing ……………………………………………………………..194
220. Operation ………………………………………………………………………………….194
221. Daily Maintenance ……………………………………………………………………..194
222. Pallet Forks ……………………………………………………………………………………195
223. Safety ………………………………………………………………………………………195
224. Changing-Repositioning the Forks ……………………………………………….195
225. Road Travel ………………………………………………………………………………196
226. Daily Maintenance ……………………………………………………………………..196
227. Work Platforms ………………………………………………………………………………197
228. Specifications
229. Static Dimensions …………………………………………………………………………..199
230. Performance Dimensions ………………………………………………………………..200
231. Lift Performance ………………………………………………………………………..200
232. Loader Performance …………………………………………………………………..201
233. Noise Data …………………………………………………………………………………….202
234. Introduction ……………………………………………………………………………….202
235. Noise Technical Information ………………………………………………………..202
236. Vibration Data ………………………………………………………………………………..203
237. Introduction ……………………………………………………………………………….203
238. 520-40 ……………………………………………………………………………………..204
239. Vibration Technical Information ……………………………………………………204
240. Tyre Sizes and Pressures ………………………………………………………………..205
241. Introduction ……………………………………………………………………………….205
242. Specifications ……………………………………………………………………………205
243. Trailer Towing ………………………………………………………………………………..206
244. Towing Limitations ……………………………………………………………………..206
245. Warranty Information
246. Machine Service Record Sheet ………………………………………………………..207
247. European Community Standards
248. EC Declaration of Conformity …………………………………………………………..209
249. Introduction ……………………………………………………………………………….209
250. Explanation of the EC Declaration of Conformity …………………………… 211

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