JCB Side Engine Tier 3 Loadalls Operator Manual 9821-0300

JCB Side Engine Tier 3 Loadalls Operator Manual 9821-0300 - Image 2

JCB Side Engine Tier 3 Loadalls Operator Manual 9821-0300 - Image 3

JCB Side Engine Tier 3 Loadalls Operator Manual 9821-0300 - Image 4

JCB Side Engine Tier 3 Loadalls Operator Manual 9821-0300 - Image 5

jcb side engine tier 3 loadalls operator manual 9821 0300 2

jcb side engine tier 3 loadalls operator manual 9821 0300 3

JCB Side Engine Tier 3 Loadalls Operator Manual 9821-0300

$20.00

Type Of Manual: Operator Manual
ManualID: 9821-0300
Number of Pages: 392
Size: 37.6MB
Format: PDF

Category: JCB Operator Manual PDF

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 …..

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