JCB 4160, 4190, 4220 Operator Manual 9831-3950

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JCB 4160, 4190, 4220 Operator Manual 9831-3950

$20.00

Type Of Manual: Operator Manual
ManualID: 9831-3950
Number of Pages: 322
Size: 40.3MB
Format: PDF

Category: JCB Operator Manual PDF

Model List:
- 4160, 4190, 4220

1. Acronyms Glossary ………………………………………………………………………………………………………………………. vii
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. Location of Manual ………………………………………………………………………………………………………………. 2
9. Safety
10. Safety – Yours and Others …………………………………………………………………………………………………….. 3
11. Safety Warnings …………………………………………………………………………………………………………………… 3
12. General Safety …………………………………………………………………………………………………………………….. 4
13. Clothing and Personal Protective Equipment (PPE) …………………………………………………………………. 4
14. About the Product
15. Introduction
16. General ……………………………………………………………………………………………………………………………….. 5
17. Name and Address of the Manufacturer …………………………………………………………………………………. 5
18. Product Compliance ……………………………………………………………………………………………………………… 5
19. Description
20. General ……………………………………………………………………………………………………………………………….. 6
21. Intended Use ……………………………………………………………………………………………………………………….. 6
22. Danger Zone ……………………………………………………………………………………………………………………….. 6
23. Main Component Locations …………………………………………………………………………………………………… 7
24. Product and Component Identification
25. Machine ………………………………………………………………………………………………………………………………. 9
26. Engine ………………………………………………………………………………………………………………………………. 10
27. Axle ………………………………………………………………………………………………………………………………….. 10
28. Gearbox …………………………………………………………………………………………………………………………….. 11
29. Operator Protective Structure ………………………………………………………………………………………………. 11
30. Safety Labels
31. General ……………………………………………………………………………………………………………………………… 13
32. Safety Label Identification ……………………………………………………………………………………………………. 13
33. Operator Station
34. Component Locations …………………………………………………………………………………………………………. 15
35. Interior Switches
36. Ignition Switch ……………………………………………………………………………………………………………………. 17
37. Multi-Purpose Switch ………………………………………………………………………………………………………….. 17
38. Cab Interior Light-Step Light ………………………………………………………………………………………………… 18
39. Console Switches
40. General ……………………………………………………………………………………………………………………………… 20
41. Hazard Warning Lights ……………………………………………………………………………………………………….. 21
42. Operation
43. Introduction
44. General ……………………………………………………………………………………………………………………………… 23
45. Operating Safety
46. General ……………………………………………………………………………………………………………………………… 24
47. Risk Assessment ……………………………………………………………………………………………………………….. 26
48. Walk-Around Inspection
49. General ……………………………………………………………………………………………………………………………… 28
50. Entering and Leaving the Operator Station
51. General ……………………………………………………………………………………………………………………………… 30
52. Emergency Exit ………………………………………………………………………………………………………………….. 30
53. Doors
54. Operator Door ……………………………………………………………………………………………………………………. 32
55. Windows
56. Rear Window …………………………………………………………………………………………………………………….. 33
57. Battery Isolator
58. General ……………………………………………………………………………………………………………………………… 35
59. Before Starting the Engine
60. General ……………………………………………………………………………………………………………………………… 36
61. Operator Seat
62. General ……………………………………………………………………………………………………………………………… 37
63. Passenger Seat
64. General ……………………………………………………………………………………………………………………………… 40
65. Seat Belt
66. Inertia Reel Seat Belt …………………………………………………………………………………………………………. 41
67. Mirrors
68. General ……………………………………………………………………………………………………………………………… 43
69. Starting the Engine
70. General ……………………………………………………………………………………………………………………………… 44
71. Stopping and Parking
72. General ……………………………………………………………………………………………………………………………… 47
73. Preparing for Travel
74. Preparing for Road Travel …………………………………………………………………………………………………… 49
75. Drive Controls
76. Steering Wheel ………………………………………………………………………………………………………………….. 50
77. Steering Column ………………………………………………………………………………………………………………… 50
78. Instruments
79. General ……………………………………………………………………………………………………………………………… 51
80. Instrument Panel ………………………………………………………………………………………………………………… 85
81. Getting the Machine Moving
82. General ……………………………………………………………………………………………………………………………… 92
83. Slopes
84. General ……………………………………………………………………………………………………………………………. 109
85. Driving on Slopes …………………………………………………………………………………………………………….. 109
86. Three Point Linkage
87. Front Three Point Linkage …………………………………………………………………………………………………. 110
88. Rear Three Point Linkage …………………………………………………………………………………………………. 113
89. Auxiliary Hydraulics
90. General ……………………………………………………………………………………………………………………………. 120
91. Auxiliary Electrics
92. General ……………………………………………………………………………………………………………………………. 127
93. Trailer Hitches
94. General ……………………………………………………………………………………………………………………………. 130
95. Ladder Hitch …………………………………………………………………………………………………………………….. 132
96. Pick-up Hitch (PUH) …………………………………………………………………………………………………………. 138
97. Swing Drawbar …………………………………………………………………………………………………………………. 141
98. 110mm Ball ……………………………………………………………………………………………………………………… 143
99. Trailer Brakes
100. General ……………………………………………………………………………………………………………………………. 145
101. Power Take-Off (PTO)
102. Power Take-Off (Front) ……………………………………………………………………………………………………… 147
103. Power Take-Off (Rear) ………………………………………………………………………………………………………. 149
104. Heating, Ventilating and Air-Conditioning (HVAC)
105. General ……………………………………………………………………………………………………………………………. 155
106. Air-Conditioning Controls …………………………………………………………………………………………………… 155
107. Power Sockets
108. Auxiliary Power Socket ……………………………………………………………………………………………………… 158
109. Moving a Disabled Machine
110. General ……………………………………………………………………………………………………………………………. 159
111. Jump-Starting the Engine ………………………………………………………………………………………………….. 159
112. Retrieval ………………………………………………………………………………………………………………………….. 160
113. Recovery Hitch …………………………………………………………………………………………………………………. 161
114. Transporting the Machine
115. General ……………………………………………………………………………………………………………………………. 164
116. Operating Environment
117. Operating in Low Temperatures …………………………………………………………………………………………. 165
118. Operating in High Temperatures …………………………………………………………………………………………. 165
119. Refuelling
120. General ……………………………………………………………………………………………………………………………. 166
121. Low Fuel Levels ……………………………………………………………………………………………………………….. 166
122. Filling the Tank …………………………………………………………………………………………………………………. 166
123. Attachments
124. Implement Mounting Frame
125. General ……………………………………………………………………………………………………………………………. 171
126. DIN Plate
127. General ……………………………………………………………………………………………………………………………. 175
128. Front Loader Attachment
129. General ……………………………………………………………………………………………………………………………. 177
130. Ballast
131. General ……………………………………………………………………………………………………………………………. 178
132. Global Positioning System (GPS)
133. General ……………………………………………………………………………………………………………………………. 180
134. Preservation and Storage
135. Cleaning
136. General ……………………………………………………………………………………………………………………………. 185
137. Preparation ………………………………………………………………………………………………………………………. 185
138. Checking For Damage
139. General ……………………………………………………………………………………………………………………………. 187
140. Storage
141. General ……………………………………………………………………………………………………………………………. 188
142. Put into Storage ……………………………………………………………………………………………………………….. 188
143. During Storage …………………………………………………………………………………………………………………. 188
144. Take out of Storage ………………………………………………………………………………………………………….. 189
145. Security
146. General ……………………………………………………………………………………………………………………………. 190
147. LiveLink …………………………………………………………………………………………………………………………… 190
148. Maintenance
149. Introduction
150. General ……………………………………………………………………………………………………………………………. 191
151. Owner-Operator Support ……………………………………………………………………………………………………. 191
152. Service-Maintenance Agreements ………………………………………………………………………………………. 191
153. Obtaining Spare Parts ………………………………………………………………………………………………………. 192
154. Maintenance Safety
155. General ……………………………………………………………………………………………………………………………. 193
156. Fluids and Lubricants ……………………………………………………………………………………………………….. 194
157. Maintenance Schedules
158. General ……………………………………………………………………………………………………………………………. 198
159. How to Use the Maintenance Schedules …………………………………………………………………………….. 198
160. Maintenance Intervals ……………………………………………………………………………………………………….. 198
161. Pre-start Cold Checks, Service Points and Fluid Levels ………………………………………………………… 198
162. Functional Tests and Final Inspection …………………………………………………………………………………. 201
163. Maintenance Positions
164. General ……………………………………………………………………………………………………………………………. 203
165. Service Points
166. General ……………………………………………………………………………………………………………………………. 205
167. Access Apertures
168. General ……………………………………………………………………………………………………………………………. 206
169. Battery Cover …………………………………………………………………………………………………………………… 206
170. Engine Compartment Cover ………………………………………………………………………………………………. 207
171. Lubrication
172. General ……………………………………………………………………………………………………………………………. 209
173. Body and Framework
174. General …………………………………………………………………………………………………………………………… 218
175. Operator Station
176. Operator Protective Structure …………………………………………………………………………………………….. 219
177. Seat ………………………………………………………………………………………………………………………………… 219
178. Seat Belt …………………………………………………………………………………………………………………………. 220
179. Heating, Ventilating and Air-Conditioning (HVAC)
180. Recirculation Filter ……………………………………………………………………………………………………………. 221
181. Fresh Air Filter …………………………………………………………………………………………………………………. 221
182. Engine
183. Oil …………………………………………………………………………………………………………………………………… 223
184. Drive Belt ………………………………………………………………………………………………………………………… 225
185. Air Filter
186. Outer Element …………………………………………………………………………………………………………………. 228
187. Fuel System
188. General …………………………………………………………………………………………………………………………… 230
189. Pre-Filter Element …………………………………………………………………………………………………………….. 230
190. Cooling System
191. General …………………………………………………………………………………………………………………………… 232
192. Coolant ……………………………………………………………………………………………………………………………. 232
193. Cooling Pack …………………………………………………………………………………………………………………… 233
194. Brakes
195. General …………………………………………………………………………………………………………………………… 236
196. Park Brake ………………………………………………………………………………………………………………………. 240
197. Gearbox
198. Oil …………………………………………………………………………………………………………………………………… 241
199. Steering System
200. General …………………………………………………………………………………………………………………………… 242
201. Wheels
202. General …………………………………………………………………………………………………………………………… 247
203. Tyres
204. General …………………………………………………………………………………………………………………………… 248
205. Trailer Hitches
206. General ……………………………………………………………………………………………………………………………. 250
207. Power Take-Off (PTO)
208. Oil …………………………………………………………………………………………………………………………………… 257
209. Hydraulic System
210. General …………………………………………………………………………………………………………………………… 258
211. Services ………………………………………………………………………………………………………………………….. 258
212. Oil …………………………………………………………………………………………………………………………………… 259
213. Coupling ………………………………………………………………………………………………………………………….. 260
214. Auxiliary Hydraulic Circuit ………………………………………………………………………………………………….. 261
215. Electrical System
216. General …………………………………………………………………………………………………………………………… 263
217. Battery …………………………………………………………………………………………………………………………….. 263
218. Battery Isolator ………………………………………………………………………………………………………………… 265
219. Fuses ……………………………………………………………………………………………………………………………… 266
220. Relays …………………………………………………………………………………………………………………………….. 267
221. Window Washer ……………………………………………………………………………………………………………….. 267
222. Technical Data
223. Static Dimensions
224. Dimensions ………………………………………………………………………………………………………………………. 269
225. Weights …………………………………………………………………………………………………………………………… 270
226. Performance Dimensions
227. General ……………………………………………………………………………………………………………………………. 272
228. Noise Emissions
229. General ……………………………………………………………………………………………………………………………. 274
230. Noise Data ………………………………………………………………………………………………………………………. 275
231. Vibration Emissions
232. General ……………………………………………………………………………………………………………………………. 276
233. Vibration Data ………………………………………………………………………………………………………………….. 277
234. Fluids, Lubricants and Capacities
235. General ……………………………………………………………………………………………………………………………. 278
236. Fuel ………………………………………………………………………………………………………………………………… 279
237. Diesel Exhaust Fluid (DEF) ……………………………………………………………………………………………….. 279
238. Coolant ……………………………………………………………………………………………………………………………. 280
239. Torque Values
240. General ……………………………………………………………………………………………………………………………. 281
241. Electrical System
242. General ……………………………………………………………………………………………………………………………. 282
243. Bulbs ………………………………………………………………………………………………………………………………. 289
244. Fuses ………………………………………………………………………………………………………………………………. 290
245. Relays …………………………………………………………………………………………………………………………….. 293
246. Wheels and Tyres
247. General ……………………………………………………………………………………………………………………………. 295
248. Tyre Sizes and Pressures …………………………………………………………………………………………………. 296
249. Adjustable Wheel Rims ……………………………………………………………………………………………………… 299
250. Declaration of Conformity
251. General ……………………………………………………………………………………………………………………………. 301
252. Data ………………………………………………………………………………………………………………………………… 301
253. Warranty Information
254. Service Record Sheet ……………………………………………………………………………………………………….. 303
255. Acronyms Glossary
256. 2WD Two Wheel Drive
257. 2WS Two Wheel Steer
258. 4WD Four Wheel Drive
259. 4WS Four Wheel Steer
260. ABS Anti-lock Braking System
261. ATC Automatic Temperature Control
262. AWS All Wheel Steer
263. CAN Controller Area Network
264. CVT Continuously Variable Transmission
265. DECU Display Electronic Control Unit
266. DEF Diesel Exhaust Fluid
267. ECU Electronic Control Unit
268. FOPS Falling Object Protective Structure
269. GPS Global Positioning System
270. HVAC Heating Ventilation Air Conditioning
271. ISO International Organization for Standardization
272. LED Light Emitting Diode
273. PIN Product Identification Number
274. PPE Personal Protective Equipment
275. PTO Power Take-Off
276. ROPS Roll-Over Protective Structure
277. RPM Revolutions Per Minute
278. SCR Selective Catalytic Reduction
279. VIN Vehicle Identification Number
280. km-h kilometers per hour
281. mph miles per hour

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