JCB Side Engine Tier 2, Tier 3 Loadalls Operator Manual 9831-6800-3

JCB Side Engine Tier 2, Tier 3 Loadalls Operator Manual 9831-6800-3 - Image 2

JCB Side Engine Tier 2, Tier 3 Loadalls Operator Manual 9831-6800-3 - Image 3

JCB Side Engine Tier 2, Tier 3 Loadalls Operator Manual 9831-6800-3 - Image 4

JCB Side Engine Tier 2, Tier 3 Loadalls Operator Manual 9831-6800-3 - Image 5

jcb side engine tier 2 tier 3 loadalls operator manual 9831 6800 3 2

jcb side engine tier 2 tier 3 loadalls operator manual 9831 6800 3 3

JCB Side Engine Tier 2, Tier 3 Loadalls Operator Manual 9831-6800-3

$20.00

Type Of Manual: Operator Manual
ManualID: 9831-6800-3
Number of Pages: 418
Size: 66.6MB
Format: PDF

Category: JCB Operator Manual PDF

Model List:
- Side Engine Tier 2, Tier 3 Loadalls

1. Safety Notices
2. Important Information …………………………………………………………………………1
3. The Operator Manual …………………………………………………………………….1
4. Safety Warnings ……………………………………………………………………………1
5. Introduction
6. About This Manual ……………………………………………………………………………..3
7. Machine Model and Serial Number ………………………………………………….3
8. Using this Manual ………………………………………………………………………….3
9. Left Side, Right Side ………………………………………………………………………3
10. Cab-Canopy …………………………………………………………………………………3
11. Cross References ………………………………………………………………………….3
12. Machine Description …………………………………………………………………………..4
13. The JCB Loadall ……………………………………………………………………………4
14. Intended Use ………………………………………………………………………………..4
15. Component Location ……………………………………………………………………..4
16. Safety Check List ……………………………………………………………………………….6
17. Safety – Yours and Others ………………………………………………………………6
18. General Safety ……………………………………………………………………………..6
19. Operating Safety …………………………………………………………………………..8
20. Maintenance Safety ……………………………………………………………………..12
21. Safety Labels …………………………………………………………………………………..17
22. Introduction …………………………………………………………………………………17
23. Safety Label Identification …………………………………………………………….18
24. Identifying Your Machine …………………………………………………………………..21
25. Machine Identification Plate ………………………………………………………….21
26. Component Identification Plates …………………………………………………….23
27. Machine Security ……………………………………………………………………………..28
28. Introduction …………………………………………………………………………………28
29. JCB Plantguard …………………………………………………………………………..28
30. Construction Equipment Security And Registration Scheme (CESAR) .28
31. Operation
32. Introduction ……………………………………………………………………………………..29
33. Before Entering the Cab ……………………………………………………………………30
34. Entering and Leaving the Cab ……………………………………………………………31
35. Emergency Exit …………………………………………………………………………..32
36. Doors and Windows …………………………………………………………………………34
37. Opening and Closing the Door ………………………………………………………34
38. Opening and Closing the Upper Door Section …………………………………34
39. Opening and Closing the Rear Window ………………………………………….35
40. Visibility Aids ……………………………………………………………………………………36
41. Mirrors and Adjustment ………………………………………………………………..36
42. Seat Controls …………………………………………………………………………………..40
43. Introduction …………………………………………………………………………………40
44. Operator Present Switch ………………………………………………………………40
45. Seat Options ……………………………………………………………………………….40
46. Suspension Seat (KAB 100 Series – Mechanical) …………………………….41
47. Suspension Seat (KAB 100 Series – Air) …………………………………………42
48. Suspension Seat (KAB 800 Series – Air) …………………………………………43
49. Suspension Seat (Grammer – Air) ………………………………………………….44
50. Seat Belt …………………………………………………………………………………………46
51. Inertia Reel Seat Belt …………………………………………………………………..46
52. Static Seat Belt ……………………………………………………………………………47
53. Cab Layout ……………………………………………………………………………………..48
54. Operating Levers …………………………………………………………………………49
55. Component Key …………………………………………………………………………..50
56. Drive Controls, Switches and Instruments ……………………………………………51
57. Drive Controls ……………………………………………………………………………..51
58. Switches …………………………………………………………………………………….58
59. Instrument Panel (SD and SF Engine) ……………………………………………66
60. Instrument Panel (SE Engine) ……………………………………………………….72
61. Torque Lock (6-Speed Transmission) ……………………………………………..84
62. Air Conditioning and Cab Heater Controls ………………………………………85
63. Operating Levers ……………………………………………………………………………..86
64. Introduction …………………………………………………………………………………86
65. Control Layouts …………………………………………………………………………..86
66. Boom and Carriage Controls …………………………………………………………87
67. Auxiliary Controls ………………………………………………………………………..93
68. Chassis Levelling (Sway) Option ……………………………………………………98
69. Stabiliser Control Option ……………………………………………………………..100
70. Safety Equipment …………………………………………………………………………..102
71. Control Locks ……………………………………………………………………………102
72. Load Charts ………………………………………………………………………………106
73. Boom Indicators ………………………………………………………………………..108
74. Longitudinal Load Moment Indicator (LLMI) …………………………………..109
75. Longitudinal Load Moment Control (LLMC) System ………………………. 113
76. LC4 Load Control System ………………………………………………………….. 117
77. Inclinometer ………………………………………………………………………………125
78. Beacon …………………………………………………………………………………….125
79. Fire Extinguisher (if fitted) …………………………………………………………..126
80. Before Starting the Engine ……………………………………………………………….127
81. Starting the Engine …………………………………………………………………………129
82. Immobiliser (if fitted) …………………………………………………………………..131
83. Preparing the Machine for Travel ……………………………………………………..134
84. Introduction ……………………………………………………………………………….134
85. Preparing for Road Travel …………………………………………………………..134
86. Preparing for Site Travel ……………………………………………………………..136
87. Smooth Ride System (SRS) ………………………………………………………..138
88. Getting the Machine Moving …………………………………………………………….139
89. Operating Practices ……………………………………………………………………139
90. Operating Procedure ………………………………………………………………….140
91. Stopping and Parking the Machine ……………………………………………………142
92. Working with the Machine ……………………………………………………………….143
93. Operating Practices and Site Safety …………………………………………….143
94. Clothing and Safety Equipment ……………………………………………………143
95. Danger Zone …………………………………………………………………………….143
96. Safety Practices ………………………………………………………………………..143
97. Working with the Boom ………………………………………………………………145
98. Use of Machines on Gradients or Slopes ………………………………………154
99. Interlock System ………………………………………………………………………..157
100. Operating Environment ……………………………………………………………………159
101. Operating in Low Temperatures …………………………………………………..159
102. Operating in High Temperatures ………………………………………………….159
103. Tow Hitch Options …………………………………………………………………………..160
104. Introduction ……………………………………………………………………………….160
105. Connecting the Trailer ………………………………………………………………..161
106. Preparing the Trailer for Towing …………………………………………………..168
107. Refuelling the Machine ……………………………………………………………………172
108. Low Fuel Levels ………………………………………………………………………..172
109. Filling the Tank ………………………………………………………………………….172
110. Moving a Disabled Machine …………………………………………………………….174
111. Recovery Hitch ………………………………………………………………………….174
112. Transporting the Machine ………………………………………………………………..175
113. Lifting a Machine ……………………………………………………………………………176
114. Storage of the Machine …………………………………………………………………..178
115. Introduction ……………………………………………………………………………….178
116. Storage Area …………………………………………………………………………….178
117. Prepare the Machine for Storage …………………………………………………178
118. Put the Machine into Storage ………………………………………………………178
119. During Storage ………………………………………………………………………….178
120. Take the Machine Out of Storage …………………………………………………179
121. Routine Maintenance
122. Service Requirements …………………………………………………………………….181
123. Introduction ……………………………………………………………………………….181
124. Owner-Operator Support …………………………………………………………….181
125. Service-Maintenance Agreements ……………………………………………….181
126. Initial Service and Inspection ……………………………………………………….181
127. Fit for Purpose Tests for Lifting Equipment …………………………………….182
128. Obtaining Replacement Parts ………………………………………………………182
129. Health and Safety …………………………………………………………………………..183
130. Lubricants …………………………………………………………………………………183
131. Battery ……………………………………………………………………………………..185
132. Service Schedules ………………………………………………………………………….187
133. Introduction ……………………………………………………………………………….187
134. How to Use the Service Schedules ………………………………………………187
135. Calendar Equivalents …………………………………………………………………187
136. Pre-start Cold Checks, Service Points and Fluid Levels ………………….188
137. Functional Test and Final Inspection …………………………………………….192
138. Fluids, Lubricants and Capacities ……………………………………………………..195
139. Coolant Mixtures ……………………………………………………………………….197
140. Fuels ………………………………………………………………………………………..198
141. Prepare the Machine for Maintenance ………………………………………………201
142. Introduction ……………………………………………………………………………….201
143. How to Make the Machine Safe (Boom Lowered) …………………………..201
144. How to Make the Machine Safe (Boom Lifted) ……………………………….202
145. Cleaning the Machine ……………………………………………………………………..206
146. Introduction ……………………………………………………………………………….206
147. Preparing the Machine for Cleaning ……………………………………………..206
148. Cleaning the Machine …………………………………………………………………207
149. Fan Reverse (if fitted) …………………………………………………………………209
150. Checking for Damage ……………………………………………………………………..210
151. Check the Machine Body and Structure ………………………………………..210
152. Check the Tyres ………………………………………………………………………..210
153. Check the Seat and Seat Belt ……………………………………………………..210
154. Check the Hydraulic Hoses and Fittings ……………………………………….210
155. Check the Electrical Circuits ……………………………………………………….. 211
156. Checking the ROPS-FOPS Structure ……………………………………………212
157. Greasing ……………………………………………………………………………………….213
158. Introduction ……………………………………………………………………………….213
159. Preparing the Machine for Greasing …………………………………………….213
160. Every 50 Hours ………………………………………………………………………….214
161. Every 500 Hours ………………………………………………………………………..223
162. Every 1000 Hours ………………………………………………………………………226
163. Oiling ……………………………………………………………………………………………227
164. Boom Chains …………………………………………………………………………….228
165. Access Panels ……………………………………………………………………………….229
166. Introduction ……………………………………………………………………………….229
167. Battery Cover ……………………………………………………………………………229
168. Engine Cover …………………………………………………………………………….230
169. Rear Cover (if fitted) …………………………………………………………………..231
170. Undershield ………………………………………………………………………………232
171. Cab Heater and Air Conditioning ………………………………………………………233
172. Changing the Air Intake Filter ………………………………………………………233
173. Boom ……………………………………………………………………………………………234
174. Re-phasing of 3-Stage Booms …………………………………………………….234
175. Boom Chains …………………………………………………………………………….234
176. Brakes ………………………………………………………………………………………….238
177. Park Brake ………………………………………………………………………………..238
178. Foot Brake (Excluding 550-80 Machines) ……………………………………..240
179. Footbrake (550-80 Machines) ……………………………………………………..240
180. Electrical System ……………………………………………………………………………241
181. Battery ……………………………………………………………………………………..241
182. Jump Starting the Engine ……………………………………………………………244
183. Fuses ……………………………………………………………………………………….245
184. Primary Fuses …………………………………………………………………………..275
185. Relays ……………………………………………………………………………………..276
186. Engine ………………………………………………………………………………………….300
187. Oil and Filter ……………………………………………………………………………..300
188. Cooling System …………………………………………………………………………302
189. Crankcase Ventilation (if fitted) …………………………………………………….304
190. Front End Accessory Drive Belt …………………………………………………..305
191. Air Filter ……………………………………………………………………………………307
192. Fuel System …………………………………………………………………………………..309
193. Introduction ……………………………………………………………………………….309
194. Water Separator and Engine Fuel Filter ………………………………………..309
195. Bleeding the System ………………………………………………………………….315
196. Hydraulic System ……………………………………………………………………………317
197. Introduction ……………………………………………………………………………….317
198. Releasing the Hydraulic Pressure ………………………………………………..318
199. Oil and FIlters ……………………………………………………………………………319
200. Hose Burst Protection Valves ………………………………………………………325
201. Transmission …………………………………………………………………………………327
202. Gearbox ……………………………………………………………………………………327
203. Front and Rear Axle …………………………………………………………………..330
204. Tyres and Wheels …………………………………………………………………………..334
205. Tyre Inflation ……………………………………………………………………………..334
206. Wheel Nuts ……………………………………………………………………………….335
207. Wheel Alignment ……………………………………………………………………………336
208. Introduction ……………………………………………………………………………….336
209. Manual Steer Mode Selector ……………………………………………………….336
210. Electronic Steer Mode Selector ……………………………………………………337
211. Wear Pads …………………………………………………………………………………….338
212. Boom Wear Pad Clearance …………………………………………………………338
213. Windscreen Washer ……………………………………………………………………….342
214. Checking the Level …………………………………………………………………….342
215. Fire Extinguisher (if fitted) ………………………………………………………………..343
216. Checking the Fire Extinguisher ……………………………………………………343
217. Optional Attachments
218. Introduction ……………………………………………………………………………………345
219. Attachments for your Machine ………………………………………………………….346
220. Connecting-Disconnecting Hydraulic Hoses ……………………………………….347
221. Introduction ……………………………………………………………………………….347
222. Connecting the Hydraulic Hoses ………………………………………………….347
223. Disconnecting the Hydraulic Hoses ………………………………………………348
224. Quick Release Couplings ……………………………………………………………349
225. Q-Fit Attachments …………………………………………………………………………..351
226. Mechanical Pin Locking Option ……………………………………………………351
227. Hydraulic Pin Locking Option ………………………………………………………353
228. Extension Jib …………………………………………………………………………………355
229. Safety ………………………………………………………………………………………355
230. Installing-Removing ……………………………………………………………………355
231. Operation ………………………………………………………………………………….355
232. Maintenance ……………………………………………………………………………..356
233. Fork Mounted Hook ………………………………………………………………………..357
234. Safety ………………………………………………………………………………………357
235. Installing …………………………………………………………………………………..357
236. Removing …………………………………………………………………………………357
237. Operation ………………………………………………………………………………….358
238. Maintenance ……………………………………………………………………………..358
239. Sideshift Carriage …………………………………………………………………………..359
240. Operation ………………………………………………………………………………….359
241. Installing the Sideshift Carriage ……………………………………………………360
242. Removing the Sideshift Carriage ………………………………………………….361
243. Maintenance ……………………………………………………………………………..362
244. Roof Truss Jib ……………………………………………………………………………….363
245. Safety ………………………………………………………………………………………363
246. Installing-Removing ……………………………………………………………………363
247. Operation ………………………………………………………………………………….363
248. Extending the Jib ……………………………………………………………………….364
249. Changing the Jib Angle ………………………………………………………………365
250. Maintenance ……………………………………………………………………………..365
251. Work Platforms ………………………………………………………………………………366
252. Specifications
253. Static Dimensions …………………………………………………………………………..367
254. 531-70, 541-70 ………………………………………………………………………….367
255. 533-105 ……………………………………………………………………………………368
256. 535-95 ……………………………………………………………………………………..370
257. 536-60 ……………………………………………………………………………………..372
258. 536-70 ……………………………………………………………………………………..374
259. 535-125 HiViz, 535-140 HiViz ……………………………………………………..375
260. 540-140 ……………………………………………………………………………………377
261. 540-170 ……………………………………………………………………………………379
262. 540-200 ……………………………………………………………………………………381
263. 550-80 ……………………………………………………………………………………..383
264. Performance Dimensions ………………………………………………………………..384
265. Lift Performance ………………………………………………………………………..384
266. Maximum Wading Depth …………………………………………………………….385
267. Axle Weight Distribution ………………………………………………………………….386
268. Machines Without Stabilisers ………………………………………………………386
269. Machines With Stabilisers …………………………………………………………..387
270. Noise Data …………………………………………………………………………………….388
271. Introduction ……………………………………………………………………………….388
272. 531-70, 533-105, 535-95, 536-60, 536-70, 541-70 …………………………388
273. 535-125 HiViz, 535-140 HiViz, 540-140 HiViz ………………………………..388
274. 540-140, 540-170, 540-200 …………………………………………………………388
275. 550-80 ……………………………………………………………………………………..388
276. Vibration Data ………………………………………………………………………………..389
277. Introduction ……………………………………………………………………………….389
278. 531-70, 533-105, 535-95, 536-60, 536-70, 541-70 …………………………390
279. 540-140 ……………………………………………………………………………………391
280. 535-125 HiViz, 535-140 HiViz, 540-140 HiViz ………………………………..392
281. 540-170, 540-200 ………………………………………………………………………393
282. 550-80 ……………………………………………………………………………………..394
283. Tyre Sizes and Pressures ………………………………………………………………..395
284. Introduction ……………………………………………………………………………….395
285. Specifica

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