jcb 516-40 TIER 3 User manual

OPERATOR’S MANUAL
This manual should always stay with the machine
9821/9750-2 09/2015
ENGLISH
LOADALL
516-40 AND
516-40 AGRI
TIER 3

THIS MANUAL SHOULD ALWAYS STAY WITH THE MACHINE
LOADALL - 516-40 AND 516-40 AGRI-TIER 3
Copyright © 2004 JCB SERVICE.
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or
by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
A4-5-Loadall - Printed In England
Dear JCB Customer
Even if you have operated this type of equipment before,
it is very important that your new machines operations and
functions are explained to you by a JCB Dealer
Representative following delivery of your new machine.
Following the installation you will know how to gain
maximum productivity and performance from your new
product.
Please contact your local JCB dealer if the Installation
Form has not yet been completed with you.
Your Local JCB Dealer is:
ENGLISH - 9821/9750 - ISSUE 2 - SEPTEMBER 2015
OPERATOR MANUAL
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0 0
9821/9750
Notes:
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Page No.Contents
i i
Safety Notices
Important Information ....................................................................................1
The Operator Manual ...............................................................................1
Safety Warnings .......................................................................................1
Introduction
About This Manual .........................................................................................3
Name and Address of Manufacturer ........................................................3
Product Compliance .................................................................................3
Machine Model and Serial Number ..........................................................3
Using this Manual .....................................................................................3
Left Side, Right Side .................................................................................4
Cab/Canopy .............................................................................................4
Cross References .....................................................................................4
Machine Description ......................................................................................5
The JCB 516-40 .......................................................................................5
Intended Use ............................................................................................5
Component Location ................................................................................5
Safety Check List ...........................................................................................6
Safety - Yours and Others ........................................................................6
General Safety .........................................................................................6
Operating Safety ......................................................................................8
Maintenance Safety ................................................................................12
Safety Labels ...............................................................................................17
Introduction .............................................................................................17
Safety Label Identification ......................................................................18
Part Numbers and Descriptions .............................................................18
Identifying Your Machine .............................................................................21
Machine Identification Plate ...................................................................21
Typical Product Identification Number .................................................21
Component Identification Plates .............................................................22
Typical Engine Identification Number ..................................................22
Emission Control Information ...............................................................22
ROPS Data Plate .................................................................................22
FOPS Data Plate .................................................................................24
Machine Security .........................................................................................25
Introduction .............................................................................................25
JCB Plantguard ......................................................................................25
Construction Equipment Security And Registration Scheme (CESAR) .25
Operation
Introduction ..................................................................................................27
Before Entering the Cab ..............................................................................28
Entering and Leaving the Cab .....................................................................29
Emergency Exit ......................................................................................30
Doors and Windows ....................................................................................31
Opening and Closing the Doors .............................................................31
Opening and Closing the Door Upper Section .......................................32
Door Catch ...........................................................................................32
Visibility Aids ................................................................................................33
Mirrors and Adjustment ..........................................................................33
Introduction ..........................................................................................33
Mirrors ..................................................................................................34
Visibility Diagrams ................................................................................35
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Contents
ii ii
Page No.Contents
Seat Controls ...............................................................................................39
Introduction .............................................................................................39
Operators Seat .......................................................................................39
Seat Belt ......................................................................................................40
Inertia Reel Seat Belt .............................................................................40
Fasten the Seat Belt ............................................................................40
Check the Seat Belt is Operating Correctly .........................................40
Release the Seat Belt ..........................................................................40
Cab Layouts ................................................................................................41
Three Lever Control ...............................................................................41
Component Key ...................................................................................41
Single Lever Control (Optional) ..............................................................42
Component Key ...................................................................................42
Drive Controls, Switches and Instrument Panel ..........................................43
Drive Controls - Manual Lever machines ...............................................43
Steering Wheel ....................................................................................43
Accelerator Pedal ................................................................................43
Brake/Inching Pedal .............................................................................43
Forward/Reverse Switch ......................................................................43
Park Brake Lever .................................................................................44
Park brake Warning .............................................................................44
Horn .....................................................................................................45
Drive Controls - Single Lever Machines (Optional) ................................46
Steering Wheel ....................................................................................46
Accelerator Pedal ................................................................................46
Brake/Inching Pedal .............................................................................46
Forward/Reverse Switch ......................................................................46
Park Brake Lever .................................................................................46
Varispeed Control (Option) ..................................................................47
Horn .....................................................................................................47
Switches .................................................................................................48
Console Panel Switches ......................................................................48
Column Switches .................................................................................51
Starter Switch .......................................................................................51
Cab Interior Light .................................................................................52
Roof-Mounted Wiper ............................................................................52
Instrument Panel ....................................................................................53
Digital LCD Fuel Gauge .......................................................................54
Indicator Lights ....................................................................................54
Blink Codes - Boom Extend - Retract ..................................................55
Blink Codes - Auxiliary Warning Light ..................................................55
Warning Lights .....................................................................................56
Heater Controls ......................................................................................58
Heater ..................................................................................................58
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Contents
iii iii
Page No.Contents
Operating Levers .........................................................................................59
Introduction .............................................................................................59
Boom and Carriage Controls - Manual Lever Machines (Option) ..........60
Introduction ..........................................................................................60
Raise Boom/Lower Boom ....................................................................60
Tilt Carriage Back/Forward (Crowd/Dump) ..........................................60
Extend Boom/Retract Boom ................................................................61
Boom and Carriage Controls - Single Lever Machines (Option) ............62
Overview ..............................................................................................62
Auxiliary Controls - Manual Lever Machines (If fitted) ............................63
Auxiliary Controls - Single Lever Machines ............................................63
Introduction ..........................................................................................63
Auxiliary (Constant Flow Mode) ...........................................................63
Safety Equipment ........................................................................................65
Load Charts ............................................................................................65
Introduction to Load Charts .................................................................65
Using the Load Charts .........................................................................65
Longitudinal Load Moment Indicator (LLMI) ...........................................67
Introduction ..........................................................................................67
Checking the Indicator .........................................................................68
Setting the Volume and Brightness ......................................................69
Diagnostic Fault Codes ........................................................................70
LLMI with Longitudinal Load Moment Control ........................................71
Introduction ..........................................................................................71
Load Control Mode ..............................................................................73
Emergency Override Function .............................................................74
Warm Up Procedure ............................................................................74
Daily Functional Check ........................................................................75
Inclinometer ............................................................................................76
Fire Extinguisher (if fitted) ......................................................................76
Operation .............................................................................................76
Beacon ...................................................................................................77
Before Starting the Engine ...........................................................................78
Starting the Engine ......................................................................................80
Preparing the Machine for Travel ................................................................82
Introduction .............................................................................................82
Preparing for Road Travel ......................................................................82
Preparing for Site Travel .........................................................................84
Getting the Machine Moving ........................................................................85
Operating Practices ................................................................................85
Operating Procedure ..............................................................................86
Stopping and Parking the Machine ..............................................................87
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Contents
iv iv
Page No.Contents
Working with the Machine ...........................................................................89
Operating Practices and Site Safety ......................................................89
Clothing and Safety Equipment ..............................................................89
Danger Zone ..........................................................................................89
Working with the Boom ..........................................................................90
Introduction ..........................................................................................90
Risk Assessment .................................................................................91
Lifting and Loading Operations ............................................................92
Fork Ratings ........................................................................................93
Handling Palleted Loads ......................................................................94
Handling Bales .....................................................................................95
Handling Uneven Loads ......................................................................96
Stacking Loads ....................................................................................97
Filling a Shovel ....................................................................................98
Loading a Truck ...................................................................................99
Use of Machines on Gradients or Slopes ...............................................99
Driving Up and Down Gradients ..........................................................99
Driving Across Gradients ...................................................................100
Lifting Operations on Gradients .........................................................101
Operating Environment ..............................................................................102
Operating in Low Temperatures ...........................................................102
Operating in High Temperatures ..........................................................102
Refuelling the Machine ..............................................................................103
Low Fuel Levels ...................................................................................103
Filling the Tank .....................................................................................103
Moving a Disabled Machine ......................................................................105
Transporting the Machine ..........................................................................106
Lifting the Machine ....................................................................................108
Introduction ...........................................................................................108
Preparing the Machine .........................................................................108
Lifting the Machine ...............................................................................109
Storage of the Machine ............................................................................. 110
Introduction ........................................................................................... 110
Storage Area ........................................................................................110
Prepare the Machine for Storage .........................................................110
Put the Machine into Storage ...............................................................110
During Storage .....................................................................................110
Take the Machine Out of Storage ......................................................... 111
Routine Maintenance
Service Requirements ...............................................................................113
Fit for Purpose Tests for Lifting Equipment ...........................................113
Obtaining Replacement Parts ...............................................................113
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Contents
v v
Page No.Contents
Health and Safety ...................................................................................... 114
Lubricants .............................................................................................114
Introduction ........................................................................................114
Hygiene ..............................................................................................114
Storage ..............................................................................................114
Waste Disposal ..................................................................................114
Handling ............................................................................................. 114
First Aid - Oil ...................................................................................... 115
Spillage ..............................................................................................115
Fires ...................................................................................................115
Battery ..................................................................................................116
Warning Symbols ............................................................................... 117
First Aid - Electrolyte ..........................................................................117
Service Schedules .....................................................................................118
Introduction ........................................................................................... 118
How to Use the Service Schedules ...................................................... 118
Calendar Equivalents ...........................................................................118
Pre-start Cold Checks, Service Points and Fluid Levels ......................119
Functional Test and Final Inspection ....................................................122
Fluids, Lubricants and Capacities ..............................................................124
Specifications .......................................................................................124
Fuels .....................................................................................................125
Acceptable and Unacceptable Fuels .................................................125
Fuels for Low Temperatures ..............................................................125
Biodiesel Fuel ....................................................................................125
Coolant Mixtures ..................................................................................127
Tools ..........................................................................................................128
Toolbox .................................................................................................128
Carrying Tools onto the Machine ..........................................................128
Prepare the Machine for Maintenance ......................................................129
Introduction ...........................................................................................129
How to Make the Machine Safe (Boom Lowered) ................................129
How to Make the Machine Safe (Boom Lifted) .....................................130
Installing the Maintenance Strut .........................................................130
Removing the Maintenance Strut .......................................................131
Using a Jack to Lift the Machine ..........................................................131
Cleaning the Machine ................................................................................134
Introduction ...........................................................................................134
Detergents .........................................................................................134
Pressure Washing and Steam Cleaning ............................................134
Preparing the Machine for Cleaning .....................................................135
Cleaning the Machine ...........................................................................135
Fan Reverse (if fitted) ...........................................................................138
Checking For Damage ...............................................................................139
Checking the ROPS/FOPS ..................................................................139
Greasing ....................................................................................................141
Preparing the Machine for Greasing ....................................................142
Greasing Sequence ..............................................................................142
Grease Points .......................................................................................143
Boom Pivot Grease Points .................................................................143
Front Steering Linkage Grease Points ...............................................144
Rear Steering Linkage Grease Points ...............................................144
Rear Axle Pivot Grease Point ............................................................145
Wear Pad Runways and Bonnet Hinge Points ..................................145
Extension Ram Pivot .........................................................................146
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Contents
vi vi
Page No.Contents
Oiling .........................................................................................................147
Access Panels ...........................................................................................148
Introduction ...........................................................................................148
Engine Cover ........................................................................................149
Maintenance Position ........................................................................149
Operation Position .............................................................................149
Engine Side Panel ................................................................................149
Maintenance Position ........................................................................149
Operation Position .............................................................................150
Rear Engine Guard ..............................................................................151
Maintenance Position ........................................................................151
Operation Position .............................................................................151
Underfloor Cover ..................................................................................152
Maintenance Position ........................................................................152
Operation Position .............................................................................152
Hydraulic Tank Cover ...........................................................................152
Maintenance Position ........................................................................152
Operation Position .............................................................................153
Operators Seat Base ............................................................................154
Maintenance Position ........................................................................154
Operation Position .............................................................................154
Rear Wheel Arch Panels ......................................................................155
Maintenance Position ........................................................................155
Operation Position .............................................................................155
Left Instrument Panel ...........................................................................155
Maintenance Position ........................................................................155
Operation Position .............................................................................155
Right Cab Panel ...................................................................................156
Maintenance Position ........................................................................156
Operation Position .............................................................................156
Air Conditioning (If Fitted) ..........................................................................157
Service Checks ....................................................................................157
Off-Season Operation ........................................................................157
Cab Heater Filter .......................................................................................158
Replacing the Cab Heater Filter ...........................................................158
Brakes .......................................................................................................159
Park Brake ............................................................................................159
Introduction ........................................................................................159
Testing the Park Brake .......................................................................159
Park Brake Adjustment up to sn 1769015 .........................................161
Park Brake Adjustment from sn 1769016 ..........................................162
Foot Brake ............................................................................................162
Checking the Foot Brake Fluid Level .................................................162
Checking the Brake Shoe Condition ..................................................164
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Contents
vii vii
Page No.Contents
Electrical System .......................................................................................165
Introduction ...........................................................................................165
Battery ..................................................................................................165
Battery Disconnection/Connection .....................................................165
Checking the Electrolyte Level ..........................................................165
Battery Isolator ...................................................................................166
Jump Starting the Engine .....................................................................167
Fuses ....................................................................................................169
Introduction ........................................................................................169
Primary Fuses ....................................................................................170
Secondary Fuses ...............................................................................171
Relays ..................................................................................................173
LLMC Components ..............................................................................174
Engine .......................................................................................................175
Component Locations ..........................................................................175
Oil and Filter .........................................................................................175
Introduction ........................................................................................175
Checking the Oil Level .......................................................................176
Changing the Oil and Filter ................................................................177
Cooling System ....................................................................................179
Introduction ........................................................................................179
Checking the Coolant Level ...............................................................179
Changing the Coolant ........................................................................180
Alternator Drive Belt .............................................................................181
Adjusting the Alternator Drive Belt .....................................................181
Alternator Belt Replacement ..............................................................181
Compressor Drive Belt (if fitted) ...........................................................183
Adjusting the Compressor Drive Belt .................................................183
Compressor Belt Replacement ..........................................................184
Hydraulic Service Pump Drive Belt ......................................................185
Adjusting the Service Pump Drive Belt ..............................................185
Service Pump Drive Belt Replacement ..............................................186
Air Filter ................................................................................................186
Cleaning the Filter and Changing the Elements ................................186
Cleaning the Air Filter Dust Valve ......................................................187
Fuel System ...............................................................................................188
Introduction ...........................................................................................188
Fuel Filter .............................................................................................189
Draining the Filter ..............................................................................189
Changing the Fuel Filter Element ......................................................189
Bleeding the Fuel System ....................................................................190
Hydraulic System .......................................................................................192
Introduction ...........................................................................................192
Release the Hydraulic Pressure ...........................................................192
Oil and Filter .........................................................................................193
Checking the Fluid Level ...................................................................193
Changing the Filter Element ..............................................................194
Filling the Hydraulic System ..............................................................194
Changing the Hydraulic Breather Cap ..................................................194
Hose Burst Protection Valves ...............................................................196
Checking the Hose Burst Protection Valves ......................................196
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