jcb 506-23 User manual

OPERATOR'S MANUAL
LOADALL (ROUGH TERRAIN VARIABLE REACH TRUCK)
506-23, 509-23, 512-26
EN - 9831/5000 ISSUE 2 - 03/2018
THIS MANUAL SHOULD ALWAYS STAY WITH THE MACHINE

OPERATOR'S
MANUAL
LOADALL (ROUGH TERRAIN
VARIABLE REACH TRUCK)
506-23, 509-23, 512-26
EN - 9831/5000 - ISSUE 2 - 03/2018
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
Copyright 2017 © 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.
www.jcb.com
Foreword
The Operator's Manual
You and others can be killed or seriously injured
if you operate or maintain the machine without
first studying the Operator's Manual. You must
understand and follow the instructions in the
Operator's Manual. If you do not understand
anything, ask your employer or JCB dealer to
explain it.
Do not operate the machine without an Operator's
Manual, or if there is anything on the machine you
do not understand.
Treat the Operator's Manual as part of the machine.
Keep it clean and in good condition. Replace the
Operator's Manual immediately if it is lost, damaged
or becomes unreadable.
Machine Delivery and Installation
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 (included in this manual) has not
yet been completed with you.
Your local JCB Dealer is
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9831/5000-2
Notes:
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Table of Contents
i 9831/5000-2 i
Contents Page No.
Acronyms Glossary ....................................................................................................................................... viii
Introduction
About this Manual
Model and Serial Number ..................................................................................................................... 1
Using the Manual .................................................................................................................................. 1
Left-Hand Side, Right-Hand Side ......................................................................................................... 1
Cab/Canopy .......................................................................................................................................... 1
Cross References ................................................................................................................................. 2
Safety
Safety - Yours and Others .................................................................................................................... 3
Safety Warnings .................................................................................................................................... 3
General Safety ...................................................................................................................................... 4
Clothing and Personal Protective Equipment (PPE) ............................................................................ 5
About the Product
Introduction
General .................................................................................................................................................. 7
Name and Address of the Manufacturer .............................................................................................. 7
Product Compliance .............................................................................................................................. 7
Description
General .................................................................................................................................................. 8
Intended Use ......................................................................................................................................... 8
Log Moving/Object Handling ................................................................................................................. 8
Optional Equipment and Attachments .................................................................................................. 8
Danger Zone ......................................................................................................................................... 8
Main Component Locations .................................................................................................................. 9
Product and Component Identification
Machine ............................................................................................................................................... 10
Engine ................................................................................................................................................. 11
Axle ..................................................................................................................................................... 12
Gearbox ............................................................................................................................................... 14
Operator Protective Structure ............................................................................................................. 15
Safety Labels
General ................................................................................................................................................ 18
Safety Label Identification ................................................................................................................... 18
Operator Station
Component Locations ......................................................................................................................... 20
Interior Switches
Ignition Switch ..................................................................................................................................... 22
Multi-Purpose Switch .......................................................................................................................... 22
Cab Interior Light ................................................................................................................................ 23
Console Switches
General ................................................................................................................................................ 25
Road Lights ......................................................................................................................................... 25
Rear Fog Lights .................................................................................................................................. 25
Hazard Warning Lights ....................................................................................................................... 25
Work Lights ......................................................................................................................................... 25
Transmission Mode ............................................................................................................................. 26
Transmission Disconnect .................................................................................................................... 26
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Table of Contents
ii 9831/5000-2 ii
Information .......................................................................................................................................... 26
Tilt Lock ............................................................................................................................................... 26
Smooth Ride System (SRS) ............................................................................................................... 26
Automatic Smooth Ride System ......................................................................................................... 26
Beacon ................................................................................................................................................ 27
Heater .................................................................................................................................................. 27
Window Heater ................................................................................................................................... 27
Inner Boom Extend/Retract ................................................................................................................ 27
Controls Isolation ................................................................................................................................ 27
Stabiliser Isolation ............................................................................................................................... 27
Chassis Levelling ................................................................................................................................ 28
Hydraulic Function .............................................................................................................................. 28
Hydraulic Mode ................................................................................................................................... 28
Hydraulic Venting ................................................................................................................................ 28
Hydraulic Tow Hitch ............................................................................................................................ 28
Reverse Fan ....................................................................................................................................... 28
Rear Window Wiper ............................................................................................................................ 29
Roof Window Wiper ............................................................................................................................ 29
Auxiliary Hydraulic Circuit ................................................................................................................... 29
ECO/Power ......................................................................................................................................... 29
Auto 2WD ............................................................................................................................................ 30
Operation
Introduction
General ................................................................................................................................................ 31
Operating Safety
General ................................................................................................................................................ 32
Worksite Safety ................................................................................................................................... 34
Risk Assessment ................................................................................................................................ 35
Walk-Around Inspection
General ................................................................................................................................................ 37
Entering and Leaving the Operator Station
General ................................................................................................................................................ 38
Emergency Exit ................................................................................................................................... 38
Doors
Operator Door ..................................................................................................................................... 40
Windows
Rear Window ...................................................................................................................................... 42
Battery Isolator
General ................................................................................................................................................ 43
Before Starting the Engine
General ................................................................................................................................................ 44
Operator Seat
General ................................................................................................................................................ 45
Basic Seat ........................................................................................................................................... 45
Suspension Seat ................................................................................................................................. 46
Heated Seat Controls ......................................................................................................................... 49
Seat Belt
General ................................................................................................................................................ 50
Inertia Reel Seat Belt ......................................................................................................................... 50
Static Seat Belt ................................................................................................................................... 51
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Table of Contents
iii 9831/5000-2 iii
Starting the Engine
General ................................................................................................................................................ 53
Immobiliser .......................................................................................................................................... 54
Stopping and Parking
General ................................................................................................................................................ 58
Preparing for Travel
General ................................................................................................................................................ 59
Preparing for Road Travel .................................................................................................................. 59
Preparing for Worksite Travel ............................................................................................................. 62
Smooth Ride System (SRS) ............................................................................................................... 65
Beacon ................................................................................................................................................ 66
Safety Equipment
Control Lock ........................................................................................................................................ 68
Drive Controls
Steering Wheel ................................................................................................................................... 71
Steering Column ................................................................................................................................. 71
Accelerator Pedal ................................................................................................................................ 71
Service Brake Pedal ........................................................................................................................... 71
Inching Pedal ...................................................................................................................................... 72
Park Brake .......................................................................................................................................... 72
Transmission Drive Lever ................................................................................................................... 72
Gear Lever .......................................................................................................................................... 76
Steer Mode Control ............................................................................................................................ 82
Transmission Mode ............................................................................................................................. 82
Instruments
Instrument Panel ................................................................................................................................. 83
Getting the Machine Moving
General .............................................................................................................................................. 105
Slopes
General .............................................................................................................................................. 108
Driving on Slopes ............................................................................................................................. 108
Working on Slopes ........................................................................................................................... 109
Driving the Machine
Steer Modes ...................................................................................................................................... 111
Limited Slip Differential (LSD) .......................................................................................................... 112
TorqueLock ........................................................................................................................................ 112
Towing Other Equipment .................................................................................................................. 113
Operating Levers/Pedals
General .............................................................................................................................................. 125
Control Layouts ................................................................................................................................. 125
Boom Controls .................................................................................................................................. 126
Chassis Levelling Controls ............................................................................................................... 130
Auxiliary Circuit Controls ................................................................................................................... 131
Lifting and Loading
General .............................................................................................................................................. 135
Load Charts ...................................................................................................................................... 135
Boom Indicators ................................................................................................................................ 138
Inclinometers ..................................................................................................................................... 138
Interlocks ........................................................................................................................................... 139
Working with the Boom
General .............................................................................................................................................. 140
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Table of Contents
iv 9831/5000-2 iv
Fork Ratings ...................................................................................................................................... 141
Repositioning the Forks .................................................................................................................... 141
Working with Pallets ......................................................................................................................... 142
Working with Bales ........................................................................................................................... 144
Working with Irregular Loads ............................................................................................................ 145
Stacking Loads ................................................................................................................................. 146
Filling the Shovel .............................................................................................................................. 147
Loading a Truck ................................................................................................................................ 148
Adjusting the Boom .......................................................................................................................... 148
Heating, Ventilating and Air-Conditioning (HVAC)
General .............................................................................................................................................. 150
Air-Conditioning Controls .................................................................................................................. 150
Face Level Fan ................................................................................................................................. 151
Fire Extinguisher
General .............................................................................................................................................. 152
Moving a Disabled Machine
Jump-Starting the Engine ................................................................................................................. 153
Recovery Hitch .................................................................................................................................. 153
Lifting the Machine
General .............................................................................................................................................. 157
Transporting the Machine
General .............................................................................................................................................. 159
Loading the Machine onto the Transporting Vehicle/Trailer ............................................................. 159
Operating Environment
General .............................................................................................................................................. 162
Operating in Low Temperatures ....................................................................................................... 162
Operating in High Temperatures ....................................................................................................... 163
Refuelling
General .............................................................................................................................................. 164
Low Fuel Levels ................................................................................................................................ 164
Filling the Tank .................................................................................................................................. 164
Attachments
Working with Attachments
Introduction ........................................................................................................................................ 167
Attachments for your Machine .......................................................................................................... 167
Connecting/Disconnecting Hydraulic Hoses ..................................................................................... 168
Quick-fit Carriage
General .............................................................................................................................................. 172
Tow Hitches
General .............................................................................................................................................. 176
Ladder Hitch ...................................................................................................................................... 179
Hydraulic Tow Hitch .......................................................................................................................... 183
Mechanical Tow Hitch ....................................................................................................................... 185
Side-Shift Carriage
General .............................................................................................................................................. 188
Jibs
General .............................................................................................................................................. 193
Extension Jib ..................................................................................................................................... 193
Roof Truss Jib ................................................................................................................................... 194
Hooks
Fork-Mounted Hook .......................................................................................................................... 197
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Table of Contents
v 9831/5000-2 v
Preservation and Storage
Cleaning
General .............................................................................................................................................. 199
Preparation ........................................................................................................................................ 200
Checking For Damage
General .............................................................................................................................................. 201
Storage
General .............................................................................................................................................. 202
Put into Storage ................................................................................................................................ 202
During Storage .................................................................................................................................. 203
Take out of Storage .......................................................................................................................... 203
Security
General .............................................................................................................................................. 204
LiveLink ............................................................................................................................................. 204
Maintenance
Introduction
General .............................................................................................................................................. 205
Owner/Operator Support ................................................................................................................... 205
Service/Maintenance Agreements .................................................................................................... 206
Initial Service and Inspection ............................................................................................................ 206
Obtaining Spare Parts ...................................................................................................................... 206
Maintenance Safety
General .............................................................................................................................................. 207
Fluids and Lubricants ....................................................................................................................... 208
Maintenance Schedules
General .............................................................................................................................................. 212
How to Use the Maintenance Schedules ......................................................................................... 212
Maintenance Intervals ....................................................................................................................... 212
Pre-start Cold Checks, Service Points and Fluid Levels .................................................................. 212
Functional Tests and Final Inspection .............................................................................................. 215
Maintenance Positions
General .............................................................................................................................................. 218
Maintenance Position - Boom Lowered ............................................................................................ 218
Maintenance Position - Boom Raised .............................................................................................. 219
Service Points
General .............................................................................................................................................. 222
Access Apertures
General .............................................................................................................................................. 229
Battery Cover .................................................................................................................................... 229
Engine Compartment Cover ............................................................................................................. 230
Rear Cover ........................................................................................................................................ 231
Undershield ....................................................................................................................................... 231
Tools
General .............................................................................................................................................. 233
Lubrication
General .............................................................................................................................................. 234
Preparation ........................................................................................................................................ 234
Attachments
General ............................................................................................................................................. 235
Body and Framework
General ............................................................................................................................................. 236
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Table of Contents
vi 9831/5000-2 vi
Pivot Pins .......................................................................................................................................... 236
Boom
General ............................................................................................................................................. 238
Operator Station
General ............................................................................................................................................. 240
Operator Protective Structure ........................................................................................................... 240
Seat ................................................................................................................................................... 240
Seat Belt ........................................................................................................................................... 240
Controls ............................................................................................................................................. 241
Engine
General ............................................................................................................................................. 242
Oil ...................................................................................................................................................... 243
Drive Belt .......................................................................................................................................... 245
Emissions Control System ............................................................................................................... 246
Air Filter
General ............................................................................................................................................. 249
Outer Element .................................................................................................................................. 249
Dust Valve ........................................................................................................................................ 250
Fuel System
General ............................................................................................................................................. 251
Tank .................................................................................................................................................. 251
Fuel Filter .......................................................................................................................................... 252
Water Separator ............................................................................................................................... 253
Cooling System
General ............................................................................................................................................. 254
Coolant .............................................................................................................................................. 254
Cooling Pack .................................................................................................................................... 254
Brakes
General ............................................................................................................................................. 256
Park Brake ........................................................................................................................................ 257
Service Brake ................................................................................................................................... 258
Gearbox
Oil ...................................................................................................................................................... 259
Axles
General ............................................................................................................................................. 260
Oil ...................................................................................................................................................... 260
Wheels
General ............................................................................................................................................. 262
Tyres
General ............................................................................................................................................. 264
Propshafts
General ............................................................................................................................................. 266
Hydraulic System
General ............................................................................................................................................. 267
Services ............................................................................................................................................ 268
Oil ...................................................................................................................................................... 268
Cylinders / Rams .............................................................................................................................. 269
Hose Burst Check Valves ................................................................................................................. 269
Electrical System
General ............................................................................................................................................. 270
Battery ............................................................................................................................................... 271
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Table of Contents
vii 9831/5000-2 vii
Battery Isolator ................................................................................................................................. 272
Fuses ................................................................................................................................................ 272
Relays ............................................................................................................................................... 274
Window Washer ................................................................................................................................ 274
Miscellaneous
Fire Extinguisher ............................................................................................................................... 276
Technical Data
Static Dimensions
Dimensions ........................................................................................................................................ 277
Weights ............................................................................................................................................. 280
Performance Dimensions
General .............................................................................................................................................. 282
Boom Dimensions and Performance ................................................................................................ 283
Towing Weights ................................................................................................................................. 286
Fluids, Lubricants and Capacities
General .............................................................................................................................................. 288
Fuel ................................................................................................................................................... 289
Diesel Exhaust Fluid (DEF) .............................................................................................................. 292
Coolant .............................................................................................................................................. 294
Torque Values
General .............................................................................................................................................. 295
Electrical System
General .............................................................................................................................................. 296
Fuses ................................................................................................................................................. 296
Relays ............................................................................................................................................... 300
Batteries ............................................................................................................................................ 302
Engine
Engine Emissions ............................................................................................................................. 303
Exhaust After Treatment (EAT) ......................................................................................................... 303
Wheels and Tyres
General .............................................................................................................................................. 306
Tyre Sizes and Pressures ................................................................................................................ 307
Warranty Information
Service Record Sheet ....................................................................................................................... 317
Engine Emissions ............................................................................................................................. 323
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