jcb 540-v140 User manual

OPERATOR'S MANUAL
LOADALL (ROUGH TERRAIN VARIABLE REACH TRUCK)
540-v140, 540-v180
EN - 9831/4000 ISSUE 2 - 03/2018
THIS MANUAL SHOULD ALWAYS STAY WITH THE MACHINE

OPERATOR'S
MANUAL
LOADALL (ROUGH TERRAIN
VARIABLE REACH TRUCK)
540-v140, 540-v180
EN - 9831/4000 - ISSUE 2 - 03/2018
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
Copyright 2016 © 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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9831/4000-2
Notes:
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Table of Contents
i 9831/4000-2 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 .................................................................................................................. 8
Product and Component Identification
Machine ............................................................................................................................................... 10
Engine ................................................................................................................................................. 12
Axle ..................................................................................................................................................... 13
Operator Protective Structure ............................................................................................................. 13
Safety Labels
General ................................................................................................................................................ 15
Safety Label Identification ................................................................................................................... 15
Operator Station
Component Locations ......................................................................................................................... 17
Interior Switches
Ignition Switch ..................................................................................................................................... 18
Multi-Purpose Switch .......................................................................................................................... 18
Cab Interior Light ................................................................................................................................ 19
Console Switches
General ................................................................................................................................................ 21
Road Lights ......................................................................................................................................... 21
Rear Fog Lights .................................................................................................................................. 21
Hazard Warning Lights ....................................................................................................................... 21
Work Lights ......................................................................................................................................... 21
Transmission Mode ............................................................................................................................. 22
Transmission Disconnect .................................................................................................................... 22
Information .......................................................................................................................................... 22
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Table of Contents
ii 9831/4000-2 ii
Tilt Lock ............................................................................................................................................... 22
Beacon ................................................................................................................................................ 22
Heater .................................................................................................................................................. 22
Window Heater ................................................................................................................................... 22
Inner Boom Extend/Retract ................................................................................................................ 23
Controls Isolation ................................................................................................................................ 23
Stabiliser Isolation ............................................................................................................................... 23
Chassis Levelling ................................................................................................................................ 23
Hydraulic Function .............................................................................................................................. 23
Hydraulic Venting ................................................................................................................................ 23
Reverse Fan ....................................................................................................................................... 23
Rear Window Wiper ............................................................................................................................ 24
Roof Window Wiper ............................................................................................................................ 24
Auxiliary Hydraulic Circuit ................................................................................................................... 24
Operation
Introduction
General ................................................................................................................................................ 25
Operating Safety
General ................................................................................................................................................ 26
Worksite Safety ................................................................................................................................... 28
Risk Assessment ................................................................................................................................ 29
Walk-Around Inspection
General ................................................................................................................................................ 31
Entering and Leaving the Operator Station
General ................................................................................................................................................ 32
Emergency Exit ................................................................................................................................... 32
Doors
Operator Door ..................................................................................................................................... 34
Windows
Rear Window ...................................................................................................................................... 36
Battery Isolator
General ................................................................................................................................................ 37
Before Starting the Engine
General ................................................................................................................................................ 38
Operator Seat
General ................................................................................................................................................ 39
Basic Seat ........................................................................................................................................... 39
Suspension Seat ................................................................................................................................. 40
Heated Seat Controls ......................................................................................................................... 43
Seat Belt
General ................................................................................................................................................ 44
Inertia Reel Seat Belt ......................................................................................................................... 44
Static Seat Belt ................................................................................................................................... 45
Mirrors
General ................................................................................................................................................ 47
Starting the Engine
General ................................................................................................................................................ 48
Immobiliser .......................................................................................................................................... 49
Stopping and Parking
General ................................................................................................................................................ 53
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Table of Contents
iii 9831/4000-2 iii
Preparing for Travel
General ................................................................................................................................................ 54
Preparing for Road Travel .................................................................................................................. 54
Preparing for Worksite Travel ............................................................................................................. 57
Beacon ................................................................................................................................................ 59
Safety Equipment
Control Lock ........................................................................................................................................ 61
Drive Controls
Steering Wheel ................................................................................................................................... 64
Steering Column ................................................................................................................................. 64
Accelerator Pedal ................................................................................................................................ 64
Service Brake Pedal ........................................................................................................................... 64
Park Brake .......................................................................................................................................... 65
Transmission Drive Lever ................................................................................................................... 65
Gear Lever .......................................................................................................................................... 67
Steer Mode Control ............................................................................................................................ 68
Instruments
Instrument Panel ................................................................................................................................. 69
Getting the Machine Moving
General ................................................................................................................................................ 89
Slopes
General ................................................................................................................................................ 91
Driving on Slopes ............................................................................................................................... 91
Working on Slopes ............................................................................................................................. 93
Driving the Machine
Steer Modes ........................................................................................................................................ 95
Limited Slip Differential (LSD) ............................................................................................................ 96
Towing Other Equipment .................................................................................................................... 96
Operating Levers/Pedals
General ................................................................................................................................................ 99
Control Layouts ................................................................................................................................... 99
Boom Controls .................................................................................................................................... 99
Chassis Levelling Controls ............................................................................................................... 102
Stabiliser Controls ............................................................................................................................. 103
Auxiliary Circuit Controls ................................................................................................................... 106
Lifting and Loading
General .............................................................................................................................................. 110
Load Charts ...................................................................................................................................... 110
Boom Indicators ................................................................................................................................ 116
Inclinometers ..................................................................................................................................... 116
Interlocks ........................................................................................................................................... 117
Longitudinal Load Moment Indicator (LLMI) ..................................................................................... 124
Longitudinal Load Moment Control (LLMC) ..................................................................................... 127
Working with the Boom
General .............................................................................................................................................. 132
Fork Ratings ...................................................................................................................................... 133
Repositioning the Forks .................................................................................................................... 133
Working with Pallets ......................................................................................................................... 134
Working with Bales ........................................................................................................................... 136
Working with Irregular Loads ............................................................................................................ 137
Stacking Loads ................................................................................................................................. 138
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Table of Contents
iv 9831/4000-2 iv
Filling the Shovel .............................................................................................................................. 139
Loading a Truck ................................................................................................................................ 140
Suspended Loads ............................................................................................................................. 140
Adjusting the Boom .......................................................................................................................... 141
Heating, Ventilating and Air-Conditioning (HVAC)
General .............................................................................................................................................. 143
Air-Conditioning Controls .................................................................................................................. 143
Face Level Fan ................................................................................................................................. 144
Fire Extinguisher
General .............................................................................................................................................. 145
Moving a Disabled Machine
Jump-Starting the Engine ................................................................................................................. 146
Recovery Hitch .................................................................................................................................. 146
Lifting the Machine
General .............................................................................................................................................. 148
Transporting the Machine
General .............................................................................................................................................. 149
Loading the Machine onto the Transporting Vehicle/Trailer ............................................................. 149
Operating Environment
General .............................................................................................................................................. 152
Operating in Low Temperatures ....................................................................................................... 152
Operating in High Temperatures ....................................................................................................... 153
Refuelling
General .............................................................................................................................................. 154
Low Fuel Levels ................................................................................................................................ 154
Filling the Tank .................................................................................................................................. 154
Attachments
Working with Attachments
Introduction ........................................................................................................................................ 157
Attachments for your Machine .......................................................................................................... 157
Connecting/Disconnecting Hydraulic Hoses ..................................................................................... 158
Quick-fit Carriage
General .............................................................................................................................................. 162
Side-Shift Carriage
General .............................................................................................................................................. 166
Fork Positioner
General .............................................................................................................................................. 171
Jibs
General .............................................................................................................................................. 173
Extension Jib ..................................................................................................................................... 173
Roof Truss Jib ................................................................................................................................... 174
Hooks
Fork-Mounted Hook .......................................................................................................................... 177
Work Platforms
General .............................................................................................................................................. 179
Preservation and Storage
Cleaning
General .............................................................................................................................................. 181
Preparation ........................................................................................................................................ 182
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Table of Contents
v 9831/4000-2 v
Checking For Damage
General .............................................................................................................................................. 183
Storage
General .............................................................................................................................................. 184
Put into Storage ................................................................................................................................ 184
During Storage .................................................................................................................................. 185
Take out of Storage .......................................................................................................................... 185
Security
General .............................................................................................................................................. 186
JCB Plantguard ................................................................................................................................. 186
Construction Equipment Security and Registration Scheme (CESAR) ............................................ 186
LiveLink ............................................................................................................................................. 186
Maintenance
Introduction
General .............................................................................................................................................. 187
Owner/Operator Support ................................................................................................................... 187
Service/Maintenance Agreements .................................................................................................... 188
Initial Service and Inspection ............................................................................................................ 188
Obtaining Spare Parts ...................................................................................................................... 188
Maintenance Safety
General .............................................................................................................................................. 189
Fluids and Lubricants ....................................................................................................................... 190
Maintenance Schedules
General .............................................................................................................................................. 194
How to Use the Maintenance Schedules ......................................................................................... 194
Maintenance Intervals ....................................................................................................................... 194
Pre-start Cold Checks, Service Points and Fluid Levels .................................................................. 194
Functional Tests and Final Inspection .............................................................................................. 197
Maintenance Positions
General .............................................................................................................................................. 200
Maintenance Position - Boom Lowered ............................................................................................ 200
Maintenance Position - Boom Raised .............................................................................................. 201
Service Points
General .............................................................................................................................................. 203
Access Apertures
General .............................................................................................................................................. 208
Battery Cover .................................................................................................................................... 208
Engine Compartment Cover ............................................................................................................. 209
Rear Cover ........................................................................................................................................ 210
Undershield ....................................................................................................................................... 210
Tools
General .............................................................................................................................................. 212
Lubrication
General .............................................................................................................................................. 213
Preparation ........................................................................................................................................ 213
Attachments
General ............................................................................................................................................. 214
Body and Framework
General ............................................................................................................................................. 215
Pivot Pins .......................................................................................................................................... 215
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Table of Contents
vi 9831/4000-2 vi
Boom
General ............................................................................................................................................. 217
Boom Chains .................................................................................................................................... 218
Operator Station
General ............................................................................................................................................. 222
Operator Protective Structure ........................................................................................................... 222
Seat ................................................................................................................................................... 222
Seat Belt ........................................................................................................................................... 222
Controls ............................................................................................................................................. 223
Engine
General ............................................................................................................................................. 224
Oil ...................................................................................................................................................... 225
Drive Belt .......................................................................................................................................... 227
Emissions Control System ............................................................................................................... 228
Air Filter
General ............................................................................................................................................. 231
Outer Element .................................................................................................................................. 231
Dust Valve ........................................................................................................................................ 232
Fuel System
General ............................................................................................................................................. 233
Tank .................................................................................................................................................. 233
Fuel Filter .......................................................................................................................................... 234
Water Separator ............................................................................................................................... 235
Cooling System
General ............................................................................................................................................. 236
Coolant .............................................................................................................................................. 236
Cooling Pack .................................................................................................................................... 236
Brakes
General ............................................................................................................................................. 238
Park Brake ........................................................................................................................................ 239
Service Brake ................................................................................................................................... 240
Gearbox
Oil ...................................................................................................................................................... 241
Axles
General ............................................................................................................................................. 242
Oil ...................................................................................................................................................... 242
Wheels
General ............................................................................................................................................. 244
Tyres
General ............................................................................................................................................. 246
Propshafts
General ............................................................................................................................................. 248
Hydraulic System
General ............................................................................................................................................. 249
Services ............................................................................................................................................ 250
Oil ...................................................................................................................................................... 250
Cylinders / Rams .............................................................................................................................. 251
Hose Burst Check Valves ................................................................................................................. 251
Electrical System
General ............................................................................................................................................. 252
Battery ............................................................................................................................................... 253
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Table of Contents
vii 9831/4000-2 vii
Battery Isolator ................................................................................................................................. 254
Fuses ................................................................................................................................................ 254
Relays ............................................................................................................................................... 256
Window Washer ................................................................................................................................ 256
Miscellaneous
Fire Extinguisher ............................................................................................................................... 258
Technical Data
Static Dimensions
Dimensions ........................................................................................................................................ 259
Weights ............................................................................................................................................. 263
Visibility Diagrams ............................................................................................................................. 265
Performance Dimensions
General .............................................................................................................................................. 272
Boom Dimensions and Performance ................................................................................................ 273
Towing Weights ................................................................................................................................. 275
Noise Emissions
General .............................................................................................................................................. 277
Noise Data ........................................................................................................................................ 277
Vibration Emissions
General .............................................................................................................................................. 278
Vibration Data ................................................................................................................................... 279
Fluids, Lubricants and Capacities
General .............................................................................................................................................. 282
Fuel ................................................................................................................................................... 283
Diesel Exhaust Fluid (DEF) .............................................................................................................. 286
Coolant .............................................................................................................................................. 288
Torque Values
General .............................................................................................................................................. 290
Electrical System
General .............................................................................................................................................. 291
Fuses ................................................................................................................................................. 291
Relays ............................................................................................................................................... 295
Engine
Exhaust After Treatment (EAT) ......................................................................................................... 298
Wheels and Tyres
General .............................................................................................................................................. 302
Tyre Sizes and Pressures ................................................................................................................ 303
Declaration of Conformity
General .............................................................................................................................................. 308
Data ................................................................................................................................................... 308
Warranty Information
Service Record Sheet ....................................................................................................................... 310
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