jcb 540-170 Work Platform Operator's Manual
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jcb 540-170 Work Platform Operator's Manual

Loadall rough terrain variable reach truck
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OPERATOR'S MANUAL
LOADALL (ROUGH TERRAIN VARIABLE REACH TRUCK)
531-70, 533-105, 535-95, 535V125, 540-170,
540-170 Work Platform, 540-200, 540V140, 540V180
EN - 9831/9950 ISSUE 7 - 12/2023
THIS MANUAL SHOULD ALWAYS STAY WITH THE MACHINE

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  • Page 1 OPERATOR'S MANUAL LOADALL (ROUGH TERRAIN VARIABLE REACH TRUCK) 531-70, 533-105, 535-95, 535V125, 540-170, 540-170 Work Platform, 540-200, 540V140, 540V180 EN - 9831/9950 ISSUE 7 - 12/2023 THIS MANUAL SHOULD ALWAYS STAY WITH THE MACHINE...
  • Page 2 www.duma-rent.com...

  • Page 3: Work Platform

    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. OPERATOR'S Do not operate the machine without an Operator's...
  • Page 4 www.duma-rent.com Notes: 9831/9950-7...

  • Page 5: Table Of Contents

    www.duma-rent.com Table of Contents Contents Page No. Acronyms Glossary ............................Introduction About this Manual Model and Serial Number ........................1 Using the Manual ..........................1 Left-Hand Side, Right-Hand Side ......................2 Cab/Canopy ............................2 Cross References ..........................2 Safety Safety - Yours and Others ........................3 Safety Warnings ............................
  • Page 6 www.duma-rent.com Table of Contents Tilt Lock ............................... 20 Beacon ..............................20 Heater ..............................20 Window Heater ........................... 20 Inner Boom Extend/Retract ........................ 21 Controls Isolation ..........................21 Stabiliser Isolation ..........................21 Hydraulic Mode ........................... 21 Hydraulic Venting ..........................21 Hydraulic Tow Hitch ..........................21 Rear Window Wiper ..........................
  • Page 7 www.duma-rent.com Table of Contents Preparing for Travel General ..............................53 Preparing for Road Travel ........................53 Preparing for Worksite Travel ......................56 Beacon ..............................58 Safety Equipment Control Lock ............................59 Drive Controls Steering Wheel ........................... 62 Steering Column ..........................62 Accelerator Pedal ..........................
  • Page 8 www.duma-rent.com Table of Contents Working with Irregular Loads ......................145 Stacking Loads ..........................146 Filling the Shovel ..........................147 Loading a Truck ..........................148 Suspended Loads ..........................148 Adjusting the Boom .......................... 149 Heating, Ventilating and Air-Conditioning (HVAC) General .............................. 151 Air-Conditioning Controls ........................
  • Page 9 Put into Storage ..........................206 During Storage ..........................206 Take out of Storage .......................... 207 Security General .............................. 208 JCB Plantguard ..........................208 Construction Equipment Security and Registration Scheme (CESAR) ..........208 LiveLink ............................. 208 Maintenance Introduction General .............................. 209 Owner/Operator Support ........................
  • Page 10 www.duma-rent.com Table of Contents Lubrication General .............................. 241 Preparation ............................241 Remote Greasing ..........................241 Attachments General ............................. 243 Body and Framework General ............................. 244 Pivot Pins ............................244 Boom General ............................. 246 Boom Chains ............................ 251 Operator Station General ............................. 256 Operator Protective Structure ......................
  • Page 11 www.duma-rent.com Table of Contents Propshafts General ............................. 283 Hydraulic System General ............................. 284 Services ............................285 Oil ..............................285 Cylinders / Rams ..........................286 Hose Burst Check Valves ......................... 286 Electrical System General ............................. 287 Battery ............................... 287 Battery Isolator ..........................289 Fuses ..............................
  • Page 12 www.duma-rent.com Table of Contents Warranty Information Service Record Sheet ........................391 Engine Emissions ..........................397 viii 9831/9950-7 viii...

  • Page 13: Acronyms Glossary

    www.duma-rent.com Table of Contents Acronyms Glossary Two Wheel Drive Four Wheel Steer CESAR Construction Equipment Security and Registration Diesel Exhaust Fluid Diesel Particulate Filter Electronic Control Unit Exhaust Gas Recirculation FEAD Front End Accessory Drive FOPS Falling Object Protective Structure HEST High Exhaust System Temperature HVAC...
  • Page 14 www.duma-rent.com Notes: 9831/9950-7...

  • Page 15: Introduction

    Particular attention must be given to all the safety aspects of operating and maintaining the machine. If there is anything you are not sure about, ask your JCB dealer or employer. Do not guess, you or others could be killed or seriously injured.

  • Page 16: Left-Hand Side, Right-Hand Side

    www.duma-rent.com Introduction About this Manual Left-Hand Side, Right-Hand Side In this manual, 'left' and 'right' mean your left and right when you are seated correctly in the machine. Figure 1. A Left B Right Cab/Canopy This manual frequently makes references to the cab. For example, 'do not operate the machine without an operator's manual in the cab'.

  • Page 17: Safety

    If you do not fully understand the warning messages, ask your employer or JCB dealer to explain them. Safety is not just a matter of responding to the warnings. All the time you are working on or with the machine you must be thinking of what hazards there might be and how to avoid them.

  • Page 18: Clothing And Personal Protective Equipment (Ppe)

    Machine Modifications This machine is manufactured in compliance with prevailing legislative requirements. It must not be altered in any way which could affect or invalidate its compliance. For advice consult your JCB dealer. Clothing and Personal Protective Equipment (PPE) Do not wear loose clothing or jewellery that can get caught on controls or moving parts. Wear protective clothing and personal safety equipment issued or called for by the job conditions, local regulations or as specified by your employer.

  • Page 19: About The Product

    Product Compliance Your JCB product was designed to comply with the laws and regulations applicable at the time of its manufacture for the market in which it was first sold. In many markets, laws and regulations exist that require the owner to maintain the product at a level of compliance relevant to the product when first produced.

  • Page 20: Description

    For more information, contact your JCB dealer. Optional Equipment and Attachments A wide range of optional attachments are available to increase the versatility of your machine. Only the JCB approved attachments are recommended for use with your machine. Contact your JCB dealer for the full list of approved attachments available.

  • Page 21: Main Component Locations

    www.duma-rent.com About the Product Description Main Component Locations Figure 3. A Lift arm/Boom B Carriage C ROPS (Roll-Over Protective Structure)/FOPS D Mechanical tow hitch (Falling Object Protective Structure) cab 9831/9950-7...

  • Page 22: Product And Component Identification

    Either get a replacement identification plate from your JCB Dealer or simply remove the old number. This will prevent the wrong unit number being quoted when replacement parts are ordered. The machine and engine serial numbers can help identify exactly the type of equipment you have.

  • Page 23: Engine

    About the Product Product and Component Identification Table 5. Digit 7 Engine Type JCB Dieselmax : 55kW 3L Stage 5 Table 6. Digit 8 Gearbox Model 3 Speed (PS750) 4 Speed (PS750) 4 Speed (PS750) Sway Table 7. Digit 9 Random check letter.

  • Page 24: Axle(S)

    www.duma-rent.com About the Product Product and Component Identification Table 10. Example of the engine identification number 320/40001 00001 Digit 3-10 12-16 17-18 Table 11. Digit 1-2 Engine Type 3L turbocharged and aftercooled electronic common rail fuel injection (STV) 55kW Table 12. Explanation of the engine identification number Digit Explanation 3-10...

  • Page 25: Gearbox

    www.duma-rent.com About the Product Product and Component Identification Figure 7. Rear axle B Data plate - rear axle Gearbox The gearbox has a serial number stamped on a data plate as shown. Figure 8. Power-shift Transmission A Data plate Operator Protective Structure WARNING You could be killed or seriously injured if you operate a machine with a damaged or missing ROPS/FOPS.
  • Page 26 Any damage or modification to the structure may invalidate the ROPS certification. If damage has occurred then an authorised JCB dealer should be consulted. A machine with a ROPS (Roll-Over Protective Structure) can be identified by referring to the cab identification plate.

  • Page 27: Safety Labels

    Keep all of the safety labels clean and readable. Replace a lost or damaged safety label. Make sure the replacement parts include the safety labels where necessary. Each safety label has a part number printed on it, use this number to order a new safety label from your JCB dealer. Safety Label Identification Figure 10.
  • Page 28 www.duma-rent.com About the Product Safety Labels Figure 11. 332/P4650-1 817/70014 817/70029 817/70040-2 Table 13. Safety Labels Item Part No. Description Qty. 817/70004 Warning. Burns to fingers and hands. Stay a safe distance away. 332/G7379 Pressure hazard. Read Operator’s Manual. 401/P0004 Pressure hazard.

  • Page 29: Operator Station

    www.duma-rent.com About the Product Operator Station Operator Station Component Locations This cab is certified to category 1 according to EN15695-1-2009. Refer to: Operator Protective Structure (Page 11). Figure 12. A Steering wheel B Transmission Lever and Gear Selection Refer to: Steering Wheel (Page 62). Refer to: Steering Wheel (Page 62).
  • Page 30 www.duma-rent.com About the Product Operator Station Refer to: Ignition Switch (Page 17). Refer to: Instrument Panel (Page 68). R Inclinometer S LLMI (Longitudinal Load Moment Indicator) T Load control system U Drive pedal V Hand throttle W Vari-speed controller 9831/9950-7...

  • Page 31: Interior Switches

    www.duma-rent.com About the Product Interior Switches Interior Switches Ignition Switch The ignition key operates the four-position ignition switch. The ignition key can only be inserted or removed in position 0. If the engine fails to start, the ignition key must be returned to position 0 before the starter motor is re-engaged. Do not operate the starter motor for more than 20s without the engine firing.

  • Page 32: Windscreen Washer

    www.duma-rent.com About the Product Interior Switches I = Slow II = Fast Windscreen Washer Push the button to activate the windscreen washer. Allow the stalk to spring back to central position when finished. Headlights Flash Lift the stalk upwards to flash the headlights. Allow the stalk to spring back to central position when finished. Main Beam When the road lights are switched on via main switch on console, push the stalk downwards to turn on the main beam.

  • Page 33: Console Switches

    www.duma-rent.com About the Product Console Switches Console Switches General The installed switches and their positions can change according to the specification of the machine. Each switch has a graphic symbol to show the function of the switch. Before you operate a switch, make sure that you understand its function.

  • Page 34: Work Lights

    www.duma-rent.com About the Product Console Switches Work Lights (If fitted) Three position rocker switch. The switch functions operate when the ignition switch is in the on position. The work lights work independently of the main circuit lights. Position : 1 = Off Position : 3 = Front work lights on Position : 2 = Front/rear/hitch work lights on.

  • Page 35: Inner Boom Extend/Retract

    www.duma-rent.com About the Product Console Switches Inner Boom Extend/Retract Two position rocker switch. The switch functions operate when the ignition switch is in the on position. Position 1: Inner boom extend/retract disabled Position 2: Inner boom extend/retract enabled Controls Isolation Three position rocker switch (spring loaded) with backlight.

  • Page 36: Rear Window Wiper

    www.duma-rent.com About the Product Console Switches Rear Window Wiper Three position rocker switch. The switch functions operate when the ignition switch is in the on position. The wiper will self park when switched off. Position 1: Wiper off. Position 3: Wiper on. Position 2: Washer on (push and hold).

  • Page 37: Operation Introduction General

    www.duma-rent.com Operation Introduction Operation Introduction General The aim of this part of the manual is to guide the operator step-by-step through the task of learning how to operate the machine efficiently and safely. Read the "Operation" section thoroughly from beginning to end. The operator must always be aware of events happening in or around the machine.

  • Page 38: Operating Safety

    On a busy site, use a signalman. Before doing any job not covered in this manual, find out the correct procedure. Your local JCB distributor will be glad to advise you.
  • Page 39 This machine is designed for use in normal outdoor atmospheric conditions. It must not be used in an enclosed area without adequate ventilation. Do not use the machine in a potentially explosive atmosphere, i.e. combustible vapours, gas or dust, without first consulting your JCB dealer. Regulations Obey all laws, worksite and local regulations which affect you and your machine.

  • Page 40: Worksite Safety

    Fast cornering, operating on slopes, high winds and unsecured loads increase the risk the machine overturning. This list is not exhaustive, other factors may contribute to an increased risk of overturning. If in doubt stop immediately and consult your JCB dealer. Worksite Safety WARNING You or others can be killed or seriously injured if you do unfamiliar operations without first practising them.

  • Page 41: Risk Assessment

    It is essential that a risk assessment of the work to be done is completed and that the operator obeys any safety precautions that the assessment identifies. If you are unsure of the suitability of the machine for a specific task, contact your JCB dealer who will be pleased to advise you.
  • Page 42 www.duma-rent.com Operation Operating Safety • Have the daily checks been carried out? • Are the tyres still at the correct pressure and in good condition and is there sufficient fuel to complete the job (if applicable)? The Load • How heavy is it? Is it within the capabilities of the machine? •...

  • Page 43: Walk-Around Inspection

    www.duma-rent.com Operation Walk-Around Inspection Walk-Around Inspection General WARNING Walking or working under raised attachments can be hazardous. You could be crushed by the attachments or get caught in the linkages. Lower the attachments to the ground before doing these checks. Also make sure that the park brake is engaged before doing these checks.

  • Page 44: Entering And Leaving The Operator Station

    www.duma-rent.com Operation Entering and Leaving the Operator Station Entering and Leaving the Operator Station General CAUTION Entering or leaving the operator station must only be made where steps and handrails are provided. Always face the machine when entering and leaving. Make sure the steps, handrails and your boot soles are clean and dry.
  • Page 45 www.duma-rent.com Operation Entering and Leaving the Operator Station Figure 18. A Pins Glazing Breaker (if installed) If the machine is installed with a glazing breaker, in an emergency use the glazing breaker to break the glass. Use the side screen as an emergency exit. Remove the glazing breaker and strike the side screen near the corner, this will shatter the screen which can then be knocked out.

  • Page 46: Doors

    www.duma-rent.com Operation Doors Doors Operator Door Notice: Do not drive the machine with the door unlatched. Door To open the door from the outside: Refer to Figure 20. 1. Unlock the door with the ignition key. 2. Pull the handle to release the latch. To close the door: Close the door from the inside by pulling the closing bar firmly;...
  • Page 47 www.duma-rent.com Operation Doors Figure 21. A Lever B Door ajar pivot To close the upper door section: 1. Press the button (if inside the cab) or release the catch (if outside the cab). 2. Swing the door closed until it latches into position. Figure 22.

  • Page 48: Windows

    www.duma-rent.com Operation Windows Windows Rear Window To open the window, swing the catches in the direction shown, as far as required. To close the window, swing the catches in the opposite direction until it locks in position. Figure 23. A Catches 9831/9950-7...

  • Page 49: Battery Isolator

    www.duma-rent.com Operation Battery Isolator Battery Isolator General Notice: Before carrying out arc welding on the machine, disconnect the battery and alternator to protect the circuits and components. The battery must still be disconnected even if a battery isolator is installed. Notice: Do not isolate the machine electrics when the engine is running, this may cause damage to the machine electrics.

  • Page 50: Before Starting The Engine

    4.5. Remove or stow all loose articles in the cab, for example tools. 4.6. Examine the ROPS (Roll-Over Protective Structure) and/or FOPS (Falling Object Protective Structure) for damage. Get your JCB dealer to repair any damage. Make sure all its securing bolts are installed and correctly tightened.

  • Page 51: Operator Seat

    CAUTION The operator seat contributes to the operators comfort and the level of vibration felt by the operator. Ensure seat is maintained and replace if damaged with a JCB approved option. The operator's seat can be adjusted for your comfort. A correctly adjusted seat will lower the operator fatigue.
  • Page 52 www.duma-rent.com Operation Operator Seat Figure 24. A Horizontal adjustment lever B Ride height indicator C Height adjustment lever D Backrest lever E Document cover Suspension Seat (KAB 100 Series - Air) Horizontal Adjustment Lift the lever and slide the seat into the required position. Release the lever. Height Turn the adjuster lever until the ride height indicator is in the green 'comfort' zone.
  • Page 53 www.duma-rent.com Operation Operator Seat Figure 25. A Horizontal adjustment lever B Ride height indicator C Height adjustment lever D Backrest lever E Document cover Suspension Seat (KAB 800 Series - Air) Horizontal Adjustment Lift the lever upwards and slide the seat into the required position. Push the lever down to lock the seat in its position.
  • Page 54 www.duma-rent.com Operation Operator Seat Figure 26. A Horizontal adjustment lever B Height adjustment lever C Ride height indicator D One touch raiser E Backrest lever F Lumbar adjuster G Backrest extension H Document cover 9831/9950-7...

  • Page 55: Seat Belt

    www.duma-rent.com Operation Seat Belt Seat Belt General WARNING Operating the machine without a seat belt can be dangerous. Before starting the engine, make sure your seat belt is fastened. Check the tightness and condition of the seat belt securing bolts regularly. WARNING When a seat belt is checked for condition if it is damaged, if the fabric is worn, or if the machine has been in an accident, replace it with a complete seat belt assembly.
  • Page 56 www.duma-rent.com Operation Seat Belt Figure 28. C Seat belt D Button Release the Seat Belt WARNING Release the seat belt only after safely stopping the machine, switching off the engine and engaging the park brake (if applicable). 1. Push the button and pull the tongue from the latch. 2.

  • Page 57: Mirrors

    www.duma-rent.com Operation Mirrors Mirrors General The following information is provided so that the operator can minimise visibility hazards when operating the machine. This machine meets the visibility requirements specified in FprEN 15830:2011. The machine has been subject to a static visibility assessment with a simulated load in two positions: the load on the forks 500 ± 50mm above the ground, and the load suspended 600mm beneath the forks while the forks are 2,200mm above the ground.

  • Page 58: Visual Aids

    www.duma-rent.com Operation Visual Aids Visual Aids General Camera The machine may be installed with one or more cameras to increase the operators forward/rearward visibility. For the one camera option a camera is installed at the rear of the machine. For the two camera option one camera is installed at the rear of the machine and another on the side roadlight arm.
  • Page 59 www.duma-rent.com Operation Visual Aids Minus Go to the next menu option or move left. Plus Go to the previous menu option or move right. Enter Switch to standby or in the menu, select or active the chosen option. 9831/9950-7...

  • Page 60: Starting The Engine

    www.duma-rent.com Operation Starting the Engine Starting the Engine General Notice: Do not use ether or other starting fluids to assist cold starting. Using these fluids may result in an explosion causing possible injury and/or damage to the engine. The engine control system automatically controls the response of the engine during its crank, start and warm up phase;...

  • Page 61: Immobiliser

    If your machine has an immobiliser system installed, then your JCB dealer should enable the system as part of the standard machine Installation. If you prefer that the system is not enabled, then you must tell your JCB dealer. Your JCB dealer can enable the system at a later date. Machines with immobilisers installed should always be parked as per the instructions in the operators manual.
  • Page 62 www.duma-rent.com Operation Starting the Engine Figure 31. A LED To Arm the Immobiliser 1. Stop the engine. Remove the ignition key. 2. The immobiliser arms automatically after two minutes. The green LED flashes for 60 seconds, then goes off. 3. If you restart the engine within two minutes, the system disarms automatically. To Add a New or Additional PIN Code Before you try to add a new or additional PIN code, make sure that the machine is ready to start and that you have your six digit master code and your new four digit PIN code available.
  • Page 63 www.duma-rent.com Operation Starting the Engine Unique Key Immobiliser System The red key must not be kept on the same key ring as the black key, If the red key is too close to the key switch the antenna can pick up on the key transponder and cause the immobiliser ECU (Electronic Control Unit) to enter the key programme mode.
  • Page 64 www.duma-rent.com Operation Starting the Engine To Remove the Program From an Ignition Keys The ignition keys can still be used on any other machine on which they have been programmed. 1. Put the master key in the ignition switch. 2. Turn the master key to position 1. The LED will flash three times. 3.

  • Page 65: Stopping And Parking

    Whenever the park brake has been used in an emergency the brake pack must be checked. Contact your JCB dealer. 1. Stop the machine on dry and level ground where the machine will not be a hazard or danger.
  • Page 66 www.duma-rent.com Operation Stopping and Parking 5. Boom angle must be less than specified value. Angle: 10° 6. Boom is fully retracted. 7. Side lights are in off condition. 8. Ambient temperature must be above the value specified. Temperature: 5°C (41.0°F) 9.

  • Page 67: Preparing For Travel

    Use a restraint device to tie the bucket to the lower structure. This information is believed to be correct, JCB cannot be aware of all circumstances in which JCB machines may be operated on a public highway and it is the responsibility of the user to make sure the compliance with the regulations.
  • Page 68 www.duma-rent.com Operation Preparing for Travel Figure 37. A Fork 7. Install the fork retention brackets (as required) and secure with the retaining pin and locking pin. Figure 38. B Retention brackets C Retaining pin D Locking pin 8. In certain countries, legislation requires forks to be removed and safety guard installed. Contact the local authorities.
  • Page 69 www.duma-rent.com Operation Preparing for Travel Figure 40. F Cluster 10. Put the boom in travel position and install the restraining strap over the boom and attach to the lifting lugs on the chassis side plates. Figure 41. G Restraining strap 11.

  • Page 70: Preparing For Worksite Travel

    www.duma-rent.com Operation Preparing for Travel Figure 42. H Tooth guard J Marker plate 12. Do not travel on public roads with the machine loaded. 13. Lock the controls (as required). 14. Align the road wheels. 15. Select 2-wheel steer, do not use crab steer or 4-wheel steer on public roads. 16.
  • Page 71 www.duma-rent.com Operation Preparing for Travel Figure 43. A Fork B Clamping screws 6. When attachments are fitted, position the boom in the 'low carry' position so that the right hand mirror is not hidden from the operator's view. 7. Tighten the clamping screws to prevent side movement of the forks (if installed). 8.

  • Page 72: Beacon

    www.duma-rent.com Operation Preparing for Travel Beacon In certain territories you will break the law if you do not install a beacon before you travel on site/public highways, make sure you comply with the local laws. Be careful when you operate the machine with a beacon. The total height of the machine is increased when the beacon is in the operating position.

  • Page 73: Safety Equipment

    www.duma-rent.com Operation Safety Equipment Safety Equipment Control Lock The requirement for control lever(s) lock/isolation varies according to the local legislation. You must comply with the local legislation at all times. The control locks/switches are designed to lock or isolate the control(s) in the neutral position. Control levers and switches could change on machines.
  • Page 74 www.duma-rent.com Operation Safety Equipment Figure 47. A Pin Tilt Lever Lock The tilt lever lock must be installed when using a platform. To lock the controls, make sure the lever tilt lever is in the neutral position, then press down pin as far as it will go. Before you start the engine make sure the controls are locked.
  • Page 75 www.duma-rent.com Operation Safety Equipment Figure 48. B Mechanical lock Figure 49. B Mechanical lock 9831/9950-7...

  • Page 76: Drive Controls

    www.duma-rent.com Operation Drive Controls Drive Controls Steering Wheel Turn the steering wheel in the direction you want to go. Refer to: Component Locations (Page 15). The steering wheel incorporates an assister knob for single handed operation. Steering Column CAUTION Make sure the steering column is locked in position. Do not adjust the steering column while driving.

  • Page 77: Park Brake

    Whenever the park brake has been used in an emergency the brake pack must be checked. Contact your JCB dealer. Use this lever to engage the park brake before leaving the machine.
  • Page 78 www.duma-rent.com Operation Drive Controls 1. Stop the machine. 2. Apply the service brake. 3. Let the engine speed drop to idle. 4. Select the required direction. 5. Release the service brake and accelerate. Drive Selection Switch (Option) Figure 52. A Drive selection switch Your machine may be installed with a drive selection switch that controls the direction of the machine.

  • Page 79: Gear Lever

    www.duma-rent.com Operation Drive Controls Gear Lever For: 4 Speed Powershift Transmission (Barrel Select) ............Page 65 For: 3/4 Speed Powershift Transmission ................. Page 65 (For: 4 Speed Powershift Transmission (Barrel Select)) CAUTION Gear or direction changes on this machine will only occur at a predetermined speed, this may result in gear/direction change delays.

  • Page 80: Transmission Dump Switch

    www.duma-rent.com Operation Drive Controls Figure 54. A Gear up shift button B Gear downshift button Transmission Dump Switch The transmission dump allows you to disconnect the transmission to improve the hydraulic performance by reducing the engine load. There are two options depending on machine type and control lever(s). Transmission Dump Switch (Non-single Lever Thumb Wheel) The transmission dump switch can be found on the control levers.

  • Page 81: Steer Mode Control

    www.duma-rent.com Operation Drive Controls When you apply brakes the transmission automatically engages 4 wheel drive, this ensures the machine brakes on all four wheels. If towing a heavy load in damp conditions hunting can sometimes be felt through the transmission, this can be resolved by selecting 4 wheel drive.

  • Page 82: Instruments

    www.duma-rent.com Operation Instruments Instruments Instrument Panel The instrument panel, warning indicator and warning lights are located in the dash panel at the front of the cab in the line of sight from the operator's seat. It provides the interface with the machines electronic system. You can navigate to different screen shown on the LCD display screen using the up and down navigation buttons and information switch.
  • Page 83 Long Press - Press the information button longer than 2s allows the operator to enter the displayed screen. Main Display Screens Start-Up Screen When the ignition switch is switched on the JCB logo is displayed. After 3s the display will show the normal operating mode screen. Figure 56.
  • Page 84 www.duma-rent.com Operation Instruments E Clock/machine hours F Machine status tray (stabilisers, joystick configuration) Travel speed - Normally displays the speed of the machine. This section is also used when a notification is activated. Transmission FNR and gear information - Displays the selected gear and direction of the machine. The current selected gear will be displayed in solid yellow.
  • Page 85 www.duma-rent.com Operation Instruments 2WD active Driver not in seat Auto Steer Mode Symbols (if installed) Displays the active steer mode in the solid grey. When changing between the steer modes the amber icons will flash at 1s intervals. If there is a fault a symbol will flash rapidly, and a notification will be displayed. Table 17.
  • Page 86 www.duma-rent.com Operation Instruments Table 18. No wheels are aligned Front wheels are aligned Rear wheels are aligned All wheels are aligned Machine Status Symbols Displays the status of various hydraulic systems of the machine. There are more icons than space in the Machine Status Tray.
  • Page 87 www.duma-rent.com Operation Instruments Joystick configuration - placing pattern Joystick configuration - loader pattern Exhaust After Treatment Symbols Table 20. (Amber) Manual regeneration inhibited (Amber) Manual regeneration required (Amber-flashing) Manual regeneration running (Amber) High exhaust outlet temperature (Amber) Engine fault (Red) Service regeneration required (Red) Stop engine 9831/9950-7...

  • Page 88: Notification Screens

    www.duma-rent.com Operation Instruments Auto-stop Symbols Table 21. Auto-stop Active Auto-stop Inhibited Notification Screens The notification screen displays temporary operator messages such as operator requested mode changes, user input screens, etc. When a request becomes active, the primary information is displayed on the left half of the main display screen and the notification is displayed on the right side of the main display screen.
  • Page 89 www.duma-rent.com Operation Instruments Icon Event Buzzer Audible/Visual. Cab heater fan speed setting. Number of yellow bars corresponds to current fan speed setting. Audible/Visual. Constant auxiliary operational position. Audible/Visual. Constant auxiliary stored position. Audible/Visual. Constant auxiliary cancelled. Audible/Visual. 2nd auxiliary ac- tive.
  • Page 90 www.duma-rent.com Operation Instruments Icon Event Buzzer Audible/Visual. Tilt lock active. Audible/Visual. Tilt lock cancelled. Audible/Visual. Transmission dis- connect active. Audible/Visual. Transmission dis- connect cancelled. Audible/Visual. LLMC (Longitudinal Load Moment Control) override ac- tive. Audible/Visual. Air conditioning system active. Audible/Visual. Air conditioning system cancelled.
  • Page 91 www.duma-rent.com Operation Instruments Icon Event Buzzer Audible/Visual. Auto reverse fan cancelled. Audible/Visual. Grid heater/glow plugs active. Audible/Visual. 2WD active. Audible/Visual. 2WD cancelled. Audible/Visual. Stabilizer isolation active. Audible/Visual. Stabilizer isolation cancelled. Audible/Visual. Immobiliser active. No Audible/Visual. Operator has left the seat, with transmission en- gaged and park brake disengaged (if applicable).
  • Page 92 www.duma-rent.com Operation Instruments Icon Event Buzzer Audible/Visual. Service/Aux vent- ing activated Audible/Visual. Auto-stop counter Regeneration Not Inhibited Regeneration Inhibited Secondary Level Display Screens Pressing the information switch and navigation arrows will take the operator to the secondary level display screens. Press the information switch for less than 2s to cycle through the main screens.

  • Page 93: Fuel Information

    www.duma-rent.com Operation Instruments Figure 61. Machine status screen Figure 62. Service information screen Figure 63. Machine setup screen Figure 64. Fault log screen Press the information switch for longer than 2s to enter the displayed screen. Press the arrows to navigate up and down within the main screens. Fuel Information To see the fuel information: Go to the fuel information screen.

  • Page 94: Machine Status

    www.duma-rent.com Operation Instruments Figure 66. Exit screen Press the information switch again for 20s to return to the default operating screen (home screen). Machine Status To see the machine status information: Go to the machine status screen. Press the information switch for more than 2s to see the machine status. Figure 67.
  • Page 95 www.duma-rent.com Operation Instruments Press the navigation arrows to switch between the screens. Figure 70. A Engine hours B Machine type C Machine serial number D Next service interval Figure 71. E Time to next service F Right hand cluster hardware version number G Right hand cluster software version number H Tyre diameter Figure 72.

  • Page 96: Machine Setup

    www.duma-rent.com Operation Instruments Figure 75. Exit screen Press the information switch again for more than 2s to return to the default operating screen (home screen). Machine Setup The machine setup screen allows the operator to configure the time, date, brightness, etc. Press the information switch for less than 2s to display the main screen.
  • Page 97 www.duma-rent.com Operation Instruments 2. Press the navigation arrows to select the clock. Figure 79. 3. Press the information switch for more than 2 seconds. 4. Press the navigation arrows to select the time format. Figure 80. 5. Press the information switch for 2 seconds to adjust the clock. 6.
  • Page 98 www.duma-rent.com Operation Instruments Figure 82. 3. Press the information switch for more than 2 seconds. 4. Press the navigation arrows to select the date format. Figure 83. 5. Press the information switch for 2 seconds to adjust the date. 6. Press the information switch for 2 seconds to switch between the day, month and year values. Use the arrows to adjust the values.

  • Page 99: Fault Log

    www.duma-rent.com Operation Instruments 4. Press the navigation arrows to increase or decrease the brightness. Figure 86. 5. Press the information switch for more than 2 seconds to confirm the setup. Auto-stop Auto-stop function is enabled as default. Operator can turn on or off the auto-stop whilst operating the machine. The timing of the auto-stop system can not be altered.
  • Page 100 www.duma-rent.com Operation Instruments Figure 89. Figure 90. Figure 91. Warning/Fault Icons There are three levels of warnings each is represented by a different colour. Depending on the level of severity it may or may not be acknowledgeable by the operator. Some icons are available at all three levels but are not shown below: •...

  • Page 101: Warning Lights

    www.duma-rent.com Operation Instruments Coolant level Air filter Battery HVAC Engine oil level Brake light TPMS (Tyre Pressure Moni- toring System) Warning Lights CAUTION If any of the audible/visual warnings operate while the engine is running, stop the engine as soon as it is safe to do so and rectify the fault.

  • Page 102: Emission Control System

    www.duma-rent.com Operation Instruments Emission Control System During regeneration the operator may experience changes in engine noise and smell emitted from the machine, which is normal. If the exhaust temperature reaches a certain limit during a regeneration, then the HEST (High Exhaust System Temperature) lamp will illuminate, this is not a fault.

  • Page 103: Manual Regeneration

    www.duma-rent.com Operation Instruments Figure 94. A Aftertreatment symbol • The operator must navigate to the aftertreatment menu and acknowledge or inhibit the regeneration. • Once in the aftertreatment menu the operator can scroll through the options by momentarily pressing the info button.
  • Page 104 www.duma-rent.com Operation Instruments Figure 97. If the amber prompts for a manual regeneration are ignored or continually inhibited the engine will de-rate and operate with limited power and torque indicated by the engine MIL (Malfunction Indicator Lamp) lamp and an error code on the display.

  • Page 105: Tyre Pressure Monitoring System (Tpms)

    An error code will be displayed on the display. The red regeneration symbol will be displayed. Contact your JCB dealer. At the end of a service regeneration it is necessary to replace the engine oil. A service regeneration will not be supported under warranty. Refer to Figure 101.
  • Page 106 Operation Instruments Only use JCB approved tyre sealant when TPMS sensors are fitted. The use of other commercially available tyre sealant may impair the functioning of the sensor. To support the machine additional TPMS information is available to the machine owner through the JCB LiveLink system.

  • Page 107: Getting The Machine Moving

    www.duma-rent.com Operation Getting the Machine Moving Getting the Machine Moving General WARNING Operating the machine on hillsides can be dangerous if proper precautions are not taken. Ground conditions can be changed by rain, snow, ice etc. Check the site carefully. Going uphill, reverse when unloaded or travel forwards when loaded.
  • Page 108 www.duma-rent.com Operation Getting the Machine Moving 6. Release the park brake, continuing to apply the foot brake. The park brake must be released before selecting forward or reverse. 7. Select forward or reverse. Dependant on software version, you cannot engage drive or operate the hydraulic controls unless you are sat in the seat.

  • Page 109: Slopes

    www.duma-rent.com Operation Slopes Slopes General WARNING Make sure that you have been trained and are familiar with the use of machines on slopes, and understand the adverse effects that slopes and site conditions can have on stability. Never use the machine on a slope if you do not understand the recommended practices for the use of machines in such applications.
  • Page 110 www.duma-rent.com Operation Slopes • As stated in the moving with suspended loads section ensure that the load is not carried higher than 300mm from the ground and the boom is not elevated above 45°. Figure 104. A 8° (15%) maximum. B 6°...

  • Page 111: Working On Slopes

    www.duma-rent.com Operation Slopes Working on Slopes Lifting Operations on Slopes WARNING Conducting lifting operations on slopes can be dangerous. The machine can become laterally unstable and tip over. You and others can be seriously injured or killed. WARNING Stop the machine and apply the park brake before conducting any lifting operations. It is recommended that the machine is operated on solid, level ground where possible for the maximum machine stability.
  • Page 112 www.duma-rent.com Operation Slopes Figure 107. A Lateral Inclinometer B Chassis level C Stabilisers level It is recommended that the machine should be operated on firm, level ground wherever possible for maximum machine stability. If the machine cannot be made level across its width, the operator must complete a risk assessment before attempting a lifting operation.

  • Page 113: Driving The Machine

    www.duma-rent.com Operation Driving the Machine Driving the Machine Steer Modes Wheel Alignment Manual Steer Mode Before you select the required steer mode, make sure the wheels are aligned correctly. To align the wheels: 1. Stop the machine. Set the gear lever to neutral position. 2.
  • Page 114 www.duma-rent.com Operation Driving the Machine 2.1. Sensors on the axles prevent the steer mode from changing until the wheels are aligned in the straight ahead position. 2.2. A symbol will appear on the main screen display to show the requested change of mode. This will flash whilst the mode change takes place.

  • Page 115: Limited Slip Differential (Lsd)

    www.duma-rent.com Operation Driving the Machine Figure 112. A Foot brake applied confirmation B Park brake applied confirmation C Hand symbol 4. Press and hold the information switch to select steer mode override. The hand symbol must be illuminated and the foot brake and handbook must be applied. 5.

  • Page 116: Connecting The Trailer

    www.duma-rent.com Operation Driving the Machine Refer to: Static Dimensions (Page 295). Connecting the Trailer Mechanical Tow Hitch To operate the pickup hitch, use the procedure as follows: 1. Engage the park brake. 2. Adjust the mirror(s) to obtain a good view of the tow hitch area. 3.
  • Page 117 www.duma-rent.com Operation Driving the Machine Figure 114. A Set switch B Switch light C Position I D Position II 5. Operate the switch to raise the hitch, this will remove the load on locking lever. Refer to Figure 115. Figure 115. A Handle B Switch C Switch...
  • Page 118 www.duma-rent.com Operation Driving the Machine 7.2. It is essential that the tow bar is parallel with the machine when the pickup hitch is raised and locked. 7.3. If a helper is available to manoeuvre the trailer he should stand well clear of the machine until the tow hitch is correctly aligned with the trailer towing eye.
  • Page 119 WARNING Do not use the rear auxiliary for trailer braking. If trailer brakes are required and the optional trailer brake valve is not installed, first consult your JCB dealer. WARNING Make sure the trailer hitch has correctly engaged and locked before driving off.
  • Page 120 www.duma-rent.com Operation Driving the Machine 5.1. Disconnect the hydraulic hitch hose from the socket and reconnect to stowage socket. Refer to Figure 119. 5.2. Connect the trailer auxiliary hose to socket. Set the trailer switch to position I, the switch light should be extinguished.

  • Page 121: Operating Levers/Pedals

    www.duma-rent.com Operation Operating Levers/Pedals Operating Levers/Pedals General WARNING Make sure it is clear overhead before raising the boom. Keep an adequate safe distance from all electrical power lines. Contact your local power company for safety procedures. CAUTION Keep the machine controls clean and dry. Your hands and feet could slide off slippery controls. If that happens you could lose control of the machine.
  • Page 122 www.duma-rent.com Operation Operating Levers/Pedals 4. To change back to main boom extend/retract, fully retract the inner boom and then press switch off position. Figure 120. A Boom raise B Boom lower C Boom/inner boom extend D Boom/inner boom retract E Carriage tilt forward F Carriage tilt back G Inner boom extend/retract switch H Inner boom (if fitted)
  • Page 123 www.duma-rent.com Operation Operating Levers/Pedals Figure 121. A Boom raise B Boom lower C Boom extend D Boom retract E Carriage tilt forward F Carriage tilt back Dual Lever Control Loading Pattern The main lever movements and their effects are described below. 1.
  • Page 124 www.duma-rent.com Operation Operating Levers/Pedals Figure 122. A Boom raise B Boom lower C Boom extend D Boom retract E Carriage tilt forward F Carriage tilt back Placing Pattern The main lever movements and their effects are described below. 1. To raise the boom pull the lever back. 2.

  • Page 125: Chassis Levelling Controls

    www.duma-rent.com Operation Operating Levers/Pedals Figure 123. A Boom raise B Boom lower C Boom extend D Boom retract E Carriage tilt forward F Carriage tilt back Chassis Levelling Controls The chassis levelling (sway) control switch allows the machine to be levelled from side to side. The chassis levelling ram will stay in any position until you move it with the switch.

  • Page 126: Stabiliser Controls

    www.duma-rent.com Operation Operating Levers/Pedals Use the indicator rod to check that the machine is level, when the indicator rod is level with the top end of tube the machine is square to the axles. Figure 125. A Indicator rod B Tube When the indicator rod is above the tube, the machine is swayed right.
  • Page 127 If the lights do not illuminate do not use the machine until the fault is investigated and corrected. Please contact your JCB dealer for any service requirements. The lights will flash if the stabiliser leg is in the down position but the machine weight is not fully supported.
  • Page 128 www.duma-rent.com Operation Operating Levers/Pedals Figure 127. A Stabiliser isolation switch B Stabiliser control levers Refer to: Console Switches (Page 19). C Stabiliser legs - lower D Stabiliser legs - raise 9831/9950-7...

  • Page 129: Auxiliary Circuit Controls

    www.duma-rent.com Operation Operating Levers/Pedals Figure 128. A Stabiliser isolation switch B Stabiliser control levers Refer to: Console Switches (Page 19). C Stabiliser legs - lower D Stabiliser legs - raise Auxiliary Circuit Controls WARNING Before operating the auxiliary control system make sure that you are aware of all safety notices that apply to the attachment you are using.
  • Page 130 www.duma-rent.com Operation Operating Levers/Pedals Single Lever Control The auxiliary control switch is a proportional roller type. It is spring loaded to it's central position. The speed of operation depends on how far the switch is moved. Figure 129. A Thumb switch B Button - activate Auxiliary I (AUX I) 1.
  • Page 131 www.duma-rent.com Operation Operating Levers/Pedals 3. The constant flow mode symbol on the screen will indicate the active and inactive mode. Refer to: Instruments (Page 68). 4. Use the thumb switch to adjust the speed and direction of the constant flow mode. 5.

  • Page 132: Dual Lever Control

    www.duma-rent.com Operation Operating Levers/Pedals Table 24. C band The bucket will oscillate with a larger amplitude, and tend to crowd more over time. This has been designed for assisting the operator with flicking material up and out of the bucket D band The bucket will oscillate with a larger amplitude, and tend to dump more over time.
  • Page 133 www.duma-rent.com Operation Operating Levers/Pedals Figure 132. A Forward B Backward C Button - AUX II Auxiliary I (AUX I) 1. Turn on the hitch/auxiliary selector switch. 2. Move the control lever forward or backward depending on the attachment installed and the function required.

  • Page 134: Lifting And Loading

    The SWL at different boom positions is shown on the load charts in the cab. The limits shown on the load chart only apply to a machine installed with JCB approved tyres. To obtain the limits shown the tyres must be in good condition and inflated to the correct pressure. If you are in doubt, contact your JCB dealer.
  • Page 135 Check the relevant load chart is available for any alternative carriage or attachment. Where appropriate, the load chart shows the part number of the carriage or attachment it refers to. If you are not sure of the correct load chart to use, contact your JCB distributor for advice. Renew any damaged or missing charts.
  • Page 136 www.duma-rent.com Operation Lifting and Loading Load Charts for Suspended Loads A suspended load is defined as any object that is lifted in such a way that it can swing freely, whilst it is being hoisted lowered and horizontally moved.(e.g. a load attached to a hook or shackle.) As a result load charts for suspended loads are related to fork mounted hook, extension jib or carriage mounted shackle attachments.
  • Page 137 www.duma-rent.com Operation Lifting and Loading Figure 134. Example A Machine designation B Attachment C Stabilisers condition D Read operator's manual E Maximum in service wind speed F Parkbrake released, maximum travel speed G Boom controls- Do not operate when travelling H Operate on hard standing J Keep the load within 0.3m from the ground K Keep the boom below 45°...
  • Page 138 www.duma-rent.com Operation Lifting and Loading W Do not travel on sides slope exceeding the X Maximum load specified in the load chart for the angle specified attachment. Y Load/reach table 9831/9950-7...

  • Page 139: Using The Load Charts

    www.duma-rent.com Operation Lifting and Loading Using the Load Charts 1. Check what boom attachment is installed on your machine, then refer to the correct load chart in the cab. 2. You must know the weight of a load before picking or placing it. 3.

  • Page 140: Boom Indicators

    www.duma-rent.com Operation Lifting and Loading 5.1. You will see on the chart that lines run from the boom angle and extension scales, through the coloured area of the chart. Find where the lines for your readings cross. If they cross inside your maximum load segment or to the right of it the load is within safe limits.

  • Page 141: Interlocks

    A Inclinometer Interlocks For: 531-70 [STV 3L], 535-95 [STV 3L] ................. Page 127 For: 540-170 Work Platform [STV 3L], 540-170 [STV 3L], 540-200 Work Platform [STV 3L], 540-200 [STV 3L], 540V180 Work Platform [STV 3L], 540V180 [STV 3L] ........... Page 127 For: 533-105 [STV 3L], 535V125 [STV 3L], 540V140 Work Platform [STV 3L], 540V140 [STV 3L] ..............................

  • Page 142: Boom Extend

    www.duma-rent.com Operation Lifting and Loading Figure 139. Boom and Stabiliser Operation Boom Raise You cannot enter zone A3 unless the stabilisers are deployed. If the stabilisers are not deployed and you try to enter zone A3 the following symbol will appear on the right hand cluster: Figure 140.
  • Page 143 www.duma-rent.com Operation Lifting and Loading Figure 142. Figure 143. Table 25. 540-170 540-200 540-180 45° 45° 45° 73° 73° 73.6° 7.09m 7.2m 7.95m 10.64m 13.5m 11.44m (For: 533-105 [STV 3L], 535V125 [STV 3L], 540V140 Work Platform [STV 3L], 540V140 [STV 3L]) Introduction Your machine has a system of interlocks to prevent the operation of the machine beyond default limits unless the boom and/or the stabiliser legs are moved to the correct position.
  • Page 144 www.duma-rent.com Operation Lifting and Loading Figure 144. Boom and Stabiliser Operation Boom Raise You cannot enter zone A2 unless the stabilisers are deployed. If the stabilisers are not deployed and you try to enter zone A2 the following symbol will appear on the right hand cluster: Figure 145.

  • Page 145: Longitudinal Load Moment Indicator (Llmi)

    The system is an enhancement to the devices that JCB currently install as standard, for example load charts and boom extension markers. The system must not to be relied upon as the primary source of protection for the machine.
  • Page 146 The loadcharts in JCB Loadall machines show the lowest of all limits. Therefore where a limit is shown on a load chart which is not a longitudinal stability limit, the LLMI control system may allow the machine to exceed the load chart limit whilst staying within the stability limitations of the machine.

  • Page 147: Operation

    www.duma-rent.com Operation Lifting and Loading Figure 149. A Maximum distance from the front of the tyres to B Maximum distance from the front of the tyres to the load centre derived from the LLMI the load centre derived from the flip chart C Load on forks at 0.5m load centres Operation WARNING Look at the indicator lights frequently while lifting or handling loads.

  • Page 148: Diagnostic Fault Codes

    If a system fault is detected, a combination of LED will indicate a fault code. Testing WARNING If the Load Moment Indicator is faulty, contact your JCB dealer. Do not try to repair it yourself. Test the LLMI unit daily: 1.

  • Page 149: Longitudinal Load Moment Control (Llmc)

    If a fault code is displayed, switch the ignition key off and on again. If the fault clears, the display will return to normal. Do not use the machine if the fault does not clear. Stop and park the machine as soon as safety permits. Switch off the engine. Contact your JCB distributor. Figure 150. Calibration faults Figure 151.
  • Page 150 A Boom retract B Boom raise The system is an enhancement to the devices that JCB currently install as standard, for example loadcharts and boom extension markers. The system must not to be relied upon as the primary source of protection for the machine.

  • Page 151: Warm Up Procedure

    www.duma-rent.com Operation Lifting and Loading Operation Figure 155. A Green colourLED (Light Emitting Diode) (x3) B Amber colour LED (x1) C Red colour LED (x1) D Green colour LED (x1) E Display button The system is permanently on when the ignition is on. The system automatically switches between active (green symbol illuminated) and not active (amber symbol illuminated) depending on the machine status.

  • Page 152: System Override

    www.duma-rent.com Operation Lifting and Loading 3.2. Extend and retract the boom five times. 3.3. Dump and crowd the carriage five times. 4. Perform the LLMC functional check. System Override WARNING In override mode the machine is not protected. Only use it to reduce the load moment of the machine.

  • Page 153: Functional Check

    Functional Check WARNING If the Load Moment Indicator is faulty, contact your JCB dealer. Do not try to repair it yourself. WARNING Do not tamper, modify or try to disable the LLMC as this can damage the operation of both the LLMI and LLMC permanently.

  • Page 154: Working With The Boom

    WARNING In the event of a breakdown with the boom not in the normal travel position, contact your local JCB dealer for assistance with getting the boom and load back to a safe position. CAUTION Make sure you know the weight of the load before trying to lift it. Raise the load only a few centimetres at first, to check that the machine is stable.

  • Page 155: Fixed Loads

    The JCB approved forks for this machine have a plate which shows their maximum load capacity rating. The rating shows the maximum load capacity in kilograms that the forks can carry safely at the maximum load centre of 500mm.

  • Page 156: Repositioning The Forks

    www.duma-rent.com Operation Working with the Boom Repositioning the Forks WARNING Loads can fall off incorrectly spaced forks. Always space the forks correctly for the load. Make sure the forks are completely under the load before lifting. CAUTION The forks are heavy. Make sure suitable lifting equipment is used to support and transport them. 1.
  • Page 157 www.duma-rent.com Operation Working with the Boom Figure 159. A Angle = 90° 5. Engage the park brake and put the transmission in neutral. 6. Do not use the side of the forks or carriage to move the load, this can cause damage to the forks. Figure 160.

  • Page 158: Working With Bales

    www.duma-rent.com Operation Working with the Boom 13. Carefully drive the machine to the unloading point. Unloading CAUTION Never unload the forks by stopping the machine suddenly. Follow the procedures in the Operator Manual for unloading. 1. Approach the unload straight-on, with all wheels straight. 2.

  • Page 159: Working With Irregular Loads

    www.duma-rent.com Operation Working with the Boom Figure 163. A Boom raise B Carriage retract Lowering Bales 1. Move the boom so that the bale is directly above its required position. 2. Lower the boom and tilt the carriage forward, so that the forward edge of the bale rests on the ground. Figure 164.

  • Page 160: Stacking Loads

    www.duma-rent.com Operation Working with the Boom 3.2. If it is not palleted, it may be necessary to secure the load to the forks using suitable chains. 4. Stop the engine before allowing anyone to approach the forks. Figure 166. Stacking Loads Box Pallets Stack the box pallets straight and square.

  • Page 161: Filling The Shovel

    www.duma-rent.com Operation Working with the Boom Figure 168. A Wedge Filling the Shovel WARNING When loading with material from a high bank or pile, remove any overhang first. Watch out for sliding material. If overhanging material falls, you and your machine could be buried. Your machine can be used with a wide variety of attachments, for example shovels.

  • Page 162: Loading A Truck

    www.duma-rent.com Operation Working with the Boom Figure 170. 7. Try to fill the shovel in one pass. Half full shovels are less productive. 8. When moving the load, roll the shovel fully back to prevent spillage. Loading a Truck Put the truck(s) at an angle of about 45° to the pile. This cuts out unnecessary manoeuvring. Allow enough distance for the shovel to reach its unloading height while you are travelling, without slowing down.

  • Page 163: Adjusting The Boom

    www.duma-rent.com Operation Working with the Boom lines. Do not lift loads when wind speeds are high enough to cause the load to swing. Before moving, ensure a visibility assessment has been carried out, to ensure both operator & banksman are fully aware of blind spots caused by the load or rigging.
  • Page 164 www.duma-rent.com Operation Working with the Boom Figure 173. To re-phase the boom sections: • Hold the control in the retract position with the engine at high speed until the boom sections are fully retracted. 9831/9950-7...

  • Page 165: Heating, Ventilating And Air-Conditioning (Hvac)

    www.duma-rent.com Operation Heating, Ventilating and Air-Conditioning (HVAC) Heating, Ventilating and Air-Conditioning (HVAC) General The operator must set the controls to obtain the best working environment in the operator station. Close doors and windows for best HVAC (Heating Ventilation Air Conditioning) performance and in dusty conditions.

  • Page 166: Face Level Fan

    www.duma-rent.com Operation Heating, Ventilating and Air-Conditioning (HVAC) Face Level Fan Figure 175. A Switch - fan on/off The face level fan is installed on the left side dash. Press the switch to turn on/off the face level fan. This functions only when the ignition key is in position I. 9831/9950-7...

  • Page 167: Fire Extinguisher

    www.duma-rent.com Operation Fire Extinguisher Fire Extinguisher General Location The fire extinguisher is stowed in a bracket behind the seat. Keep the fire extinguisher in the bracket until you need to use it. Operation WARNING Do not use the fire extinguisher in a confined space. Make sure that the area is well ventilated during and after using the fire extinguisher.

  • Page 168: Moving A Disabled Machine

    Using a higher voltage supply will damage your machine's electrical system. If you do not know the voltage of your booster (slave) supply, then contact your JCB dealer for advice. Do not attempt to jump-start the engine until you are sure of the voltage of the booster (slave) supply. The negative (-) terminal on the battery is connected to frame earth.
  • Page 169 The procedure for doing this will depend on the machine's condition and its hydraulic circuits. For assistance, contact your JCB dealer. 4. Attach the draw-bars or chains to the points marked with a recovery decal. Do not use the trailer hitch or any part of the machine other than those marked with a recovery decal.

  • Page 170: Lifting The Machine

    www.duma-rent.com Operation Lifting the Machine Lifting the Machine General DANGER Do not stand underneath the raised load during the lifting/lowering procedure. Stand clear and to one side until the load has been safely lowered. Make sure that the area is clear of other people before lowering the load.

  • Page 171: Transporting The Machine

    www.duma-rent.com Operation Transporting the Machine Transporting the Machine General WARNING The safe transit of the load is the responsibility of the transport contractor and driver. Any machine, attachments or parts that may move during transit must be adequately secured. CAUTION Before moving the machine onto the trailer, make sure that the trailer and ramp are free from oil, grease and ice.
  • Page 172 www.duma-rent.com Operation Transporting the Machine Figure 179. Figure 180. 6. The correct tie down positions are identified on the machine by their labels. Refer to Figure 181. 9831/9950-7...
  • Page 173 Table 29. Tie down chain angles Model A angle ° B angle ° Minimum Minimum chain grade chain grade (kN) 531-70 front 10mm grade 46kN 'T' 8 BS 818-2 (63KN lashing capacity) 531-70 rear 10mm grade 44kN 'T' 8 BS 818-2...
  • Page 174 www.duma-rent.com Operation Transporting the Machine Model A angle ° B angle ° Minimum Minimum chain grade chain grade (kN) 535-125 rear 10mm grade 70kN 'T' 8 BS 818-2 (100KN lash- ing capacity) 540-V140 10mm grade 77kN front 'T' 8 BS 818-2 (100KN lash- ing capacity) 540-V140 rear 15...

  • Page 175: Operating Environment

    7. Protect the machine when its not in use. Park the machine inside a building or cover it with a tarpaulin. 8. Install a cold weather starting aid. In very low temperatures (less than the value shown) additional starting aids may be needed. For example are fuel, oil and coolant heaters. Ask your JCB dealer for advice. Temperature: -18°C (-0.4°F) 9.

  • Page 176: Operating In High Temperatures

    www.duma-rent.com Operation Operating Environment 3. For every degree below 0 degrees Celsius the engine should be left at low idle for one minute. 4. With the engine at approximately 1500 rpm: 4.1. Raise and lower the lift arm five times. 4.2.

  • Page 177: Refuelling

    Do not use fuel to clean the machine. When filling with fuel, choose a well aired and ventilated area. Notice: Consult your fuel supplier or JCB dealer about the suitability of any fuel you are unsure of. Low Fuel Levels If you operate the machine on very low fuel levels, then air can enter the fuel system.
  • Page 178 www.duma-rent.com Notes: 9831/9950-7...

  • Page 179: Working With Attachments

    Always check the instruction supplied with the attachment, or if in doubt check with a JCB Dealer for advice. Some specification limits may also be shown on the data/rating plate on the attachment.

  • Page 180: Connecting/Disconnecting Hydraulic Hoses

    If the Q-Fit Carriage is changed or modified it may alter the setting of the LMI (Load Moment Indicator). Always consult your JCB distributor. Attachments will help increase the productivity of your machine, for more information contact your JCB distributor.
  • Page 181 www.duma-rent.com Attachments Working with Attachments 4.4. Use the hose clamps (where possible) to support long hose runs and keep the hoses away from moving parts, etc. Figure 183. 4.5. To allow for length changes when the hose is pressurised, do not clamp at the bend. The curve absorbs the change.

  • Page 182: Quick Release Couplings

    www.duma-rent.com Attachments Working with Attachments 6.4. Check for indications of leakage at the hose connections. Correct, as necessary. Quick Release Couplings WARNING The external surfaces of the couplings must be clean before connecting or disconnecting. Ingress of dirt will cause fluid leaks and difficulty in connecting or disconnecting. You could be killed or seriously injured by faulty quick release couplings.
  • Page 183 www.duma-rent.com Attachments Working with Attachments • Never subject the couplings to external forces, especially side load. This can decrease the life of the coupling or cause failure. • Never allow the torsional forces transmitted from the hoses to unscrew/screw together the couplings. •...

  • Page 184: Quick-Fit Carriage

    www.duma-rent.com Attachments Quick-fit Carriage Quick-fit Carriage General WARNING Do not retract the locking pins when the attachment is raised, the attachment could fall and kill or seriously injure someone. Retract the locking pins only after the attachment has been placed on the ground. WARNING Keep other people clear of the area while you disengage the attachment.

  • Page 185: Removing Attachments

    www.duma-rent.com Attachments Quick-fit Carriage 8. At the carrier, operate the lower carrier locking lever to engage the lower carrier lock pins. When using the carrier lock plates rotate the hook plate locking levers into their closed positions and secure them with the upper locking pins.
  • Page 186 www.duma-rent.com Attachments Quick-fit Carriage Figure 188. A Lever - Hydraulic pin locking isolation valve B Lever - Hydraulic pin locking isolation valve (horizontal position) (vertical position) C Attachment hook plates D Hose(s) couplings Installing Attachments 1. Make the machine safe. Refer to: Stopping and Parking (Page 51).
  • Page 187 www.duma-rent.com Attachments Quick-fit Carriage 12. If the attachment is hydraulically operated, connect the hose(s) to the couplings. Refer to Figure 188. Refer to: Connecting/Disconnecting Hydraulic Hoses (Page 166). Removing Attachments 1. Make the machine safe. Refer to: Stopping and Parking (Page 51). 2.

  • Page 188: Tow Hitches

    www.duma-rent.com Attachments Tow Hitches Tow Hitches General Introduction WARNING Do not exceed the permitted limits on trailer gross weight or hitch load. The machine may become unstable. WARNING Examine the tow hitch and the trailer draw bar towing ring for signs of wear before each use. A badly installed or worn hitch or towing ring could cause loss of the trailer and injury to yourself or other people.
  • Page 189 Attachments Tow Hitches Table 30. Hydraulic pick-up hitch Ring (ISO (International Orga- JCB 40kN nization for Standardization) 5692-1:2004) Internal Ø 50, Out- erØ110, Section Ø30. Ring (ISO 20019-1:2001) Internal Ø 50, Out- erØ110 - 132, Section Ø 30 to 41...
  • Page 190 www.duma-rent.com Attachments Tow Hitches Rockinger automatic Ring (ISO 5692-2:2002) Internal 810U140 hitch ø 30.6mm Ø 40, Outer Ø100, Section Ø 42 Rockinger manual hitch H6 Ring (ISO 5692-2:2002) Internal 850D70 Ø 40, Outer Ø100, Section Ø 42 Rockinger ladder hitch - Ring (ISO 5692-1:2004) Internal 850D70 piton...

  • Page 191: Hydraulic Tow Hitch

    www.duma-rent.com Attachments Tow Hitches Ladder hitch with Ring (ISO 5692-2:2002) Internal 881C27 Rockinger fixed clevis Ø 40, Outer Ø100, Section Ø 42 hitch Ladder hitch - piton Ring (ISO 5692-1:2004) Internal 881I27 Ø 50, OuterØ110, Section Ø 30 Rockinger ladder hitch Ring (ISO 5692-2:2002) Internal 881A27 (only)
  • Page 192 www.duma-rent.com Attachments Tow Hitches Figure 189. A Mirror B Locking lever 3. Make sure the auxiliary/hitch switchover lever is in the position shown. Figure 190. A Auxiliary/hitch switchover lever 4. To select the rear auxiliary circuit, set switch to position I. The switch light should be extinguished. Figure 191.

  • Page 193: Mechanical Tow Hitch

    www.duma-rent.com Attachments Tow Hitches C Position I D Position II 5. Operate the switch to raise the hitch, this will remove the load on locking lever. Figure 192. A Lever B Lower the hitch position C Raise the hitch position 6.
  • Page 194 www.duma-rent.com Attachments Tow Hitches To operate the pickup hitch, use the procedure as follows: 1. Apply the park brake. 2. Adjust the mirror(s) to obtain a good view of the pickup hitch. 3. Engage the Trailer: Figure 193. A Mirror B Secure pin 3.1.
  • Page 195 www.duma-rent.com Attachments Tow Hitches Figure 194. A Set switch B Control direction - forward C Control direction - backward D Electric socket E Trailer brake connector F Rear auxiliary connector G Position 1 H Position 2 1. To select the rear auxiliary circuit, set switch to position 1. The switch light should be extinguished. 2.

  • Page 196: Side-Shift Carriage

    www.duma-rent.com Attachments Side-Shift Carriage Side-Shift Carriage General The side-shift carriage allows you to accurately position both forks simultaneously with 100mm of sideways movement with a load on the forks. The forks are controlled by the auxiliary control in the cab. Operate the auxiliary controls as required to move the forks.
  • Page 197 www.duma-rent.com Attachments Side-Shift Carriage Figure 196. A Fork fingers - left hand B Fork fingers - right hand Manual Fork Spacing WARNING Forks are heavy. Take care when spacing forks or folding back the forks. 1. Raise the boom. 2. Tilt the carriage forward until both the left and right forks disengage from the cylinder. 3.
  • Page 198 www.duma-rent.com Attachments Side-Shift Carriage Figure 198. A Carriage locking pins B Hook plates C Side-shift - central position 6. Apply the park brake, set the transmission to neutral. 7. Align the sections of the side-shift attachment centrally. 8. Remove the protective cover for clarity. 9.

  • Page 199: Maintenance

    www.duma-rent.com Attachments Side-Shift Carriage Figure 199. A Hoses Removing the Side-shift Carriage WARNING Keep other people clear of the area while you disengage the attachment. If a second person is to be involved in this procedure, ensure that they keep clear of the machine and attachment until signalled by you to proceed.
  • Page 200 www.duma-rent.com Attachments Side-Shift Carriage Figure 200. Protective cover removed for clarity. 9831/9950-7...

  • Page 201: Fork Positioner

    www.duma-rent.com Attachments Fork Positioner Fork Positioner General The fork positioner allows the operator to accurately position both the forks simultaneously with 410mm of sideways movement on each fork when under load. The forks are controlled by the auxiliary control in the cab. Operate the auxiliary controls as required to move the forks.
  • Page 202 www.duma-rent.com Attachments Fork Positioner Installing the Fork Positioner 1. Position the attachment. 1.1. Make sure the attachment is on firm, level ground. 1.2. Make sure the attachment will not roll over. 2. Remove the existing attachment. 3. Leave the Q-fit carrier lock pin disengaged. 4.

  • Page 203: Precision Placer

    A Mass of attachment B Lost load centre Note: If no load chart or data plate is available, contact JCB Service before using the attachment. Fork Spacing WARNING Loads can fall off incorrectly spaced forks. Always space the forks correctly for the load. Make sure the forks are completely under the load before lifting.
  • Page 204 www.duma-rent.com Attachments Precision Placer Figure 203. C Valve block D Valve control Configuration Figure 204. P Long adaptors Q Short adaptors Figure 205. Single and Dual Aux Operations E Single aux (long adaptors - aux 1) F Dual aux (long adaptors - aux 1, short adaptors aux 2) G Fork position function H Side shift function...
  • Page 205 www.duma-rent.com Attachments Precision Placer Single Aux Operation 1. Make sure the machine is switched off and the hydraulic lines are vented. Refer to machine Operator's Manual. 2. Connect the 2 hoses with the longer adaptors to auxiliary 1 of the machine. Refer to Figure 205. Refer to Figure 204.

  • Page 206: Installation

    The precision placer is designed for fitment to a JCB Q-fit carriage. The attachment is to be used with forks compatible with a 57mm (2 1/4") diameter bar and a nominal fork width of 100mm (4").
  • Page 207 www.duma-rent.com Attachments Precision Placer 2.1. Make sure the attachment is on firm, level ground. 2.2. Make sure the attachment will not roll over. 3. Refer to machine Operator's manual for coupling procedure. 4. Connect all the hydraulic hoses. Refer to: Connecting/Disconnecting Hydraulic Hoses (Page 166). Pallet Forks to Precision Placer 1.
  • Page 208 www.duma-rent.com Attachments Precision Placer Removing Precision Placer from Q-Fit Carriage 1. Lower the attachment on to firm level ground. 2. Vent the auxiliary hydraulics. Refer to machine Operator's manual. 2.1. For dual aux hydraulics both circuits need venting to allow easy re-coupling. 2.2.

  • Page 209: General

    www.duma-rent.com Attachments Jibs Jibs General Safety WARNING Never exceed the capacity of the Loadall. Also make sure that the load rating for slings, chains, or straps used with the hook are equal to or exceed the rating of both the Loadall and the hook, if not; always limit the load to the lowest rated part of the lifting system.

  • Page 210: Roof Truss Jib

    www.duma-rent.com Attachments Jibs Figure 208. Extension jib Roof Truss Jib This a Q-fit attachment. It gives your machine greater reach and height. This attachment is supplied with test certificates for its fabrication, its hook and its shackle. The safe working load is stamped on a plate mounted on the attachment.
  • Page 211 www.duma-rent.com Attachments Jibs Figure 210. A Skid B Lynch pin C Pin D Jib- fully extended E Jib- extended position 1 F Jib- extended position 2 G Jib- fully retracted 1. Remove the load and lower the jib to the ground. 2.
  • Page 212 www.duma-rent.com Attachments Jibs Figure 211. A Placing position B Travel position C Lynch pin D Stops E Bar F Stops When in the travel position, do not extend the boom and do not raise the boom more than 45° To change the jib position: 1.

  • Page 213: Shackle

    www.duma-rent.com Attachments Shackle Shackle General WARNING Do not exceed the safe working load limit stated on the shackle. Carriage mounted shackle The carriage mounted shackle allows the machine to safely carry slung loads. Figure 212. A Shackle B Screw Pin Installing 1.

  • Page 214: Work Platforms

    In the case of uncertainty, guidance should be sought from the relevant local or government authority. JCB supply integrated work platforms solely for use in Europe which comply with the requirements of European Directive 2006/42/EC. Contact your dealer for further details. Health and safety legislation also varies from territory to territory.

  • Page 215: Fork-Mounted Hook

    www.duma-rent.com Attachments Hooks Hooks Fork-Mounted Hook WARNING The attachment is heavy. Take care when lifting and handling it. Use suitable lifting equipment. Make sure the lifting equipment is in good condition. Make sure the lifting equipment complies with all pertinent regulations. Wear gloves and safety shoes. WARNING Never exceed the capacity of the Loadall.
  • Page 216 This may be needed every six months or at least annually in many countries to meet and comply with local legislation and for insurance purposes. Contact your JCB dealer for further advice. 9831/9950-7...

  • Page 217: Preservation And Storage

    www.duma-rent.com Preservation and Storage Cleaning Preservation and Storage Cleaning General WARNING When using cleaning agents, solvents or other chemicals, you must adhere to the manufacturer's instructions and safety precautions. WARNING Airborne particles of light combustible material such as straw, grass, wood shavings, etc. must not be allowed to accumulate within the engine compartment or in the propshaft guards (when installed).

  • Page 218: Preparation

    www.duma-rent.com Preservation and Storage Cleaning • Use a spray nozzle with a 40° wide angle spray pattern. • Keep the nozzle at least 300mm (11.81 in) away from and perpendicular (at 90° degrees) to the decal. The machine must always be greased (if appropriate) after pressure washing or steam cleaning. Preparation 1.

  • Page 219: Checking For Damage

    www.duma-rent.com Preservation and Storage Checking For Damage Checking For Damage General Refer to the individual condition checks throughout the Maintenance section. Refer to: Maintenance Schedules (Page 216). 9831/9950-7...

  • Page 220: Storage

    www.duma-rent.com Preservation and Storage Storage Storage General If the machine will not be used for an extended period, you must store the machine correctly. If you prepare the machine carefully and apply on-going care you can prevent deterioration and damage to the machine while it is in storage.

  • Page 221: Take Out Of Storage

    www.duma-rent.com Preservation and Storage Storage 3. Examine all fluid levels. If necessary, add more fuel. 4. Install a charged battery. 5. Start the engine. 6. Operate the hydraulic controls. Make sure that the hydraulic functions operate correctly. 7. Prepare the machine for storage. Take out of Storage 1.

  • Page 222: Security

    The Construction Equipment Association is managing the scheme, and Datatag are providing the security material and support. JCB is fully supportive of the CESAR initiative and will offer it as a factory option across the range.

  • Page 223: Maintenance Introduction

    JCB trained specialist competent person. JCB dealer service engineers have been trained by JCB to do such specialist tasks, and are equipped with the necessary special tools and test equipment to do such tasks, thoroughly, safely, accurately and efficiently.

  • Page 224: Service/Maintenance Agreements

    The health and safety of the operator and bystanders could be compromised. A parts book for your machine is available from your JCB dealer. The parts book will help you identify parts and order them from your JCB dealer.

  • Page 225: Maintenance Safety

    The air tank contains air at high pressure. Prior to any work being carried out the Air Trailer Brake System, the system pressure must be discharged by a JCB dealer, as the sudden release of the air may cause serious injury or death.
  • Page 226 The accumulators contain hydraulic fluid and gas at high pressure. Prior to any work being carried out on systems incorporating accumulators, the system pressure must be discharged by a JCB dealer, as the sudden release of the hydraulic fluid or gas may cause serious injury or death.

  • Page 227: Fluids And Lubricants

    Completely wipe off any spilt fuel which could cause a fire. There could be a fire and injury if you do not follow these precautions. Hygiene JCB lubricants are not a health risk when used correctly for their intended purposes. However, excessive or prolonged skin contact can remove the natural fats from your skin, causing dryness and irritation.

  • Page 228: Warning Symbols

    www.duma-rent.com Maintenance Maintenance Safety Handling CAUTION The temperature of the hydraulic oil will be high soon after stopping the machine. Wait until it cools before beginning maintenance. New Oil There are no special precautions needed for the handling or use of new oil, beside the normal care and hygiene practices.
  • Page 229 www.duma-rent.com Maintenance Maintenance Safety Skin In the case of excessive skin contact, wash with soap and water. Spillage Absorb with sand or a locally approved brand of absorbent granules. Scrape up and remove to a chemical disposal area. Fires WARNING Do not use water to put out an oil fire. This will only spread it because oil floats on water. Extinguish oil and lubricant fires with carbon dioxide, dry chemical or foam.

  • Page 230: Maintenance Schedules

    www.duma-rent.com Maintenance Maintenance Schedules Maintenance Schedules General WARNING Maintenance must be done only by suitably qualified and competent persons. Before doing any maintenance make sure the machine is safe, it must be correctly parked on firm, level ground. To prevent anyone starting the engine, remove the ignition key. Disconnect the battery (by means of the battery isolator if installed) when you are not using electrical power.

  • Page 231: Pre-Start Cold Checks, Service Points And Fluid Levels

    www.duma-rent.com Maintenance Maintenance Schedules Pre-start Cold Checks, Service Points and Fluid Levels Table 33. Component Task 500 1,000 1,500 2,000 ENGINE Oil level Check Replace Oil and Filter (2, 3, 4) Check Coolant Quality and Level (18) Drain and Refill Cooling System (inorganic) (18) Cooling System (OAT - organic acid...
  • Page 232 www.duma-rent.com Maintenance Maintenance Schedules Component Task 500 1,000 1,500 2,000 Steering Stops (if fitted) Security Wheel Nut Security Check Tire Pressures/Condition Check Wheel Alignment Check Transmission Strainer Clean Security and grease Drive Shafts and Universal Joints (10) Axle Pivots and Linkages Grease HYDRAULICS Oil Level...
  • Page 233 (18) Check which coolant type is installed in the machine before topping up the coolant. Mixing of different coolant types is not recommended and may result in invalidation of the warranty offered by JCB. In the event of mixing or if the coolant type is to be changed, the coolant circuit should be completely drained and flushed twice with clean water before re-filling with fresh coolant.

  • Page 234: Functional Tests And Final Inspection

    www.duma-rent.com Maintenance Maintenance Schedules Functional Tests and Final Inspection Table 34. Component Task 500 1,000 1,500 2,000 ENGINE Check Idle speed Check Torque converter stall speed Check Max. no load speed Check Exhaust system security Air inlet system security Check TRANSMISSION, AXLES AND STEERING Steering - Operation/Phasing Check...
  • Page 235 Check Fit for Purpose Test (1) First 100 Hours Service only, to be completed by your JCB Distributor. (2) Jobs which should only be done by a specialist. (3) This may be required every six months or at least annually in some countries to meet and comply with legislation and for insurance purposes.

  • Page 236: Maintenance Positions

    www.duma-rent.com Maintenance Maintenance Positions Maintenance Positions General WARNING Maintenance must be done only by suitably qualified and competent persons. Before doing any maintenance make sure the machine is safe, it must be correctly parked on firm, level ground. To prevent anyone starting the engine, remove the ignition key. Disconnect the battery (by means of the battery isolator if installed) when you are not using electrical power.

  • Page 237: Maintenance Position - Boom Raised

    WARNING Make sure that you use the correct JCB maintenance strut for the machine. Make sure that the safety strut is only used with the correct JCB retaining bolt or securing device. Never substitute this bolt or securing device, always use the correct JCB part.
  • Page 238 www.duma-rent.com Maintenance Maintenance Positions Lift Arm Raised If you raise the lift arm to get access for maintenance, you must install the maintenance strut on the lift arm. Before you install the maintenance strut remove any load on the forks and empty shovels or attachments. Figure 218.
  • Page 239 WARNING Make sure that you use the correct JCB maintenance strut for the machine. Make sure that the safety strut is only used with the correct JCB retaining bolt or securing device. Never substitute this bolt or securing device, always use the correct JCB part.
  • Page 240 www.duma-rent.com Maintenance Maintenance Positions Figure 221. Lift arm raised Install the Maintenance Strut 1. Make the machine safe. 2. Retract the lift arm. 3. Raise the lift arm. 4. Stop the engine and remove the ignition key. 5. Remove the maintenance strut from its stowage position. Figure 222.
  • Page 241 www.duma-rent.com Maintenance Maintenance Positions Figure 223. 508-66, 540-200 A Maintenance strut 6. Install the maintenance strut. 7. Place the strut around the lift ram piston rod. Secure it in position with the strap. Figure 224. A Maintenance strut B Lift arm 8.
  • Page 242 WARNING Make sure that you use the correct JCB maintenance strut for the machine. Make sure that the safety strut is only used with the correct JCB retaining bolt or securing device. Never substitute this bolt or securing device, always use the correct JCB part.
  • Page 243 www.duma-rent.com Maintenance Maintenance Positions 6. Install the maintenance strut. 7. Place the strut around the lift ram piston rod. Secure it in position with the strap. Figure 227. A Maintenance strut B lift arm 8. To prevent any chance of the lift arm creeping down and trapping your fingers, the lift arm should be lowered onto the strut.

  • Page 244: Service Points

    www.duma-rent.com Maintenance Service Points Service Points General Engine Compartment Figure 228. A Air filter B Transmission oil dipstick C Water separator D Radiator E Engine oil filter F Drive belt guard G Engine oil dipstick H Engine oil filler cap J Coolant expansion tank 9831/9950-7...
  • Page 245 www.duma-rent.com Maintenance Service Points Battery Isolator Figure 229. A Battery isolator 9831/9950-7...
  • Page 246 www.duma-rent.com Maintenance Service Points Hydraulic Oil Level Indicator and Filler Figure 230. A Hydraulic oil level indicator B Label - hydraulic oil filling point C Hydraulic tank filler cap Figure 231. A Secondary hydraulic tank filler cap - If applicable Machines with External Sight Gauge On some machines the sight gauge is mounted externally.
  • Page 247 www.duma-rent.com Maintenance Service Points Axles Arrangement Figure 233. Machines with Powered Track Rods A Axle fill/level plug 9831/9950-7...
  • Page 248 www.duma-rent.com Maintenance Service Points Alternate arrangement Figure 234. Machines with Powered Track Rods A Axle fill/level plug Figure 235. Machines with Double Acting Cylinders A Axle fill/level plug 9831/9950-7...
  • Page 249 www.duma-rent.com Maintenance Service Points Filling the Tank Figure 236. A Fuel cap Gearbox Breather Figure 237. A Gearbox breather 9831/9950-7...

  • Page 250: Access Apertures

    www.duma-rent.com Maintenance Access Apertures Access Apertures General When moved to their maintenance position, the access panels give you access to parts or areas of the machine that are not required during machine operation. Before you operate the machine, make sure that all of the access panels are correctly in their closed or installed positions.

  • Page 251: Engine Compartment Cover

    www.duma-rent.com Maintenance Access Apertures Figure 239. A Bolts B Battery compartment cover Close 1. Position the battery compartment cover. 2. Install the bolts. 3. Tighten the bolts to the correct torque value. Engine Compartment Cover Open WARNING The engine has exposed rotating parts. Switch off the engine before working in the engine compartment.

  • Page 252: Rear Cover

    www.duma-rent.com Maintenance Access Apertures Close 1. Push the cover down. 2. Make sure that the cover is correctly latched. 3. Make sure to lock the engine cover. Rear Cover Open the rear cover for access to the filler cap and sight glass. Open 1.
  • Page 253 www.duma-rent.com Maintenance Access Apertures Figure 242. A Undershields B Bolts C Lips Install 1. Install the undershields. 2. Before you install the bolts, make sure the lips on the two smaller undershields are located above the frame. 9831/9950-7...

  • Page 254: General

    www.duma-rent.com Maintenance Tools Tools General All tools must be kept in the toolbox (if installed) when not in use. 9831/9950-7...

  • Page 255: Lubrication

    www.duma-rent.com Maintenance Lubrication Lubrication General CAUTION Waxoyl contains turpentine substitute which is flammable. Keep flames away when applying Waxoyl. Waxoyl can take a few weeks to dry completely. Keep flames away during the drying period. Do not weld near the affected area during the drying period. Take the same precautions as for oil to keep Waxoyl off your skin.
  • Page 256 www.duma-rent.com Maintenance Lubrication Rear axle rear trunion Right hand boom pivot Disp. ram eye end Left hand boom pivot Figure 244. Front axle front trunion Right hand axle hub bottom Right hand axle hub top Sway ram dump end Sway ram eye end Front axle rear trunion Left hand stab ram eye end Left hand stab ram dump end...

  • Page 257: General

    www.duma-rent.com Maintenance Attachments Attachments General Lubricate Where applicable, refer to the specific manufacturers manual for instructions on the lubrication of optional attachments. Check (Condition) Where applicable, refer to the specific manufacturers manual for instructions on the maintenance of optional attachments. 9831/9950-7...

  • Page 258: Body And Framework

    www.duma-rent.com Maintenance Body and Framework Body and Framework General Clean Keep all intakes and grilles clear from snow, ice and debris. Debris can collect under the boom. Remove all debris from under the boom. Thoroughly dry the piston rams and protect them with clean transmission or hydraulic oil if necessary. Check (Condition) 1.
  • Page 259 www.duma-rent.com Maintenance Body and Framework Figure 246. A Upper grease point B Lower grease point Figure 247. A Grease points - stabiliser legs (if installed) 9831/9950-7...

  • Page 260: Boom

    Boom General Lubricate For: 531-70 [STV 3L] ......................Page 246 For: 533-105 [STV 3L], 535-95 [STV 3L] ................Page 247 For: 540-170 Work Platform [STV 3L], 540-170 [STV 3L] ............Page 248 For: 535V125 [STV 3L], 540V140 Work Platform [STV 3L], 540V140 [STV 3L] ..... Page 249 For: 540-200 Work Platform [STV 3L], 540-200 [STV 3L] ............

  • Page 261: For: 533-105 [Stv 3L], 535-95 [Stv 3L]

    www.duma-rent.com Maintenance Boom (For: 533-105 [STV 3L], 535-95 [STV 3L]) Figure 249. Make the machine safe. Refer to: Maintenance Positions (Page 222). Apply grease to all the points and linkages. 9831/9950-7...

  • Page 262: For: 540-170 Work Platform [Stv 3L], 540-170 [Stv 3L]

    www.duma-rent.com Maintenance Boom (For: 540-170 Work Platform [STV 3L], 540-170 [STV 3L]) Figure 250. Make the machine safe. Refer to: Maintenance Positions (Page 222). Apply grease to all the points and linkages. 9831/9950-7...

  • Page 263: For: 535V125 [Stv 3L], 540V140 Work Platform [Stv 3L], 540V140 [Stv 3L]

    www.duma-rent.com Maintenance Boom (For: 535V125 [STV 3L], 540V140 Work Platform [STV 3L], 540V140 [STV 3L]) Figure 251. Make the machine safe. Refer to: Maintenance Positions (Page 222). Apply grease to all the points and linkages. (For: 540-200 Work Platform [STV 3L], 540-200 [STV 3L]) CAUTION Waxoyl contains turpentine substitute which is flammable.
  • Page 264 www.duma-rent.com Maintenance Boom Figure 252. 1. Make the machine safe. 2. Apply grease to all the points and linkages where applicable. 9831/9950-7...

  • Page 265: Boom Chains

    Boom Chains Lubricate (For: 540-200 Work Platform [STV 3L], 540-200 [STV 3L]) The boom drive chains should be sprayed with JCB Chain Lubricant at the periods stated in the Service Schedules Spray the chain with an even coating, avoid over oiling.
  • Page 266 www.duma-rent.com Maintenance Boom Figure 254. A Drive Chains Check (Condition) (For: 540-200 Work Platform [STV 3L], 540-200 [STV 3L], 540V180 Work Platform [STV 3L], 540V180 [STV 3L]) Boom Chains 1. Position the machine on firm level ground 2. Fully extend the boom and then retract by approximately 1m. Measure the gap between the underside of the extend chain and the top of the intermediate boom at the mid-point of each span.
  • Page 267 www.duma-rent.com Maintenance Boom 3. The boom should then be retracted before repeating steps . Visual indication of chain stretch and tension: Chain tension can be observed by watching the amount of slack in the upper chains during the retract cycle. Additional features to the front and rear cab side of the boom also give indication to the tension or stretch condition of the chains.
  • Page 268 www.duma-rent.com Maintenance Boom Figure 259. Figure 260. 9831/9950-7...
  • Page 269 www.duma-rent.com Maintenance Boom Figure 261. Damage may occur to the boom structure or internals if boom is allowed to achieve this condition Figure 262. A gap between the outer and 1st intermediate, even though the remaining booms are together. This means that the upper chains have stretched and need to be tightened 9831/9950-7...

  • Page 270: Operator Station

    ROPS/FOPS certification. A failure to adhere to these precautions can cause death or injury to the operator. For assistance, contact your JCB dealer. 1. Make the machine safe. Refer Maintenance, Maintenance positions. 2. Check the structure for damage.

  • Page 271: Controls

    www.duma-rent.com Maintenance Operator Station 4. Check that the belt mounting bolts are undamaged, correctly installed and tight. 5. Check that the buckle assembly is undamaged and operates correctly. Controls Check (Operation) Check the operation of the non-hydraulic and non-electrical operator station controls. 9831/9950-7...

  • Page 272: Engine

    www.duma-rent.com Maintenance Engine Engine General Clean WARNING Airborne particles of light combustible material such as straw, grass, wood shavings, etc. must not be allowed to accumulate within the engine compartment or in the propshaft guards (when installed). Examine these areas frequently and clean at the beginning of each work shift or more often if required. Before opening the engine cover, make sure that the top is clear of debris.

  • Page 273: Oil

    3. Check the engine and the area below for oil leaks. 4. Close the engine cover (if applicable). 5. If necessary, contact your JCB dealer. Check (Level) WARNING Never check the oil level or add oil with the engine running. Be careful of hot lubricating oil.
  • Page 274 www.duma-rent.com Maintenance Engine 8.5. Check the oil level, if necessary add more oil. 8.6. Replace the dipstick 8.7. Replace the filler cap. 9. Close and secure the engine cover (if applicable). Replace CAUTION Oil will gush from the hole when the drain plug is removed. Keep to one side when you remove the plug.

  • Page 275: Front End Accessory Drive (Fead) Belt

    www.duma-rent.com Maintenance Engine 5. Clean the sump drain plug. Install the sump drain plug with a new O-ring. Tighten the sump drain plug to the correct torque value. Torque: 45–55N·m 6. Loosen and remove the filter housing drain plug. Drain the oil. 7.

  • Page 276: Emissions Control System

    Maintenance Engine 4. Inspect the belt for cracks, fraying or missing pieces. If necessary contact your JCB dealer for service requirements. 5. When maintenance is complete, make sure that the guard is installed. Do not operate the machine unless the guard is installed correctly.

  • Page 277: Air Filter

    Air Filter Air Filter General Check (Condition) Notice: Do not modify or install non JCB approved components to the engine induction system, otherwise the engine emissions will be compromised. 1. Make the machine safe. 2. Get access to induction system.

  • Page 278: Dust Valve

    www.duma-rent.com Maintenance Air Filter Figure 264. A Air holes B Prefilter element C Main element D Safety element E Main housing Dust Valve Check (Condition) • Check the dust valve for rips/tears. • Check there are no obstructions. • Check that the dust valve is free of dirt and dust. •...

  • Page 279: Fuel System

    Duration: 10s 6. Start the engine and make sure it runs smoothly. 7. If the engine fails to start or does not run smoothly contact your JCB dealer. Check (Leaks) 1. Make the machine safe.

  • Page 280: Fuel Filter

    www.duma-rent.com Maintenance Fuel System 7. Clean and install the outer threaded cover. Do not over tighten the cover. 8. Install the cover plate. Clean the Filler Cap 1. Make the machine safe. Refer to: Maintenance Positions (Page 222). 2. Get access to the fuel filler cap. Refer to: Service Points (Page 230).
  • Page 281 www.duma-rent.com Maintenance Fuel System Figure 265. A Filter Element B Filter Element locking ring C Water separator bowl locking ring D Water separator bowl E WIF (Water in Fuel) sensor/water separator F WIF sensor electrical connector drain valve 5.1. Any fuel and water mix drained must be disposed of in accordance with local regulations. Do not reuse the drained fuel.

  • Page 282: Water Separator

    www.duma-rent.com Maintenance Fuel System Table 35. Torque Values Item 27 ± 2.7 27 ± 2.7 Water Separator Clean 1. Make the machine safe. 2. Get access to the filter. 3. If there is water but no sediment, open the tap to drain the water. If there is any sediment in the bowl replace the fuel filter element.

  • Page 283: Cooling System

    Notice: Check which coolant type is installed in the machine before topping up the coolant. Mixing of different coolant types is not recommended and may result in invalidation of the warranty offered by JCB. In the event of mixing or if the coolant type is to be changed, the coolant circuit should be completely drained and flushed twice with clean water before re-filling with fresh coolant.

  • Page 284: Cooling Pack

    www.duma-rent.com Maintenance Cooling System Cooling Pack Clean 1. Make the machine safe. Do not stop the engine at this time. Refer to: Maintenance Positions (Page 222). 2. Position the machine in a relatively clean area before reversing the fan to make sure that other debris is not drawn in.

  • Page 285: General

    WARNING Faulty brakes can kill. If you have to top up the brake oil reservoir frequently, get the brake system checked by your JCB Dealer. Do not use the machine until the fault has been rectified. Notice: Using incorrect fluid could damage the system. See Fluids, Capacities and Lubricants for the correct fluid.

  • Page 286: Park Brake

    If the machine moved during the test, drive the machine to a suitable flat location and contact your JCB dealer to inspect the brake.

  • Page 287: Service Brake

    2. Start the engine. 3. Wait for the brake accumulator amber warning symbol to extinguish from the main display screen. 4. If the brake accumulator red warning symbol illuminates do not use the machine. Contact your JCB dealer for any service requirements.

  • Page 288: Gearbox

    www.duma-rent.com Maintenance Gearbox Gearbox Check (Level) 1. Make the machine safe with the boom lowered. 2. Start the engine and operate at low idle for few minutes. This allows the oil to fill the filter, pump, torque converter, oil cooler and hoses. Duration: 4min 3.

  • Page 289: General

    Axles General Lubricate For: 531-70 [STV 3L], 533-105 [STV 3L], 535-95 [STV 3L], 535V125 [STV 3L], 540V140 Work Platform [STV 3L], 540V140 [STV 3L], 540V180 Work Platform [STV 3L], 540V180 [STV 3L] ..............................Page 275 For: 540-170 Work Platform [STV 3L], 540-170 [STV 3L], 540-200 Work Platform [STV 3L], 540-200 [STV 3L] ..........................

  • Page 290: Oil

    www.duma-rent.com Maintenance Axles Figure 272. Figure 273. Check (Level) Notice: The oil level must be checked with the machine level, otherwise a false indication of the amount of oil will be given. Notice: It is not recommended that the machine be driven with the axle partially filled with oil. 1.

  • Page 291: General

    Where a wheel has been replaced, ensure that the offset of the central nave plate of the wheel rim is as specified for the tyre by JCB. If in doubt request additional information from your JCB Dealer. Remove 1.
  • Page 292 www.duma-rent.com Maintenance Wheels Figure 274. 7. Lower the machine to the ground. 8. Torque tighten the nuts in the sequence shown. Refer to: Torque Values (Page 362). Checking the Wheel Nut Torques WARNING If, for whatever reason, a wheel stud is renewed, all the studs for that wheel must be changed as a set, since the remaining studs may have been damaged.

  • Page 293: General

    Use suitable lifting equipment if necessary. Where a replacement tyre is necessary, seek advice from your JCB Dealer. Always use a trained tyre technician to replace the tyre onto the rim. Tyres are critical to the machines stability and performance. Always select replacement tyres from approved options for your machine as listed.
  • Page 294 www.duma-rent.com Maintenance Tyres 1. Prepare the wheel. Before you add air to the tyre, make sure it is correctly fitted on the machine or installed in a tyre inflation cage. Refer to Figure 275. Figure 275. 2. Prepare the equipment. 2.1.

  • Page 295: Tyre Pressure Monitoring System

    Replacing a sensor requires the new sensor MAC address to be assigned to the correct machine location in the JCB Live Link system. In addition to standard tyre fitting procedures the following instructions must be followed for the correct replacement of a TPMS (Tyre Pressure Monitoring System) sensor.
  • Page 296 www.duma-rent.com Maintenance Tyre Pressure Monitoring System Make a note that there are four small holes in the centre of the top surface of the sensor, if the holes are blocked the sensor will fail to monitor the tyre pressure. Make sure that the holes are clear during sensor installation and tyre fitting.

  • Page 297: General

    www.duma-rent.com Maintenance Propshafts Propshafts General Lubricate Make the machine safe. Apply grease to all the points and linkages shown. Refer to Figure 278. Figure 278. 9831/9950-7...

  • Page 298: Hydraulic System

    www.duma-rent.com Maintenance Hydraulic System Hydraulic System General Discharge CAUTION Allow the hydraulic fluid temperature to cool before removing the hydraulic tank filler cap. Open the cap slowly to prevent oil being forced out of the filler neck. CAUTION Do not run the machine with the hydraulic tank filler cap removed. Notice: Do not allow dirt to enter the system.

  • Page 299: Services

    1. Make the machine safe. 2. Open the access covers. 3. Check the hydraulic hoses for damage. 4. Close the access covers. 5. If necessary, contact your JCB dealer. Services Check (Operation) Check the operation of all the hydraulic services. Check for: •...

  • Page 300: Cylinders / Rams

    Extend each ram fully, one at a time and visually examine for score marks, dents, leaks or similar defects. Make the machine safe before inspecting each ram. If a ram piston appears defective, contact your service engineer or JCB dealer. Hose Burst Check Valves Check (Operation) WARNING Keep people clear of the machine while you do these checks.

  • Page 301: Electrical System

    www.duma-rent.com Maintenance Electrical System Electrical System General Check (Operation) Make sure all of the electrical equipment operates correctly, for example: • Switches • Warning lights • Beacon • Alarms • Horn • Wipers • Hourmeter/display • Battery • Lights All defective equipment must be repaired before the machine is used. Check (Condition) Examine the electrical circuits regularly for: •...
  • Page 302 www.duma-rent.com Maintenance Electrical System Figure 279. 4. Apply a thin layer of petroleum jelly to the terminal posts. Connect WARNING Keep metal watch straps and any metal fasteners on your clothes, clear of the positive (+) battery terminal. Such items can short between the terminal and nearby metal work. If it happens you can get burned.

  • Page 303: Battery Isolator

    Notice: Do not isolate the machine electrics when the engine is running, this may cause damage to the machine electrics. 1. Isolate the machine electrics. 2. Make sure that the machine electrics are isolated. A defective isolator must be repaired before the machine is used. For more information, contact your JCB dealer. Fuses Replace Notice: Always replace fuses with ones of correct ampere rating to avoid electrical system damage.

  • Page 304: Primary Fuses

    www.duma-rent.com Maintenance Electrical System Figure 280. A Fuses B Cover C Screws (x2) Primary Fuses To further protect the machine wiring harnesses and electrical circuits, a fuse link box is fitted as shown. Remember to check the main circuit fuses as well as the primary fuses shown on this page. Your machine may not be equipped with all the fuses shown.

  • Page 305: Window Washer

    www.duma-rent.com Maintenance Electrical System The relays are separated into banks. Each relay position in each bank is numbered to aid identification. Refer to: Relays (Page 366). 1. Make the machine safe. Refer to: Stopping and Parking (Page 51). 2. Open the cab door. 3.
  • Page 306 www.duma-rent.com Maintenance Electrical System Figure 283. A Knob 3. Locate the washer bottle in the panel in front of the cab. 4. Remove the washer bottle filler cap. Refer to Figure 284. Figure 284. A Filler cap 5. Check the water level. If necessary, fill in the washer bottle with clean water. Add de-icing fluid to prevent it freezing.

  • Page 307: Fire Extinguisher

    www.duma-rent.com Maintenance Miscellaneous Miscellaneous Fire Extinguisher Check (Condition) In addition to the operator check the extinguisher must be serviced every 12 months by a suitably qualified person. 1. Examine the fire extinguisher for damage and leaks. 2. Make sure the fire extinguisher is correctly attached. 3.
  • Page 308 www.duma-rent.com Notes: 9831/9950-7...

  • Page 309: Technical Data

    Static Dimensions Technical Data Static Dimensions Dimensions For: 531-70 [STV 3L] ......................Page 296 For: 533-105 [STV 3L] ......................Page 298 For: 535-95 [STV 3L] ......................Page 300 For: 535V125 [STV 3L] ......................Page 302 For: 540-170 Work Platform [STV 3L], 540-170 [STV 3L] ............Page 304 For: 540V140 Work Platform [STV 3L], 540V140 [STV 3L] ...........

  • Page 310: For: 531-70 [Stv 3L]

    Technical Data Static Dimensions (For: 531-70 [STV 3L]) Figure 286. Table 36. Item Description Dimension Overall height 2,500mm Overall width (over tyres) 2,280mm Inside width of cab (between win- 940mm dows) Front track 1,870mm Wheelbase 2,750mm Overall length to front tyres...
  • Page 311 www.duma-rent.com Technical Data Static Dimensions Figure 287. M1/M2 R1/R2 U1/U2 V1/V2 Table 37. Item Description Dimension Fork length 1,060mm Fork length 1,200mm Turn radius over forks at spacing S 4,640mm Turn radius over forks at spacing S 4,760mm Outside turn radius over tyres 3,720mm Inside turn radius to cab 1,100mm...

  • Page 312: For: 533-105 [Stv 3L]

    www.duma-rent.com Technical Data Static Dimensions (For: 533-105 [STV 3L]) Figure 288. Table 38. Item Description Dimension Overall height 2,500mm Overall width (over tyres) 2,280mm Inside width of cab (between win- 940mm dows) Front track 1,870mm Wheelbase 2,750mm Overall length to front tyres 4,360mm Overall length to front of carriage 5,330mm...
  • Page 313 www.duma-rent.com Technical Data Static Dimensions Figure 289. M1/M2 R1/R2 U1/U2 V1/V2 Table 39. Item Description Dimension Fork length 1,060mm Fork length 1,200mm Turn radius over forks at spacing S 4,930mm Turn radius over forks at spacing S 5,050mm Outside turn radius over tyres 3,720mm Inside turn radius to cab 1,100mm...

  • Page 314: For: 535-95 [Stv 3L]

    www.duma-rent.com Technical Data Static Dimensions (For: 535-95 [STV 3L]) Figure 290. Table 40. Item Description Dimension Overall height 2,500mm Overall width (over tyres) 2,280mm Inside width of cab (between win- 940mm dows) Front track 1,870mm Wheelbase 2,750mm Overall length to front tyres 4,360mm Overall length to front of carriage 4,930mm...
  • Page 315 www.duma-rent.com Technical Data Static Dimensions Figure 291. R1/R2 U1/U2 Table 41. Item Description Dimension Fork length 1,060mm Fork length 1,200mm Turn radius over forks at spacing S 4,610mm Turn radius over forks at spacing S 4,720mm Outside turn radius over tyres 3,720mm Inside turn radius to cab 1,070mm...

  • Page 316: For: 535V125 [Stv 3L]

    www.duma-rent.com Technical Data Static Dimensions (For: 535V125 [STV 3L]) Figure 292. Table 42. Item Description Dimension Overall height 2,600mm Overall width (over tyres) 2,320mm Inside width of cab (between win- 940mm dows) Front track 1,900mm Wheelbase 2,750mm Overall length to front tyres 4,750mm Overall length to front of carriage 5,790mm...
  • Page 317 www.duma-rent.com Technical Data Static Dimensions Figure 293. R1/R2 U1/U2 Table 43. Item Description Dimension Fork length 1,060mm Fork length 1,200mm Turn radius over forks at spacing S 5,020mm Turn radius over forks at spacing S 5,140mm Outside turn radius over tyres 3,800mm Inside turn radius to cab 1,080mm...

  • Page 318: For: 540-170 Work Platform [Stv 3L], 540-170 [Stv 3L]

    www.duma-rent.com Technical Data Static Dimensions (For: 540-170 Work Platform [STV 3L], 540-170 [STV 3L]) Figure 294. Table 44. Item Description Dimension Overall height 2,740mm Overall width (over tyres) 2,430mm Inside width of cab (between win- 940mm dows) Front track 1,970mm Wheelbase 2,750mm Overall length to front tyres...
  • Page 319 www.duma-rent.com Technical Data Static Dimensions Figure 295. R1/R2 U1/U2 Table 45. Item Description Dimension Fork length 1,060mm Fork length 1,200mm Turn radius over forks at spacing S 5,440mm Turn radius over forks at spacing S 5,560mm Outside turn radius over tyres 4,230mm Inside turn radius to cab 1,460mm...

  • Page 320: For: 540V140 Work Platform [Stv 3L], 540V140 [Stv 3L]

    www.duma-rent.com Technical Data Static Dimensions (For: 540V140 Work Platform [STV 3L], 540V140 [STV 3L]) Figure 296. Table 46. Item Description Dimension Overall height 2,600mm Overall width (over tyres) 2,320mm Inside width of cab (between win- 940mm dows) Front track 1,900mm Wheelbase 2,750mm Overall length to front tyres...
  • Page 321 www.duma-rent.com Technical Data Static Dimensions Figure 297. R1/R2 U1/U2 Table 47. Item Description Dimension Fork length 1,060mm Fork length 1,200mm Turn radius over forks at spacing S 5,400mm Turn radius over forks at spacing S 5,520mm Outside turn radius over tyres 3,800mm Inside turn radius to cab 1,100mm...

  • Page 322: For: 540-200 Work Platform [Stv 3L], 540-200 [Stv 3L]

    www.duma-rent.com Technical Data Static Dimensions (For: 540-200 Work Platform [STV 3L], 540-200 [STV 3L]) Figure 298. Table 48. Item Description Dimension Overall height 2,740mm Overall width (over tyres) 2,430mm Inside width of cab (between win- 940mm dows) Front track 1,970mm Wheelbase 2,750mm Overall length to front tyres...
  • Page 323 www.duma-rent.com Technical Data Static Dimensions Figure 299. R1/R2 U1/U2 Table 49. Item Description Dimension Fork length 1,060mm Fork length 1,200mm Turn radius over forks at spacing S 5,870mm Turn radius over forks at spacing S 5,990mm Outside turn radius over tyres 4,230mm Inside turn radius to cab 1,460mm...

  • Page 324: For: 540V180 Work Platform [Stv 3L], 540V180 [Stv 3L]

    www.duma-rent.com Technical Data Static Dimensions (For: 540V180 Work Platform [STV 3L], 540V180 [STV 3L]) Figure 300. Table 50. Item Description Dimension Overall height 2,700mm Overall width (over tyres) 2,320mm Inside width of cab (between win- 940mm dows) Front track 1,900mm Wheelbase 2,750mm Overall length to front tyres...
  • Page 325 www.duma-rent.com Technical Data Static Dimensions Figure 301. R1/R2 U1/U2 Table 51. Item Description Dimension Fork length 1,060mm Fork length 1,200mm Turn radius over forks at spacing S 5,380mm Turn radius over forks at spacing S 5,500mm Outside turn radius over tyres 3,800mm Inside turn radius to cab 1,060mm...

  • Page 326: Weights

    For: 540-200 Work Platform [STV 3L], 540-200 [STV 3L] ............Page 312 For: 535-95 [STV 3L] ......................Page 313 For: 531-70 [STV 3L] ......................Page 313 For: 540V140 Work Platform [STV 3L], 540V140 [STV 3L] ........... Page 313 For: 540V180 Work Platform [STV 3L], 540V180 [STV 3L] ........... Page 313...
  • Page 327 10,120kg 1,890kg 12,010kg (For: 531-70 [STV 3L]) The figures below are based on the machine operating mass as defined by ISO 6016:2008, describing operating mass as; The base machine mass with equipment and empty attachment in the most usual configuration (machine with...
  • Page 328 www.duma-rent.com Technical Data Static Dimensions including a 75kg operator, a full fuel tank and all operating fluids (hydraulic oil, transmission oil, engine oil, engine coolant, Adblue/DEF etc.) at the level specified by the manufacturer. Table 59. Axle Load Total Lift Capacity Axle Load at Maximum Lift Total Capacity...

  • Page 329: Visibility Diagrams

    For: 535V125 [STV 3L] ......................Page 316 For: 540V140 Work Platform [STV 3L], 540V140 [STV 3L] ........... Page 319 For: 531-70 [STV 3L] ......................Page 322 For: 535-95 [STV 3L] ......................Page 325 For: 540-170 Work Platform [STV 3L], 540-170 [STV 3L] ............Page 328 For: 533-105 [STV 3L] ......................

  • Page 330: For: 535V125 [Stv 3L]

    www.duma-rent.com Technical Data Static Dimensions (For: 535V125 [STV 3L]) Figure 302. Mirror Setup SECTOR A SECTOR B SECTOR C SECTOR D SECTOR E SECTOR F A Left hand mirror B Right hand mirror C Right hand wide angle D Rear mounted wide angle 9831/9950-7...
  • Page 331 www.duma-rent.com Technical Data Static Dimensions Figure 303. Visibility Masking in Suspended Load Condition SECTOR A SECTOR C SECTOR B SECTOR D SECTOR E SECTOR F A Masking at 12m radius measured at ground B Masking at 12m radius measured at 0.75m level above ground level 9831/9950-7...
  • Page 332 www.duma-rent.com Technical Data Static Dimensions Figure 304. Visibility Masking in Lorry Trailer Loading Condition SECTOR A SECTOR C SECTOR B SECTOR D SECTOR E SECTOR F A Masking at 12m radius measured at ground B Masking at 12m radius measured at 0.75m level above ground level C Masking at 1m boundary measured between...

  • Page 333: For: 540V140 Work Platform [Stv 3L], 540V140 [Stv 3L]

    www.duma-rent.com Technical Data Static Dimensions (For: 540V140 Work Platform [STV 3L], 540V140 [STV 3L]) Figure 305. Mirror Setup SECTOR A SECTOR B SECTOR C SECTOR D SECTOR E SECTOR F A Left hand mirror B Right hand mirror C Right hand wide angle D Rear mounted wide angle 9831/9950-7...
  • Page 334 www.duma-rent.com Technical Data Static Dimensions Figure 306. Visibility Masking in Suspended Load Condition SECTOR A SECTOR B SECTOR C SECTOR D SECTOR E SECTOR F A Masking at 12m radius measured at ground B Masking at 12m radius measured at 0.75m level above ground level C Masking at 1m boundary measured between...
  • Page 335 www.duma-rent.com Technical Data Static Dimensions Figure 307. Visibility Masking in Lorry Trailer Loading Condition SECTOR A SECTOR C SECTOR B SECTOR D SECTOR E SECTOR F A Masking at 12m radius measured at ground B Masking at 12m radius measured at 0.75m level above ground level C Masking at 1m boundary measured between...

  • Page 336: For: 531-70 [Stv 3L]

    Technical Data Static Dimensions (For: 531-70 [STV 3L]) Figure 308. Mirror Setup SECTOR A SECTOR B SECTOR C SECTOR D SECTOR E SECTOR F A Left hand mirror B Right hand mirror C Right hand wide angle 9831/9950-7...
  • Page 337 www.duma-rent.com Technical Data Static Dimensions Figure 309. Visibility Masking in Suspended Load Condition SECTOR A SECTOR B SECTOR C SECTOR D SECTOR E SECTOR F A Masking at 12m radius measured at ground B Masking at 12m radius measured at 0.75m level above ground level 9831/9950-7...
  • Page 338 www.duma-rent.com Technical Data Static Dimensions Figure 310. Visibility Masking in Lorry Trailer Loading Condition SECTOR A SECTOR B SECTOR C SECTOR D SECTOR E SECTOR F A Masking at 12m radius measured at 0.75m B Masking at 12m radius measured at ground above ground level level C Masking at 12m radius that disappears at 0.74m...

  • Page 339: For: 535-95 [Stv 3L]

    www.duma-rent.com Technical Data Static Dimensions (For: 535-95 [STV 3L]) Figure 311. Mirror Setup SECTOR A SECTOR B SECTOR C SECTOR D SECTOR E SECTOR F A Left hand mirror B Right hand mirror C Right hand wide angle D Rear mounted wide angle 9831/9950-7...
  • Page 340 www.duma-rent.com Technical Data Static Dimensions Figure 312. Visibility Masking in Suspended Load Condition SECTOR A SECTOR C SECTOR B SECTOR D SECTOR E SECTOR F A Masking at 12m radius measured at ground B Masking at 12m radius measured at 0.75m level above ground level 9831/9950-7...
  • Page 341 www.duma-rent.com Technical Data Static Dimensions Figure 313. Visibility Masking in Lorry Trailer Loading Condition SECTOR A SECTOR C SECTOR B SECTOR D SECTOR E SECTOR F A Masking at 12m radius measured at ground B Masking at 12m radius measured at 0.75m level above ground level C Masking at 1m boundary measured between...

  • Page 342: For: 540-170 Work Platform [Stv 3L], 540-170 [Stv 3L]

    www.duma-rent.com Technical Data Static Dimensions (For: 540-170 Work Platform [STV 3L], 540-170 [STV 3L]) Figure 314. Mirror Setup SECTOR A SECTOR B SECTOR C SECTOR D SECTOR E SECTOR F A Left hand wide angle B Right hand wide angle C Right hand road mirror D Left hand road mirror E Rear mounted wide angle...
  • Page 343 www.duma-rent.com Technical Data Static Dimensions Figure 315. Visibility Masking in Suspended Load Condition SECTOR A SECTOR B SECTOR C SECTOR D SECTOR E SECTOR F A Masking at 12m radius measured at ground B Masking at 12m radius measured at 0.75m level above ground level 9831/9950-7...
  • Page 344 www.duma-rent.com Technical Data Static Dimensions Figure 316. Visibility Masking in Lorry Trailer Loading Condition SECTOR A SECTOR B SECTOR C SECTOR D SECTOR E SECTOR F A Masking at 12m radius measured at 0.75m B Masking at 12m radius measured at ground above ground level level C Masking at 1m boundary (>200mm) measured...

  • Page 345: For: 533-105 [Stv 3L]

    www.duma-rent.com Technical Data Static Dimensions (For: 533-105 [STV 3L]) Figure 317. Mirror Setup SECTOR A SECTOR B SECTOR C SECTOR D SECTOR E SECTOR F A Left hand wide angle B Right hand wide angle C Right hand road mirror D Left hand road mirror 9831/9950-7...
  • Page 346 www.duma-rent.com Technical Data Static Dimensions Figure 318. Visibility Masking in Suspended Load Condition SECTOR A SECTOR B SECTOR C SECTOR D SECTOR E SECTOR F A Masking at 12m radius measured at ground B Masking at 12m radius measured at 0.75m level above ground level 9831/9950-7...
  • Page 347 www.duma-rent.com Technical Data Static Dimensions Figure 319. Visibility Masking in Lorry Trailer Loading Condition SECTOR A SECTOR B SECTOR C SECTOR D SECTOR E SECTOR F A Masking at 12m radius measured at 0.75m B Masking at 12m radius measured at ground above ground level level C Masking at 1m boundary (>200mm) measured...

  • Page 348: For: 540-200 Work Platform [Stv 3L], 540-200 [Stv 3L]

    www.duma-rent.com Technical Data Static Dimensions (For: 540-200 Work Platform [STV 3L], 540-200 [STV 3L]) Figure 320. Mirror Setup SECTOR A SECTOR B SECTOR C SECTOR D SECTOR E SECTOR F A Right hand road mirror B Left hand road mirror C Right hand wide angle D Left hand wide angle E Rear mounted wide angle...
  • Page 349 www.duma-rent.com Technical Data Static Dimensions Figure 321. Visibility Masking in Suspended Load Condition SECTOR A SECTOR B SECTOR C SECTOR D SECTOR E SECTOR F A Masking at 12m radius measured at ground B Masking at 12m radius measured above ground level level up to 0.75m C Overall masking...
  • Page 350 www.duma-rent.com Technical Data Static Dimensions Figure 322. Visibility Masking in Lorry Trailer Loading Condition SECTOR A SECTOR B SECTOR C SECTOR D SECTOR E SECTOR F A Masking at 12m radius measured at ground B Overall masking level C Masking at 1m boundary (>200mm width) measured between ground level and 1.5m above ground level 9831/9950-7...
  • Page 351 www.duma-rent.com Technical Data Static Dimensions Figure 323. Visibility Masking in Sectors A and C at the 12m Ra- dius, With the Machine in Normal Travel Mode No Load Condition SECTORA SECTORB SECTOR C SECTOR D SECTORE SECTORF A Masking at 12m radius measured at ground level 9831/9950-7...
  • Page 352 www.duma-rent.com Technical Data Static Dimensions Figure 324. Visibility Masking in Sectors A and C at the 12m Ra- dius, With the Machine in Normal Travel Mode Fork Load Condition SECTORA SECTORB SECTOR C SECTOR D SECTORE SECTORF A Masking at 12m radius measured at ground B Overall masking level 9831/9950-7...

  • Page 353: For: 540V180 Work Platform [Stv 3L], 540V180 [Stv 3L]

    www.duma-rent.com Technical Data Static Dimensions (For: 540V180 Work Platform [STV 3L], 540V180 [STV 3L]) Figure 325. Mirror Setup A Right hand road mirror B Left hand road mirror C Right hand wide angle D Left hand wide angle E Rear mounted wide angle 9831/9950-7...
  • Page 354 www.duma-rent.com Technical Data Static Dimensions Figure 326. Visibility Masking in Suspended Load Condition A Masking at 12m radius measured at ground B Masking at 12m radius measured at 0.75m level above ground level C Masking at 1m boundary (>200mm width) measured between ground level and 1.5m above ground level 9831/9950-7...
  • Page 355 www.duma-rent.com Technical Data Static Dimensions Figure 327. Visibility Masking in Lorry Trailer Loading Condition A Masking at 12m radius measured at ground B Masking at 12m radius measured at 0.75m level above ground level C Masking at 1m boundary (>200mm width) measured between ground level and 1.5m above ground level 9831/9950-7...

  • Page 356: Performance Dimensions

    For: 535-95 [STV 3L] ......................Page 344 For: 535V125 [STV 3L] ......................Page 345 For: 531-70 [STV 3L] ......................Page 346 For: 540-170 Work Platform [STV 3L], 540-170 [STV 3L] ............Page 347 For: 540-200 Work Platform [STV 3L], 540-200 [STV 3L] ............Page 348 For: 540V140 Work Platform [STV 3L], 540V140 [STV 3L] ...........

  • Page 357: For: 533-105 [Stv 3L]

    www.duma-rent.com Technical Data Performance Dimensions (For: 533-105 [STV 3L]) Table 60. Description Weight Maximum lift capacity 3,300kg Lift capacity to full height 3,300kg Lift capacity at full reach 1,050kg Table 61. Description Length Maximum lift height 10,220mm Reach at maximum lift height 1,910mm Maximum forward reach 6,830mm...

  • Page 358: For: 535-95 [Stv 3L]

    www.duma-rent.com Technical Data Performance Dimensions (For: 535-95 [STV 3L]) Table 63. Description Weight Maximum lift capacity 3,500kg Lift capacity to full height 3,500kg Lift capacity at full reach 550kg Table 64. Description Length Maximum lift height 9,500mm Reach at maximum lift height 2,430mm Maximum forward reach 6,520mm...

  • Page 359: For: 535V125 [Stv 3L]

    www.duma-rent.com Technical Data Performance Dimensions (For: 535V125 [STV 3L]) Table 65. Description Weight Maximum lift capacity 3,500kg Lift capacity to full height 3,500kg Lift capacity at full reach 1,150kg Table 66. Description Length Maximum lift height 12,280mm Reach at maximum lift height 460mm Maximum forward reach 8,060mm...

  • Page 360: For: 531-70 [Stv 3L]

    Technical Data Performance Dimensions (For: 531-70 [STV 3L]) Table 68. Description Weight Maximum lift capacity 3,100kg Lift capacity to full height 2,400kg Lift capacity at full reach 1,250kg Table 69. Description Length Maximum lift height 7,000mm Reach at maximum lift height...

  • Page 361: For: 540-170 Work Platform [Stv 3L], 540-170 [Stv 3L]

    www.duma-rent.com Technical Data Performance Dimensions (For: 540-170 Work Platform [STV 3L], 540-170 [STV 3L]) Table 70. Description Weight Maximum lift capacity 4,000kg Lift capacity to full height 2,500kg Lift capacity at full reach 600kg Table 71. Description Length Maximum lift height 16,700mm Reach at maximum lift height 2,050mm...

  • Page 362: For: 540-200 Work Platform [Stv 3L], 540-200 [Stv 3L]

    www.duma-rent.com Technical Data Performance Dimensions (For: 540-200 Work Platform [STV 3L], 540-200 [STV 3L]) Extended Stabiliser Table 73. Description Dimension Maximum lift capacity 4,000kg Lift capacity to full height 1,500kg Lift capacity at full reach 200kg Maximum lift height 20,000mm Reach at maximum lift height 2,820mm Maximum forward reach...

  • Page 363: For: 540V140 Work Platform [Stv 3L], 540V140 [Stv 3L]

    www.duma-rent.com Technical Data Performance Dimensions (For: 540V140 Work Platform [STV 3L], 540V140 [STV 3L]) Table 76. Description Weight Maximum lift capacity 4,000kg Lift capacity to full height 3,000kg Lift capacity at full reach 1,250kg Table 77. Description Length Maximum lift height 13,780mm Reach at maximum lift height 930mm...

  • Page 364: Towing Weights

    540-200 Work Platform [STV 3L], 540-200 [STV 3L], 540V140 Work Platform [STV 3L], 540V140 [STV 3L], 540V180 Work Platform [STV 3L], 540V180 [STV 3L] ........... Page 350 For: 531-70 [STV 3L], 535-95 [STV 3L] ................. Page 351 (For: 533-105 [STV 3L], 535V125 [STV 3L], 540-170 Work Platform [STV 3L], 540-170...
  • Page 365 WARNING Do not exceed the permitted limits on trailer gross weight or hitch load. The machine may become unstable. Maximum Gross Trailer Weight The maximum gross trailer weight permitted to be towed by your machine (when fitted with JCB approved towing equipment) is shown. Refer to: Wheels and Tyres (Page 370).
  • Page 366 Technical Data Performance Dimensions Maximum Gross Trailer Weight The maximum gross trailer weight permitted to be towed by your machine (when fitted with JCB approved towing equipment) is shown. Refer to: Wheels and Tyres (Page 370). Tyre Pressures and Hitch Loads The correct tyre pressures and maximum speeds relative to trailer hitch loads MAX KG are shown on a tyre chart (found in the cab).

  • Page 367: Noise Emissions

    The noise data values shown only apply to CE marked machines. For information relating to this machine when used with other JCB approved attachments, please refer to the literature accompanying the attachments. Table 82. Definition of terms...

  • Page 368: Vibration Emissions

    www.duma-rent.com Technical Data Vibration Emissions Vibration Emissions General CAUTION In some operating conditions the specified vibration emission levels may be different to those shown. Factors such as workplace, other machinery and duration of exposure may require additional personal protective equipment to be provided. To assist in compliance with the European Directive 2002/44/EC, the duty specific vibration emission values for this machine type have been provided on the following page(s) and may be used for the assessment of risks to exposure from vibration.

  • Page 369: Vibration Data

    www.duma-rent.com Technical Data Vibration Emissions Vibration Data The whole-body vibration emission under representative operating conditions (according to the intended use) are shown. Figure 330. Dominant axis D1 Machine operating duty: Roading (tarmac) Machine operating duty: Roading (rough D3 Machine operating duty: Loader work (soil) terrain) Machine operating duty: Loader work (stone) D5 Machine operating duty: Lift cycles...

  • Page 370: Fluids, Lubricants And Capacities

    Fluids, Lubricants and Capacities General JCB recommend that you use the JCB lubricants shown as they have been verified by JCB for use on JCB machines. However, you could use other lubricants that are equivalent to the JCB standards and quality or offer the same machine component protection.

  • Page 371: Fuel

    (10) Check which coolant type is installed in the machine before topping up the coolant. Mixing of different coolant types is not recommended and may result in invalidation of the warranty offered by JCB. In the event of mixing or if the coolant type is to be changed, the coolant circuit should be completely drained and flushed twice with clean water before re-filling with fresh coolant.
  • Page 372 EN 16734 diesel with up to 10% riorate under storage. volume FAME meeting EN 14214. (1) See your JCB dealer for advice on service requirements. Table 87. Group 3 Fuel Advice Service Requirements...

  • Page 373: Warranty

    Paradyne 7505 (from Infineum). Dosage 500 ppm (0.05%). Warranty JCB have shown a commitment to support the environment by approving the use of biodiesel blended fuels. Using a B5 blend of biodiesel requires caution and additional servicing of the engine is required.

  • Page 374: Coolant

    Notice: Check which coolant type is installed in the machine before topping up the coolant. Mixing of different coolant types is not recommended and may result in invalidation of the warranty offered by JCB. In the event of mixing or if the coolant type is to be changed, the coolant circuit should be completely drained and flushed twice with clean water before re-filling with fresh coolant.
  • Page 375 www.duma-rent.com Technical Data Fluids, Lubricants and Capacities Table 89. Concentration Level of protection 50% (Standard) Protects against damage down to -40°C (-40°F) 60% (Extreme Conditions Only) Protects against damage down to -56°C (-69°F) Do not exceed a 60% concentration, as the freezing protection provided reduces beyond this point. •...

  • Page 376: Torque Values

    www.duma-rent.com Technical Data Torque Values Torque Values General ROPS/FOPS Table 90. Mounting bolts torque 205N·m Wheels Table 91. Front Wheel Nut Torque Rear Wheel Nut Torque 680N·m 680N·m Step/Battery Compartment Cover Table 92. Mounting bolt torque 25N·m Axles Table 93. Fill/level plug torque 79N·m 9831/9950-7...

  • Page 377: Electrical System

    www.duma-rent.com Technical Data Electrical System Electrical System General Table 94. Item Specification Battery voltage/system voltage 9831/9950-7...

  • Page 378: Fuses

    www.duma-rent.com Technical Data Electrical System Fuses Standard Figure 331. 9831/9950-7...
  • Page 379 www.duma-rent.com Technical Data Electrical System Table 95. Fuse Circuit(s) Protected Rating Ignition Starter solenoid Heated Glass Front/rear Auxiliary Heater Hose and SCR (Selective Catalytic Reduction) ECU (Electronic Control Unit) Crank signal Heater Blower Brake Lights Seat Pressure Switch and Park Brake Directional Indicators Roof Air Conditioning Fans Rear Wiper + Roof Wiper...

  • Page 380: Relays

    www.duma-rent.com Technical Data Electrical System Fuse Circuit(s) Protected Rating Trailer Directional Indicators DEF (Diesel Exhaust Fluid) Heated Hoses Interior Light and Radio Daily Checks (when fitted) Daily Checks (when fitted) Man Basket - Recovery Pump (when fitted) Man Basket - Radio (when fitted) Heater Blower (when fitted) Relays Standard...
  • Page 381 www.duma-rent.com Technical Data Electrical System Relay Circuit(s) DEF Heated line all DEF Heated line 2 NOx Sensor Boom worklight Roof air conditioning fans Reverse alarm and lamp Rear work lights Roadlights Air conditioning Man basket - Recovery pump Brake lights Air conditioning Crank Front work lights...

  • Page 382: General

    www.duma-rent.com Technical Data Engine Engine General Table 97. Description DP Engine Engine Variant Turbocharged with intercooler and exhaust after treatment system Emission compliance EU Stage V Rated power 97kW at 2200 rpm Number of cylinders Nominal bore size 106mm Stroke 135mm Cylinder arrangement In line...
  • Page 383 www.duma-rent.com Technical Data Engine During regeneration the exhaust gases temperature is raised and the operator has the option to inhibit a regeneration if for example the machine is in a hazardous area. Should the duty cycle continue to be very light the operator will be warned. If this occurs the operator has a choice to either operate the engine at a higher duty or complete the regeneration cycle with a manual regeneration.

  • Page 384: Wheels And Tyres

    Hence when establishing the machine load chart, through performance and stability testing, JCB works with tyre manufacturers to agree suitable tyres and tyre pressures for the machine and its application. The use of tyres not approved by JCB may effect the stability of the machine and its ability to conform to its load chart.
  • Page 385 www.duma-rent.com Technical Data Wheels and Tyres If the tyres in opposite sides are different sizes the machine will not be vertical when standing on level ground. This will cause the combined centre of gravity of the machine and load to move sideways, which may lead to instability.

  • Page 386: Tyre Sizes And Pressures

    Tyre Sizes and Pressures For: 535-95 [STV 3L] ......................Page 373 For: 531-70 [STV 3L] ......................Page 375 For: 540-170 Work Platform [STV 3L], 540-170 [STV 3L] ............Page 377 For: 540-200 Work Platform [STV 3L], 540-200 [STV 3L] ............Page 379 For: 535V125 [STV 3L] ......................
  • Page 387 Wheels and Tyres (For: 535-95 [STV 3L]) Table 98. Tyre Specifications Brand Size Designation Rim Size & Off- Inflation Pres- JCB Tyre Part sure (bar 0/+ 0.2) MICHELIN 400/80-24 . 162 POWER CL TW14L x 24 [15 4bar (58.0psi) 332/C4655...
  • Page 388 (1) Only approved for off-highway towing. Local legislation may limit the maximum trailer mass. Table 101. Permissible Vertical Hitch Load Hitch Type MC1 HYD PUH 40kN MC3, MC4 or MC5 JCB Tyre Part No Permissible vertical hitch load 332/C4655 2,000 2,000...
  • Page 389 Technical Data Wheels and Tyres (For: 531-70 [STV 3L]) Table 102. Tyre Specifications Brand Size Designation Rim Size & Off- Inflation Pres- JCB Tyre Part sure (bar 0/+ 0.2) MICHELIN 400/80-24 . 162 POWER CL TW14L x 24 [15 4bar (58.0psi)
  • Page 390 (1) Only approved for off-highway towing. Local legislation may limit the maximum trailer mass. Table 105. Permissible Vertical Hitch Load Hitch Type MC1 HYD PUH 40kN MC3, MC4 or MC5 JCB Tyre Part No Permissible vertical hitch load 332/C4655 2,000 2,000...
  • Page 391 (For: 540-170 Work Platform [STV 3L], 540-170 [STV 3L]) Table 106. Tyre Specifications Brand Size Designation Rim Size & Off- Inflation Pres- JCB Tyre Part sure (bar 0/+ 0.2) MICHELIN 440/80-24 . 168 POWER CL TW14L x 24 [2 4.5bar (65.3psi)
  • Page 392 (1) Only approved for off-highway towing. Local legislation may limit the maximum trailer mass. Table 109. Permissible Vertical Hitch Load Hitch Type MC1 HYD PUH 40kN MC3, MC4 or MC5 JCB Tyre Part No Permissible vertical hitch load 332/C4139 334/E3667 332/D0017...
  • Page 393 (For: 540-200 Work Platform [STV 3L], 540-200 [STV 3L]) Table 110. Tyre Specifications Brand Size Designation Rim Size & Off- Inflation Pres- JCB Tyre Part sure (bar 0/+ 0.2) MICHELIN 440/80-24 . 168 POWER CL DW13 x 24 [2 4.5bar (65.3psi)
  • Page 394 (1) Only approved for off-highway towing. Local legislation may limit the maximum trailer mass. Table 113. Permissible Vertical Hitch Load Hitch Type MC1 HYD PUH 40kN MC3, MC4 or MC5 JCB Tyre Part No Permissible vertical hitch load 332/C4139 42/925256 400/G1340...
  • Page 395 Wheels and Tyres (For: 535V125 [STV 3L]) Table 114. Tyre Specifications Brand Size Designation Rim Size & Off- Inflation Pres- JCB Tyre Part sure (bar 0/+ 0.2) MICHELIN 400/80-24 . 162 POWER CL TW14L x 24 [-32 4.8bar (69.6psi) 332/C4655...
  • Page 396 (1) Only approved for off-highway towing. Local legislation may limit the maximum trailer mass. Table 117. Permissible Vertical Hitch Load Hitch Type MC1 HYD PUH 40kN MC3, MC4 or MC5 JCB Tyre Part No Permissible vertical hitch load 332/C4655 1,000 42/405700...
  • Page 397 (For: 540V140 Work Platform [STV 3L], 540V140 [STV 3L]) Table 118. Tyre Specifications Brand Size Designation Rim Size & Off- Inflation Pres- JCB Tyre Part sure (bar 0/+ 0.2) MICHELIN 400/80-24 . 162 POWER CL TW14L x 24 [-32 4.8bar (69.6psi)
  • Page 398 15,020 19,520 (1) Only approved for off-highway towing. Local legislation may limit the maximum trailer mass. Table 121. Permissible Vertical Hitch Load Hitch Type MC3, MC4 or MC5 JCB Tyre Part No Permissible vertical hitch load 332/C4655 1,000 42/405700 1,000...
  • Page 399 (For: 540V180 Work Platform [STV 3L], 540V180 [STV 3L]) Table 122. Tyre Specifications Brand Size Designation Rim Size & Off- Inflation Pres- JCB Tyre Part sure (bar 0/+ 0.2) GOODYEAR 15.5-25 12PR 12 x 25 DC [-32 4.3bar (62.4psi) 42/405700...
  • Page 400 (1) Only approved for off-highway towing. Local legislation may limit the maximum trailer mass. Table 125. Permissible Vertical Hitch Load Hitch Type MC1 HYD PUH 40kN MC3, MC4 or MC5 JCB Tyre Part No Permissible vertical hitch load 42/405700 400/C6523 332/H7461...
  • Page 401 Wheels and Tyres (For: 533-105 [STV 3L]) Table 126. Tyre Specifications Brand Size Designation Rim Size & Off- Inflation Pres- JCB Tyre Part sure (bar 0/+ 0.2) MICHELIN 400/80-24 . 162 POWER CL TW14L x 24 [15 4bar (58.0psi) 332/C4655...
  • Page 402 (1) Only approved for off-highway towing. Local legislation may limit the maximum trailer mass. Table 129. Permissible Vertical Hitch Load Hitch Type MC1 HYD PUH 40kN MC3, MC4 or MC5 JCB Tyre Part No Permissible vertical hitch load 332/C4655 2,000 2,000...

  • Page 403: Declaration Of Conformity

    Refer to: Machine (Page 8). EN 1459-1: 2017. Managing Director, JCB Vibromax GMBH, Europaallee 113a, 50226 Frenchen, Germany Principal Engineer NVH, JCB Excavators Limited, Lakeside Works, Rocester, Staffordshire, Unit- ed Kingdom, ST14 5JP. ANNEX VI PROCEDURE 1. A. V. Technology Unit 2 Easter Court Europa Boulevard Warrington Cheshire WA5 7ZB.
  • Page 404 www.duma-rent.com Technical Data Declaration of Conformity Figure 333. 9831/9950-7...

  • Page 405: Service Record Sheet

    www.duma-rent.com Technical Data Warranty Information Warranty Information Service Record Sheet Table 131. Signature and stamp Date Annual Insurance (Yes) Hours Figure 334. Installation Checklist Figure 335. 500h Figure 336. 1000h 9831/9950-7...
  • Page 406 www.duma-rent.com Technical Data Warranty Information Figure 337. 1500h Figure 338. 2000h Figure 339. 2500h Figure 340. 3000h 9831/9950-7...
  • Page 407 www.duma-rent.com Technical Data Warranty Information Figure 341. 3500h Figure 342. 4000h Figure 343. 4500h Figure 344. 5000h 9831/9950-7...
  • Page 408 www.duma-rent.com Technical Data Warranty Information Figure 345. 5500h Figure 346. 6000h Figure 347. 6500h Figure 348. 7000h 9831/9950-7...
  • Page 409 www.duma-rent.com Technical Data Warranty Information Figure 349. 7500h Figure 350. 8000h Figure 351. 8500h Figure 352. 9000h 9831/9950-7...
  • Page 410 www.duma-rent.com Technical Data Warranty Information Figure 353. 9500h Figure 354. 10000h Figure 355. 10500h Figure 356. 11000h 9831/9950-7...
  • Page 411 JCB shall only deny claims in the warranty period due to: • Improper maintenance • Accidents (where JCB have no control) If a failure is caused by the operator fitting of non-exempted or add-on components JCB shall not deny warranty for: • Maintenance we or an authorised facility performed. •...
  • Page 412 www.duma-rent.com Notes: 9831/9950-7...

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