jcb 540-200 User Manual

SERVICE MANUAL
LOADALL (ROUGH TERRAIN
VARIABLE REACH TRUCK)
533-105, 535-v125, 540-140,
540-170, 540-200, 540-v140,
540-v180, 550-140, 550-170
EN - 9813/7650 - ISSUE 2 - 04/2018
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
Copyright 2018 © JCB SERVICE
All rights reserved. No part of this publication may
be reproduced, stored in a retrieval system, or
transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise,
without prior permission from JCB SERVICE.
www.jcb.com
Foreword
The Operator's Manual
You and others can be killed or seriously injured
if you operate or maintain the machine without
first studying the Operator's Manual. You must
understand and follow the instructions in the
Operator's Manual. If you do not understand
anything, ask your employer or JCB dealer to
explain it.
Do not operate the machine without an Operator's
Manual, or if there is anything on the machine you
do not understand.
Treat the Operator's Manual as part of the machine.
Keep it clean and in good condition. Replace the
Operator's Manual immediately if it is lost, damaged
or becomes unreadable.
Contents
01 - Machine
03 - Attachments, Couplings and Load
Handling
06 - Body and Framework
09 - Operator Station
12 - Heating, Ventilating and Air-
Conditioning (HVAC)
15 - Engine
18 - Fuel and Exhaust System
21 - Cooling System
24 - Brake System
25 - Steering System
27 - Driveline
30 - Hydraulic System
33 - Electrical System
72 - Fasteners and Fixings
75 - Consumable Products
78 - After Sales

jcb 540-200 Specifications

General

Brand	jcb
Model	540-200
Category	Compact Loader
Language	English

Summary

03 - Safety

03 - Safety - Yours and Others

Emphasizes safe operation practices and personal responsibility for user and others.

06 - Safety Warnings

Explains signal words (DANGER, WARNING, CAUTION, Notice) and the safety alert symbol.

09 - General Safety

Covers training, alertness, clothing, alcohol, drugs, and feeling unwell.

12 - Maintenance Safety

Details safety precautions for machine maintenance, including specific components and repairs.

18 - Operating Safety

Outlines safe operating procedures, machine limits, fuel handling, and worksite hazards.

21 - Worksite Safety

Focuses on worksite hazards, utility lines, and safe practices for operating in various environments.

24 - Risk Assessment

Guides on assessing risks related to personnel, the machine, load, route, and weather conditions.

27 - Maintenance Positions

Details safe procedures and positions for performing maintenance tasks on the machine.

12 - Maintenance Safety

Working Under the Machine

Steps to ensure safety before working beneath the machine, including securing it.

Personal Protective Equipment

Advises using appropriate PPE before performing maintenance to prevent injury.

Working at Height

Stresses the use of suitable access equipment for tasks at height to prevent falls.

18 - Operating Safety

Worksites

Highlights hazards on worksites, including ground conditions, obstacles, and utilities.

Hands and Feet

Instructs to keep hands and feet inside the operator compartment while the vehicle is in motion.

Controls

Warns against operating controls from outside the machine, stressing correct seating.

Fires

Provides guidance on fire extinguisher use and appropriate fire-fighting agents.

Roll Over Protection

Safe Working Loads

21 - Worksite Safety

24 - Risk Assessment

27 - Maintenance Positions

Lift Arm Lowered

Lift Arm Raised

Health and Safety