JCB JS Auto Range – Tracked Excavator – Tier 3 Isuzu Engine Operator Manual 9811-6700

Description

• Model List:
  • JS Auto Range – Tracked Excavator – Tier 3 Isuzu Engine

• 1. Safety Notices
• 2. Important Information …………………………………………………………………………1
• 3. The Operator Manual …………………………………………………………………….1
• 4. Safety Warnings ……………………………………………………………………………1
• 5. Introduction
• 6. About this Manual ………………………………………………………………………………3
• 7. Machine Model and Serial Number ………………………………………………….3
• 8. Using this Manual ………………………………………………………………………….3
• 9. Left Side, Right Side ………………………………………………………………………4
• 10. Cross References ………………………………………………………………………….4
• 11. Machine Description …………………………………………………………………………..5
• 12. The JCB Tracked Excavator ……………………………………………………………5
• 13. Intended Use ………………………………………………………………………………..5
• 14. Component Location ……………………………………………………………………..6
• 15. Safety Check List ……………………………………………………………………………….8
• 16. Safety – Yours and Others ………………………………………………………………8
• 17. General Safety ……………………………………………………………………………..8
• 18. Operating Safety …………………………………………………………………………10
• 19. Maintenance Safety ……………………………………………………………………..13
• 20. Safety Labels …………………………………………………………………………………..18
• 21. Introduction …………………………………………………………………………………18
• 22. Safety Label Identification …………………………………………………………….19
• 23. Identifying Your Machine …………………………………………………………………..23
• 24. Machine Identification Plate ………………………………………………………….23
• 25. Component Identification Plates …………………………………………………….24
• 26. Machine Security ……………………………………………………………………………..27
• 27. Introduction …………………………………………………………………………………27
• 28. JCB Plantguard …………………………………………………………………………..27
• 29. Construction Equipment Security And Registration Scheme (CESAR) .27
• 30. LiveLink ……………………………………………………………………………………..27
• 31. Immobiliser …………………………………………………………………………………27
• 32. Operation
• 33. Introduction ……………………………………………………………………………………..29
• 34. Before Entering the Cab ……………………………………………………………………30
• 35. Entering and Leaving the Cab ……………………………………………………………31
• 36. Standard Cab Machines ……………………………………………………………….31
• 37. Hydraulically Raised Cab Machines ……………………………………………….32
• 38. Fixed Raised Cab Machines …………………………………………………………33
• 39. Emergency Exit …………………………………………………………………………..35
• 40. Doors and Windows …………………………………………………………………………36
• 41. Opening and Closing the Door ………………………………………………………36
• 42. Opening and Closing the Front Upper Window ………………………………..37
• 43. Opening and Closing The Front Lower Window ……………………………….38
• 44. Door Sliding Window ……………………………………………………………………40
• 45. Opening and Closing the Sunblind …………………………………………………41
• 46. Access to the Upper Structure ……………………………………………………………43
• 47. Standard Machines ………………………………………………………………………43
• 48. Seat Controls …………………………………………………………………………………..44
• 49. Introduction …………………………………………………………………………………44
• 50. Operators Seat-Console ……………………………………………………………….44
• 51. Operators Seat – Standard-Heated …………………………………………………44
• 52. Air Suspension Seat …………………………………………………………………….45
• 53. Seat Belts (if fitted) …………………………………………………………………………..46
• 54. Static Seat Belt ……………………………………………………………………………46
• 55. Visibility Aids ……………………………………………………………………………………47
• 56. Mirrors ……………………………………………………………………………………….47
• 57. Cab Layout ……………………………………………………………………………………..51
• 58. Components Key …………………………………………………………………………51
• 59. Drive Controls, Switches and Instruments ……………………………………………53
• 60. Drive Controls ……………………………………………………………………………..53
• 61. Switches …………………………………………………………………………………….54
• 62. Instruments …………………………………………………………………………………63
• 63. Air Conditioning and Heater Controls ……………………………………………..68
• 64. Operating Levers-Pedals …………………………………………………………………..70
• 65. Excavating Controls …………………………………………………………………….70
• 66. Travel Speed Change Button ………………………………………………………..77
• 67. Operation Levers …………………………………………………………………………78
• 68. Optional Circuit Pedal (if fitted) ………………………………………………………79
• 69. ISO Operating Method …………………………………………………………………79
• 70. Safety Equipment …………………………………………………………………………….80
• 71. Control Locks ……………………………………………………………………………..80
• 72. Dipper Stroke Limiter (If fitted) ……………………………………………………….81
• 73. Overload Warning System …………………………………………………………….84
• 74. Before Starting the Engine …………………………………………………………………85
• 75. Starting the Engine …………………………………………………………………………..86
• 76. Warming-Up ……………………………………………………………………………….87
• 77. JCB Immobiliser System ………………………………………………………………88
• 78. Getting the Machine Moving ………………………………………………………………90
• 79. Stopping and Parking the Machine ……………………………………………………..91
• 80. Stopping and Parking …………………………………………………………………..91
• 81. Engine Shutdown ………………………………………………………………………..92
• 82. Working with your Machine ……………………………………………………………….93
• 83. Operating Practices and Site Safety ………………………………………………93
• 84. Clothing and Safety Equipment ……………………………………………………..93
• 85. Danger Zone ………………………………………………………………………………93
• 86. Log Moving-Handling ……………………………………………………………………93
• 87. Safety Practices ………………………………………………………………………….94
• 88. Working With the Excavator ………………………………………………………….95
• 89. Lifting (Object Handling) ……………………………………………………………..102
• 90. Hydraulically Raised Cab (if fitted) ……………………………………………….105
• 91. Use of Machines on Gradients and Slopes ……………………………………107
• 92. Pulling out of Soft Ground ………………………………………………………….. 110
• 93. Water ………………………………………………………………………………………. 111
• 94. Towing Other Equipment ……………………………………………………………. 111
• 95. Machine Stability ………………………………………………………………………. 112
• 96. Reducing Wear …………………………………………………………………………. 113
• 97. Operating Environment …………………………………………………………………… 116
• 98. Maintenance in Cold Climates …………………………………………………….. 116
• 99. Operating in a Cold Climate (Below 0°C) ……………………………………… 116
• 100. Operating in a Hot Climate (Above 35°C) …………………………………….. 116
• 101. Operating in Dusty or Sandy Areas ……………………………………………… 117
• 102. Operating in Coastal Regions …………………………………………………….. 117
• 103. Operating on Wet or Soft Ground ………………………………………………… 117
• 104. Cab Filters ……………………………………………………………………………….. 117
• 105. Refuelling the Machine …………………………………………………………………… 118
• 106. Low Fuel Levels ……………………………………………………………………….. 118
• 107. Filling the Tank …………………………………………………………………………. 118
• 108. Fuel Level ………………………………………………………………………………… 119
• 109. Refuelling Pump ………………………………………………………………………..120
• 110. Moving a Disabled Machine …………………………………………………………….121
• 111. Lowering the Boom in an Emergency …………………………………………..121
• 112. Retrieval …………………………………………………………………………………..121
• 113. Limp Mode ………………………………………………………………………………..122
• 114. Transporting the Machine ………………………………………………………………..123
• 115. Lifting the Machine …………………………………………………………………………125
• 116. JS115 – JS360 Machines …………………………………………………………….125
• 117. Storage of the Machine …………………………………………………………………..127
• 118. Introduction ……………………………………………………………………………….127
• 119. Storage Area …………………………………………………………………………….127
• 120. Prepare the Machine for Storage …………………………………………………127
• 121. Put the Machine into Storage ………………………………………………………127
• 122. During Storage ………………………………………………………………………….127
• 123. Take the Machine Out of Storage …………………………………………………128
• 124. Anti-Vandalism Guards (option) ………………………………………………………..129
• 125. Unpacking the Guards ………………………………………………………………..129
• 126. Fitting the Guards ………………………………………………………………………129
• 127. Removing the Guards ………………………………………………………………..130
• 128. Storing the Guards …………………………………………………………………….130
• 129. Routine Maintenance
• 130. Service Requirements …………………………………………………………………….131
• 131. Introduction ……………………………………………………………………………….131
• 132. Owner-Operator Support …………………………………………………………….131
• 133. Service-Maintenance Agreements ……………………………………………….131
• 134. Fit for Purpose Tests for Lifting Equipment …………………………………….132
• 135. Obtaining Replacement Parts ………………………………………………………132
• 136. Health and Safety …………………………………………………………………………..133
• 137. Lubricants …………………………………………………………………………………133
• 138. Battery ……………………………………………………………………………………..135
• 139. Service Schedules ………………………………………………………………………….137
• 140. Introduction ……………………………………………………………………………….137
• 141. How to Use the Service Schedules ………………………………………………137
• 142. Calendar Equivalents …………………………………………………………………137
• 143. Pre Start Cold Checks, Service Points and Fluid Levels ………………….138
• 144. Functional Test and Final Inspection …………………………………………….142
• 145. Service Intervals for Attachments …………………………………………………144
• 146. Periodic Replacement of Safety Related Components ……………………145
• 147. Fluids, Lubricants and Capacities ……………………………………………………..146
• 148. JS115 – JS145 and Variants ………………………………………………………..146
• 149. JS160 – JS190 and Variants ………………………………………………………..147
• 150. JS200 – JS235 and Variants ………………………………………………………..148
• 151. JS240-260 and Variants ……………………………………………………………..149
• 152. JS290 and Variants ……………………………………………………………………150
• 153. JS330 and Variants ……………………………………………………………………151
• 154. JS360 and Variants ……………………………………………………………………152
• 155. Typical Lubrication Chart …………………………………………………………….153
• 156. Coolant Mixtures ……………………………………………………………………….155
• 157. Fuel …………………………………………………………………………………………155
• 158. Tools …………………………………………………………………………………………….158
• 159. Carrying Tools onto the Machine ………………………………………………….158
• 160. Locations ………………………………………………………………………………….158
• 161. Prepare the Machine for Maintenance ………………………………………………159
• 162. Introduction ……………………………………………………………………………….159
• 163. How to Make the Machine Safe (Excavator Lowered) …………………….159
• 164. Cleaning the Machine ……………………………………………………………………..160
• 165. Introduction ……………………………………………………………………………….160
• 166. Preparing the Machine for Cleaning ……………………………………………..160
• 167. Cleaning the Machine …………………………………………………………………161
• 168. Cleaning the Tracks ……………………………………………………………………161
• 169. Cleaning the Radiator and Oil Cooler ……………………………………………161
• 170. Checking for Damage ……………………………………………………………………..162
• 171. Check the Machine Body and Structure ………………………………………..162
• 172. Check the Seat and Seat Belt ……………………………………………………..162
• 173. Checking the FOPS Structure ……………………………………………………..162
• 174. Daily Checking ……………………………………………………………………………….164
• 175. Greasing ……………………………………………………………………………………….166
• 176. Introduction ……………………………………………………………………………….166
• 177. Slew Ring Bearing ……………………………………………………………………..166
• 178. Slew Ring Teeth and Slew Pinion …………………………………………………166
• 179. Greasing Points …………………………………………………………………………167
• 180. Electrical System ……………………………………………………………………………169
• 181. Battery ……………………………………………………………………………………..169
• 182. Jump-Starting the Engine ……………………………………………………………174
• 183. Fuses ……………………………………………………………………………………….175
• 184. Bolt and Nut Torque Specifications ……………………………………………………177
• 185. JS115 – JS360 and Variants ………………………………………………………..177
• 186. Engine ………………………………………………………………………………………….186
• 187. Oil and Filter ……………………………………………………………………………..186
• 188. Cooling System …………………………………………………………………………189
• 189. Fan Belt ……………………………………………………………………………………201
• 190. Engine Air Filter …………………………………………………………………………202
• 191. Fuel System …………………………………………………………………………………..204
• 192. Introduction ……………………………………………………………………………….204
• 193. Draining Fuel Tank Impurities ………………………………………………………204
• 194. Draining the Primary Filter-Sedimenter …………………………………………205
• 195. Changing the Primary Filter-Sedimenter Element …………………………..206
• 196. Changing the Fuel Feed Pump Filter ……………………………………………206
• 197. Draining the Main Filter-Sedimenter ……………………………………………..207
• 198. Changing the Main Filter-Sedimenter Element ……………………………….207
• 199. Bleeding the System ………………………………………………………………….209
• 200. Hydraulic System ……………………………………………………………………………210
• 201. Introduction ……………………………………………………………………………….210
• 202. Releasing Tank Pressure …………………………………………………………… 211
• 203. Releasing the Hydraulic Pressure ……………………………………………….. 211
• 204. Oil and Filters ……………………………………………………………………………212
• 205. Draining Water and Sediment from the Hydraulic Tank ……………………219
• 206. Air Bleeding Procedures ……………………………………………………………..219
• 207. Slew Gearbox ………………………………………………………………………………..222
• 208. Checking the Slew Gearbox Oil Level …………………………………………..222
• 209. Changing the Slew Gearbox Oil …………………………………………………..222
• 210. Tracks and Running Gear ……………………………………………………………….223
• 211. Tracks ………………………………………………………………………………………223
• 212. Running Gear ……………………………………………………………………………225
• 213. Bucket ………………………………………………………………………………………….226
• 214. Checking-Adjusting For Side Play ………………………………………………..226
• 215. Windscreen Washer ……………………………………………………………………….227
• 216. Checking the Level …………………………………………………………………….227
• 217. Fire Extinguisher (If fitted) ……………………………………………………………….228
• 218. Troubleshooting ……………………………………………………………………………..229
• 219. Engine and Related Area ……………………………………………………………229
• 220. Monitor Display – Fault Messages ………………………………………………..232
• 221. Operations ………………………………………………………………………………..233
• 222. Hydraulic pump …………………………………………………………………………234
• 223. Working Attachments …………………………………………………………………235
• 224. Travel ……………………………………………………………………………………….236
• 225. Slew …………………………………………………………………………………………237
• 226. Hydraulic ram ……………………………………………………………………………237
• 227. Optional Attachments
• 228. Introduction ……………………………………………………………………………………239
• 229. Attachments For Your Machine ………………………………………………………..240
• 230. Connecting-Disconnecting Hydraulic Hoses ……………………………………….241
• 231. Introduction ……………………………………………………………………………….241
• 232. Connecting the Hydraulic Hoses ………………………………………………….241
• 233. Disconnecting the Hydraulic Hoses ………………………………………………242
• 234. Quick Release Couplings ……………………………………………………………243
• 235. Operating Attachments ……………………………………………………………………245
• 236. Grab-Changeover Valves (if fitted) ……………………………………………….246
• 237. Hydraulic Rockbreaker ……………………………………………………………………248
• 238. Preparation ……………………………………………………………………………….248
• 239. Operation and Maintenance ………………………………………………………..248
• 240. Hammer Speed Settings …………………………………………………………….249
• 241. Crusher …………………………………………………………………………………………252
• 242. General …………………………………………………………………………………….252
• 243. Preparation ……………………………………………………………………………….252
• 244. Weedcutter ……………………………………………………………………………………253
• 245. Operation ………………………………………………………………………………….253
• 246. Maintenance ……………………………………………………………………………..253
• 247. Specifications
• 248. Static Dimensions …………………………………………………………………………..255
• 249. JS115 – Monoboom ……………………………………………………………………255
• 250. JS130 – Monoboom ……………………………………………………………………256
• 251. JS130 – Triple Articulated Boom …………………………………………………..257
• 252. JS145 – Monoboom ……………………………………………………………………258
• 253. JS145HD – Monoboom ……………………………………………………………….259
• 254. JS145 – Triple Articulated Boom …………………………………………………..260
• 255. JS160 – Monoboom ……………………………………………………………………261
• 256. JS160 – Triple Articulated Boom …………………………………………………..262
• 257. JS180-190 – Monoboom ……………………………………………………………..263
• 258. JS180-190 – Triple Articulated Boom …………………………………………….264
• 259. JS200-210-220 – Monoboom ……………………………………………………….265
• 260. JS200-210-220 – Triple Articulated Boom ………………………………………266
• 261. JS235 – Monoboom ……………………………………………………………………267
• 262. JS235 – Triple Articulated Boom …………………………………………………..268
• 263. JS240-260 – Monoboom ……………………………………………………………..269
• 264. JS240-260 – Triple Articulated Boom …………………………………………….270
• 265. JS290 – Monoboom ……………………………………………………………………271
• 266. JS330 – Monoboom ……………………………………………………………………272
• 267. JS330 – Triple Articulated Boom …………………………………………………..273
• 268. JS360 – Monoboom ……………………………………………………………………274
• 269. Dig Depth Chart ……………………………………………………………………………..275
• 270. JS115 – Monoboom ……………………………………………………………………275
• 271. JS130 – Monoboom ……………………………………………………………………276
• 272. JS130 – Triple Articulated Boom …………………………………………………..277
• 273. JS145 – Monoboom ……………………………………………………………………278
• 274. JS145HD – Monoboom ……………………………………………………………….279
• 275. JS145 – Triple Articulated Boom …………………………………………………..280
• 276. JS160 – Monoboom ……………………………………………………………………281
• 277. JS160 – Triple Articulated Boom …………………………………………………..282
• 278. JS180-190 – Monoboom ……………………………………………………………..283
• 279. JS180-190 – Triple Articulated Boom …………………………………………….284
• 280. JS200-210-220 – Monoboom ……………………………………………………….285
• 281. JS200-210-220 – Triple Articulated Boom ………………………………………286
• 282. JS220-260LR – Long Reach ………………………………………………………..287
• 283. JS235HD – Monoboom ……………………………………………………………….288
• 284. JS235HD – Triple Articulated Boom ………………………………………………289
• 285. JS240-260 – Monoboom ……………………………………………………………..290
• 286. JS240-260 – Triple Articulated Boom …………………………………………….291
• 287. JS290 – Standard Monoboom ………………………………………………………292
• 288. JS330 – Standard Monoboom ………………………….