JCB JS Auto Range – Tracked Excavators – JCB Engine Operator Manual 9821-2450

Description

• Model List:
  • JS Auto Range – Tracked Excavators – JCB 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 ………………………………………………………………………3
• 10. Cross References ………………………………………………………………………….3
• 11. Machine Description …………………………………………………………………………..4
• 12. The JCB Tracked Excavator ……………………………………………………………4
• 13. Intended Use ………………………………………………………………………………..4
• 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 …………………………………………………………………………………62
• 63. Air Conditioning and Heater Controls ……………………………………………..67
• 64. Operating Levers-Pedals …………………………………………………………………..69
• 65. Excavating Controls …………………………………………………………………….69
• 66. Travel Speed Change Button ………………………………………………………..76
• 67. Operation Levers …………………………………………………………………………77
• 68. Optional Circuit Pedal (if fitted) ………………………………………………………78
• 69. ISO Operating Method …………………………………………………………………78
• 70. Safety Equipment …………………………………………………………………………….79
• 71. Control Locks ……………………………………………………………………………..79
• 72. Dipper Stroke Limiter (If fitted) ……………………………………………………….80
• 73. Overload Warning System …………………………………………………………….83
• 74. Before Starting the Engine …………………………………………………………………84
• 75. Starting the Engine …………………………………………………………………………..85
• 76. Warming-Up ……………………………………………………………………………….86
• 77. JCB Immobiliser System ………………………………………………………………87
• 78. Getting the Machine Moving ………………………………………………………………89
• 79. Stopping and Parking the Machine ……………………………………………………..90
• 80. Stopping and Parking …………………………………………………………………..90
• 81. Engine Shutdown ………………………………………………………………………..91
• 82. Working with your Machine ……………………………………………………………….92
• 83. Operating Practices and Site Safety ………………………………………………92
• 84. Clothing and Safety Equipment ……………………………………………………..92
• 85. Danger Zone ………………………………………………………………………………92
• 86. Log Moving-Handling ……………………………………………………………………92
• 87. Safety Practices ………………………………………………………………………….92
• 88. Working With the Excavator ………………………………………………………….94
• 89. Lifting (Object Handling) ……………………………………………………………..101
• 90. Hydraulically Raised Cab (if fitted) ……………………………………………….104
• 91. Use of Machines on Gradients and Slopes ……………………………………106
• 92. Pulling out of Soft Ground …………………………………………………………..109
• 93. Water ………………………………………………………………………………………. 110
• 94. Towing Other Equipment ……………………………………………………………. 110
• 95. Machine Stability ………………………………………………………………………. 111
• 96. Reducing Wear …………………………………………………………………………. 112
• 97. Operating Environment …………………………………………………………………… 115
• 98. Maintenance in Cold Climates …………………………………………………….. 115
• 99. Operating in a Cold Climate (Below 0°C) ……………………………………… 115
• 100. Operating in a Hot Climate (Above 35°C) …………………………………….. 115
• 101. Operating in Dusty or Sandy Areas ……………………………………………… 116
• 102. Operating in Coastal Regions …………………………………………………….. 116
• 103. Operating on Wet or Soft Ground ………………………………………………… 116
• 104. Cab Filters ……………………………………………………………………………….. 116
• 105. Refuelling the Machine …………………………………………………………………… 117
• 106. Low Fuel Levels ……………………………………………………………………….. 117
• 107. Filling the Tank …………………………………………………………………………. 117
• 108. Fuel Level ………………………………………………………………………………… 118
• 109. Refuelling Pump ……………………………………………………………………….. 119
• 110. Moving a Disabled Machine …………………………………………………………….120
• 111. Lowering the Boom in an Emergency …………………………………………..120
• 112. Retrieval …………………………………………………………………………………..120
• 113. Limp Mode ………………………………………………………………………………..121
• 114. Transporting the Machine ………………………………………………………………..122
• 115. Lifting the Machine …………………………………………………………………………124
• 116. JS115 – JS220 Machines …………………………………………………………….124
• 117. Storage of the Machine …………………………………………………………………..126
• 118. Introduction ……………………………………………………………………………….126
• 119. Storage Area …………………………………………………………………………….126
• 120. Prepare the Machine for Storage …………………………………………………126
• 121. Put the Machine into Storage ………………………………………………………126
• 122. During Storage ………………………………………………………………………….126
• 123. Take the Machine Out of Storage …………………………………………………127
• 124. Anti-Vandalism Guards (option) ………………………………………………………..128
• 125. Unpacking the Guards ………………………………………………………………..128
• 126. Fitting the Guards ………………………………………………………………………128
• 127. Removing the Guards ………………………………………………………………..129
• 128. Storing the Guards …………………………………………………………………….129
• 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-JS130-JS145 and Variants ………………………………………………..146
• 149. JS160-JS180 and Variants ………………………………………………………….147
• 150. JS200-JS210-JS220 and Variants ………………………………………………..148
• 151. Typical Lubrication Chart …………………………………………………………….149
• 152. Coolant Mixtures ……………………………………………………………………….150
• 153. Fuel …………………………………………………………………………………………151
• 154. Tools …………………………………………………………………………………………….154
• 155. Carrying Tools onto the Machine ………………………………………………….154
• 156. Locations ………………………………………………………………………………….154
• 157. Prepare the Machine for Maintenance ………………………………………………155
• 158. Introduction ……………………………………………………………………………….155
• 159. How to Make the Machine Safe (Excavator Lowered) …………………….155
• 160. Cleaning the Machine ……………………………………………………………………..156
• 161. Introduction ……………………………………………………………………………….156
• 162. Preparing the Machine for Cleaning ……………………………………………..156
• 163. Cleaning the Machine …………………………………………………………………157
• 164. Cleaning the Tracks ……………………………………………………………………157
• 165. Cleaning the Radiator and Oil Cooler ……………………………………………157
• 166. Checking for Damage ……………………………………………………………………..158
• 167. Check the Machine Body and Structure ………………………………………..158
• 168. Check the Seat and Seat Belt ……………………………………………………..158
• 169. Checking the FOPS Structure ……………………………………………………..158
• 170. Daily Checking ……………………………………………………………………………….160
• 171. Greasing ……………………………………………………………………………………….162
• 172. Introduction ……………………………………………………………………………….162
• 173. Slew Ring Bearing ……………………………………………………………………..162
• 174. Slew Ring Teeth and Slew Pinion …………………………………………………162
• 175. Greasing Points …………………………………………………………………………163
• 176. Electrical System ……………………………………………………………………………165
• 177. Battery ……………………………………………………………………………………..165
• 178. Jump-Starting the Engine ……………………………………………………………168
• 179. Fuses and Relays – Cab ……………………………………………………………..169
• 180. Fuses and Relays – Battery Bay …………………………………………………..171
• 181. Bolt and Nut Torque Specifications ……………………………………………………173
• 182. JS115-JS220 and Variants ………………………………………………………….173
• 183. Engine ………………………………………………………………………………………….179
• 184. Oil and Filter ……………………………………………………………………………..179
• 185. Cooling System …………………………………………………………………………181
• 186. Engine Air Filter …………………………………………………………………………184
• 187. Fan Belt ……………………………………………………………………………………186
• 188. Front End Accessory Drive Belt …………………………………………………..187
• 189. Crankcase Ventilation (if fitted, JS200-220) …………………………………..188
• 190. Fuel System …………………………………………………………………………………..189
• 191. Introduction ……………………………………………………………………………….189
• 192. Draining Fuel Tank Impurities ………………………………………………………189
• 193. Draining the Primary Fuel Filter-Sedimenter ………………………………….190
• 194. Changing the Primary Fuel Filter-Sedimenter Element ……………………191
• 195. Draining the Main Fuel Filter-Sedimenter ………………………………………192
• 196. Changing the Main Fuel Filter-Sedimenter Element ………………………..193
• 197. Draining the Engine Fuel Filter-Sedimenter …………………………………..194
• 198. Changing the Engine Fuel Filter-Sedimenter Element …………………….194
• 199. Bleeding the System ………………………………………………………………….195
• 200. Hydraulic System ……………………………………………………………………………196
• 201. Introduction ……………………………………………………………………………….196
• 202. Releasing Tank Pressure ……………………………………………………………197
• 203. Releasing the Hydraulic Pressure ………………………………………………..197
• 204. Oil and Filters ……………………………………………………………………………198
• 205. Draining Water and Sediment from the Hydraulic Tank ……………………205
• 206. Air Bleeding Procedures ……………………………………………………………..205
• 207. Slew Gearbox ………………………………………………………………………………..207
• 208. Checking the Slew Gearbox Oil Level …………………………………………..207
• 209. Changing the Slew Gearbox Oil …………………………………………………..207
• 210. Tracks and Running Gear ……………………………………………………………….208
• 211. Tracks ………………………………………………………………………………………208
• 212. Running Gear ……………………………………………………………………………210
• 213. Bucket …………………………………………………………………………………………. 211
• 214. Checking-Adjusting For Side Play ……………………………………………….. 211
• 215. Windscreen Washer ……………………………………………………………………….212
• 216. Checking the Level …………………………………………………………………….212
• 217. Fire Extinguisher (If fitted) ……………………………………………………………….213
• 218. Troubleshooting ……………………………………………………………………………..214
• 219. Engine and Related Area ……………………………………………………………214
• 220. Monitor Display – Fault Messages ………………………………………………..217
• 221. Operations ………………………………………………………………………………..218
• 222. Hydraulic pump …………………………………………………………………………219
• 223. Working Attachments …………………………………………………………………220
• 224. Travel ……………………………………………………………………………………….221
• 225. Slew …………………………………………………………………………………………222
• 226. Hydraulic ram ……………………………………………………………………………222
• 227. Optional Attachments
• 228. Introduction ……………………………………………………………………………………223
• 229. Attachments For Your Machine ………………………………………………………..224
• 230. Connecting-Disconnecting Hydraulic Hoses ……………………………………….225
• 231. Introduction ……………………………………………………………………………….225
• 232. Connecting the Hydraulic Hoses ………………………………………………….225
• 233. Disconnecting the Hydraulic Hoses ………………………………………………226
• 234. Quick Release Couplings ……………………………………………………………227
• 235. Operating Attachments ……………………………………………………………………229
• 236. Grab-Changeover Valves (if fitted) ……………………………………………….230
• 237. Hydraulic Rockbreaker ……………………………………………………………………232
• 238. Preparation ……………………………………………………………………………….232
• 239. Operation and Maintenance ………………………………………………………..232
• 240. Hammer Speed Settings …………………………………………………………….233
• 241. Crusher …………………………………………………………………………………………235
• 242. General …………………………………………………………………………………….235
• 243. Preparation ……………………………………………………………………………….235
• 244. Weedcutter ……………………………………………………………………………………236
• 245. Operation ………………………………………………………………………………….236
• 246. Maintenance ……………………………………………………………………………..236
• 247. Specifications
• 248. Static Dimensions …………………………………………………………………………..237
• 249. JS115 – Monoboom ……………………………………………………………………237
• 250. JS130 – Monoboom ……………………………………………………………………238
• 251. JS145 – Monoboom ……………………………………………………………………239
• 252. JS145HD – Monoboom ……………………………………………………………….240
• 253. JS145 – Triple Articulated Boom …………………………………………………..241
• 254. JS160 – Monoboom ……………………………………………………………………242
• 255. JS160 – Triple Articulated Boom …………………………………………………..243
• 256. JS180 – Monoboom ……………………………………………………………………244
• 257. JS180 – Triple Articulated Boom …………………………………………………..245
• 258. JS200-210-220 – Monoboom ……………………………………………………….246
• 259. JS200-210-220 – Triple Articulated Boom ………………………………………247
• 260. Dig Depth Chart ……………………………………………………………………………..248
• 261. JS115 – Monoboom ……………………………………………………………………248
• 262. JS130 – Monoboom ……………………………………………………………………249
• 263. JS145 – Monoboom ……………………………………………………………………250
• 264. JS145HD – Monoboom ……………………………………………………………….251
• 265. JS145 – Triple Articulated Boom …………………………………………………..252
• 266. JS160 – Monoboom ……………………………………………………………………253
• 267. JS160 – Triple Articulated Boom …………………………………………………..254
• 268. JS180 – Monoboom ……………………………………………………………………255
• 269. JS180 – Triple Articulated Boom …………………………………………………..256
• 270. JS200-210-220 – Monoboom ……………………………………………………….257
• 271. JS200-210-220 – Triple Articulated Boom ………………………………………258
• 272. Shipping Weight …………………………………………………………………………….259
• 273. Travel Speeds ………………………………………………………………………………..261
• 274. Noise Data …………………………………………………………………………………….262
• 275. Introduction ……………………………………………………………………………….262
• 276. All Machines ……………………………………………………………………………..262
• 277. Vibration Data ………………………………………………………………………………..263
• 278. Introduction ……………………………………………………………………………….263
• 279. JS115-145 ………………………………………………………………………………..264
• 280. JS160-JS180 …………………………………………………………………………….265
• 281. Lifting (Object Handling) Regulations and Safe Working Loads …………….266
• 282. Introduction ……………………………………………………………………………….266
• 283. Load Charts ………………………………………………………………………………267
• 284. Warranty Information
• 285. Machine Service Record Sheet ………………………………………………………..283
• 286. Registration Information ………………………………………………………………….285
• 287. European Community Standards
• 288. EC Declaration of Conformity …………………………………………………………..287
• 289. Introduction ………