JCB JS Auto Range – Wheeled Excavators – JCB Engine Operator Manual 9821-2550

Description

• Model List:
  • JS Auto Range – Wheeled 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 Wheeled Excavator ………………………………………………………….4
• 13. Intended Use ………………………………………………………………………………..4
• 14. Component Location ……………………………………………………………………..5
• 15. Safety Check List ……………………………………………………………………………….7
• 16. Safety – Yours and Others ………………………………………………………………7
• 17. General Safety ……………………………………………………………………………..7
• 18. Operating Safety …………………………………………………………………………..9
• 19. Maintenance Safety ……………………………………………………………………..12
• 20. Safety Labels …………………………………………………………………………………..17
• 21. Introduction …………………………………………………………………………………17
• 22. Safety Label Identification …………………………………………………………….18
• 23. Part Numbers and Description ………………………………………………………20
• 24. Identifying Your Machine …………………………………………………………………..22
• 25. Machine Identification Plate ………………………………………………………….22
• 26. Component Identification Plates …………………………………………………….23
• 27. Machine Security ……………………………………………………………………………..26
• 28. Introduction …………………………………………………………………………………26
• 29. JCB Plantguard …………………………………………………………………………..26
• 30. Construction Equipment Security And Registration Scheme (CESAR) .26
• 31. LiveLink ……………………………………………………………………………………..26
• 32. Immobiliser …………………………………………………………………………………26
• 33. Operation
• 34. Introduction ……………………………………………………………………………………..27
• 35. Before Entering the Cab ……………………………………………………………………28
• 36. Entering and Leaving the Cab ……………………………………………………………29
• 37. Standard Cab Machines ……………………………………………………………….29
• 38. Hydraulic Raised Cab Machines ……………………………………………………30
• 39. Fixed Raised Cab Machines …………………………………………………………32
• 40. Emergency Exit …………………………………………………………………………..33
• 41. Doors and Windows …………………………………………………………………………34
• 42. Opening and Closing the Door ………………………………………………………34
• 43. Opening and Closing the Front Upper Window ………………………………..34
• 44. Opening and Closing The Front Lower Window ……………………………….35
• 45. Door Sliding Window. …………………………………………………………………..36
• 46. Opening and Closing the Sunblind …………………………………………………36
• 47. Access to the Upper Structure ……………………………………………………………38
• 48. Standard Machines ………………………………………………………………………38
• 49. Seat Controls …………………………………………………………………………………..39
• 50. Introduction …………………………………………………………………………………39
• 51. Operators Seat-Console ……………………………………………………………….39
• 52. Operators Seat – Standard-Heated …………………………………………………39
• 53. Air Suspension Seat …………………………………………………………………….40
• 54. Seat Belt …………………………………………………………………………………………41
• 55. Static Seat Belt ……………………………………………………………………………41
• 56. Visibility Aids ……………………………………………………………………………………42
• 57. Mirrors ……………………………………………………………………………………….42
• 58. Cab Layout ……………………………………………………………………………………..45
• 59. Components Key …………………………………………………………………………45
• 60. Drive Controls, Switches and Instruments ……………………………………………47
• 61. Drive Controls ……………………………………………………………………………..47
• 62. Switches …………………………………………………………………………………….49
• 63. Instruments …………………………………………………………………………………60
• 64. Air Conditioning and Heater Controls ……………………………………………..66
• 65. Operating Levers-Pedals …………………………………………………………………..68
• 66. Excavating Controls …………………………………………………………………….68
• 67. Operation Levers …………………………………………………………………………73
• 68. Safety Equipment …………………………………………………………………………….75
• 69. Control Locks ……………………………………………………………………………..75
• 70. Dipper Stroke Limiter (If fitted) ……………………………………………………….76
• 71. Overload Warning System …………………………………………………………….78
• 72. Before Starting the Engine …………………………………………………………………80
• 73. Starting the Engine …………………………………………………………………………..81
• 74. Warming-Up ……………………………………………………………………………….82
• 75. JCB Immobiliser System ………………………………………………………………83
• 76. Getting the Machine Moving ………………………………………………………………85
• 77. Travel Mode-Road Travel ……………………………………………………………..85
• 78. Stopping and Parking the Machine ……………………………………………………..90
• 79. Stopping and Parking …………………………………………………………………..90
• 80. Engine Shutdown ………………………………………………………………………..91
• 81. Working with the Machine …………………………………………………………………92
• 82. Operating Practices and Site Safety ………………………………………………92
• 83. Clothing and Safety Equipment ……………………………………………………..92
• 84. Danger Zone ………………………………………………………………………………92
• 85. Log Moving-Handling ……………………………………………………………………92
• 86. Safety Practices ………………………………………………………………………….92
• 87. Working With the Excavator ………………………………………………………….94
• 88. Lifting (Object Handling) ……………………………………………………………..103
• 89. Hydraulically Raised Cab (if fitted) ……………………………………………….106
• 90. Stabilisers (if fitted) …………………………………………………………………….108
• 91. Dozer (if fitted) …………………………………………………………………………..109
• 92. Use of Machines on Gradients and Slopes …………………………………… 110
• 93. Pulling Out of Soft Ground …………………………………………………………. 112
• 94. Water ………………………………………………………………………………………. 113
• 95. Towing Other Equipment-Tow Points ……………………………………………. 114
• 96. Machine Stability ………………………………………………………………………. 115
• 97. Reducing Wear …………………………………………………………………………. 116
• 98. Operating Environment …………………………………………………………………… 118
• 99. Maintenance in Cold Climates …………………………………………………….. 118
• 100. Operating in a Cold Climate (Below 0°C) ……………………………………… 118
• 101. Operating in a Hot Climate (Above 35°C) …………………………………….. 118
• 102. Operating in Dusty or Sandy Areas ……………………………………………… 119
• 103. Operating in Coastal Regions …………………………………………………….. 119
• 104. Operating on Wet or Soft Ground ………………………………………………… 119
• 105. Cab Filters ……………………………………………………………………………….. 119.
• 106. Refuelling the Machine ……………………………………………………………………120
• 107. Low Fuel Levels ………………………………………………………………………..120
• 108. Filling the Tank ………………………………………………………………………….120
• 109. Fuel Level …………………………………………………………………………………121
• 110. Refuelling Pump ………………………………………………………………………..122
• 111. Moving a Disabled Machine …………………………………………………………….123
• 112. Lowering the Boom in an Emergency …………………………………………..123
• 113. Retrieval …………………………………………………………………………………..123
• 114. Limp Mode ………………………………………………………………………………..125
• 115. Transporting the Machine ………………………………………………………………..126
• 116. Lifting the Machine …………………………………………………………………………129
• 117. All Machines ……………………………………………………………………………..129
• 118. Storage of the Machine …………………………………………………………………..131
• 119. Introduction ……………………………………………………………………………….131
• 120. Storage Area …………………………………………………………………………….131
• 121. Prepare the Machine for Storage …………………………………………………131
• 122. Put the Machine into Storage ………………………………………………………131
• 123. During Storage ………………………………………………………………………….131
• 124. Take the Machine Out of Storage …………………………………………………132
• 125. Anti-Vandalism Guards (option) ………………………………………………………..133
• 126. Unpacking the Guards ………………………………………………………………..133
• 127. Fitting the Guards ………………………………………………………………………133
• 128. Removing the Guards ………………………………………………………………..134
• 129. Storing the Guards …………………………………………………………………….134
• 130. Routine Maintenance
• 131. Service Requirements …………………………………………………………………….135
• 132. Introduction ……………………………………………………………………………….135
• 133. Owner-Operator Support …………………………………………………………….135
• 134. Service-Maintenance Agreements ……………………………………………….135
• 135. Fit for Purpose Tests for Lifting Equipment …………………………………….136
• 136. Obtaining Replacement Parts ………………………………………………………136
• 137. Health and Safety …………………………………………………………………………..137
• 138. Lubricants …………………………………………………………………………………137
• 139. Battery ……………………………………………………………………………………..139
• 140. Service Schedules ………………………………………………………………………….141
• 141. Introduction ……………………………………………………………………………….141
• 142. How to Use the Service Schedules ………………………………………………141
• 143. Calendar Equivalents …………………………………………………………………141
• 144. Pre Start Cold Checks, Service Points and Fluid Levels ………………….142
• 145. Functional Test and Final Inspection …………………………………………….147
• 146. Service Intervals for Attachments …………………………………………………149
• 147. Periodic Replacement of Safety Related Components ……………………150
• 148. Fluids, Lubricants and Capacities ……………………………………………………..151
• 149. JS145W and Variants …………………………………………………………………151
• 150. JS160W and Variants …………………………………………………………………152
• 151. Typical Lubrication Chart …………………………………………………………….153
• 152. Coolant Mixtures ……………………………………………………………………….155
• 153. Fuel …………………………………………………………………………………………156
• 154. Tools …………………………………………………………………………………………….159
• 155. Carrying Tools onto the Machine ………………………………………………….159
• 156. Locations ………………………………………………………………………………….159
• 157. Prepare the Machine for Maintenance ………………………………………………160
• 158. Introduction ……………………………………………………………………………….160
• 159. How to Make the Machine Safe (Excavator Lowered) …………………….160
• 160. Cleaning the Machine ……………………………………………………………………..161
• 161. Introduction ……………………………………………………………………………….161
• 162. Preparing the Machine for Cleaning ……………………………………………..161
• 163. Cleaning the Machine …………………………………………………………………162
• 164. Cleaning the Radiator and Oil Cooler ……………………………………………162
• 165. Check the Machine for Damage ……………………………………………………….163
• 166. Check the Machine Body and Structure ………………………………………..163
• 167. Check the Seat and Seat Belt ……………………………………………………..163
• 168. Checking the FOPS Structure ……………………………………………………..163
• 169. Check the Tyres ………………………………………………………………………..165
• 170. Daily Checking ……………………………………………………………………………….166
• 171. Greasing ……………………………………………………………………………………….168
• 172. Introduction ……………………………………………………………………………….168
• 173. Single Point Greasing …………………………………………………………………168
• 174. Multi Point Greasing …………………………………………………………………..169
• 175. Tyres and Wheels …………………………………………………………………………..172
• 176. Tyre Inflation ……………………………………………………………………………..172
• 177. Checking the Wheel Nut Tightness ………………………………………………173
• 178. Electrical System ……………………………………………………………………………174
• 179. Battery ……………………………………………………………………………………..174
• 180. Jump-Starting the Engine ……………………………………………………………178
• 181. Fuses and Relays – Cab ……………………………………………………………..179
• 182. Fuses and Relays – Battery Bay …………………………………………………..181
• 183. Bolt and Nut Torque Specifications ……………………………………………………183
• 184. JS145W-JS160W and Variants ……………………………………………………183
• 185. Engine ………………………………………………………………………………………….186
• 186. Oil and Filter ……………………………………………………………………………..186
• 187. Cooling System …………………………………………………………………………188
• 188. Engine Air Filter …………………………………………………………………………191
• 189. Fan Belt ……………………………………………………………………………………193
• 190. Front End Accessory Drive Belt …………………………………………………..194
• 191. Fuel System …………………………………………………………………………………..196
• 192. Introduction ……………………………………………………………………………….196
• 193. Draining Fuel Tank Impurities ………………………………………………………196
• 194. Draining the Primary Fuel Filter-Sedimenter ………………………………….197
• 195. Changing the Primary Fuel Filter-Sedimenter Element ……………………198
• 196. Draining the Main Fuel Filter-Sedimenter ………………………………………199
• 197. Changing the Main Fuel Filter-Sedimenter Element ………………………..200
• 198. Draining the Engine Fuel Filter-Sedimenter …………………………………..201
• 199. Changing the Engine Fuel Filter-Sedimenter Element …………………….201
• 200. Bleeding the System ………………………………………………………………….202
• 201. Hydraulic System ……………………………………………………………………………203
• 202. Introduction ……………………………………………………………………………….203
• 203. Releasing Tank Pressure ……………………………………………………………204
• 204. Releasing the Hydraulic Pressure ………………………………………………..204
• 205. Oil and Filters ……………………………………………………………………………205
• 206. Draining Water and Sediment from the Hydraulic Tank ……………………213
• 207. Air Bleeding Procedures ……………………………………………………………..213
• 208. Slew Gearbox ………………………………………………………………………………..215
• 209. Checking the Slew Gearbox Oil Level …………………………………………..215
• 210. Changing the Slew Gearbox Oil Level ………………………………………….215
• 211. Drive Gearbox ……………………………………………………………………………….216
• 212. Checking the Drive Gearbox Oil Level ………………………………………….216
• 213. Changing the Drive Gearbox Oil ………………………………………………….217
• 214. Axles …………………………………………………………………………………………….218
• 215. Front Axle …………………………………………………………………………………218
• 216. Rear Axle ………………………………………………………………………………….221
• 217. Bucket ………………………………………………………………………………………….223
• 218. Checking-Adjusting For Side Play ………………………………………………..223
• 219. Windscreen Washer ……………………………………………………………………….224
• 220. Checking the Level …………………………………………………………………….224
• 221. Fire Extinguisher (If fitted) ……………………………………………………………….225
• 222. Troubleshooting ……………………………………………………………………………..226
• 223. Engine and Related Area ……………………………………………………………226
• 224. Monitor Display – Fault Messages ………………………………………………..229
• 225. Operations ………………………………………………………………………………..230
• 226. Hydraulic pump …………………………………………………………………………231
• 227. Working Attachments …………………………………………………………………232
• 228. Slew …………………………………………………………………………………………233
• 229. Hydraulic ram ……………………………………………………………………………233
• 230. Optional Attachments
• 231. Introduction ……………………………………………………………………………………235
• 232. Attachments For Your Machine ………………………………………………………..236
• 233. Connecting-Disconnecting Hydraulic Hoses ……………………………………….237
• 234. Introduction ……………………………………………………………………………….237
• 235. Connecting the Hydraulic Hoses ………………………………………………….237
• 236. Disconnecting the Hydraulic Hoses ………………………………………………238
• 237. Quick Release Couplings ……………………………………………………………239
• 238. Operating Attachments ……………………………………………………………………241
• 239. Grab-Changeover Valves (if fitted) ……………………………………………….242
• 240. Hydraulic Rockbreaker ……………………………………………………………………244
• 241. Preparation ……………………………………………………………………………….244
• 242. Operation and Maintenance ………………………………………………………..244
• 243. Crusher …………………………………………………………………………………………245
• 244. General …………………………………………………………………………………….245
• 245. Preparation ……………………………………………………………………………….245
• 246. Weedcutter ……………………………………………………………………………………246
• 247. Operation ………………………………………………………………………………….246
• 248. Maintenance ……………………………………………………………………………..246
• 249. Specifications
• 250. Static Dimensions …………………………………………………………………………..247
• 251. JS145W – Monoboom …………………………………………………………………247
• 252. JS145W – Triple Articulated Boom ……………………………………………….248
• 253. JS160 – Monoboom ……………………………………………………………………249
• 254. JS160 – Triple Articulated Boom …………………………………………………..250
• 255. Dig Depth Chart ……………………………………………………………………………..251
• 256. JS145W ……………………………………………………………………………………251
• 257. JS160W ……………………………………………………………………………………252
• 258. Shipping Weight …………………………………………………………………………….253
• 259. Tyre Pressures ………………………………………………………………………………254
• 260. Turning Radius ………………………………………………………………………………255
• 261. Travel Speeds ………………………………………………………………………………..256
• 262. Noise Data …………………………………………………………………………………….257
• 263. Introduction ……………………………………………………………………………….257
• 264. All Machines ……………………………………………………………………………..257
• 265. Vibration Data ………………………………………………………………………………..258
• 266. Introduction ……………………………………………………………………………….258
• 267. JS145W ……………………………………………………………………………………259
• 268. JS160W ……………………………………………………………………………………260
• 269. Lifting (Object Handling) Regulations and Safe Working Loads …………….261
• 270. Introduction ……………………………………………………………………………….261
• 271. Load Charts ………………………………………………………………………………262
• 272. Warranty Information
• 273. Machine Service Record Sheet ………………………………………………………..265
• 274. Registration Information ………………………………………………………………….267
• 275. European Community Standards
• 276. EC Declaration of Conformity …………………………………………………………..269
• 277. Introduction ……………………………………………………………………………….269
• 278. Explanation of the EC Declaration of Conformity ……………………………271