JCB JS Auto Range – Wheeled Excavators – Tier 3 Isuzu Engine Operator Manual 9811-6750

Description

• Model List:
  • JS Auto Range – Wheeled Excavators – 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 Wheeled 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. Part Numbers and Description ………………………………………………………21
• 24. Identifying Your Machine …………………………………………………………………..23
• 25. Machine Identification Plate ………………………………………………………….23
• 26. Component Identification Plates …………………………………………………….24
• 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 …………………………………………………………………………..34
• 41. Doors and Windows …………………………………………………………………………35
• 42. Opening and Closing the Door ………………………………………………………35
• 43. Opening and Closing the Front Upper Window ………………………………..36
• 44. Opening and Closing The Front Lower Window ……………………………….37
• 45. Door Sliding Window ……………………………………………………………………39
• 46. Opening and Closing the Sunblind …………………………………………………40
• 47. Seat Controls …………………………………………………………………………………..42
• 48. Introduction …………………………………………………………………………………42
• 49. Operators Seat-Console ……………………………………………………………….42
• 50. Operators Seat – Standard-Heated …………………………………………………42
• 51. Air Suspension Seat …………………………………………………………………….43
• 52. Access to the Upper Structure ……………………………………………………………44
• 53. Standard Machines ………………………………………………………………………44
• 54. Seat Belt …………………………………………………………………………………………45
• 55. Static Seat Belt ……………………………………………………………………………45
• 56. Visibility Aids ……………………………………………………………………………………46
• 57. Mirrors ……………………………………………………………………………………….46
• 58. Cab Layout ……………………………………………………………………………………..49
• 59. Components Key …………………………………………………………………………49
• 60. Drive Controls, Switches and Instruments ……………………………………………51
• 61. Drive Controls ……………………………………………………………………………..51
• 62. Switches …………………………………………………………………………………….53
• 63. Instruments …………………………………………………………………………………64
• 64. Air Conditioning and Heater Controls ……………………………………………..70
• 65. Operating Levers-Pedals …………………………………………………………………..72
• 66. Excavating Controls …………………………………………………………………….72
• 67. Operation Levers …………………………………………………………………………78
• 68. Safety Equipment …………………………………………………………………………….80
• 69. Control Locks ……………………………………………………………………………..80
• 70. Dipper Stroke Limiter (If fitted) ……………………………………………………….81
• 71. Overload Warning System …………………………………………………………….84
• 72. Before Starting the Engine …………………………………………………………………85
• 73. Starting the Engine …………………………………………………………………………..86
• 74. Warming-Up ……………………………………………………………………………….87
• 75. JCB Immobiliser System ………………………………………………………………88
• 76. Getting the Machine Moving ………………………………………………………………90
• 77. Travel Mode-Road Travel ……………………………………………………………..90
• 78. Stopping and Parking the Machine ……………………………………………………..95
• 79. Stopping and Parking …………………………………………………………………..95
• 80. Engine Shutdown ………………………………………………………………………..96
• 81. Working with the Machine …………………………………………………………………97
• 82. Operating Practices and Site Safety ………………………………………………97
• 83. Clothing and Safety Equipment ……………………………………………………..97
• 84. Danger Zone ………………………………………………………………………………97
• 85. Log Moving-Handling ……………………………………………………………………97
• 86. Safety Practices ………………………………………………………………………….98
• 87. Working With the Excavator ………………………………………………………….99
• 88. Lifting (Object Handling) ……………………………………………………………..108
• 89. Hydraulically Raised Cab (if fitted) ………………………………………………. 111
• 90. Stabilisers (if fitted) ……………………………………………………………………. 113
• 91. Dozer (if fitted) ………………………………………………………………………….. 114
• 92. Use of Machines on Gradients and Slopes …………………………………… 115
• 93. Pulling Out of Soft Ground …………………………………………………………. 117
• 94. Water ………………………………………………………………………………………. 118
• 95. Towing Other Equipment-Tow Points ……………………………………………. 119
• 96. Machine Stability ……………………………………………………………………….120
• 97. Reducing Wear ………………………………………………………………………….121
• 98. Operating Environment ……………………………………………………………………123
• 99. Maintenance in Cold Climates ……………………………………………………..123
• 100. Operating in a Cold Climate (Below 0°C) ………………………………………123
• 101. Operating in a Hot Climate (Above 35°C) ……………………………………..123
• 102. Operating in Dusty or Sandy Areas ………………………………………………124
• 103. Operating in Coastal Regions ……………………………………………………..124
• 104. Operating on Wet or Soft Ground …………………………………………………124
• 105. Cab Filters ………………………………………………………………………………..124
• 106. Refuelling the Machine ……………………………………………………………………125
• 107. Low Fuel Levels ………………………………………………………………………..125
• 108. Filling the Tank ………………………………………………………………………….125
• 109. Fuel Level …………………………………………………………………………………126
• 110. Refuelling Pump ………………………………………………………………………..127
• 111. Moving a Disabled Machine …………………………………………………………….128
• 112. Lowering the Boom in an Emergency …………………………………………..128
• 113. Retrieval …………………………………………………………………………………..128
• 114. Limp Mode ………………………………………………………………………………..130
• 115. Transporting the Machine ………………………………………………………………..131
• 116. Lifting the Machine …………………………………………………………………………134
• 117. JS130W – JS200W Machines ………………………………………………………134
• 118. Storage of the Machine …………………………………………………………………..136
• 119. Introduction ……………………………………………………………………………….136
• 120. Storage Area …………………………………………………………………………….136
• 121. Prepare the Machine for Storage …………………………………………………136
• 122. Put the Machine into Storage ………………………………………………………136
• 123. During Storage ………………………………………………………………………….136
• 124. Take the Machine Out of Storage …………………………………………………137
• 125. Anti-Vandalism Guards (option) ………………………………………………………..138
• 126. Unpacking the Guards ………………………………………………………………..138
• 127. Fitting the Guards ………………………………………………………………………138
• 128. Removing the Guards ………………………………………………………………..139
• 129. Storing the Guards …………………………………………………………………….139
• 130. Routine Maintenance
• 131. Service Requirements …………………………………………………………………….141
• 132. Introduction ……………………………………………………………………………….141
• 133. Owner-Operator Support …………………………………………………………….141
• 134. Service-Maintenance Agreements ……………………………………………….141
• 135. Fit for Purpose Tests for Lifting Equipment …………………………………….142
• 136. Obtaining Replacement Parts ………………………………………………………142
• 137. Health and Safety …………………………………………………………………………..143
• 138. Lubricants …………………………………………………………………………………143
• 139. Battery ……………………………………………………………………………………..145
• 140. Service Schedules ………………………………………………………………………….147
• 141. Introduction ……………………………………………………………………………….147
• 142. How to Use the Service Schedules ………………………………………………147
• 143. Calendar Equivalents …………………………………………………………………147
• 144. Pre Start Cold Checks, Service Points and Fluid Levels ………………….148
• 145. Functional Test and Final Inspection …………………………………………….152
• 146. Service Intervals for Attachments …………………………………………………154
• 147. Periodic Replacement of Safety Related Components ……………………155
• 148. Fluids, Lubricants and Capacities ……………………………………………………..156
• 149. JS130W-160W and Variants ……………………………………………………….156
• 150. JS175W and Variants …………………………………………………………………157
• 151. JS200W and Variants …………………………………………………………………158
• 152. Typical Lubrication Chart …………………………………………………………….159
• 153. Coolant Mixtures ……………………………………………………………………….161
• 154. Fuel …………………………………………………………………………………………161
• 155. Tools …………………………………………………………………………………………….164
• 156. Carrying Tools onto the Machine ………………………………………………….164
• 157. Locations ………………………………………………………………………………….164
• 158. Prepare the Machine for Maintenance ………………………………………………165
• 159. Introduction ……………………………………………………………………………….165
• 160. How to Make the Machine Safe (Excavator Lowered) …………………….165
• 161. Cleaning the Machine ……………………………………………………………………..166
• 162. Introduction ……………………………………………………………………………….166
• 163. Preparing the Machine for Cleaning ……………………………………………..166
• 164. Cleaning the Machine …………………………………………………………………167
• 165. Cleaning the Radiator and Oil Cooler ……………………………………………167
• 166. Check the Machine for Damage ……………………………………………………….168
• 167. Check the Machine Body and Structure ………………………………………..168
• 168. Check the Seat and Seat Belt ……………………………………………………..168
• 169. Checking the FOPS Structure ……………………………………………………..168
• 170. Check the Tyres ………………………………………………………………………..169
• 171. Daily Checking ……………………………………………………………………………….170
• 172. Greasing ……………………………………………………………………………………….172
• 173. Introduction ……………………………………………………………………………….172
• 174. Single Point Greasing …………………………………………………………………172
• 175. Multi Point Greasing …………………………………………………………………..173
• 176. Tyres and Wheels …………………………………………………………………………..176
• 177. Tyre Inflation ……………………………………………………………………………..176
• 178. Checking the Wheel Nut Tightness ………………………………………………177
• 179. Electrical System ……………………………………………………………………………178
• 180. Battery ……………………………………………………………………………………..178
• 181. Jump-Starting the Engine ……………………………………………………………182
• 182. Fuses ……………………………………………………………………………………….183
• 183. Bolt and Nut Torque Specifications ……………………………………………………185
• 184. JS130W – 200W and Variants ……………………………………………………..185
• 185. Engine ………………………………………………………………………………………….188
• 186. Oil and Filter ……………………………………………………………………………..188
• 187. Cooling System …………………………………………………………………………191
• 188. Fan Belt ……………………………………………………………………………………203
• 189. Engine Air Filter …………………………………………………………………………204
• 190. Fuel System …………………………………………………………………………………..206
• 191. Introduction ……………………………………………………………………………….206
• 192. Draining Fuel Tank Impurities ………………………………………………………206
• 193. Draining the Primary Filter-Sedimenter …………………………………………207
• 194. Changing the Primary Filter-Sedimenter Element …………………………..208
• 195. Changing the Fuel Feed Pump Filter ……………………………………………208
• 196. Draining the Main Filter-Sedimenter ……………………………………………..210
• 197. Changing the Main Filter-Sedimenter Element ………………………………. 211
• 198. Bleeding the System ………………………………………………………………….212
• 199. Hydraulic System ……………………………………………………………………………213
• 200. Introduction ……………………………………………………………………………….213
• 201. Releasing Tank Pressure ……………………………………………………………214
• 202. Releasing the Hydraulic Pressure ………………………………………………..214
• 203. Oil and Filters ……………………………………………………………………………215
• 204. Draining Water and Sediment from the Hydraulic Tank ……………………223
• 205. Air Bleeding Procedures ……………………………………………………………..223
• 206. Slew Gearbox ………………………………………………………………………………..225
• 207. Checking the Slew Gearbox Oil Level …………………………………………..225
• 208. Changing the Slew Gearbox Oil Level ………………………………………….225
• 209. Drive Gearbox ……………………………………………………………………………….226
• 210. Checking the Drive Gearbox Oil Level ………………………………………….226
• 211. Changing the Drive Gearbox Oil ………………………………………………….227Contents
• 212. v v
• 213. Contents Page No.
• 214. Axles …………………………………………………………………………………………….228
• 215. Front Axle …………………………………………………………………………………228
• 216. Rear Axle ………………………………………………………………………………….231
• 217. Bucket ………………………………………………………………………………………….233
• 218. Checking-Adjusting For Side Play ………………………………………………..233
• 219. Windscreen Washer ……………………………………………………………………….234
• 220. Checking the Level …………………………………………………………………….234
• 221. Fire Extinguisher (If fitted) ……………………………………………………………….235
• 222. Troubleshooting ……………………………………………………………………………..236
• 223. Engine and Related Area ……………………………………………………………236
• 224. Monitor Display – Fault Messages ………………………………………………..239
• 225. Operations ………………………………………………………………………………..240
• 226. Hydraulic pump …………………………………………………………………………241
• 227. Working Attachments …………………………………………………………………242
• 228. Slew …………………………………………………………………………………………243
• 229. Hydraulic ram ……………………………………………………………………………243
• 230. Optional Attachments
• 231. Introduction ……………………………………………………………………………………245
• 232. Attachments For Your Machine ………………………………………………………..246
• 233. Connecting-Disconnecting Hydraulic Hoses ……………………………………….247
• 234. Introduction ……………………………………………………………………………….247
• 235. Connecting the Hydraulic Hoses ………………………………………………….247
• 236. Disconnecting the Hydraulic Hoses ………………………………………………248
• 237. Quick Release Couplings ……………………………………………………………249
• 238. Operating Attachments ……………………………………………………………………251
• 239. Grab-Changeover Valves (if fitted) ……………………………………………….252
• 240. Hydraulic Rockbreaker ……………………………………………………………………254
• 241. Preparation ……………………………………………………………………………….254
• 242. Operation and Maintenance ………………………………………………………..254
• 243. Hammer Speed Settings …………………………………………………………….255
• 244. Crusher …………………………………………………………………………………………256
• 245. General …………………………………………………………………………………….256
• 246. Preparation ……………………………………………………………………………….256
• 247. Weedcutter ……………………………………………………………………………………257
• 248. Operation ………………………………………………………………………………….257
• 249. Maintenance ……………………………………………………………………………..257
• 250. Specifications
• 251. Static Dimensions …………………………………………………………………………..259
• 252. JS130W-JS145W – Monoboom ……………………………………………………259
• 253. JS130W-JS145W – Triple Articulated Boom …………………………………..260
• 254. JS160-175W – Monoboom …………………………………………………………..261
• 255. JS160-175W – Triple Articulated Boom …………………………………………262
• 256. JS200W – Monoboom …………………………………………………………………263
• 257. JS200W – Triple Articulated Boom ……………………………………………….264
• 258. JS200W – Wide Axle ………………………………………………………………….265
• 259. Dig Depth Chart ……………………………………………………………………………..266
• 260. JS130W-JS145W ………………………………………………………………………266
• 261. JS160W-JS175W ………………………………………………………………………267
• 262. JS200W ……………………………………………………………………………………268
• 263. Shipping Weight …………………………………………………………………………….269
• 264. Tyre Pressures ………………………………………………………………………………271
• 265. Turning Radius ………………………………………………………………………………272
• 266. Travel Speeds ………………………………………………………………………………..273
• 267. Noise Data …………………………………………………………………………………….274
• 268. Introduction ……………………………………………………………………………….274
• 269. All Machines ……………………………………………………………………………..274
• 270. Vibration Data ………………………………………………………………………………..275
• 271. Introduction ……………………………………………………………………………….275
• 272. JS130W-JS145W ………………………………………………………………………276
• 273. JS160W ……………………………………………………………………………………277
• 274. JS175W ……………………………………………………………………………………278
• 275. JS200W ……………………………………………………………………………………279
• 276. Lifting (Object Handling) Regulations and Safe Working Loads …………….280
• 277. Introduction ……………………………………………………………………………….280
• 278. Load Charts ………………………………………………………………………………281
• 279. Warranty Information
• 280. Machine Service Record Sheet ………………………………………………………..293
• 281. Registration Information ………………………………………………………………….295
• 282. European Community Standards
• 283. EC Declaration of Conformity …………………………………………………………..297
• 284. Introduction ……………………………………………………………………………….297
• 285. Explanation of the EC Declaration of Conformity ……………………………299