JCB JS115, JS130, JS130LC, JS145, JS160, JS180, JS190, JS200, JS235, JS240, JS260, JS330 Operator Manual

Description

• Model List:
  • JS115, JS130, JS130LC, JS145, JS160, JS180, JS190, JS200, JS235, JS240, JS260, JS330

• 1. Safety Notices
• 2. Introduction ……………………………………………………………………………………….1
• 3. Introduction
• 4. About this Operator Manual …………………………………………………………………3
• 5. Machine Model and Serial Number ………………………………………………….3
• 6. Using this Manual ………………………………………………………………………….3
• 7. Units of Measurement ……………………………………………………………………3
• 8. Left Side, Right Side ………………………………………………………………………3
• 9. Using the Machine …………………………………………………………………………3
• 10. Cross References ………………………………………………………………………….3
• 11. Machine Description …………………………………………………………………………..4
• 12. The JCB Tracked Excavator ……………………………………………………………4
• 13. Safety Check List ……………………………………………………………………………….6
• 14. Safety – Yours and Others ………………………………………………………………6
• 15. General Safety ……………………………………………………………………………..6
• 16. Operating Safety …………………………………………………………………………..7
• 17. Maintenance Safety ……………………………………………………………………..10
• 18. Safety Decals ……………………………………………………………………………..15
• 19. Identifying Your Machine …………………………………………………………………..21
• 20. Data Plate …………………………………………………………………………………..21
• 21. Typical Product Identification Number (PIN) ……………………………………21
• 22. Typical Engine Identification Number ……………………………………………..21
• 23. Machine Security ……………………………………………………………………………..22
• 24. JCB Plantguard …………………………………………………………………………..22
• 25. Operation
• 26. Introduction ……………………………………………………………………………………..23
• 27. Before Entering the Cab ……………………………………………………………………24
• 28. Entering and Leaving the Cab ……………………………………………………………25
• 29. Entering the Cab …………………………………………………………………………25
• 30. Leaving the Cab ………………………………………………………………………….25
• 31. Doors and Windows …………………………………………………………………………26
• 32. Opening and Closing the Door ………………………………………………………26
• 33. Opening and Closing the Front Upper Window ………………………………..26
• 34. Opening and Closing The Front Lower Window ……………………………….27
• 35. Door Sliding Window. …………………………………………………………………..27
• 36. Opening and Closing the Sunblind …………………………………………………28
• 37. Emergency Exit …………………………………………………………………………..28
• 38. Seat Controls …………………………………………………………………………………..29
• 39. Operators Seat-Console ……………………………………………………………….29
• 40. Operators Seat – Standard-Heated …………………………………………………29
• 41. Air Suspension Seat …………………………………………………………………….30
• 42. Seat Belts (if fitted) …………………………………………………………………………..31
• 43. Static Seat Belt ……………………………………………………………………………31
• 44. Cab Layout ……………………………………………………………………………………..32
• 45. Location of Controls and Components ……………………………………………32
• 46. Driver Controls and Switches …………………………………………………………….34
• 47. Right Console ……………………………………………………………………………..34
• 48. Left Console ……………………………………………………………………………….36
• 49. Monitor Panel ……………………………………………………………………………..37
• 50. Fascia Panel ……………………………………………………………………………….42
• 51. Emergency back-up switch …………………………………………………………..43
• 52. Heater-Air Conditioning Controls ……………………………………………………44
• 53. Cab Interior Lights ……………………………………………………………………….45
• 54. Radio (If Fitted) ……………………………………………………………………………45
• 55. Operating Levers-Pedals …………………………………………………………………..46
• 56. Travel Levers ………………………………………………………………………………46
• 57. Travel Speed Change Button ………………………………………………………..46
• 58. Operation Levers …………………………………………………………………………47
• 59. Optional Circuit Pedal (if fitted) ………………………………………………………47
• 60. ISO Operating Method …………………………………………………………………47
• 61. Overload Protection ………………………………………………………………………….48
• 62. Overload Warning System …………………………………………………………….48
• 63. Safety Equipment …………………………………………………………………………….49
• 64. Servo Controls Immobilisation ……………………………………………………….49
• 65. Mirrors ……………………………………………………………………………………….50
• 66. Fire Extinguisher (If fitted) …………………………………………………………….51
• 67. Dipper Stroke Limiter (if fitted) ……………………………………………………….52
• 68. Before Starting the Engine …………………………………………………………………54
• 69. Starting the Engine …………………………………………………………………………..55
• 70. Warming-Up ……………………………………………………………………………….56
• 71. Stopping and Parking the Machine ……………………………………………………..57
• 72. Stopping and Parking …………………………………………………………………..57
• 73. Emergency Stopping of the Engine ………………………………………………..58
• 74. Operating Environment ……………………………………………………………………..59
• 75. Operating in Cold Climates …………………………………………………………..59
• 76. Operating in a Cold Climate (Below 0°C) ………………………………………..59
• 77. Operating in a Hot Climate (Above 35°C) ……………………………………….59
• 78. Operating in Dusty or Sandy Areas ………………………………………………..60
• 79. Operating in Coastal Regions ……………………………………………………….60
• 80. Operating on Wet or Soft Ground …………………………………………………..60
• 81. Working with your Machine ……………………………………………………………….61
• 82. Operating Practices and Site Safety ………………………………………………61
• 83. Travel Mode ………………………………………………………………………………..64
• 84. Reversing …………………………………………………………………………………..65
• 85. Travelling on Slopes …………………………………………………………………….65
• 86. Working on Slopes ………………………………………………………………………66
• 87. Digging on Slopes ……………………………………………………………………….67
• 88. Slewing ………………………………………………………………………………………67
• 89. Excavating Controls …………………………………………………………………….68
• 90. Bucket ……………………………………………………………………………………….74
• 91. Digging ………………………………………………………………………………………78
• 92. Dumping into a Truck …………………………………………………………………..78
• 93. Backfilling …………………………………………………………………………………..78
• 94. Pulling out of Soft Ground …………………………………………………………….78
• 95. Lifting …………………………………………………………………………………………80
• 96. Refuelling ……………………………………………………………………………………….81
• 97. Fuel Level …………………………………………………………………………………..81
• 98. Filling the Tank ……………………………………………………………………………81
• 99. Petrol …………………………………………………………………………………………81
• 100. Refuelling Pump – Early Machines …………………………………………………81
• 101. Refuelling Pump – Later Machines …………………………………………………82
• 102. Moving a Disabled Machine ………………………………………………………………83
• 103. Limp Mode ………………………………………………………………………………….83
• 104. Mechanical Engine RPM Override …………………………………………………83
• 105. Transporting the Machine ………………………………………………………………….84
• 106. Lifting the Machine …………………………………………………………………………..86
• 107. JS115 – JS260 Machines ………………………………………………………………86
• 108. JS330 Machine ……………………………………………………………………………87
• 109. Storage …………………………………………………………………………………………..88
• 110. Storage Sites ………………………………………………………………………………88
• 111. Putting into Storage ……………………………………………………………………..88
• 112. During Storage ……………………………………………………………………………88
• 113. Taking Out of Storage …………………………………………………………………..88
• 114. Anti-Vandalism Guards (option) ………………………………………………………….89
• 115. Unpacking the Guards ………………………………………………………………….89
• 116. Fitting the Guards ………………………………………………………………………..89
• 117. Removing the Guards ………………………………………………………………….90
• 118. Storing the Guards ………………………………………………………………………90
• 119. Routine Maintenance
• 120. Service Requirements ………………………………………………………………………91
• 121. Introduction …………………………………………………………………………………91
• 122. Owner-Operator Support ………………………………………………………………91
• 123. Service-Maintenance Agreements …………………………………………………91
• 124. Obtaining Replacement Parts ………………………………………………………..91
• 125. Lifting Regulations – Inspections and Tests ……………………………………..92
• 126. Health and Safety …………………………………………………………………………….93
• 127. Lubricants …………………………………………………………………………………..93
• 128. Battery ……………………………………………………………………………………….95
• 129. First Aid – Electrolyte ……………………………………………………………………95
• 130. Service Schedules ……………………………………………………………………………97
• 131. Introduction …………………………………………………………………………………97
• 132. How to Use the Service Schedules ………………………………………………..97
• 133. Pre Start Cold Checks, Service Points and Fluid Levels ……………………98
• 134. Functional Test and Final Inspection …………………………………………….101
• 135. Service Intervals for Attachments …………………………………………………102
• 136. Periodic Replacement of Safety Related Components ……………………103
• 137. Lubricants and Capacities ……………………………………………………………….104
• 138. JS115 – JS145 and Variants ………………………………………………………..104
• 139. JS160 – JS190 and Variants ………………………………………………………..105
• 140. JS200 – JS235HD and Variants ……………………………………………………106
• 141. JS240-260 and Variants ……………………………………………………………..107
• 142. JS330 and Variants ……………………………………………………………………108
• 143. Engine Lubrication Chart …………………………………………………………….109
• 144. Hydraulic Oil Chart …………………………………………………………………….109
• 145. Cleaning the Machine …………………………………………………………………….. 110
• 146. Exterior ……………………………………………………………………………………. 110
• 147. Interior …………………………………………………………………………………….. 110
• 148. Checking for Damage …………………………………………………………………….. 111
• 149. Daily Checking ………………………………………………………………………………. 112
• 150. Bolt and Nut Torque Specifications …………………………………………………… 115
• 151. JS115 – JS330 and Variants ……………………………………………………….. 115
• 152. Checking the FOPS Structure ………………………………………………………….123
• 153. Cab Mounted …………………………………………………………………………….123
• 154. Frame Mounted …………………………………………………………………………123
• 155. Seat Belt ……………………………………………………………………………………….124
• 156. Checking the Seat Belt Condition and Security ………………………………124
• 157. Greasing ……………………………………………………………………………………….125
• 158. General Notes …………………………………………………………………………..125
• 159. Slew Ring Bearing ……………………………………………………………………..125
• 160. Slew Ring Teeth and Slew Pinion …………………………………………………125
• 161. Greasing Points …………………………………………………………………………126
• 162. Electrical System ……………………………………………………………………………128
• 163. Battery ……………………………………………………………………………………..128
• 164. Jump-Starting the Engine ……………………………………………………………130
• 165. Fuses ……………………………………………………………………………………….131
• 166. Engine ………………………………………………………………………………………….132
• 167. Checking the Oil Level ……………………………………………………………….132
• 168. Changing the Oil and Filter ………………………………………………………….132
• 169. Changing the Outer Air Filter Element ………………………………………….134
• 170. Changing the Inner Air Filter Element …………………………………………..135
• 171. Checking the Fan Belt Tension …………………………………………………….136
• 172. Fitting a New Fan Belt ………………………………………………………………..136
• 173. Checking the Coolant Level ………………………………………………………..137
• 174. Cleaning the Radiator and Oil Cooler ……………………………………………137
• 175. Changing The Coolant ……………………………………………………………….138
• 176. Coolant Mixtures ……………………………………………………………………….138
• 177. Fuel System …………………………………………………………………………………..140
• 178. Types of Fuel …………………………………………………………………………….140
• 179. Filling the Tank and Fuel Level Checking ………………………………………141
• 180. Petrol ……………………………………………………………………………………….141
• 181. Changing the Fuel Filter Element …………………………………………………142
• 182. Cleaning the Lift Pump Strainer ……………………………………………………142
• 183. Draining Fuel Tank Impurities ………………………………………………………143
• 184. Draining the Water Separator – early models …………………………………144
• 185. Cleaning the Water Separator – early models ………………………………..144
• 186. Draining the Water Separator and Engine Fuel Filter – later models ….145
• 187. Changing the Water Separator Filter – later models ………………………..145
• 188. Bleeding the Fuel System …………………………………………………………..146
• 189. Hydraulic System ……………………………………………………………………………147
• 190. Checking the Fluid Level …………………………………………………………….147
• 191. Releasing Tank Pressure ……………………………………………………………148
• 192. Topping-up Fluid Level ……………………………………………………………….148
• 193. Changing the Fluid …………………………………………………………………….149
• 194. Draining Water and Sediment from the Hydraulic Tank ……………………149
• 195. Cleaning-Changing the Suction Strainer ……………………………………….150
• 196. Changing the Return Filter ………………………………………………………….150
• 197. Changing the Plexus Filter ………………………………………………………….151
• 198. Changing the Air Breather Element ………………………………………………152
• 199. Changing the Pilot Oil Filter …………………………………………………………153
• 200. Changing the Breaker In-line Filter ……………………………………………….154
• 201. Changing the Drain Line Filter ……………………………………………………..154
• 202. Checking the Slew Gearbox Oil Level …………………………………………..155
• 203. Changing the Slew Gearbox Oil Level ………………………………………….155
• 204. Air Bleeding Procedures ……………………………………………………………..156
• 205. Travel Gearbox ………………………………………………………………………………158
• 206. Checking the Track Gearbox Oil Level ………………………………………….158
• 207. Changing the Track Gearbox Oil ………………………………………………….158
• 208. Tracks and Running Gear ……………………………………………………………….159
• 209. Cleaning the Tracks ……………………………………………………………………159
• 210. Checking-Adjusting the Track Tension ………………………………………….159
• 211. Checking Rollers and Idler Wheels for Oil Leaks ……………………………160
• 212. Track Plate Inspection ………………………………………………………………..161
• 213. Bucket ………………………………………………………………………………………….162
• 214. Checking-Adjusting for side play ………………………………………………….162
• 215. Windscreen ……………………………………………………………………………………163
• 216. Washers …………………………………………………………………………………..163
• 217. Troubleshooting ……………………………………………………………………………..164
• 218. Engine and Related Area ……………………………………………………………164
• 219. Monitor Display – Fault Messages ………………………………………………..167
• 220. Operations ………………………………………………………………………………..168
• 221. Hydraulic pump …………………………………………………………………………169
• 222. Working Attachments …………………………………………………………………170
• 223. Travel ……………………………………………………………………………………….171
• 224. Slew …………………………………………………………………………………………172
• 225. Hydraulic ram ……………………………………………………………………………172
• 226. Optional Attachments
• 227. Introduction ……………………………………………………………………………………173
• 228. Attachments For Your Machine ……………………………………………………173
• 229. Operating Attachments ……………………………………………………………………174
• 230. Hydraulic Rockbreaker ……………………………………………………………………177
• 231. Preparation ……………………………………………………………………………….177
• 232. Operation and Maintenance ………………………………………………………..177
• 233. Hammer Speed Settings …………………………………………………………….178
• 234. Crusher …………………………………………………………………………………………181
• 235. General …………………………………………………………………………………….181
• 236. Preparation ……………………………………………………………………………….181
• 237. Weedcutter ……………………………………………………………………………………182
• 238. Operation ………………………………………………………………………………….182
• 239. Maintenance ……………………………………………………………………………..182
• 240. Specifications
• 241. Static Dimensions …………………………………………………………………………..183
• 242. JS115 – Monoboom ……………………………………………………………………183
• 243. JS130LC – Monoboom ……………………………………………………………….184
• 244. JS130 – Monoboom ……………………………………………………………………185
• 245. JS130 – Triple Articulated Boom …………………………………………………..186
• 246. JS145 – Monoboom ……………………………………………………………………187
• 247. JS145 – Triple Articulated Boom …………………………………………………..188
• 248. JS160 – Monoboom ……………………………………………………………………189
• 249. JS160 – Triple Articulated Boom …………………………………………………..190
• 250. JS180-190 – Monoboom ……………………………………………………………..191
• 251. JS180-190 – Triple Articulated Boom …………………………………………….192
• 252. JS200-210-220 – Monoboom ……………………………………………………….193
• 253. JS200-210-220 – Triple Articulated Boom ………………………………………194
• 254. JS235 – Monoboom ……………………………………………………………………195
• 255. JS235 – Triple Articulated Boom …………………………………………………..196
• 256. JS240-260 – Monoboom ……………………………………………………………..197
• 257. JS240-260 – Triple Articulated Boom …………………………………………….198
• 258. JS330 – Monoboom ……………………………………………………………………199
• 259. JS220-260 – Long Reach (LR) ……………………………………………………..200
• 260. Shipping Weight …………………………………………………………………………….201
• 261. Lifting (Craning) Regulations and Safe Working Loads ………………………..203
• 262. Lifting Regulations ……………………………………………………………………..203
• 263. Safe Working Loads …………………………………………………………………..203
• 264. Dig Depth Chart ……………………………………………………………………………..204
• 265. JS115 – Monoboom ……………………………………………………………………204
• 266. JS130LC – Monoboom ……………………………………………………………….205
• 267. JS130 – Monoboom ……………………………………………………………………206
• 268. JS130 – Triple Articulated Boom …………………………………………………..207
• 269. JS145 – Monoboom ……………………………………………………………………208
• 270. JS145 – Triple Articulated Boom …………………………………………………..209
• 271. JS160 – Monoboom ……………………………………………………………………210
• 272. JS160 – Triple Articulated Boom ………………………………………………….. 211
• 273. JS180-190 – Monoboom ……………………………………………………………..212
• 274. JS180-190 – Triple Articulated Boom …………………………………………….213
• 275. JS200-210-220 – Monoboom ……………………………………………………….214
• 276. JS200-210-220 – Triple Articulated Boom ………………………………………215
• 277. JS220-260LR – Long Reach ………………………………………………………..216
• 278. JS235HD – Monoboom ……………………………………………………………….217
• 279. JS235HD – Triple Articulated Boom ………………………………………………218
• 280. JS240-260 – Monoboom ……………………………………………………………..219
• 281. JS240-260 – Triple Articulated Boom …………………………………………….220
• 282. JS330 – Monoboom ……………………………………………………………………221
• 283. Noise Data …………………………………………………………………………………….222
• 284. Vibration Data ………………………………………………………………………………..223
• 285. Introduction ……………………………………………………………………………….223
• 286. JS115-180 ………………………………………………………………………………..224
• 287. JS190-210 ………………………………………………………………………………..225