JCB JS120 Tracked Excavator Operator Handbook 9821-2100

Description

• Model List:
  • JS120 Tracked Excavator

• 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 …………………………………………………………………..22
• 24. Machine Identification Plate ………………………………………………………….22
• 25. Component Identification Plates …………………………………………………….23
• 26. Operation
• 27. Introduction ……………………………………………………………………………………..25
• 28. Before Entering the Cab ……………………………………………………………………26
• 29. Entering and Leaving the Cab ……………………………………………………………27
• 30. Standard Cab Machines ……………………………………………………………….27
• 31. Doors and Windows …………………………………………………………………………28
• 32. Opening and Closing the Door ………………………………………………………28
• 33. Opening and Closing the Front Upper Window ………………………………..28
• 34. Opening and Closing The Front Lower Window ……………………………….29
• 35. Door Sliding Window ……………………………………………………………………29
• 36. Seat Controls …………………………………………………………………………………..30
• 37. Introduction …………………………………………………………………………………30
• 38. Operators Seat-Console ……………………………………………………………….30
• 39. Operators Seat – Standard-Heated …………………………………………………30
• 40. Air Suspension Seat …………………………………………………………………….31
• 41. Seat Belts (if fitted) …………………………………………………………………………..32
• 42. Static Seat Belt ……………………………………………………………………………32
• 43. Visibility Aids (if fitted) ……………………………………………………………………….33
• 44. Mirrors ……………………………………………………………………………………….33
• 45. Cab Layout ……………………………………………………………………………………..37
• 46. Components Key …………………………………………………………………………37
• 47. Drive Controls, Switches and Instruments ……………………………………………38
• 48. Drive Controls ……………………………………………………………………………..38
• 49. Switches …………………………………………………………………………………….39
• 50. Instruments …………………………………………………………………………………43
• 51. Operating Levers-Pedals …………………………………………………………………..45
• 52. Excavating Controls …………………………………………………………………….45
• 53. Operation Levers …………………………………………………………………………48
• 54. Optional Circuit Pedal (if fitted) ………………………………………………………49
• 55. ISO Operating Method …………………………………………………………………49
• 56. Safety Equipment …………………………………………………………………………….50
• 57. Control Locks ……………………………………………………………………………..50
• 58. Typical Load Chart ………………………………………………………………………51
• 59. Before Starting the Engine …………………………………………………………………52
• 60. Starting the Engine …………………………………………………………………………..53
• 61. Warming-Up ……………………………………………………………………………….53
• 62. Getting the Machine Moving ………………………………………………………………54
• 63. Stopping and Parking the Machine ……………………………………………………..55
• 64. Stopping and Parking …………………………………………………………………..55
• 65. Working with your Machine ……………………………………………………………….56
• 66. Operating Practices and Site Safety ………………………………………………56
• 67. Clothing and Safety Equipment ……………………………………………………..56
• 68. Danger Zone ………………………………………………………………………………56
• 69. Log Moving-Handling ……………………………………………………………………56
• 70. Safety Practices ………………………………………………………………………….56
• 71. Working With the Excavator ………………………………………………………….58
• 72. Use of Machines on Gradients and Slopes ……………………………………..67
• 73. Pulling out of Soft Ground …………………………………………………………….70
• 74. Water …………………………………………………………………………………………71
• 75. Towing Other Equipment ………………………………………………………………71
• 76. Machine Stability …………………………………………………………………………72
• 77. Reducing Wear ……………………………………………………………………………73
• 78. Operating Environment ……………………………………………………………………..76
• 79. Operating in Cold Climates …………………………………………………………..76
• 80. Operating in a Cold Climate (Below 0°C) ………………………………………..76
• 81. Operating in a Hot Climate (Above 35°C) ……………………………………….76
• 82. Operating in Dusty or Sandy Areas ………………………………………………..77
• 83. Operating in Coastal Regions ……………………………………………………….77
• 84. Operating on Wet or Soft Ground …………………………………………………..77
• 85. Refuelling the Machine ……………………………………………………………………..78
• 86. Low Fuel Levels ………………………………………………………………………….78
• 87. Filling the Tank ……………………………………………………………………………78
• 88. Fuel Level …………………………………………………………………………………..79
• 89. Refuelling Pump (if fitted) ……………………………………………………………..80
• 90. Moving a Disabled Machine ………………………………………………………………81
• 91. Lowering the Boom in an Emergency …………………………………………….81
• 92. Retrieval …………………………………………………………………………………….81
• 93. Transporting the Machine ………………………………………………………………….82
• 94. Lifting the Machine …………………………………………………………………………..84
• 95. JS120 Machines ………………………………………………………………………….84
• 96. Storage of the Machine …………………………………………………………………….85
• 97. Introduction …………………………………………………………………………………85
• 98. Storage Area ………………………………………………………………………………85
• 99. Prepare the Machine for Storage …………………………………………………..85
• 100. Put the Machine into Storage ………………………………………………………..85
• 101. During Storage ……………………………………………………………………………85
• 102. Take the Machine Out of Storage …………………………………………………..86
• 103. Routine Maintenance
• 104. Service Requirements ………………………………………………………………………87
• 105. Introduction …………………………………………………………………………………87
• 106. Owner-Operator Support ………………………………………………………………87
• 107. Service-Maintenance Agreements …………………………………………………87
• 108. Fit for Purpose Tests for Lifting Equipment ………………………………………88
• 109. Obtaining Replacement Parts ………………………………………………………..88
• 110. Health and Safety …………………………………………………………………………….89
• 111. Lubricants …………………………………………………………………………………..89
• 112. Battery ……………………………………………………………………………………….91
• 113. Warning Symbols ………………………………………………………………………..92
• 114. Battery Maintenance Check ………………………………………………………….92
• 115. First Aid-Electrolyte ……………………………………………………………………..92
• 116. Service Schedules ……………………………………………………………………………93
• 117. Introduction …………………………………………………………………………………93
• 118. How to Use the Service Schedules ………………………………………………..93
• 119. Calendar Equivalents …………………………………………………………………..93
• 120. Pre Start Cold Checks, Service Points and Fluid Levels ……………………94
• 121. Functional Test and Final Inspection ………………………………………………97
• 122. Service Intervals for Attachments …………………………………………………..99
• 123. Periodic Replacement of Safety Related Components ……………………100
• 124. Fluids, Lubricants and Capacities ……………………………………………………..101
• 125. JS120 ………………………………………………………………………………………101
• 126. Engine Lubrication Chart …………………………………………………………….102
• 127. Hydraulic Oil Chart …………………………………………………………………….102
• 128. Typical Lubrication Chart …………………………………………………………….103
• 129. Coolant Mixtures ……………………………………………………………………….104
• 130. Fuel …………………………………………………………………………………………105
• 131. Tools …………………………………………………………………………………………….107
• 132. Carrying Tools onto the Machine ………………………………………………….107
• 133. Locations ………………………………………………………………………………….107
• 134. Prepare the Machine for Maintenance ………………………………………………108
• 135. Introduction ……………………………………………………………………………….108
• 136. How to Make the Machine Safe (Excavator Lowered) …………………….108
• 137. Cleaning the Machine ……………………………………………………………………..109
• 138. Introduction ……………………………………………………………………………….109
• 139. Preparing the Machine for Cleaning ……………………………………………..109
• 140. Cleaning the Machine ………………………………………………………………… 110
• 141. Cleaning the Tracks …………………………………………………………………… 110
• 142. Cleaning the Radiator and Oil Cooler …………………………………………… 110
• 143. Checking for Damage …………………………………………………………………….. 111
• 144. Check the Machine Body and Structure ……………………………………….. 111
• 145. Check the Seat and Seat Belt …………………………………………………….. 111
• 146. Daily Checking ………………………………………………………………………………. 112
• 147. Greasing ………………………………………………………………………………………. 115
• 148. General Notes ………………………………………………………………………….. 115
• 149. Slew Ring Bearing …………………………………………………………………….. 115
• 150. Slew Ring Teeth and Slew Pinion ………………………………………………… 115
• 151. Greasing Points ………………………………………………………………………… 116
• 152. Electrical System …………………………………………………………………………… 118
• 153. Battery …………………………………………………………………………………….. 118
• 154. Jump-Starting the Engine ……………………………………………………………120
• 155. Fuses ……………………………………………………………………………………….121
• 156. Bolt and Nut Torque Specifications ……………………………………………………123
• 157. JS120 ………………………………………………………………………………………123
• 158. Engine ………………………………………………………………………………………….127
• 159. Checking the Oil Level ……………………………………………………………….127
• 160. Changing the Oil and Filter ………………………………………………………….128
• 161. Changing the Outer Air Filter Element ………………………………………….129
• 162. Changing the Inner Air Filter Element …………………………………………..130
• 163. Checking the Fan Belt Tension …………………………………………………….131
• 164. Checking the Coolant Level ………………………………………………………..131
• 165. Cleaning the Radiator and Oil Cooler ……………………………………………132
• 166. Changing The Coolant ……………………………………………………………….132
• 167. Fuel System …………………………………………………………………………………..133
• 168. Introduction ……………………………………………………………………………….133
• 169. Filling the Tank and Fuel Level Checking ………………………………………133
• 170. Petrol ……………………………………………………………………………………….134
• 171. Front End Accessory Drive Belt …………………………………………………..135
• 172. Water Separator and Engine Fuel Filter ………………………………………..136
• 173. Bleeding the System ………………………………………………………………….141
• 174. Hydraulic System ……………………………………………………………………………142
• 175. Checking the Fluid Level …………………………………………………………….142
• 176. Releasing Tank Pressure ……………………………………………………………143
• 177. Topping-up Fluid Level ……………………………………………………………….143
• 178. Changing the Fluid …………………………………………………………………….144
• 179. Draining Water and Sediment from the Hydraulic Tank ……………………144
• 180. Cleaning-Changing the Suction Strainer ……………………………………….145
• 181. Changing the Return Filter ………………………………………………………….145
• 182. Changing the Plexus Filter ………………………………………………………….146
• 183. Changing the Air Breather Element ………………………………………………147
• 184. Changing the Pilot Oil Filter …………………………………………………………148
• 185. Changing the Breaker In-line Filter ……………………………………………….149
• 186. Changing the Drain Line Filter ……………………………………………………..149
• 187. Air Bleeding Procedures ……………………………………………………………..150
• 188. Slew Gearbox ………………………………………………………………………………..152
• 189. Checking the Slew Gearbox Oil Level …………………………………………..152
• 190. Changing the Slew Gearbox Oil Level ………………………………………….152
• 191. Tracks and Running Gear ……………………………………………………………….153
• 192. Tracks ………………………………………………………………………………………153
• 193. Running Gear ……………………………………………………………………………156
• 194. Bucket ………………………………………………………………………………………….157
• 195. Checking-Adjusting For Side Play ………………………………………………..157
• 196. Fire Extinguisher (If fitted) ……………………………………………………………….158
• 197. Troubleshooting ……………………………………………………………………………..159
• 198. Engine and Related Area ……………………………………………………………159
• 199. Monitor Display – Fault Messages ………………………………………………..162
• 200. Operations ………………………………………………………………………………..164
• 201. Hydraulic pump …………………………………………………………………………164
• 202. Working Attachments …………………………………………………………………165
• 203. Travel ……………………………………………………………………………………….166
• 204. Slew …………………………………………………………………………………………167
• 205. Hydraulic ram ……………………………………………………………………………167
• 206. Optional Attachments
• 207. Introduction ……………………………………………………………………………………169
• 208. Attachments For Your Machine ………………………………………………………..170
• 209. Connecting-Disconnecting Hydraulic Hoses ……………………………………….171
• 210. Introduction ……………………………………………………………………………….171
• 211. Connecting the Hydraulic Hoses ………………………………………………….171
• 212. Disconnecting the Hydraulic Hoses ………………………………………………172
• 213. Hydraulic Rockbreaker ……………………………………………………………………173
• 214. Preparation ……………………………………………………………………………….173
• 215. Operation and Maintenance ………………………………………………………..173
• 216. Crusher …………………………………………………………………………………………174
• 217. General …………………………………………………………………………………….174
• 218. Preparation ……………………………………………………………………………….174
• 219. Specifications
• 220. Static Dimensions …………………………………………………………………………..175
• 221. JS120 ………………………………………………………………………………………175
• 222. Dig Depth Chart ……………………………………………………………………………..176
• 223. JS120 ………………………………………………………………………………………176
• 224. Shipping Weight …………………………………………………………………………….177
• 225. Travel Speeds ………………………………………………………………………………..178