JCB JS460, JS500 Tier 2 Operator Manual 9821-3600

Description

• Model List:
  • JS460, JS500 Tier 2

• 1. Safety Notices
• 2. Important Information ………………………………………………………………………..vii
• 3. The Operator Manual ……………………………………………………………………vii
• 4. Safety Warnings …………………………………………………………………………..vii
• 5. Introduction
• 6. About this Manual ………………………………………………………………………………1
• 7. Machine Model and Serial Number ………………………………………………….1
• 8. Using this Manual ………………………………………………………………………….1
• 9. Left Side, Right Side ………………………………………………………………………1
• 10. Cross References ………………………………………………………………………….1
• 11. Machine Description …………………………………………………………………………..3
• 12. The JCB Tracked Excavator ……………………………………………………………3
• 13. Intended Use ………………………………………………………………………………..3
• 14. Component Location ……………………………………………………………………..4
• 15. Safety Check List ……………………………………………………………………………….6
• 16. Safety – Yours and Others ………………………………………………………………6
• 17. General Safety ……………………………………………………………………………..6
• 18. Operating Safety …………………………………………………………………………..8
• 19. Maintenance Safety …………………………………………………………………….. 11
• 20. Safety Labels …………………………………………………………………………………..16
• 21. Introduction …………………………………………………………………………………16
• 22. Safety Label Identification …………………………………………………………….17
• 23. Identifying Your Machine …………………………………………………………………..21
• 24. Machine Identification Plate ………………………………………………………….21
• 25. Typical Product Identification Number …………………………………………….21
• 26. Component Identification Plates …………………………………………………….22
• 27. Machine Security ……………………………………………………………………………..24
• 28. Introduction …………………………………………………………………………………24
• 29. JCB Plantguard …………………………………………………………………………..24
• 30. Construction Equipment Security And Registration Scheme (CESAR) .24
• 31. LiveLink ……………………………………………………………………………………..24
• 32. Immobiliser …………………………………………………………………………………24
• 33. Operation
• 34. Introduction ……………………………………………………………………………………..25
• 35. Before Entering the Cab ……………………………………………………………………26
• 36. Entering and Leaving the Cab ……………………………………………………………27
• 37. Standard Cab Machines ……………………………………………………………….27
• 38. Emergency Exit …………………………………………………………………………..28
• 39. Doors and Windows …………………………………………………………………………29
• 40. Opening and Closing the Door ………………………………………………………29
• 41. Opening and Closing the Front Upper Window ………………………………..29
• 42. Opening and Closing The Front Lower Window ……………………………….30
• 43. Door Sliding Window ……………………………………………………………………31
• 44. Opening and Closing the Sunblind …………………………………………………31
• 45. Access to the Upper Structure ……………………………………………………………33
• 46. Standard Machines ………………………………………………………………………33
• 47. Seat Controls …………………………………………………………………………………..34
• 48. Introduction …………………………………………………………………………………34
• 49. Operators Seat-Console ……………………………………………………………….34
• 50. Operators Seat – Standard-Heated …………………………………………………34
• 51. Air Suspension Seat …………………………………………………………………….35
• 52. Seat Belts (if fitted) …………………………………………………………………………..36
• 53. Static Seat Belt ……………………………………………………………………………36
• 54. Visibility Aids ……………………………………………………………………………………37
• 55. Mirrors ……………………………………………………………………………………….37
• 56. Cab Layout ……………………………………………………………………………………..40
• 57. Components Key …………………………………………………………………………40
• 58. Drive Controls, Switches and Instruments ……………………………………………42
• 59. Drive Controls ……………………………………………………………………………..42
• 60. Switches …………………………………………………………………………………….43
• 61. Instruments …………………………………………………………………………………49
• 62. Heater-Air Conditioning Controls ……………………………………………………54
• 63. Operating Levers-Pedals …………………………………………………………………..55
• 64. Excavating Controls …………………………………………………………………….55
• 65. Travel Speed Change Button ………………………………………………………..59
• 66. Operation Levers …………………………………………………………………………60
• 67. Optional Circuit Pedal (if fitted) ………………………………………………………61
• 68. ISO Operating Method …………………………………………………………………61
• 69. Safety Equipment …………………………………………………………………………….62
• 70. Control Locks ……………………………………………………………………………..62
• 71. Dipper Stroke Limiter (If fitted) ……………………………………………………….63
• 72. Overload Warning System …………………………………………………………….65
• 73. Before Starting the Engine …………………………………………………………………66
• 74. Starting the Engine …………………………………………………………………………..67
• 75. Warming-Up ……………………………………………………………………………….68
• 76. JCB Immobiliser System ………………………………………………………………68
• 77. Getting the Machine Moving ………………………………………………………………71
• 78. Stopping and Parking the Machine ……………………………………………………..72
• 79. Stopping and Parking …………………………………………………………………..72
• 80. Engine Shutdown ………………………………………………………………………..72
• 81. Working with your Machine ……………………………………………………………….73
• 82. Operating Practices and Site Safety ………………………………………………73
• 83. Clothing and Safety Equipment ……………………………………………………..73
• 84. Danger Zone ………………………………………………………………………………73
• 85. Log Moving-Handling ……………………………………………………………………73
• 86. Safety Practices ………………………………………………………………………….73
• 87. Working With the Excavator ………………………………………………………….75
• 88. Lifting (Object Handling) ……………………………………………………………….82
• 89. Use of Machines on Gradients and Slopes ……………………………………..85
• 90. Getting Out of Soft Ground ……………………………………………………………88
• 91. Water …………………………………………………………………………………………89
• 92. Towing Other Equipment ………………………………………………………………89
• 93. Machine Stability …………………………………………………………………………90
• 94. Reducing Wear ……………………………………………………………………………91
• 95. Operating Environment ……………………………………………………………………..94
• 96. Maintenance in Cold Climates ……………………………………………………….94
• 97. Operating in a Cold Climate (Below 0°C) ………………………………………..94
• 98. Operating in a Hot Climate (Above 35°C) ……………………………………….94
• 99. Operating in Dusty or Sandy Areas ………………………………………………..95
• 100. Operating in Coastal Regions ……………………………………………………….95
• 101. Operating on Wet or Soft Ground …………………………………………………..95
• 102. Cab Filters ………………………………………………………………………………….95
• 103. Refuelling the Machine ……………………………………………………………………..96
• 104. Low Fuel Levels ………………………………………………………………………….96
• 105. Filling the Tank ……………………………………………………………………………96
• 106. Fuel Level …………………………………………………………………………………..97
• 107. Refuelling Pump ………………………………………………………………………….98
• 108. Moving a Disabled Machine ………………………………………………………………99
• 109. Lowering the Boom in an Emergency …………………………………………….99
• 110. Retrieval …………………………………………………………………………………….99
• 111. Limp Mode ………………………………………………………………………………..100
• 112. Mechanical Engine RPM Override ……………………………………………….100
• 113. Transporting the Machine ………………………………………………………………..101
• 114. Lifting the Machine …………………………………………………………………………104
• 115. Storage of the Machine …………………………………………………………………..106
• 116. Introduction ……………………………………………………………………………….106
• 117. Storage Area …………………………………………………………………………….106
• 118. Prepare the Machine for Storage …………………………………………………106
• 119. Put the Machine into Storage ………………………………………………………106
• 120. During Storage ………………………………………………………………………….106
• 121. Take the Machine Out of Storage …………………………………………………107
• 122. Anti-Vandalism Guards (option) ………………………………………………………..108
• 123. Unpacking the Guards ………………………………………………………………..108
• 124. Fitting the Guards ………………………………………………………………………108
• 125. Removing the Guards ………………………………………………………………..109
• 126. Storing the Guards …………………………………………………………………….109
• 127. Routine Maintenance
• 128. Service Requirements ……………………………………………………………………. 111
• 129. Introduction ………………………………………………………………………………. 111
• 130. Owner-Operator Support ……………………………………………………………. 111
• 131. Service-Maintenance Agreements ………………………………………………. 111
• 132. Fit for Purpose Tests for Lifting Equipment ……………………………………. 112
• 133. Obtaining Replacement Parts ……………………………………………………… 112
• 134. Health and Safety ………………………………………………………………………….. 113
• 135. Lubricants ………………………………………………………………………………… 113
• 136. Battery …………………………………………………………………………………….. 115
• 137. Service Schedules …………………………………………………………………………. 117
• 138. Introduction ………………………………………………………………………………. 117
• 139. How to Use the Service Schedules ……………………………………………… 117
• 140. Calendar Equivalents ………………………………………………………………… 117
• 141. Pre Start Cold Checks, Service Points and Fluid Levels …………………. 118
• 142. Functional Test and Final Inspection …………………………………………….122
• 143. Service Intervals for Attachments …………………………………………………124
• 144. Periodic Replacement of Safety Related Components ……………………125
• 145. Fluids, Lubricants and Capacities ……………………………………………………..126
• 146. Specifications ……………………………………………………………………………126
• 147. Typical Lubrication Chart …………………………………………………………….127
• 148. Coolant Mixtures ……………………………………………………………………….128
• 149. Fuel …………………………………………………………………………………………129
• 150. Tools …………………………………………………………………………………………….132
• 151. Carrying Tools onto the Machine ………………………………………………….132
• 152. Location ……………………………………………………………………………………132
• 153. Prepare the Machine for Maintenance ………………………………………………133
• 154. Introduction ……………………………………………………………………………….133
• 155. How to Make the Machine Safe (Excavator Lowered) …………………….133
• 156. Cleaning the Machine ……………………………………………………………………..134
• 157. Introduction ……………………………………………………………………………….134
• 158. Preparing the Machine for Cleaning ……………………………………………..134
• 159. Cleaning the Machine …………………………………………………………………135
• 160. Cleaning the Tracks ……………………………………………………………………135
• 161. Cleaning the Radiator and Oil Cooler ……………………………………………135
• 162. Checking for Damage ……………………………………………………………………..136
• 163. Check the Machine Body and Structure ………………………………………..136
• 164. Check the Seat and Seat Belt ……………………………………………………..136
• 165. Check the Tyres ………………………………………………………………………..136
• 166. Check the Electrical Circuits ………………………………………………………..136
• 167. Checking the FOPS Structure ……………………………………………………..137
• 168. Daily Checking ……………………………………………………………………………….139
• 169. Greasing ……………………………………………………………………………………….141
• 170. Introduction ……………………………………………………………………………….141
• 171. Slew Ring Bearing ……………………………………………………………………..141
• 172. Slew Ring Teeth and Slew Pinion …………………………………………………141
• 173. Greasing Points …………………………………………………………………………142
• 174. Electrical System ……………………………………………………………………………144
• 175. Battery ……………………………………………………………………………………..144
• 176. Jump-Starting the Engine ……………………………………………………………148
• 177. Fuses – Cab ………………………………………………………………………………149
• 178. Fuses and Relays – Battery Compartment …………………………………….150
• 179. Bolt and Nut Torque Specifications ……………………………………………………151
• 180. JS460, JS500 (fixed undercarriage) ……………………………………………..151
• 181. Engine ………………………………………………………………………………………….154
• 182. Oil and Filter ……………………………………………………………………………..154
• 183. Cooling System …………………………………………………………………………155
• 184. Fan Belt ……………………………………………………………………………………156
• 185. Engine Air Filter …………………………………………………………………………157
• 186. Fuel System …………………………………………………………………………………..159
• 187. Introduction ……………………………………………………………………………….159
• 188. Draining the Impurities from the Fuel Tank …………………………………….159
• 189. Draining the Primary Filter-Sedimenters ……………………………………….160
• 190. Changing the Primary Filter-Sedimenter Element …………………………..160
• 191. Bleeding the System ………………………………………………………………….161
• 192. Hydraulic System ……………………………………………………………………………162
• 193. Introduction ……………………………………………………………………………….162
• 194. Releasing the Hydraulic Pressure ………………………………………………..162
• 195. Releasing the Tank Pressure ………………………………………………………163
• 196. Fluid and Filters …………………………………………………………………………163
• 197. Air Bleeding Procedures ……………………………………………………………..169
• 198. Slew Gearbox ………………………………………………………………………………..171
• 199. Checking the Slew Gearbox Oil Level …………………………………………..171
• 200. Changing the Slew Gearbox Oil …………………………………………………..171
• 201. Tracks and Running Gear ……………………………………………………………….172
• 202. Tracks ………………………………………………………………………………………172
• 203. Running Gear ……………………………………………………………………………174
• 204. Bucket ………………………………………………………………………………………….175
• 205. Checking For Side Play ………………………………………………………………175
• 206. Windscreen Washer ……………………………………………………………………….176
• 207. Checking the Level …………………………………………………………………….176
• 208. Fire Extinguisher (If fitted) ……………………………………………………………….177
• 209. Troubleshooting ……………………………………………………………………………..178
• 210. Engine and Related Area ……………………………………………………………178
• 211. Monitor Display – Fault Messages ………………………………………………..181
• 212. Operations ………………………………………………………………………………..182
• 213. Hydraulic pump …………………………………………………………………………183
• 214. Working Attachments …………………………………………………………………184
• 215. Travel ……………………………………………………………………………………….185
• 216. Slew …………………………………………………………………………………………186
• 217. Hydraulic ram ……………………………………………………………………………186
• 218. Optional Attachments
• 219. Introduction ……………………………………………………………………………………187
• 220. Attachments For Your Machine ………………………………………………………..188
• 221. Connecting-Disconnecting Hydraulic Hoses ……………………………………….189
• 222. Introduction ……………………………………………………………………………….189
• 223. Connecting the Hydraulic Hoses ………………………………………………….189
• 224. Disconnecting the Hydraulic Hoses ………………………………………………190
• 225. Quick Release Couplings ……………………………………………………………191
• 226. Operating the Attachments ………………………………………………………………193
• 227. Specifications
• 228. Static Dimensions …………………………………………………………………………..196
• 229. Dig Depth Chart ……………………………………………………………………………..197
• 230. Shipping Weight …………………………………………………………………………….198
• 231. Travel Speeds ………………………………………………………………………………..199
• 232. Noise Data …………………………………………………………………………………….200
• 233. Introduction ……………………………………………………………………………….200
• 234. All Machines ……………………………………………………………………………..200
• 235. Vibration Data ………………………………………………………………………………..201
• 236. Introduction ……………………………………………………………………………….201
• 237. Specifications ……………………………………………………………………………201
• 238. Lifting (Object Handling) Regulations and Safe Working Loads …………….202
• 239. Introduction ……………………………………………………………………………….202
• 240. Load Charts ………………………………………………………………………………203
• 241. Warranty Information
• 242. Machine Service Record Sheet ………………………………………………………..205
• 243. Registration Information ………………………………………………………………….207
• 244. European Community Standards
• 245. EC Declaration of Conformity …………………………………………………………..209
• 246. Introduction ……………………………………………………………………………….209
• 247. Explanation of the EC Declaration of Conformity …………………………… 211