JCB JS500 Tier 2 Operator Manual 9821-9550

Description

• Model List:
  • JS500 Tier 2

• 1. Safety Notices
• 2. Important Information ………………………………………………………………………..xii
• 3. The Operator Manual ……………………………………………………………………xii
• 4. Safety Warnings …………………………………………………………………………..xii
• 5. Introduction
• 6. About this Manual ………………………………………………………………………………1
• 7. Name of Manufacturer ……………………………………………………………………1
• 8. Product Compliance ………………………………………………………………………1
• 9. Machine Model and Serial Number ………………………………………………….1
• 10. Using this Manual ………………………………………………………………………….1
• 11. Left Side, Right Side ………………………………………………………………………2
• 12. Cross References ………………………………………………………………………….2
• 13. Machine Description …………………………………………………………………………..3
• 14. The JCB Tracked Excavator ……………………………………………………………3
• 15. Intended Use ………………………………………………………………………………..3
• 16. Component Location ……………………………………………………………………..4
• 17. Safety Check List ……………………………………………………………………………….6
• 18. Safety – Yours and Others ………………………………………………………………6
• 19. General Safety ……………………………………………………………………………..6
• 20. Operating Safety …………………………………………………………………………..8
• 21. Maintenance Safety …………………………………………………………………….. 11
• 22. Safety Labels …………………………………………………………………………………..16
• 23. Introduction …………………………………………………………………………………16
• 24. Safety Label Identification …………………………………………………………….17
• 25. Part Numbers and Description …………………………………………………….19
• 26. Identifying Your Machine …………………………………………………………………..21
• 27. Machine Identification Plate ………………………………………………………….21
• 28. Typical Product Identification Number …………………………………………….21
• 29. Component Identification Plates …………………………………………………….22
• 30. FOPS Data Plate ………………………………………………………………………22
• 31. ROPS Data Plate ………………………………………………………………………22
• 32. Engine Identification Plate ………………………………………………………….23
• 33. Machine Security ……………………………………………………………………………..24
• 34. Introduction …………………………………………………………………………………24
• 35. JCB Plantguard …………………………………………………………………………..24
• 36. Construction Equipment Security And Registration Scheme (CESAR) .24
• 37. LiveLink ……………………………………………………………………………………..24
• 38. Immobiliser …………………………………………………………………………………24
• 39. Operation
• 40. Introduction ……………………………………………………………………………………..25
• 41. Before Entering the Cab ……………………………………………………………………26
• 42. Entering and Leaving the Cab ……………………………………………………………27
• 43. Standard Cab Machines ……………………………………………………………….27
• 44. Entering the Cab ……………………………………………………………………….27
• 45. Leaving the Cab ………………………………………………………………………..27
• 46. Emergency Exit …………………………………………………………………………..28
• 47. Doors and Windows …………………………………………………………………………29
• 48. Opening and Closing the Door ………………………………………………………29
• 49. Opening and Closing the Front Upper Window ………………………………..29
• 50. Opening …………………………………………………………………………………..29
• 51. Closing …………………………………………………………………………………….29
• 52. Opening and Closing The Front Lower Window ……………………………….30
• 53. Door Sliding Window ……………………………………………………………………31
• 54. Opening and Closing the Sunblind …………………………………………………31
• 55. Standard Sun Blind ……………………………………………………………………31
• 56. Optional Sun Blind – Type 1 ………………………………………………………..32
• 57. Optional Sun Blind – Type 2 ………………………………………………………..32
• 58. Access to the Upper Structure ……………………………………………………………33
• 59. Standard Machines ………………………………………………………………………33
• 60. Seat Controls …………………………………………………………………………………..34
• 61. Introduction …………………………………………………………………………………34
• 62. Operators Seat-Console ……………………………………………………………….34
• 63. Operators Seat – Standard-Heated …………………………………………………34
• 64. Fore-Aft ……………………………………………………………………………………34
• 65. Weight ……………………………………………………………………………………..34
• 66. Cushion Height-Angle ………………………………………………………………..34
• 67. Backrest …………………………………………………………………………………..34
• 68. Headrest (if fitted) ……………………………………………………………………..34
• 69. Armrest ……………………………………………………………………………………34
• 70. The Operator Manual …………………………………………………………………34
• 71. Heated Seat (if fitted) …………………………………………………………………34
• 72. Air Suspension Seat …………………………………………………………………….35
• 73. Raising-Lowering the Seat ………………………………………………………….35
• 74. Seat Belts (if fitted) …………………………………………………………………………..36
• 75. Static Seat Belt ……………………………………………………………………………36
• 76. Fasten the Seat Belt ………………………………………………………………….36
• 77. Release the Seat Belt ………………………………………………………………..36
• 78. Adjusting the Seat Belt ………………………………………………………………36
• 79. Visibility Aids ……………………………………………………………………………………37
• 80. Mirrors ……………………………………………………………………………………….37
• 81. Introduction ………………………………………………………………………………37
• 82. Installation ………………………………………………………………………………..37
• 83. Adjusting the Mirrors ………………………………………………………………….38
• 84. Checking the Field of Vision ……………………………………………………….39
• 85. Cab Layout ……………………………………………………………………………………..40
• 86. Components Key …………………………………………………………………………40
• 87. Drive Controls, Switches and Instruments ……………………………………………42
• 88. Drive Controls ……………………………………………………………………………..42
• 89. Track Controls …………………………………………………………………………..42
• 90. Switches …………………………………………………………………………………….43
• 91. Console Switches ……………………………………………………………………..43
• 92. Starter Switch ……………………………………………………………………………46
• 93. Cab Interior Lights …………………………………………………………………….46
• 94. Courtesy Light …………………………………………………………………………..46
• 95. Fascia Panel …………………………………………………………………………….47
• 96. Emergency Back-up Switch ………………………………………………………..48
• 97. Instruments …………………………………………………………………………………49
• 98. Monitor Panel ……………………………………………………………………………49
• 99. Heater-Air Conditioning Controls ……………………………………………………54
• 100. Heater Controls …………………………………………………………………………54
• 101. Using the Air Conditioning ………………………………………………………….54
• 102. Operating Levers-Pedals …………………………………………………………………..55
• 103. Excavating Controls …………………………………………………………………….55
• 104. ISO-SAE Controls ……………………………………………………………………..55
• 105. Boom and Bucket ……………………………………………………………………..57
• 106. Superstructure and Dipper ………………………………………………………….58
• 107. One Touch – Automatic Idle Switch ………………………………………………59
• 108. Travel Speed Change Button ………………………………………………………..59
• 109. Operation Levers …………………………………………………………………………60
• 110. Slewing ……………………………………………………………………………………60
• 111. Optional Circuit Pedal (if fitted) ………………………………………………………61
• 112. Locking Pedal …………………………………………………………………………..61
• 113. ISO Operating Method …………………………………………………………………61
• 114. Safety Equipment …………………………………………………………………………….62
• 115. Control Locks ……………………………………………………………………………..62
• 116. Servo Controls Immobilisation …………………………………………………….62
• 117. Enable the Controls …………………………………………………………………..62
• 118. Controls Isolation Lever ……………………………………………………………..62
• 119. Dipper Stroke Limiter (If fitted) ……………………………………………………….63
• 120. Operation …………………………………………………………………………………63
• 121. Adjust the Clearance …………………………………………………………………64
• 122. Check the Clearance …………………………………………………………………65
• 123. Overload Warning System …………………………………………………………….65
• 124. Before Starting the Engine …………………………………………………………………66
• 125. Starting the Engine …………………………………………………………………………..67
• 126. Warming-Up ……………………………………………………………………………….68
• 127. JCB Immobiliser System ………………………………………………………………68
• 128. Disarm the Immobiliser ………………………………………………………………68
• 129. Immobiliser Configuration …………………………………………………………..69
• 130. Getting the Machine Moving ………………………………………………………………71
• 131. Stopping and Parking the Machine ……………………………………………………..72
• 132. Stopping and Parking …………………………………………………………………..72
• 133. Engine Shutdown ………………………………………………………………………..72
• 134. Working with your Machine ……………………………………………………………….73
• 135. Undercarriage ……………………………………………………………………………..73
• 136. Extending the Undercarriage into the Working Position ………………….73
• 137. Retracting the Undercarriage into the Transport Position ………………..75
• 138. Operating Practices and Site Safety ………………………………………………77
• 139. Clothing and Safety Equipment ……………………………………………………..77
• 140. Danger Zone ………………………………………………………………………………77
• 141. Log Moving-Handling ……………………………………………………………………77
• 142. Safety Practices ………………………………………………………………………….77
• 143. Working With the Excavator ………………………………………………………….79
• 144. Digging …………………………………………………………………………………….79
• 145. Bucket ……………………………………………………………………………………..80
• 146. Backfilling …………………………………………………………………………………84
• 147. Travelling with a Load (Pick and Carry) ………………………………………..84
• 148. Dumping into a Truck …………………………………………………………………85
• 149. Lifting (Object Handling) ……………………………………………………………….86
• 150. Introduction ………………………………………………………………………………86
• 151. Lifting With the Excavator …………………………………………………………..86
• 152. Load Charts ……………………………………………………………………………..88
• 153. Use of Machines on Gradients and Slopes ……………………………………..89
• 154. Travelling on Slopes ………………………………………………………………….89
• 155. Working on Slopes …………………………………………………………………….90
• 156. Getting Out of Soft Ground ……………………………………………………………92
• 157. Water …………………………………………………………………………………………93
• 158. Towing Other Equipment ………………………………………………………………93
• 159. Machine Stability …………………………………………………………………………94
• 160. Reducing Wear ……………………………………………………………………………95
• 161. Operating Environment ……………………………………………………………………..98
• 162. Maintenance in Cold Climates ……………………………………………………….98
• 163. On Completion of Work ………………………………………………………………98
• 164. Operating in a Cold Climate (Below 0°C) ………………………………………..98
• 165. Operating in a Hot Climate (Above 35°C) ……………………………………….98
• 166. Operating in Dusty or Sandy Areas ………………………………………………..99
• 167. Operating in Coastal Regions ……………………………………………………….99
• 168. Operating on Wet or Soft Ground …………………………………………………..99
• 169. Cab Filters ………………………………………………………………………………….99
• 170. Refuelling the Machine ……………………………………………………………………100
• 171. Low Fuel Levels ………………………………………………………………………..100
• 172. Filling the Tank ………………………………………………………………………….100
• 173. Fuel Level …………………………………………………………………………………101
• 174. Refuelling Pump ………………………………………………………………………..102
• 175. Auto mode ……………………………………………………………………………..102
• 176. Manual mode ………………………………………………………………………….102
• 177. Moving a Disabled Machine …………………………………………………………….103
• 178. Lowering the Boom in an Emergency …………………………………………..103
• 179. Retrieval …………………………………………………………………………………..103
• 180. Limp Mode ………………………………………………………………………………..104
• 181. Mechanical Engine RPM Override ……………………………………………….104
• 182. Transporting the Machine ………………………………………………………………..105
• 183. Lifting the Machine …………………………………………………………………………108
• 184. Storage of the Machine ………………………………………………………………….. 110
• 185. Introduction ………………………………………………………………………………. 110
• 186. Storage Area ……………………………………………………………………………. 110
• 187. Prepare the Machine for Storage ………………………………………………… 110
• 188. Put the Machine into Storage ……………………………………………………… 110
• 189. During Storage …………………………………………………………………………. 110
• 190. Take the Machine Out of Storage ………………………………………………… 111
• 191. Anti-Vandalism Guards (option) ……………………………………………………….. 112
• 192. Unpacking the Guards ……………………………………………………………….. 112
• 193. Fitting the Guards ……………………………………………………………………… 112
• 194. Guard 7 (7), Front top panel – position A ……………………………………. 112
• 195. Guard 6 (3), Front bottom panel – position B ………………………………. 112
• 196. Guard 1 (4), Door front panel – position C …………………………………… 112
• 197. Guard 5 (1), Door rear panel – position D …………………………………… 112
• 198. Guard 2 (5) and 3 (6) (Hinged), Boom side panels – position E and F …..
• 199. 112
• 200. Guard 4 (2), Rear window panel – position G ………………………………. 113
• 201. Removing the Guards ……………………………………………………………….. 113
• 202. Storing the Guards ……………………………………………………………………. 113
• 203. Guards ………………………………………………………………………………….. 113
• 204. Older guards ………………………………………………………………………….. 113
• 205. Routine Maintenance
• 206. Service Requirements ……………………………………………………………………. 115
• 207. Introduction ………………………………………………………………………………. 115
• 208. Owner-Operator Support ……………………………………………………………. 115
• 209. Service-Maintenance Agreements ………………………………………………. 115
• 210. Fit for Purpose Tests for Lifting Equipment ……………………………………. 116
• 211. Obtaining Replacement Parts ……………………………………………………… 116
• 212. Health and Safety ………………………………………………………………………….. 117
• 213. Lubricants ………………………………………………………………………………… 117
• 214. Introduction ……………………………………………………………………………. 117
• 215. Hygiene …………………………………………………………………………………. 117
• 216. Storage …………………………………………………………………………………. 117
• 217. Waste Disposal ………………………………………………………………………. 117
• 218. Handling ………………………………………………………………………………… 117
• 219. First Aid – Oil ………………………………………………………………………….. 118
• 220. Spillage …………………………………………………………………………………. 118
• 221. Fires ……………………………………………………………………………………… 118
• 222. Battery …………………………………………………………………………………….. 119
• 223. Warning Symbols …………………………………………………………………….120
• 224. First Aid – Electrolyte ………………………………………………………………..120
• 225. Service Schedules ………………………………………………………………………….121
• 226. Introduction ……………………………………………………………………………….121
• 227. How to Use the Service Schedules ………………………………………………121
• 228. Calendar Equivalents …………………………………………………………………121
• 229. Pre Start Cold Checks, Service Points and Fluid Levels ………………….122
• 230. Functional Test and Final Inspection …………………………………………….126
• 231. Service Intervals for Attachments …………………………………………………128
• 232. Periodic Replacement of Safety Related Components ……………………129
• 233. Fluids, Lubricants and Capacities ……………………………………………………..130
• 234. Specifications ……………………………………………………………………………130
• 235. Typical Lubrication Chart …………………………………………………………….131
• 236. Coolant Mixtures ……………………………………………………………………….132
• 237. Fuel …………………………………………………………………………………………133
• 238. Acceptable and Unacceptable Fuels ………………………………………….133
• 239. Cleanliness …………………………………………………………………………….135
• 240. Fuel Bulk Storage ……………………………………………………………………135
• 241. Fuel Analysis ………………………………………………………………………….135
• 242. Tools …………………………………………………………………………………………….136
• 243. Carrying Tools onto the Machine ………………………………………………….136
• 244. Location ……………………………………………………………………………………136
• 245. Prepare the Machine for Maintenance ………………………………………………137
• 246. Introduction ……………………………………………………………………………….137
• 247. How to Make the Machine Safe (Excavator Lowered) …………………….137
• 248. Cleaning the Machine ……………………………………………………………………..138
• 249. Introduction ……………………………………………………………………………….138
• 250. Detergents ……………………………………………………………………………..138
• 251. Pressure Washing and Steam Cleaning ……………………………………..138
• 252. Preparing the Machine for Cleaning ……………………………………………..138
• 253. Cleaning the Machine …………………………………………………………………139
• 254. Exterior ………………………………………………………………………………….139
• 255. Interior ……………………………………………………………………………………139
• 256. Cleaning the Tracks ……………………………………………………………………139
• 257. Cleaning the Radiator and Oil Cooler ……………………………………………139
• 258. Checking for Damage ……………………………………………………………………..140
• 259. Check the Machine Body and Structure ………………………………………..140
• 260. Check the Seat and Seat Belt ……………………………………………………..140
• 261. Check the Tyres ………………………………………………………………………..140
• 262. Check the Electrical Circuits ………………………………………………………..140
• 263. Checking the FOPS Structure ……………………………………………………..141
• 264. Introduction …………………………………………………………………………….141
• 265. Frame Mounted ………………………………………………………………………141
• 266. Cab Mounted ………………………………………………………………………….141
• 267. Daily Checking ……………………………………………………………………………….142
• 268. Greasing ……………………………………………………………………………………….144
• 269. Introduction ……………………………………………………………………………….144
• 270. Slew Ring Bearing ……………………………………………………………………..144
• 271. Slew Ring Teeth and Slew Pinion …………………………………………………144
• 272. Greasing Points …………………………………………………………………………145
• 273. Electrical System ……………………………………………………………………………147
• 274. Battery ……………………………………………………………………………………..147
• 275. Battery Isolator ………………………………………………………………………..147
• 276. Battery Disconnection-Connection ……………………………………………..148
• 277. Terminal Cleaning ……………………………………………………………………148
• 278. Checking the Electrolyte Level – Low Maintenance Batteries …………149
• 279. Breather Cleaning – Low Maintenance Batteries ………………………….150
• 280. Battery Inspection – Maintenance Free Batteries ………………………….150
• 281. Jump-Starting the Engine ……………………………………………………………151
• 282. Fuses – Cab ………………………………………………………………………………152
• 283. Fuses and Relays – Battery Compartment …………………………………….153
• 284. Bolt and Nut Torque Specifications ……………………………………………………154
• 285. JS500 ………………………………………………………………………………………154
• 286. Engine ………………………………………………………………………………………….157
• 287. Oil and Filter ……………………………………………………………….