JCB JZ Auto Range – Tracked Excavators – Tier 3 Isuzu Engine Operator Manual 9811-6800

Description

• Model List:
  • JZ Auto Range – Tracked 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 Tracked 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 ……………………………………………………………………………..25
• 28. Introduction …………………………………………………………………………………25
• 29. JCB Plantguard …………………………………………………………………………..25
• 30. Construction Equipment Security And Registration Scheme (CESAR) .25
• 31. LiveLink ……………………………………………………………………………………..25
• 32. Operation
• 33. Introduction ……………………………………………………………………………………..27
• 34. Before Entering the Cab ……………………………………………………………………28
• 35. Entering and Leaving the Cab ……………………………………………………………29
• 36. Standard Cab Machines ……………………………………………………………….29
• 37. Two Man Cab ……………………………………………………………………………..30
• 38. Emergency Exit …………………………………………………………………………..31
• 39. Doors and Windows …………………………………………………………………………32
• 40. Opening and Closing the Door ………………………………………………………32
• 41. Opening and Closing the Front Upper Window ………………………………..33
• 42. Opening and Closing The Front Lower Window ……………………………….33
• 43. Door Sliding Window. …………………………………………………………………..34
• 44. Opening and Closing the Sunblind …………………………………………………34
• 45. Seat Controls …………………………………………………………………………………..35
• 46. Introduction …………………………………………………………………………………35
• 47. Operators Seat-Console ……………………………………………………………….35
• 48. Operators Seat – Standard-Heated …………………………………………………35
• 49. Air Suspension Seat …………………………………………………………………….36
• 50. Seat Belts (if fitted) …………………………………………………………………………..37
• 51. Static Seat Belt ……………………………………………………………………………37
• 52. Visibility Aids ……………………………………………………………………………………38
• 53. Mirrors ……………………………………………………………………………………….38
• 54. Cab Layout ……………………………………………………………………………………..42
• 55. Components Key …………………………………………………………………………42
• 56. Drive Controls, Switches and Instruments ……………………………………………44
• 57. Drive Controls ……………………………………………………………………………..44
• 58. Switches …………………………………………………………………………………….45
• 59. Instruments …………………………………………………………………………………53
• 60. Air Conditioning and Heater Controls ……………………………………………..58
• 61. Operating Levers-Pedals …………………………………………………………………..60
• 62. Excavating Controls …………………………………………………………………….60
• 63. Travel Speed Change Button ………………………………………………………..66
• 64. Operation Levers …………………………………………………………………………66
• 65. Optional Circuit Pedal (if fitted) ………………………………………………………67
• 66. ISO Operating Method …………………………………………………………………67
• 67. Safety Equipment …………………………………………………………………………….68
• 68. Control Locks ……………………………………………………………………………..68
• 69. Dipper Stroke Limiter (If fitted) ……………………………………………………….69
• 70. Overload Warning System …………………………………………………………….71
• 71. Before Starting the Engine …………………………………………………………………73
• 72. Starting the Engine …………………………………………………………………………..74
• 73. Warming-Up ……………………………………………………………………………….75
• 74. JCB Immobiliser System ………………………………………………………………75
• 75. Getting the Machine Moving ………………………………………………………………78
• 76. Stopping and Parking the Machine ……………………………………………………..79
• 77. Stopping and Parking …………………………………………………………………..79
• 78. Engine Shutdown ………………………………………………………………………..80
• 79. Working with your Machine ……………………………………………………………….81
• 80. Operating Practices and Site Safety ………………………………………………81
• 81. Clothing and Safety Equipment ……………………………………………………..81
• 82. Danger Zone ………………………………………………………………………………81
• 83. Log Moving-Handling ……………………………………………………………………81
• 84. Safety Practices ………………………………………………………………………….82
• 85. Working With the Excavator ………………………………………………………….83
• 86. Lifting (Object Handling) ……………………………………………………………….90
• 87. Use of the Machine on Gradients and Slopes ………………………………….93
• 88. Pulling out of Soft Ground …………………………………………………………….96
• 89. Water …………………………………………………………………………………………97
• 90. Towing Other Equipment ………………………………………………………………97
• 91. Machine Stability …………………………………………………………………………98
• 92. Reducing Wear ……………………………………………………………………………99
• 93. Operating Environment ……………………………………………………………………102
• 94. Maintenance in Cold Climates ……………………………………………………..102
• 95. Operating in a Cold Climate (Below 0°C) ………………………………………102
• 96. Operating in a Hot Climate (Above 35°C) ……………………………………..102
• 97. Operating in Dusty or Sandy Areas ………………………………………………103
• 98. Operating in Coastal Regions ……………………………………………………..103
• 99. Operating on Wet or Soft Ground …………………………………………………103
• 100. Cab Filters ………………………………………………………………………………..103
• 101. Refuelling the Machine ……………………………………………………………………104
• 102. Low Fuel Levels ………………………………………………………………………..104
• 103. Filling the Tank ………………………………………………………………………….104
• 104. Fuel Level …………………………………………………………………………………105
• 105. Refuelling Pump ………………………………………………………………………..106
• 106. Moving a Disabled Machine …………………………………………………………….107
• 107. Lowering the Boom in an Emergency …………………………………………..107
• 108. Retrieval …………………………………………………………………………………..107
• 109. Limp Mode ………………………………………………………………………………..108
• 110. Transporting the Machine ………………………………………………………………..109
• 111. Lifting the Machine ………………………………………………………………………… 111
• 112. JZ140 – JZ255 Machines ……………………………………………………………. 111
• 113. Storage of the Machine ………………………………………………………………….. 112
• 114. Introduction ………………………………………………………………………………. 112
• 115. Storage Area ……………………………………………………………………………. 112
• 116. Prepare the Machine for Storage ………………………………………………… 112
• 117. Put the Machine into Storage ……………………………………………………… 112
• 118. During Storage …………………………………………………………………………. 112
• 119. Take the Machine Out of Storage ………………………………………………… 113
• 120. Anti-Vandalism Guards (option) ……………………………………………………….. 114
• 121. Unpacking the Guards ……………………………………………………………….. 114
• 122. Fitting the Guards ……………………………………………………………………… 114
• 123. Removing the Guards ……………………………………………………………….. 115
• 124. Storing the Guards ……………………………………………………………………. 115
• 125. Routine Maintenance
• 126. Service Requirements ……………………………………………………………………. 117
• 127. Introduction ………………………………………………………………………………. 117
• 128. Owner-Operator Support ……………………………………………………………. 117
• 129. Service-Maintenance Agreements ………………………………………………. 117
• 130. Fit for Purpose Tests for Lifting Equipment ……………………………………. 118
• 131. Obtaining Replacement Parts ……………………………………………………… 118
• 132. Health and Safety ………………………………………………………………………….. 119
• 133. Lubricants ………………………………………………………………………………… 119
• 134. Battery ……………………………………………………………………………………..121
• 135. Service Schedules ………………………………………………………………………….123
• 136. Introduction ……………………………………………………………………………….123
• 137. How to Use the Service Schedules ………………………………………………123
• 138. Calendar Equivalents …………………………………………………………………123
• 139. Pre Start Cold Checks, Service Points and Fluid Levels ………………….124
• 140. Functional Test and Final Inspection …………………………………………….128
• 141. Service Intervals for Attachments …………………………………………………130
• 142. Periodic Replacement of Safety Related Components ……………………131
• 143. Fluids, Lubricants and Capacities ……………………………………………………..132
• 144. JZ140 and Variants …………………………………………………………………….132
• 145. JZ235-255 and Variants ………………………………………………………………133
• 146. Engine Lubrication Chart …………………………………………………………….134
• 147. Hydraulic Oil Chart …………………………………………………………………….134
• 148. Typical Lubrication Chart …………………………………………………………….135
• 149. Coolant Mixtures ……………………………………………………………………….137
• 150. Fuel …………………………………………………………………………………………137
• 151. Tools …………………………………………………………………………………………….140
• 152. Carrying Tools onto the Machine ………………………………………………….140
• 153. Locations ………………………………………………………………………………….140
• 154. Prepare the Machine for Maintenance ………………………………………………141
• 155. Introduction ……………………………………………………………………………….141
• 156. How to Make the Machine Safe (Excavator Lowered) …………………….141
• 157. Cleaning the Machine ……………………………………………………………………..142
• 158. Introduction ……………………………………………………………………………….142
• 159. Preparing the Machine for Cleaning ……………………………………………..142
• 160. Cleaning the Machine …………………………………………………………………143
• 161. Cleaning the Tracks ……………………………………………………………………143
• 162. Cleaning the Radiator and Oil Cooler ……………………………………………143
• 163. Check the Machine for Damage ……………………………………………………….144
• 164. Check the Machine Body and Structure ………………………………………..144
• 165. Check the Seat and Seat Belt ……………………………………………………..144
• 166. Checking the FOPS Structure ……………………………………………………..144
• 167. Daily Checking ……………………………………………………………………………….145
• 168. Greasing ……………………………………………………………………………………….148
• 169. Introduction ……………………………………………………………………………….148
• 170. Slew Ring Bearing ……………………………………………………………………..148
• 171. Slew Ring Teeth and Slew Pinion …………………………………………………148
• 172. Greasing Points …………………………………………………………………………149
• 173. Electrical System ……………………………………………………………………………152
• 174. Battery ……………………………………………………………………………………..152
• 175. Jump-Starting the Engine ……………………………………………………………156
• 176. Fuses ……………………………………………………………………………………….157
• 177. Bolt and Nut Torque Specifications ……………………………………………………159
• 178. JZ140 – JZ255 and Variants ………………………………………………………..159
• 179. Engine ………………………………………………………………………………………….163
• 180. Oil and Filter ……………………………………………………………………………..163
• 181. Cooling System …………………………………………………………………………166
• 182. Fan Belt ……………………………………………………………………………………178
• 183. Engine Air Filter …………………………………………………………………………179
• 184. Fuel System …………………………………………………………………………………..181
• 185. Introduction ……………………………………………………………………………….181
• 186. Draining Fuel Tank Impurities ………………………………………………………181
• 187. Draining the Primary Filter-Sedimenter …………………………………………182
• 188. Changing the Primary Filter-Sedimenter Element …………………………..183
• 189. Changing the Fuel Feed Pump Filter ……………………………………………183
• 190. Draining the Main Filter-Sedimenter ……………………………………………..184
• 191. Changing the Main Filter-Sedimenter Element ……………………………….184
• 192. Bleeding the System ………………………………………………………………….186
• 193. Hydraulic System ……………………………………………………………………………187
• 194. Introduction ……………………………………………………………………………….187
• 195. Releasing Tank Pressure ……………………………………………………………188
• 196. Releasing the Hydraulic Pressure ………………………………………………..188
• 197. Oil and Filters ……………………………………………………………………………189
• 198. Draining Water and Sediment from the Hydraulic Tank ……………………197
• 199. Air Bleeding Procedures ……………………………………………………………..197
• 200. Slew Gearbox ………………………………………………………………………………..199
• 201. Checking the Slew Gearbox Oil Level …………………………………………..199
• 202. Changing the Slew Gearbox Oil Level ………………………………………….199
• 203. Tracks and Running Gear ……………………………………………………………….200
• 204. Tracks ………………………………………………………………………………………200
• 205. Running Gear ……………………………………………………………………………202
• 206. Bucket ………………………………………………………………………………………….203
• 207. Checking-Adjusting for side play ………………………………………………….203
• 208. Windscreen Washer ……………………………………………………………………….204
• 209. Checking the Level …………………………………………………………………….204
• 210. Fire Extinguisher (If fitted) ……………………………………………………………….205
• 211. Troubleshooting ……………………………………………………………………………..206
• 212. Engine and Related Area ……………………………………………………………206
• 213. Monitor Display – Fault Messages ………………………………………………..209
• 214. Operations ………………………………………………………………………………..210
• 215. Hydraulic pump ………………………………………………………………………… 211
• 216. Working Attachments …………………………………………………………………212
• 217. Travel ……………………………………………………………………………………….213
• 218. Slew …………………………………………………………………………………………214
• 219. Hydraulic ram ……………………………………………………………………………214
• 220. Optional Attachments
• 221. Introduction ……………………………………………………………………………………215
• 222. Attachments For Your Machine ………………………………………………………..216
• 223. Connecting-Disconnecting Hydraulic Hoses ……………………………………….217
• 224. Introduction ……………………………………………………………………………….217
• 225. Connecting the Hydraulic Hoses ………………………………………………….217
• 226. Disconnecting the Hydraulic Hoses ………………………………………………218
• 227. Quick Release Couplings ……………………………………………………………219
• 228. Operating Attachments ……………………………………………………………………221
• 229. Grab-Changeover Valves (if fitted) ……………………………………………….222
• 230. Hydraulic Rockbreaker ……………………………………………………………………224
• 231. Preparation ……………………………………………………………………………….224
• 232. Operation and Maintenance ………………………………………………………..224
• 233. Crusher …………………………………………………………………………………………225
• 234. General …………………………………………………………………………………….225
• 235. Preparation ……………………………………………………………………………….225
• 236. Weedcutter ……………………………………………………………………………………226
• 237. Operation ………………………………………………………………………………….226
• 238. Maintenance ……………………………………………………………………………..226
• 239. Specifications
• 240. Static Dimensions …………………………………………………………………………..227
• 241. JZ140 – Monoboom ……………………………………………………………………227
• 242. JZ140 – Triple Articulated Boom …………………………………………………..228
• 243. JZ140HD – Monoboom ……………………………………………………………….229
• 244. JZ140HD – Triple Articulated Boom ………………………………………………230
• 245. JZ235 – Monoboom ……………………………………………………………………231
• 246. JZ235 – Triple Articulated Boom …………………………………………………..232
• 247. JZ255 – Monoboom ……………………………………………………………………233
• 248. JZ255 – Triple Articulated Boom …………………………………………………..234
• 249. Dig Depth Chart ……………………………………………………………………………..235
• 250. JZ140 – Monoboom ……………………………………………………………………235
• 251. JZ140 – Triple Articulated Boom …………………………………………………..236
• 252. JZ140HD – Monoboom ……………………………………………………………….237
• 253. JZ235 – Monoboom ……………………………………………………………………238
• 254. JZ235 – Triple Articulated Boom …………………………………………………..239
• 255. JZ255 – Monoboom ……………………………………………………………………240
• 256. JZ255 – Triple Articulated Boom …………………………………………………..241
• 257. Shipping Weight …………………………………………………………………………….242
• 258. Travel Speeds ………………………………………………………………………………..243
• 259. Noise Data …………………………………………………………………………………….244
• 260. Introduction ……………………………………………………………………………….244
• 261. All Machines ……………………………………………………………………………..244
• 262. Vibration Data ………………………………………………………………………………..245
• 263. Introduction ……………………………………………………………………………….245
• 264. JZ140 ………………………………………………………………………………………246
• 265. JZ235-255 ………………………………………………………………………………..247
• 266. Lifting (Object Handling) Regulations and Safe Working Loads …………….248
• 267. Introduction ……………………………………………………………………………….248
• 268. Load Charts ………………………………………………………………………………249
• 269. Warranty Information
• 270. Machine Service Record Sheet ………………………………………………………..257
• 271. Registration Information ………………………………………………………………….259
• 272. European Community Standards
• 273. EC Declaration of Conformity …………………………………………………………..261
• 274. Introduction ……………………………………………………………………………….261
• 275. Explanation of the EC Declaration of Conformity ……………………………263