jcb 55Z-1 User manual

OPERATOR'S MANUAL
EXCAVATOR
55 Z-1, 57 C-1
EN - 9831/1250
ISSUE 2 - 10/2016
THIS MANUAL SHOULD ALWAYS STAY WITH THE MACHINE

OPERATOR'S
MANUAL
EXCAVATOR
55 Z-1, 57 C-1
EN - 9831/1250 - ISSUE 2 - 10/2016
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
Copyright 6-10-17 © JCB SERVICE
All rights reserved. No part of this publication may
be reproduced, stored in a retrieval system, or
transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise,
without prior permission from JCB SERVICE.
www.jcb.com
Foreword
The Operator's Manual
You and others can be killed or seriously injured
if you operate or maintain the machine without
first studying the Operator's Manual. You must
understand and follow the instructions in the
Operator's Manual. If you do not understand
anything, ask your employer or JCB dealer to
explain it.
Do not operate the machine without an Operator's
Manual, or if there is anything on the machine you
do not understand.
Treat the Operator's Manual as part of the machine.
Keep it clean and in good condition. Replace the
Operator's Manual immediately if it is lost, damaged
or becomes unreadable.
Machine Delivery and Installation
Even if you have operated this type of equipment
before, it is very important that your new machines
operations and functions are explained to you by
a JCB Dealer Representative following delivery of
your new machine.
Following the installation you will know how to gain
maximum productivity and performance from your
new product.
Please contact your local JCB dealer if the
Installation Form (included in this manual) has not
yet been completed with you.
Your local JCB Dealer is
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9831/1250-2
Notes:
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Table of Contents
i 9831/1250-2 i
Contents Page No.
Acronyms Glossary ........................................................................................................................................ vii
Introduction
About this Manual
Model and Serial Number ..................................................................................................................... 1
Using the Manual .................................................................................................................................. 1
Left-Hand Side, Right-Hand Side ......................................................................................................... 1
Cab/Canopy .......................................................................................................................................... 1
Cross References ................................................................................................................................. 2
Location of Manual ............................................................................................................................... 2
Safety
Safety - Yours and Others .................................................................................................................... 3
Safety Warnings .................................................................................................................................... 3
General Safety ...................................................................................................................................... 4
Clothing and Personal Protective Equipment (PPE) ............................................................................ 5
About the Product
Introduction
General .................................................................................................................................................. 7
Name and Address of the Manufacturer .............................................................................................. 7
Product Compliance .............................................................................................................................. 7
Description
General .................................................................................................................................................. 8
Intended Use ......................................................................................................................................... 8
Log Moving/Object Handling ................................................................................................................. 8
Optional Equipment and Attachments .................................................................................................. 8
Danger Zone ......................................................................................................................................... 8
Main Component Locations .................................................................................................................. 9
Product and Component Identification
Machine ............................................................................................................................................... 10
Engine ................................................................................................................................................. 10
Operator Protective Structure ............................................................................................................. 11
Safety Labels
General ................................................................................................................................................ 13
Safety Label Identification ................................................................................................................... 14
Operator Station
Component Locations ......................................................................................................................... 17
Console Switches
General ................................................................................................................................................ 19
Interior Switches
Ignition Switch ..................................................................................................................................... 21
Cab Interior Light ................................................................................................................................ 21
Control Pattern Selector ..................................................................................................................... 22
Operation
Introduction
General ................................................................................................................................................ 23
Operating Safety
General ................................................................................................................................................ 24
Worksite Safety ................................................................................................................................... 26
Risk Assessment ................................................................................................................................ 27
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Table of Contents
ii 9831/1250-2 ii
Walk-Around Inspection
General ................................................................................................................................................ 29
Entering and Leaving the Operator Station
General ................................................................................................................................................ 30
Emergency Exit ................................................................................................................................... 32
Doors
Operator Door ..................................................................................................................................... 33
Windows
Front Window ...................................................................................................................................... 35
Side Window ....................................................................................................................................... 36
Sun Visor/Sunblind
Sunblind .............................................................................................................................................. 38
Before Starting the Engine
General ................................................................................................................................................ 39
Operator Seat
General ................................................................................................................................................ 40
Suspension Seat ................................................................................................................................. 40
Seat Belt
General ................................................................................................................................................ 43
Inertia Reel Seat Belt ......................................................................................................................... 43
Static Seat Belt ................................................................................................................................... 44
Mirrors
General ................................................................................................................................................ 47
Starting the Engine
General ................................................................................................................................................ 49
Immobiliser .......................................................................................................................................... 49
Warming Up ........................................................................................................................................ 53
Stopping and Parking
General ................................................................................................................................................ 54
Preparing for Travel
General ................................................................................................................................................ 55
Preparing for Worksite Travel ............................................................................................................. 55
Beacon ................................................................................................................................................ 55
Safety Equipment
General ................................................................................................................................................ 57
Control Lock ........................................................................................................................................ 57
Drive Controls
Track Controls ..................................................................................................................................... 59
Hand Throttle Control ......................................................................................................................... 59
Instruments
General ................................................................................................................................................ 60
Instrument Panel ................................................................................................................................. 60
Getting the Machine Moving
General ................................................................................................................................................ 71
Driving the Machine
General ................................................................................................................................................ 72
Operating Levers/Pedals
General ................................................................................................................................................ 73
Control Layouts ................................................................................................................................... 73
Excavator Arm Controls ...................................................................................................................... 73
Dozer Blade Controls ......................................................................................................................... 76
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Table of Contents
iii 9831/1250-2 iii
Auxiliary Circuit Controls ..................................................................................................................... 77
Lifting and Loading
General ................................................................................................................................................ 78
Load Charts ........................................................................................................................................ 78
Overload Warning System .................................................................................................................. 79
Working with the Excavator Arm
General ................................................................................................................................................ 80
Preparing to Use the Excavator Arm ................................................................................................. 80
Lifting With the Excavator Arm ........................................................................................................... 80
Digging ................................................................................................................................................ 81
Working with the Dozer Blade
General ................................................................................................................................................ 84
Dozing and Grading ............................................................................................................................ 84
Scraping and Cutting .......................................................................................................................... 84
Backfilling ............................................................................................................................................ 84
Slopes
General ................................................................................................................................................ 86
Driving on Slopes ............................................................................................................................... 86
Working on Slopes ............................................................................................................................. 86
Heating, Ventilating and Air-Conditioning (HVAC)
General ................................................................................................................................................ 87
Air-Conditioning Controls .................................................................................................................... 87
Power Sockets
Auxiliary Power Socket ....................................................................................................................... 89
Cab Options
Multimedia Interface ............................................................................................................................ 90
Battery Isolator
General ................................................................................................................................................ 91
Fire Extinguisher
General ................................................................................................................................................ 92
Moving a Disabled Machine
General ................................................................................................................................................ 93
Getting the Machine Unstuck ............................................................................................................. 93
Jump-Starting the Engine ................................................................................................................... 93
Retrieval .............................................................................................................................................. 94
Excavator Arm (Emergency Operation) .............................................................................................. 95
Lifting the Machine
General ................................................................................................................................................ 96
Transporting the Machine
General ................................................................................................................................................ 98
Loading the Machine onto the Transporting Vehicle/Trailer ............................................................... 98
Unloading the Machine from the Transporting Vehicle/Trailer .......................................................... 100
Operating Environment
General .............................................................................................................................................. 102
Operating in Low Temperatures ....................................................................................................... 102
Operating in High Temperatures ....................................................................................................... 103
Refuelling
General .............................................................................................................................................. 104
Low Fuel Levels ................................................................................................................................ 104
Filling the Tank .................................................................................................................................. 104
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Table of Contents
iv 9831/1250-2 iv
Attachments
Working with Attachments
Introduction ........................................................................................................................................ 107
Attachments for your Machine .......................................................................................................... 107
Connecting/Disconnecting Hydraulic Hoses ..................................................................................... 108
Impact Protection .............................................................................................................................. 111
Direct-Mounted Attachments
General .............................................................................................................................................. 112
Quickhitch
Excavator Arm Quickhitch ................................................................................................................ 113
Buckets
General .............................................................................................................................................. 121
Bucket Teeth ..................................................................................................................................... 121
Rockbreaker
General .............................................................................................................................................. 123
Preservation and Storage
Cleaning
General .............................................................................................................................................. 127
Preparation ........................................................................................................................................ 127
Checking For Damage
General .............................................................................................................................................. 129
Storage
General .............................................................................................................................................. 130
Put into Storage ................................................................................................................................ 130
During Storage .................................................................................................................................. 130
Take out of Storage .......................................................................................................................... 131
Security
General .............................................................................................................................................. 132
JCB Plantguard ................................................................................................................................. 132
Construction Equipment Security and Registration Scheme (CESAR) ............................................ 132
Maintenance
Introduction
General .............................................................................................................................................. 133
Owner/Operator Support ................................................................................................................... 133
Service/Maintenance Agreements .................................................................................................... 133
Obtaining Spare Parts ...................................................................................................................... 134
Maintenance Safety
General .............................................................................................................................................. 135
Fluids and Lubricants ....................................................................................................................... 136
Maintenance Schedules
General .............................................................................................................................................. 140
How to Use the Maintenance Schedules ......................................................................................... 140
Maintenance Intervals ....................................................................................................................... 140
Pre-start Cold Checks, Service Points and Fluid Levels .................................................................. 141
Functional Tests and Final Inspection .............................................................................................. 143
Maintenance Positions
General .............................................................................................................................................. 144
Maintenance Position (Excavator Arm Lowered) ............................................................................. 144
Service Points
General .............................................................................................................................................. 145
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Table of Contents
v 9831/1250-2 v
Access Apertures
General .............................................................................................................................................. 147
Engine Compartment Cover ............................................................................................................. 147
Hydraulic Compartment Cover ......................................................................................................... 147
Tools
General .............................................................................................................................................. 149
Toolbox .............................................................................................................................................. 149
Lubrication
General .............................................................................................................................................. 150
Preparation ........................................................................................................................................ 150
Attachments
General ............................................................................................................................................. 151
Body and Framework
General ............................................................................................................................................. 152
Slew Ring Bearings .......................................................................................................................... 152
Pivot Pins .......................................................................................................................................... 153
Operator Station
General ............................................................................................................................................. 155
Operator Protective Structure ........................................................................................................... 155
Seat ................................................................................................................................................... 155
Seat Belt ........................................................................................................................................... 155
Controls ............................................................................................................................................. 156
Engine
General ............................................................................................................................................. 157
Oil ...................................................................................................................................................... 157
Drive Belt .......................................................................................................................................... 159
Air Filter
General ............................................................................................................................................. 160
Outer Element .................................................................................................................................. 160
Dust Valve ........................................................................................................................................ 161
Fuel System
General ............................................................................................................................................. 162
Engine Fuel Filter ............................................................................................................................. 163
Water Separator ............................................................................................................................... 163
Cooling System
General ............................................................................................................................................. 164
Coolant .............................................................................................................................................. 164
Cooling Pack .................................................................................................................................... 164
Tracks
General ............................................................................................................................................. 166
Steel .................................................................................................................................................. 166
Rubber .............................................................................................................................................. 168
Hydraulic System
General ............................................................................................................................................. 169
Services ............................................................................................................................................ 171
Oil ...................................................................................................................................................... 172
Cylinder Rams .................................................................................................................................. 172
Electrical System
General ............................................................................................................................................. 173
Battery ............................................................................................................................................... 173
Battery Isolator ................................................................................................................................. 174
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Table of Contents
vi 9831/1250-2 vi
Fuses ................................................................................................................................................ 175
Relays ............................................................................................................................................... 175
Window Washer ................................................................................................................................ 176
Miscellaneous
Fire Extinguisher ............................................................................................................................... 177
Technical Data
Static Dimensions
Dimensions ........................................................................................................................................ 179
Weights ............................................................................................................................................. 180
Performance Dimensions
Excavator Arm Dimensions and Performance .................................................................................. 182
Noise Emissions
General .............................................................................................................................................. 186
Noise Data ........................................................................................................................................ 186
Vibration Emissions
General .............................................................................................................................................. 187
Vibration Data ................................................................................................................................... 187
Fluids, Lubricants and Capacities
General .............................................................................................................................................. 189
Fuel ................................................................................................................................................... 189
Coolant .............................................................................................................................................. 191
Torque Values
General .............................................................................................................................................. 193
Electrical System
General .............................................................................................................................................. 194
Fuses ................................................................................................................................................. 194
Relays ............................................................................................................................................... 195
Engine
General .............................................................................................................................................. 196
Hydraulic System
Auxiliary Circuits ............................................................................................................................... 197
Tracks
General .............................................................................................................................................. 198
Declaration of Conformity
General .............................................................................................................................................. 199
Data ................................................................................................................................................... 200
Warranty Information
Service Record Sheet ....................................................................................................................... 202
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Table of Contents
vii 9831/1250-2 vii
Acronyms Glossary
CAN Controller Area Network
CESAR Construction Equipment Security and Registration
DECU Display Electronic Control Unit
DEF Diesel Exhaust Fluid
ECM Engine Control Module
ECU Electronic Control Unit
ESOS Engine Shut-Off Solenoid
FOGS Falling Object Guard System
FOPS Falling Object Protective Structure
HAV Hand-Arm Vibration
HVAC Heating Ventilation Air Conditioning
ISO International Organization for Standardization
LCD Liquid Crystal Display
LED Light Emitting Diode
MECU Machine Electronic Control Unit
MRV Main Relief Valve
PIN Product Identification Number
PPE Personal Protective Equipment
RMS Root Mean Square
ROPS Roll-Over Protective Structure
RPM Revolutions Per Minute
SAE Society of Automotive Engineers
SWL Safe Working Load
TOPS Tip-Over Protective Structure
USB Universal Serial Bus
VIN Vehicle Identification Number
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