jcb JS210 User manual

OPERATOR'S MANUAL
EXCAVATOR
JS210, JS220, JS235
EN - 9831/5600 ISSUE 1 - 07/2017
THIS MANUAL SHOULD ALWAYS STAY WITH THE MACHINE

OPERATOR'S
MANUAL
EXCAVATOR
JS210, JS220, JS235
EN - 9831/5600 - ISSUE 1 - 07/2017
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
Copyright 2017 © 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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9831/5600-1
Notes:
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Table of Contents
i 9831/5600-1 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
Cross References ................................................................................................................................. 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
Operator Protective Structure ............................................................................................................. 10
Safety Labels
General ................................................................................................................................................ 12
Safety Label Identification ................................................................................................................... 12
Operator Station
Component Locations ......................................................................................................................... 15
Interior Switches
Ignition Switch ..................................................................................................................................... 16
Cab Interior Light ................................................................................................................................ 16
Console Switches
General ................................................................................................................................................ 18
Work Lights ......................................................................................................................................... 18
Seat Ventilation ................................................................................................................................... 18
Control Locks ...................................................................................................................................... 18
Excavator Arm Quickhitch .................................................................................................................. 19
Radio Mute .......................................................................................................................................... 19
Engine Stop Switch ............................................................................................................................ 19
Slew Lock ........................................................................................................................................... 19
Cushion ............................................................................................................................................... 19
Window Washer .................................................................................................................................. 19
Window Wipers ................................................................................................................................... 19
Front Lower Window Wiper ................................................................................................................ 20
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Table of Contents
ii 9831/5600-1 ii
Operation
Introduction
General ................................................................................................................................................ 21
Operating Safety
General ................................................................................................................................................ 22
Worksite Safety ................................................................................................................................... 24
Risk Assessment ................................................................................................................................ 25
Walk-Around Inspection
General ................................................................................................................................................ 27
Entering and Leaving the Operator Station
General ................................................................................................................................................ 28
Emergency Exit ................................................................................................................................... 30
Doors
Operator Door ..................................................................................................................................... 31
Windows
Front Window ...................................................................................................................................... 33
Side Window ....................................................................................................................................... 34
Sun Visor/Sunblind
Sunblind .............................................................................................................................................. 36
Battery Isolator
General ................................................................................................................................................ 38
Before Starting the Engine
General ................................................................................................................................................ 39
Operator Seat
General ................................................................................................................................................ 40
Suspension Seat ................................................................................................................................. 40
Heated Seat Controls ......................................................................................................................... 42
Seat Ventilation Controls .................................................................................................................... 42
Seat Belt
General ................................................................................................................................................ 43
Inertia Reel Seat Belt ......................................................................................................................... 43
Static Seat Belt ................................................................................................................................... 44
Mirrors
General ................................................................................................................................................ 46
Starting the Engine
General ................................................................................................................................................ 51
Immobiliser .......................................................................................................................................... 52
Warming Up ........................................................................................................................................ 53
Stopping and Parking
General ................................................................................................................................................ 55
Preparing for Travel
General ................................................................................................................................................ 56
Preparing for Worksite Travel ............................................................................................................. 56
Beacon ................................................................................................................................................ 57
Safety Equipment
General ................................................................................................................................................ 58
Control Lock ........................................................................................................................................ 58
Drive Controls
Track Controls ..................................................................................................................................... 60
Travel Speed Selector ........................................................................................................................ 61
Instruments
General ................................................................................................................................................ 63
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Table of Contents
iii 9831/5600-1 iii
Instrument Panel ................................................................................................................................. 64
Getting the Machine Moving
General ................................................................................................................................................ 86
Slopes
General ................................................................................................................................................ 89
Driving on Slopes ............................................................................................................................... 89
Working on Slopes ............................................................................................................................. 91
Driving the Machine
General ................................................................................................................................................ 93
Towing Other Equipment .................................................................................................................... 93
Operating Levers/Pedals
General ................................................................................................................................................ 95
Control Layouts ................................................................................................................................... 95
Excavator Arm Controls ...................................................................................................................... 95
Dozer Blade Controls ....................................................................................................................... 103
Auxiliary Circuit Controls ................................................................................................................... 103
Lifting and Loading
General .............................................................................................................................................. 107
Load Charts ...................................................................................................................................... 107
Overload Warning System ................................................................................................................ 108
Working with the Excavator Arm
General .............................................................................................................................................. 110
Preparing to Use the Excavator Arm ............................................................................................... 110
Lifting With the Excavator Arm ......................................................................................................... 110
Digging .............................................................................................................................................. 111
Changing the Bucket Linkage .......................................................................................................... 116
Dipper Stroke Limiter ........................................................................................................................ 117
Working with the Dozer Blade
General .............................................................................................................................................. 120
Dozing and Grading .......................................................................................................................... 120
Scraping and Cutting ........................................................................................................................ 120
Backfilling .......................................................................................................................................... 120
Heating, Ventilating and Air-Conditioning (HVAC)
General .............................................................................................................................................. 122
Air-Conditioning Controls .................................................................................................................. 122
Power Sockets
Auxiliary Power Socket ..................................................................................................................... 125
Fire Extinguisher
General .............................................................................................................................................. 126
Moving a Disabled Machine
General .............................................................................................................................................. 128
Getting the Machine Unstuck ........................................................................................................... 128
Jump-Starting the Engine ................................................................................................................. 129
Retrieval ............................................................................................................................................ 130
Excavator Arm (Emergency Operation) ............................................................................................ 130
Lifting the Machine
General .............................................................................................................................................. 132
Transporting the Machine
General .............................................................................................................................................. 134
Loading the Machine onto the Transporting Vehicle/Trailer ............................................................. 134
Unloading the Machine from the Transporting Vehicle/Trailer .......................................................... 137
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Table of Contents
iv 9831/5600-1 iv
Operating Environment
General .............................................................................................................................................. 139
Operating in Low Temperatures ....................................................................................................... 139
Operating in High Temperatures ....................................................................................................... 139
Cab Filters ......................................................................................................................................... 140
Refuelling
General .............................................................................................................................................. 141
Low Fuel Levels ................................................................................................................................ 141
Filling the Tank .................................................................................................................................. 141
Attachments
Working with Attachments
Introduction ........................................................................................................................................ 145
Attachments for your Machine .......................................................................................................... 145
Connecting/Disconnecting Hydraulic Hoses ..................................................................................... 146
Impact Protection .............................................................................................................................. 149
Direct-Mounted Attachments
General .............................................................................................................................................. 150
Quickhitch
Excavator Arm Quickhitch ................................................................................................................ 153
Buckets
General .............................................................................................................................................. 160
Bucket Teeth ..................................................................................................................................... 160
Preservation and Storage
Cleaning
General .............................................................................................................................................. 165
Preparation ........................................................................................................................................ 165
Checking For Damage
General .............................................................................................................................................. 167
Storage
General .............................................................................................................................................. 168
Put into Storage ................................................................................................................................ 168
During Storage .................................................................................................................................. 168
Take out of Storage .......................................................................................................................... 169
Security
General .............................................................................................................................................. 170
LiveLink ............................................................................................................................................. 170
Anti-Vandal Guards ........................................................................................................................... 170
Maintenance
Introduction
General .............................................................................................................................................. 173
Owner/Operator Support ................................................................................................................... 173
Service/Maintenance Agreements .................................................................................................... 174
Obtaining Spare Parts ...................................................................................................................... 174
Maintenance Safety
General .............................................................................................................................................. 175
Fluids and Lubricants ....................................................................................................................... 176
Maintenance Schedules
General .............................................................................................................................................. 180
How to Use the Maintenance Schedules ......................................................................................... 180
Maintenance Intervals ....................................................................................................................... 180
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Table of Contents
v 9831/5600-1 v
Pre-start Cold Checks, Service Points and Fluid Levels .................................................................. 181
Functional Tests and Final Inspection .............................................................................................. 184
Maintenance Positions
General .............................................................................................................................................. 186
Maintenance Position (Excavator Arm Lowered) ............................................................................. 186
Service Points
General .............................................................................................................................................. 187
Access Apertures
General .............................................................................................................................................. 193
Battery Cover .................................................................................................................................... 193
Engine Compartment Cover ............................................................................................................. 193
Hydraulic Compartment Cover ......................................................................................................... 194
Radiator Cover .................................................................................................................................. 195
Tools
General .............................................................................................................................................. 197
Toolbox .............................................................................................................................................. 197
Lubrication
General .............................................................................................................................................. 198
Preparation ........................................................................................................................................ 198
Attachments
General ............................................................................................................................................. 199
Body and Framework
General ............................................................................................................................................. 200
Slew Ring Bearings .......................................................................................................................... 200
Pivot Pins .......................................................................................................................................... 201
Operator Station
General ............................................................................................................................................. 203
Operator Protective Structure ........................................................................................................... 203
Seat ................................................................................................................................................... 205
Seat Belt ........................................................................................................................................... 205
Controls ............................................................................................................................................. 206
Engine
General ............................................................................................................................................. 207
Oil ...................................................................................................................................................... 207
Drive Belt .......................................................................................................................................... 209
Air Filter
General ............................................................................................................................................. 210
Pre-Cleaner ....................................................................................................................................... 210
Dust Valve ........................................................................................................................................ 210
Fuel System
General ............................................................................................................................................. 211
Tank .................................................................................................................................................. 211
Fuel Filter .......................................................................................................................................... 212
Water Separator ............................................................................................................................... 213
Cooling System
General ............................................................................................................................................. 215
Coolant .............................................................................................................................................. 215
Cooling Pack .................................................................................................................................... 216
Tracks
General ............................................................................................................................................. 217
Steel .................................................................................................................................................. 218
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Table of Contents
vi 9831/5600-1 vi
Idler Wheels ...................................................................................................................................... 219
Rollers ............................................................................................................................................... 219
Track Gearbox
Oil ...................................................................................................................................................... 220
Hydraulic System
General ............................................................................................................................................. 221
Services ............................................................................................................................................ 222
Oil ...................................................................................................................................................... 222
Cylinders / Rams .............................................................................................................................. 223
Electrical System
General ............................................................................................................................................. 224
Battery ............................................................................................................................................... 225
Battery Isolator ................................................................................................................................. 226
Fuses ................................................................................................................................................ 226
Relays ............................................................................................................................................... 227
Window Washer ................................................................................................................................ 228
Miscellaneous
Fire Extinguisher ............................................................................................................................... 229
Technical Data
Static Dimensions
General .............................................................................................................................................. 231
Dimensions ........................................................................................................................................ 231
Weights ............................................................................................................................................. 234
Visibility Diagrams ............................................................................................................................. 237
Performance Dimensions
Driving Performance ......................................................................................................................... 241
Noise Emissions
Noise Data ........................................................................................................................................ 242
Vibration Emissions
Vibration Data ................................................................................................................................... 243
Fluids, Lubricants and Capacities
General .............................................................................................................................................. 244
Fuel ................................................................................................................................................... 244
Coolant .............................................................................................................................................. 248
Torque Values
General .............................................................................................................................................. 249
Electrical System
General .............................................................................................................................................. 254
Fuses ................................................................................................................................................. 254
Relays ............................................................................................................................................... 256
Engine
Engine Emissions ............................................................................................................................. 258
Tracks
General .............................................................................................................................................. 259
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Table of Contents
vii 9831/5600-1 vii
Acronyms Glossary
ARV Auxiliary Relief Valve
DECU Display Electronic Control Unit
ECM Engine Control Module
ECU Electronic Control Unit
EGR Exhaust Gas Recirculation
FOGS Falling Object Guard System
FOPS Falling Object Protective Structure
HVAC Heating Ventilation Air Conditioning
ISO International Organization for Standardization
LED Light Emitting Diode
PPE Personal Protective Equipment
ROPS Roll-Over Protective Structure
SWL Safe Working Load
TOPS Tip-Over Protective Structure
VGT Variable Geometry Turbocharger
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