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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Notes:
viii 9831/5600-1 viii

Introduction
About this Manual
1 9831/5600-1 1
Introduction
About this Manual
Model and Serial Number
This manual provides information for the following model(s) in the JCB machine range:
Model From: To:
2451101 2451200JS210
2460501 2460600
2451101 2451200JS220
2460501 2460600
2451101 2451200JS235
2460501 2460600
Using the Manual
This operator's manual is arranged to give you a good understanding of the machine and its safe operation.
It also contains maintenance and technical data.
Read this manual from the front to the back before you use the machine for the first time, even if you have used
machines of a similar/same type before as the technical specification, systems and controls of the machine
may have changed. Particular attention must be given to all the safety aspects of operating and maintaining
the machine.
If there is anything you are not sure about, ask your JCB dealer or employer. Do not guess, you or others could
be killed or seriously injured.
The general and specific warnings in this section are repeated throughout the manual. Read all the safety
statements regularly, so you do not forget them. Remember that the best operators are the safest operators.
The illustrations in this manual are for guidance only. Where the machines are different, the text and or the
illustration will specify.
The manufacturer's policy is one of continuous improvement. The right to change the specification of the
machine without notice is reserved. No responsibility will be accepted for discrepancies which may occur
between specifications of the machine and the descriptions contained in this manual.
All of the optional equipment included in this manual may not be available in all territories
Left-Hand Side, Right-Hand Side
In this manual, 'left' and 'right' mean your left and right when you are seated correctly in the machine.
Figure 1.
B
A
ALeft BRight

Introduction
About this Manual
2 9831/5600-1 2
Cross References
In this manual, cross references are made by presenting the subject title in blue (electronic copy only). The
number of the page upon which the subject begins is indicated within the brackets. For example: Refer to:
Cross References (Page 2).

Introduction
Safety
3 9831/5600-1 3
Safety
Safety - Yours and Others
All machinery can be hazardous. When a machine is correctly operated and maintained, it is a safe machine
to work with. When it is carelessly operated or poorly maintained it can become a danger to you (the operator)
and others.
In this manual and on the machine you will find warning messages, read and understand them. They inform
you of potential hazards and how to avoid them. If you do not fully understand the warning messages, ask your
employer or JCB dealer to explain them.
Safety is not just a matter of responding to the warnings. All the time you are working on or with the machine
you must be thinking of what hazards there might be and how to avoid them.
Do not work with the machine until you are sure that you can control it.
Do not start any work until you are sure that you and those around you will be safe.
If you are not sure of anything, about the machine or the work, ask someone who knows. Do not assume
anything.
Remember:
• Be careful
• Be alert
• Be safe.
Safety Warnings
In this manual and on the machine, there are safety notices. Each notice starts with a signal word. The signal
word meanings are given below.
The signal word 'DANGER' indicates a hazardous situation which, if not avoided, will result in death or serious
injury.
The signal word 'WARNING' indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
The signal word 'CAUTION' indicates a hazardous situation which, if not avoided, could result in minor or
moderate injury.
The signal word 'Notice' indicates a hazardous situation which, if not avoided, could result in machine damage.
The safety alert system (shown) also helps to identify important safety messages in this manual and on the
machine. When you see this symbol, be alert, your safety is involved, carefully read the message that follows,
and inform other operators.
Figure 2. The safety alert system

Introduction
Safety
4 9831/5600-1 4
General Safety
Training
To operate the machine safely you must know the machine and have the skill to use it. You must abide by
all relevant laws, health and safety regulations that apply to the country you are operating in. The operator's
manual instructs you on the machine, its controls and its safe operation; it is not a training manual. If you are a
new operator, get yourself trained in the skills of using a machine before trying to work with it. If you don't, you
will not do your job well, and you will be a danger to yourself and others. In some markets and for work on certain
jobsites you may be required to have been trained and assessed in accordance with an operator competence
scheme. Make sure that you and your machine comply with relevant local laws and jobsite requirements - it
is your responsibility.
Care and Alertness
All the time you are working with or on the machine, take care and stay alert. Always be careful. Always be
alert for hazards.
Clothing
You can be injured if you do not wear the correct clothing. Loose clothing can get caught in the machinery.
Keep cuffs fastened. Do not wear a necktie or scarf. Keep long hair restrained. Remove rings, watches and
personal jewellery.
Alcohol and Drugs
It is extremely dangerous to operate machinery when under the influence of alcohol or drugs. Do not consume
alcoholic drinks or take drugs before or while operating the machine or attachments. Be aware of medicines
which can cause drowsiness.
Feeling Unwell
Do not attempt to operate the machine if you are feeling unwell. By doing so you could be a danger to yourself
and those you work with.
Mobile Phones
Switch off your mobile phone before entering an area with a potentially explosive atmosphere. Sparks in such
an area could cause an explosion or fire resulting in death or serious injury.
Switch off and do not use your mobile phone when refuelling the machine.
Lifting Equipment
You can be injured if you use incorrect or faulty lifting equipment. You must identify the weight of the item to
be lifted then choose lifting equipment that is strong enough and suitable for the job. Make sure that lifting
equipment is in good condition and complies with all local regulations.
Raised Equipment
Never walk or work under raised equipment unless it is supported by a mechanical device. Equipment which
is supported only by a hydraulic device can drop and injure you if the hydraulic system fails or if the control
is operated (even with the engine stopped).
Make sure that no-one goes near the machine while you install or remove the mechanical device.
Raised Machine
Never position yourself or any part of your body under a raised machine which is not correctly supported. If the
machine moves unexpectedly you could become trapped and suffer serious injury or be killed.
Lightning
Lightning can kill you. Do not use the machine if there is lightning in your area.
Machine Modifications
This machine is manufactured in compliance with prevailing legislative requirements. It must not be altered in
any way which could affect or invalidate its compliance. For advice consult your JCB dealer.

Introduction
Safety
5 9831/5600-1 5
Clothing and Personal Protective Equipment (PPE)
Do not wear loose clothing or jewellery that can get caught on controls or moving parts. Wear protective clothing
and personal safety equipment issued or called for by the job conditions, local regulations or as specified by
your employer.

Notes:
6 9831/5600-1 6

About the Product
Introduction
7 9831/5600-1 7
About the Product
Introduction
General
Before you start using the machine, you must know how the machine operates. Use this part of the manual
to identify each control lever, switch, gauge, button and pedal. Do not guess, if there is anything you do not
understand, ask your JCB dealer.
Name and Address of the Manufacturer
Av. Joseph Cyril Bamford, Éden, Km 86,5 Castelo Branco - Rodovia Presidente Castelo Branco, 3600, SP,
18103-139, Brazil
Product Compliance
Your JCB product was designed to comply with the laws and regulations applicable at the time of its manufacture
for the market in which it was first sold. In many markets, laws and regulations exist that require the owner to
maintain the product at a level of compliance relevant to the product when first produced. Even in the absence
of defined requirements for the product owner, JCB recommend that the product compliance be maintained
to ensure safety of the operator and exposed persons and to ensure the correct environmental performance.
Your product must not be altered in any way which could affect or invalidate any of these requirements. For
advice consult your JCB dealer.
For its compliance as a new product, your JCB and some of its components may bear approval numbers
and marking's, and may have been supplied with a Declaration/Certificate of Conformity. These marking's and
documents are relevant only for the country/region in which the product was first sold to the extent that the
laws and regulations required them.
Re-sales and import/export of products across territories with different laws and regulations can cause new
requirements to become relevant for which the product was not originally designed or specified. In some cases,
pre owned products irrespective of their age are considered new for the purposes of compliance and may be
required to meet the latest requirements which could present an insurmountable barrier to their sale/use.
Despite the presence of any compliance related marking's on the product and components, you should not
assume that compliance in a new market will be possible. In many cases it is the person responsible for import
of a pre owned product into a market that becomes responsible for compliance and who is also considered
the manufacturer.
JCB may be unable to support any product compliance related enquiry for a product which has been moved out
of the legislative country/region where it was first sold, and in particular where a product specification change
or additional certification would have been required in order for the product to be in compliance.

About the Product
Description
8 9831/5600-1 8
Description
General
The JCB Tracked Excavator is a self propelled machine with a tracked undercarriage and a revolving upper
structure which has a boom, dipper, bucket and swing mechanism.
The excavator is mainly used to dig below ground level with bucket motions towards the machine. The upper
structure can slew 360° and discharge material when the tracked undercarriage is stationary.
Intended Use
The machine is intended to be used in normal conditions for the applications and in the environmental conditions
as described in this manual.
When used normally with a bucket fitted to the machine the work cycle consists of, digging, elevating, slewing
and the discharging of material without movement of the undercarriage.
Applications include earthmoving, road construction, building and construction, landscaping and similar
applications.
An excavator can also be used for object handling if it is suitably equipped with relevant parts and systems.
Refer to: Lifting and Loading (Page 107).
The machine must not be used in the following scenarios because of the risk of overturning; used for forestry,
used with attachments of unknown weight, used on surfaces of unknown stability. This list is not exhaustive.
If the machine is to be used in applications where there is a high silica concentration, risk due to materials
containing asbestos or similar hazards, additional protective measures such as the use of PPE (Personal
Protective Equipment) may be required.
The machine should not be operated by any person who does not have an appropriate level of qualification,
training or experience of use of this type of machine.
Prior to use of the machine, its suitability (size, performance, specification etc.) should be considered with
regards to the intended application and any relevant hazards that may exist. Contact your JCB dealer for
support in determining the appropriate JCB machine, attachment and any optional equipment that is suitable
for the application and environment.
Log Moving/Object Handling
Do not use the machine to move or handle logs unless sufficient log protection is installed. You could cause
serious injury to yourself and damage to the machine. For more information, contact your JCB dealer.
Optional Equipment and Attachments
A wide range of optional attachments are available to increase the versatility of your machine. Only the JCB
approved attachments are recommended for use with your machine. Contact your JCB dealer for the full list
of approved attachments available.
Danger Zone
The danger zone is any zone within and/or around the machinery in which a person is subject to a risk to their
health or safety. The danger zone includes the area in immediate proximity to any hazardous moving parts,
areas into which working equipment and attachments can be moved to quickly, the machine normal stopping
distances and also areas into which the machine can quickly turn under normal conditions of use. Depending
on the application at the time, the danger zone could also include the area into which debris, from use of an
attachment or working tool, could be projected and any area into which debris could fall from the machine.
During the operation of the machine, keep all persons out of the danger zone. Persons in the danger zone
could be injured.
Before you do a maintenance task, make the product safe.

About the Product
Description
9 9831/5600-1 9
Main Component Locations
Figure 3.
D
CB
A
E
F
GH
J
K
L
ABucket BBucket link
CBucket ram DDipper
EDipper link FDipper ram
GBoom HBoom ram
JOperators cab KCounterweight
LUndercarriage
The boom dipper and bucket are collectively referred to as the excavator end, or dig end.