JCB JS130W,JS145W,JS160W,JS175W,JS200W-Operator Handbook

Operator Handbook JS130W, JS145W, JS160W, JS175W, JS200W ! THIS HANDBOOK MUST BE KEPT IN THE MACHINE AT ALL TIMES ! Publication Number 9801/6980 Nov 01 Issue 4 Purchased from www.WorkshopManuals.co.uk www.maskinisten.net

Purchased from www.WorkshopManuals.co.uk ww .maskinisten.net

! WARNING Study this Handbook Before Starting the Machine You must understand and follow the instructions in this handbook. You must observe all relevant laws and regulations. If you are unsure about anything, ask your JCB Distributor or employer. Do not guess, you or others could be killed or seriously injured. INT-1-1-1 6980-1 SAFETY NOTICES In this handbook and on the machine there are safety notices. Each notice starts with a signal word. The meanings of the signal words are given below. !DANGER Denotes an extreme hazard exists. If proper precautions are not taken, it is highly probable that the operator (or others) could be killed or seriously injured. INT-1-2-1 !WARNING Denotes a hazard exists. If proper precautions are not taken, the operator (or others) could be killed or seriously injured. INT-1-2-2 !CAUTION Denotes a reminder of safety practices. Failure to follow these safety practices could result in injury to the operator (or others) and possible damage to the machine. INT-1-2-3 MACHINE SECURITY Vandalism and theft of unattended machines is an ever increasing problem and JCB is doing everything possible to help combat this. JCB PLANTGUARD is a comprehensive package available to help you safeguard your machine. It includes such devices as vandal proof covers, window etching, immobiliser, concealed serial number, battery isolator, Tracker security system and much more. Remember that the fitting of any one of these security devices will help to minimise not only the damage or loss of your machine but also subsequent lost productivity. It could also result in reduced insurance premiums. Your JCB Distributor or Dealer will be pleased to provide information on any of these sensible precautions. ACT NOW! INT-1-2-4 i i Purchased from www.WorkshopManuals.co.uk ww .maskinisten.net

SAFETY NOTICES ! CAUTION A wide range of optional attachments is available to increase the versatility of your machine. Only JCB approved attachments are recommended for use with your machine. Consult your JCB Distributor for the full list of approved attachments available. JCB attachments are designed and manufactured specifically to suit the machine’s hydraulic system, mounting arrangements and safe load requirements. Attachments which are not designed for use with this machine may cause damage and create safety hazards for which JCB cannot be held responsible. In addition the machine’s warranty, “CE” and other legislative compliance may be affected by the use of non- JCB approved attachments. 2-4-1-13/2 ! CAUTION This machine is manufactured in compliance with legislative and other requirements. It should not be altered in any way which could affect or invalidate any of these requirements. For advice consult your JCB Distributor. Reference should also be made to Optional Attachments section where appropriate. INT-1-3-10 6980-1 ii ii Purchased from www.WorkshopManuals.co.uk ww .maskinisten.net

iii iii CONTENTS INTRODUCTION About this Handbook Machine Description 1 Machine and Serial Numbers 1 Using this Handbook 1 Left and Right Hand Convention 1 Units of Measurement. 1 Service Contract 1 Safety First - Yours and Other People's 2 Safety First - Check List General Safety 2 Operating Safety 3 Maintenance Safety 4 Safety Decals 6 Identifying Your Machine 8 OPERATION Introduction 21 Before Entering the Cab 21 Entering and Leaving the Cab 22 Cab Door Opening/Closing the Door 23 Cab Windows Opening/Closing the Upper Front Window 24 Opening and Closing the Lower Front Window 25 Emergency Exit 25 Opening/Closing the Sunblind 25 Adjusting the Seat 26 Adjusting the Steering Column 27 Seat Belt Fasten the Seatbelt 27 Release the Seatbelt 27 Adjusting the Seatbelt 27 Heater Controls 28 Heater/Air Conditioning Controls 28 Cab Radio 29 Cab Layout JS130W/JS145W/JS160W/JS175W 30 JS 200W 31 Switches and Controls Right Console 32 Lightswitch Panel 34 Left Console 35 Left Console Switch Panel 36 Cab Light Switch 37 Multipurpose Steering Column Switch 38 Monitor Panel 39 Facia Panel 43 Redundancy Back-up Switch 44 Mechanical engine RPM Override 44 Servo Controls Immobilisation 45 Driving Controls Steering Wheel 46 Speed Controls 46 Travel Pedal 46 Foot Brake Pedal 47 Excavating Controls Excavating 48 Operation 48 Boom and Bucket 49 Superstructure and Dipper 50 Other Controls Horn Button 51 One Touch Idle Switch 51 Slew Lock Lever 51 Triple Articulated Boom Position Ram (if fitted) 52 Dozer Blade (if fitted) 52 Stabilisers (if fitted) 53 Attachments Control 54 Preparing for Road Travel 55 Using your Machine Before Starting the Engine 57 Starting the Engine 58 Stopping the Engine 59 Emergency Stopping the Engine 59 Parking the Machine 60 Jump Starting the Engine 61 Manual Engine Warm-up After Starting 62 Warming-up Procedure 62 Cold Climate Warm-up 62 Stopping the Engine Routine Stopping 63 Stopping Following Overheating 63 Operating Precautions In Low Temperatures 64 In High Temperatures 64 In Dusty or Sandy Areas 64 In Coastal Regions 64 6980-2 Purchased from www.WorkshopManuals.co.uk ww .maskinisten.net

iv iv CONTENTS Cleaning the Machine 88 Checking for Damage 88 Seat Belt Checking the Seat Belt Condition and Security 88 Greasing Slew Ring Teeth and Slew Pinion 89 Slew Ring Bearing 89 Greasing (50 hours) 90 Greasing (General) 92 Tyres and Wheels Tyre Inflation 93 Checking the Wheel Nut Torques 93 Engine Air Filter Changing the Outer Element 94 Changing the Inner Element 95 Engine Oil and Filter Checking the Oil Level 96 Changing the Oil and Filter 96 Engine Cooling System Checking the Coolant Level 97 Coolant Mixtures 97 Changing the Coolant 98 Cleaning the Radiator and Oil Cooler 98 Adjusting the Fan Belt 99 Fitting a New Fan Belt 99 Fuel System Types of Fuel 100 Filling the Tank 100 Draining Fuel Tank Impurities 101 Draining the Water Separator 101 Cleaning the Water Separator 101 Changing the Filter Element 102 Cleaning the Lift Pump Strainer 102 Bleeding the Fuel System 103 Hydraulic System Checking the Fluid Level 104 Releasing Tank Pressure 104 Topping-up Fluid Level 104 Changing the Fluid 105 Changing the Return Filter Element 106 Cleaning/Changing the Suction Strainer 106 Changing the Nephron Filter 107 Changing the Air Breather Element 108 Draining Tank Impurities 108 Changing the Servo Oil Filter 109 Changing the Drain Line Filter Element 110 Changing the Steering Line Filter Element 110 Changing the Breaker In-line Filter (if fitted) 111 Air Bleeding Procedures 112 6980-1 Transporting the Machine 65 Using your Machine and Site Safety 67 Installing a Bucket 69 Removing a Bucket 70 Connecting Hydraulic Hoses 71 Bucket Teeth 72 Removing Bucket Teeth 73 Fitting Bucket Teeth 73 Digging 74 Digging Near Walls 75 Digging on Slopes 75 Dumping into a Truck 75 Backfilling (with bucket) 75 Dozing/Grading (with bucket) 75 Scraping and Cutting (with bucket) 75 Backfilling (with blade) 75 Dozing/Grading (with blade) 75 Scraping and Cutting (with blade) 75 Lifting 76 Overload Warning System 77 Pulling Out From Soft Ground 77 Refuelling Fuel Level 78 Filling the Tank 78 Refuelling Pump (optional) 78 Storage 79 Towing a Disabled Machine 80 MAINTENANCE Service Contracts 81 Regular Maintenance and Lubrication Schedules Initial Precautions for New Machine Usage 81 Every 10 Operating Hours or Daily 82 Every 50 Operating Hours or Weekly 82 Every 100 Operating Hours or 2-Weekly 83 Every 250 Operating Hours or Monthly 83 Every 500 Operating Hours or 3-Monthly 84 Every 1000 Operating Hours or 6-Monthly 84 Every 2000 Operating Hours or Yearly 84 Every 4000 Operating Hours or 2 Years 85 Every 5000 Operating Hours or 2 Years 6 Months 85 Revised Service Schedules - Rockbreaker Usage 86 Lubricants - Health and Safety First Aid - Oil 87 Hygiene 87 Storage 87 Handling 87 Waste Disposal 87 Spillage 87 Purchased from www.WorkshopManuals.co.uk ww .maskinisten.net

v v CONTENTS Gearboxes Checking the Slew Gearbox Oil Level 114 Changing the Slew Gearbox Oil 114 Slew Gearbox Grease 114 Checking the Drive Gearbox Oil Level 115 Changing the Drive Gearbox Oil 115 Front Axle - JS130W/JS145W/JS160W/JS175W Checking the Differential Oil Level 116 Changing the Differential Oil 116 Checking the Hub Oil Level 117 Changing the Hub Oil 117 Rear Axle - JS130W/JS145W/JS160W/JS175W Checking the Differential/Hub Oil Level 118 Changing the Differential/Hub Oil 118 Front Axle - JS200W Checking the Differential Oil Level 119 Changing the Differential Oil 119 Checking the Hub Oil Level 120 Changing the Hub Oil 120 Rear Axle - JS200W Checking the Differential/Hub Oil Level 121 Changing the Differential/Hub Oil 121 Electrical System Fuses 122 Battery First Aid - Electrolyte 123 Checking the Electrolyte Level 123 Warning Symbols 124 Battery Disconnection/Replacement 125 Terminal Cleaning 125 Windscreen Washer 126 Obtaining Replacement Parts 126 Lubricants and Capacities 127 Component Location Diagrams 129 SPECIFICATIONS Lifting (Craning) Regulations and Safe Working Loads 141 Static Dimensions JS130W/JS145W 142 JS160W/JS175W 143 JS200W 144 Shipping Weight 145 Tyre Pressures 146 Dig Depth Chart JS130W/JS145W 147 JS160W/JS175W 148 JS200W 149 Noise and Vibration Data 150 6980-2 Purchased from www.WorkshopManuals.co.uk ww .maskinisten.net

Purchased from www.WorkshopManuals.co.uk ww .maskinisten.net

1 1 INTRODUCTION ABOUT THIS HANDBOOK Machine Description JS130W JS160W and JS200W are self-propelled wheeled excavators with an upper structure capable of 360° rotation. They excavate, elevate, swing and discharge material by the action of a bucket fitted to the boom and dipper, without moving the chassis during any part of the working cycle of the machine. Machine and Serial Numbers This handbook covers the following machines: JS130W from machine serial number 716500 JS145W from machine serial number 810000 JS160W from machine serial number 718500 JS175W from machine serial number 875000 JS200W from machine serial number 809000 The machines are available with either a monoboom or a triple articulating boom. Using this Handbook The illustrations in this handbook are for guidance only. Where the machines differ, the text and/or the illustration will specify. This handbook is arranged to give you a good understanding of the machine and its safe operation. It also contains maintenance information and specification data. Read this handbook from front to back before using the machine for the first time. Particular attention must be given to all the safety aspects of operating and maintaining the machine. General warnings in this chapter are repeated throughout the book, as well as specific warnings. Read all the safety statements regularly, so you do not forget them. Remember that the best operators are the safest operators. Finally, treat this handbook as part of the machine. Keep it clean and in good condition. Do not operate the machine without a handbook in the cab. If there is anything you are not sure about, ask your JCB distributor or employer. Do not guess, you or others could be killed or seriously injured. 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 publication. INT-1-2-5/1 Left and Right Hand Convention In this handbook, left and right refer to the left and right when you are correctly seated in the machine, with the superstructure facing the correct way, i.e. with the non- pivoting axle to the rear. Units of Measurement In this handbook, the units of measurement are metric with imperial following in brackets, e.g. 10 mm (0.4 in). Service Contract In order to keep your machine working efficiently, it is essential that it is properly and regularly maintained in accordance with the service schedules included in this handbook. Your distributor will already have discussed your service requirements. When the distributor service has been completed, you are strongly advised to take advantage of a regular service contract. 6980-2 Purchased from www.WorkshopManuals.co.uk ww .maskinisten.net

Do not start any job until you are sure that you and those around you will be safe. If you are unsure of anything, about the machine or the job, ask someone who knows. Do not assume anything. Remember BE CAREFUL BE ALERT BE SAFE INT-1-3-1/1 ! WARNING 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. INT-1-3-5 ! WARNING Clothing You can be injured if you do not wear the proper clothing. Loose clothing can get caught in the machinery. Wear protective clothing to suit the job. Examples of protective clothing are: a hard hat, safety shoes, safety glasses, a well fitting overall, ear-protectors and industrial gloves. Keep cuffs fastened. Do not wear a necktie or scarf. Keep long hair restrained. INT-1-3-6 ! WARNING Lifting Equipment You can be injured if you use faulty lifting equipment. Make sure that lifting equipment is in good condition. Make sure that lifting tackle complies with all local regulations and is suitable for the job. Make sure that lifting equipment is strong enough for the job. INT-1-3-7 All construction equipment can be hazardous. When a Wheeled Excavator is correctly operated and properly maintained, it is a safe machine to work with. But when it is carelessly operated or poorly maintained it can become a danger to you (the operator) and others. In this handbook and on the machine you will find warning messages. Read and understand them. They tell you of potential hazards and how to avoid them. If you do not understand the warning messages, ask your employer or JCB distributor to explain them. But 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 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. General Safety ! WARNING Handbook You and others can be injured if you operate or maintain the machine without first studying this handbook. Read the safety instructions before operating the machine. If you do not understand anything, ask your employer or JCB distributor to explain it. Keep this handbook clean and in good condition. Do not operate the machine without a handbook in the cab, or if there is anything on the machine you do not understand. INT-1-3-2 ! CAUTION Regulations Obey all laws, work site and local regulations which affect you and your machine. INT-1-3-3 ! WARNING Decals You can be injured if you do not obey the decal safety instructions. Keep decals clean. Replace unreadable or missing decals with new ones before operating the machine. Make sure replacement parts include warning decals where necessary. INT-1-3-4 ! WARNING Airborne particles of light combustible material such as straw, grass, wood shavings, etc. must not be allowed to accumulate within the engine compartment or in the propshaft guards (when fitted). Please inspect these areas frequently and clean at the beginning of each work shift or more often if required. Before opening the engine cover, ensure that the top is clear of debris. 5-3-1-12/2 2 2 INTRODUCTION SAFETY FIRST - YOURS AND OTHER PEOPLES SAFETY CHECK LIST 6890-1 Purchased from www.WorkshopManuals.co.uk ww .maskinisten.net

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JCB JS130W,JS145W,JS160W,JS175W,JS200W-Operator Handbook

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