JCB JS460, JS500 Tier 2 Operator Manual 9821-3600

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JCB JS460, JS500 Tier 2 Operator Manual 9821-3600 - Image 5

jcb js460 js500 tier 2 operator manual 9821 3600 2

jcb js460 js500 tier 2 operator manual 9821 3600 3

JCB JS460, JS500 Tier 2 Operator Manual 9821-3600

$20.00

Type Of Manual: Operator Manual
ManualID: 9821-3600
Number of Pages: 222
Size: 18.7MB
Format: PDF

Category: JCB Operator Manual PDF

Model List:
- JS460, JS500 Tier 2

1. Safety Notices
2. Important Information ………………………………………………………………………..vii
3. The Operator Manual ……………………………………………………………………vii
4. Safety Warnings …………………………………………………………………………..vii
5. Introduction
6. About this Manual ………………………………………………………………………………1
7. Machine Model and Serial Number ………………………………………………….1
8. Using this Manual ………………………………………………………………………….1
9. Left Side, Right Side ………………………………………………………………………1
10. Cross References ………………………………………………………………………….1
11. Machine Description …………………………………………………………………………..3
12. The JCB Tracked Excavator ……………………………………………………………3
13. Intended Use ………………………………………………………………………………..3
14. Component Location ……………………………………………………………………..4
15. Safety Check List ……………………………………………………………………………….6
16. Safety – Yours and Others ………………………………………………………………6
17. General Safety ……………………………………………………………………………..6
18. Operating Safety …………………………………………………………………………..8
19. Maintenance Safety …………………………………………………………………….. 11
20. Safety Labels …………………………………………………………………………………..16
21. Introduction …………………………………………………………………………………16
22. Safety Label Identification …………………………………………………………….17
23. Identifying Your Machine …………………………………………………………………..21
24. Machine Identification Plate ………………………………………………………….21
25. Typical Product Identification Number …………………………………………….21
26. Component Identification Plates …………………………………………………….22
27. Machine Security ……………………………………………………………………………..24
28. Introduction …………………………………………………………………………………24
29. JCB Plantguard …………………………………………………………………………..24
30. Construction Equipment Security And Registration Scheme (CESAR) .24
31. LiveLink ……………………………………………………………………………………..24
32. Immobiliser …………………………………………………………………………………24
33. Operation
34. Introduction ……………………………………………………………………………………..25
35. Before Entering the Cab ……………………………………………………………………26
36. Entering and Leaving the Cab ……………………………………………………………27
37. Standard Cab Machines ……………………………………………………………….27
38. Emergency Exit …………………………………………………………………………..28
39. Doors and Windows …………………………………………………………………………29
40. Opening and Closing the Door ………………………………………………………29
41. Opening and Closing the Front Upper Window ………………………………..29
42. Opening and Closing The Front Lower Window ……………………………….30
43. Door Sliding Window ……………………………………………………………………31
44. Opening and Closing the Sunblind …………………………………………………31
45. Access to the Upper Structure ……………………………………………………………33
46. Standard Machines ………………………………………………………………………33
47. Seat Controls …………………………………………………………………………………..34
48. Introduction …………………………………………………………………………………34
49. Operators Seat-Console ……………………………………………………………….34
50. Operators Seat – Standard-Heated …………………………………………………34
51. Air Suspension Seat …………………………………………………………………….35
52. Seat Belts (if fitted) …………………………………………………………………………..36
53. Static Seat Belt ……………………………………………………………………………36
54. Visibility Aids ……………………………………………………………………………………37
55. Mirrors ……………………………………………………………………………………….37
56. Cab Layout ……………………………………………………………………………………..40
57. Components Key …………………………………………………………………………40
58. Drive Controls, Switches and Instruments ……………………………………………42
59. Drive Controls ……………………………………………………………………………..42
60. Switches …………………………………………………………………………………….43
61. Instruments …………………………………………………………………………………49
62. Heater-Air Conditioning Controls ……………………………………………………54
63. Operating Levers-Pedals …………………………………………………………………..55
64. Excavating Controls …………………………………………………………………….55
65. Travel Speed Change Button ………………………………………………………..59
66. Operation Levers …………………………………………………………………………60
67. Optional Circuit Pedal (if fitted) ………………………………………………………61
68. ISO Operating Method …………………………………………………………………61
69. Safety Equipment …………………………………………………………………………….62
70. Control Locks ……………………………………………………………………………..62
71. Dipper Stroke Limiter (If fitted) ……………………………………………………….63
72. Overload Warning System …………………………………………………………….65
73. Before Starting the Engine …………………………………………………………………66
74. Starting the Engine …………………………………………………………………………..67
75. Warming-Up ……………………………………………………………………………….68
76. JCB Immobiliser System ………………………………………………………………68
77. Getting the Machine Moving ………………………………………………………………71
78. Stopping and Parking the Machine ……………………………………………………..72
79. Stopping and Parking …………………………………………………………………..72
80. Engine Shutdown ………………………………………………………………………..72
81. Working with your Machine ……………………………………………………………….73
82. Operating Practices and Site Safety ………………………………………………73
83. Clothing and Safety Equipment ……………………………………………………..73
84. Danger Zone ………………………………………………………………………………73
85. Log Moving-Handling ……………………………………………………………………73
86. Safety Practices ………………………………………………………………………….73
87. Working With the Excavator ………………………………………………………….75
88. Lifting (Object Handling) ……………………………………………………………….82
89. Use of Machines on Gradients and Slopes ……………………………………..85
90. Getting Out of Soft Ground ……………………………………………………………88
91. Water …………………………………………………………………………………………89
92. Towing Other Equipment ………………………………………………………………89
93. Machine Stability …………………………………………………………………………90
94. Reducing Wear ……………………………………………………………………………91
95. Operating Environment ……………………………………………………………………..94
96. Maintenance in Cold Climates ……………………………………………………….94
97. Operating in a Cold Climate (Below 0°C) ………………………………………..94
98. Operating in a Hot Climate (Above 35°C) ……………………………………….94
99. Operating in Dusty or Sandy Areas ………………………………………………..95
100. Operating in Coastal Regions ……………………………………………………….95
101. Operating on Wet or Soft Ground …………………………………………………..95
102. Cab Filters ………………………………………………………………………………….95
103. Refuelling the Machine ……………………………………………………………………..96
104. Low Fuel Levels ………………………………………………………………………….96
105. Filling the Tank ……………………………………………………………………………96
106. Fuel Level …………………………………………………………………………………..97
107. Refuelling Pump ………………………………………………………………………….98
108. Moving a Disabled Machine ………………………………………………………………99
109. Lowering the Boom in an Emergency …………………………………………….99
110. Retrieval …………………………………………………………………………………….99
111. Limp Mode ………………………………………………………………………………..100
112. Mechanical Engine RPM Override ……………………………………………….100
113. Transporting the Machine ………………………………………………………………..101
114. Lifting the Machine …………………………………………………………………………104
115. Storage of the Machine …………………………………………………………………..106
116. Introduction ……………………………………………………………………………….106
117. Storage Area …………………………………………………………………………….106
118. Prepare the Machine for Storage …………………………………………………106
119. Put the Machine into Storage ………………………………………………………106
120. During Storage ………………………………………………………………………….106
121. Take the Machine Out of Storage …………………………………………………107
122. Anti-Vandalism Guards (option) ………………………………………………………..108
123. Unpacking the Guards ………………………………………………………………..108
124. Fitting the Guards ………………………………………………………………………108
125. Removing the Guards ………………………………………………………………..109
126. Storing the Guards …………………………………………………………………….109
127. Routine Maintenance
128. Service Requirements ……………………………………………………………………. 111
129. Introduction ………………………………………………………………………………. 111
130. Owner-Operator Support ……………………………………………………………. 111
131. Service-Maintenance Agreements ………………………………………………. 111
132. Fit for Purpose Tests for Lifting Equipment ……………………………………. 112
133. Obtaining Replacement Parts ……………………………………………………… 112
134. Health and Safety ………………………………………………………………………….. 113
135. Lubricants ………………………………………………………………………………… 113
136. Battery …………………………………………………………………………………….. 115
137. Service Schedules …………………………………………………………………………. 117
138. Introduction ………………………………………………………………………………. 117
139. How to Use the Service Schedules ……………………………………………… 117
140. Calendar Equivalents ………………………………………………………………… 117
141. Pre Start Cold Checks, Service Points and Fluid Levels …………………. 118
142. Functional Test and Final Inspection …………………………………………….122
143. Service Intervals for Attachments …………………………………………………124
144. Periodic Replacement of Safety Related Components ……………………125
145. Fluids, Lubricants and Capacities ……………………………………………………..126
146. Specifications ……………………………………………………………………………126
147. Typical Lubrication Chart …………………………………………………………….127
148. Coolant Mixtures ……………………………………………………………………….128
149. Fuel …………………………………………………………………………………………129
150. Tools …………………………………………………………………………………………….132
151. Carrying Tools onto the Machine ………………………………………………….132
152. Location ……………………………………………………………………………………132
153. Prepare the Machine for Maintenance ………………………………………………133
154. Introduction ……………………………………………………………………………….133
155. How to Make the Machine Safe (Excavator Lowered) …………………….133
156. Cleaning the Machine ……………………………………………………………………..134
157. Introduction ……………………………………………………………………………….134
158. Preparing the Machine for Cleaning ……………………………………………..134
159. Cleaning the Machine …………………………………………………………………135
160. Cleaning the Tracks ……………………………………………………………………135
161. Cleaning the Radiator and Oil Cooler ……………………………………………135
162. Checking for Damage ……………………………………………………………………..136
163. Check the Machine Body and Structure ………………………………………..136
164. Check the Seat and Seat Belt ……………………………………………………..136
165. Check the Tyres ………………………………………………………………………..136
166. Check the Electrical Circuits ………………………………………………………..136
167. Checking the FOPS Structure ……………………………………………………..137
168. Daily Checking ……………………………………………………………………………….139
169. Greasing ……………………………………………………………………………………….141
170. Introduction ……………………………………………………………………………….141
171. Slew Ring Bearing ……………………………………………………………………..141
172. Slew Ring Teeth and Slew Pinion …………………………………………………141
173. Greasing Points …………………………………………………………………………142
174. Electrical System ……………………………………………………………………………144
175. Battery ……………………………………………………………………………………..144
176. Jump-Starting the Engine ……………………………………………………………148
177. Fuses – Cab ………………………………………………………………………………149
178. Fuses and Relays – Battery Compartment …………………………………….150
179. Bolt and Nut Torque Specifications ……………………………………………………151
180. JS460, JS500 (fixed undercarriage) ……………………………………………..151
181. Engine ………………………………………………………………………………………….154
182. Oil and Filter ……………………………………………………………………………..154
183. Cooling System …………………………………………………………………………155
184. Fan Belt ……………………………………………………………………………………156
185. Engine Air Filter …………………………………………………………………………157
186. Fuel System …………………………………………………………………………………..159
187. Introduction ……………………………………………………………………………….159
188. Draining the Impurities from the Fuel Tank …………………………………….159
189. Draining the Primary Filter-Sedimenters ……………………………………….160
190. Changing the Primary Filter-Sedimenter Element …………………………..160
191. Bleeding the System ………………………………………………………………….161
192. Hydraulic System ……………………………………………………………………………162
193. Introduction ……………………………………………………………………………….162
194. Releasing the Hydraulic Pressure ………………………………………………..162
195. Releasing the Tank Pressure ………………………………………………………163
196. Fluid and Filters …………………………………………………………………………163
197. Air Bleeding Procedures ……………………………………………………………..169
198. Slew Gearbox ………………………………………………………………………………..171
199. Checking the Slew Gearbox Oil Level …………………………………………..171
200. Changing the Slew Gearbox Oil …………………………………………………..171
201. Tracks and Running Gear ……………………………………………………………….172
202. Tracks ………………………………………………………………………………………172
203. Running Gear ……………………………………………………………………………174
204. Bucket ………………………………………………………………………………………….175
205. Checking For Side Play ………………………………………………………………175
206. Windscreen Washer ……………………………………………………………………….176
207. Checking the Level …………………………………………………………………….176
208. Fire Extinguisher (If fitted) ……………………………………………………………….177
209. Troubleshooting ……………………………………………………………………………..178
210. Engine and Related Area ……………………………………………………………178
211. Monitor Display – Fault Messages ………………………………………………..181
212. Operations ………………………………………………………………………………..182
213. Hydraulic pump …………………………………………………………………………183
214. Working Attachments …………………………………………………………………184
215. Travel ……………………………………………………………………………………….185
216. Slew …………………………………………………………………………………………186
217. Hydraulic ram ……………………………………………………………………………186
218. Optional Attachments
219. Introduction ……………………………………………………………………………………187
220. Attachments For Your Machine ………………………………………………………..188
221. Connecting-Disconnecting Hydraulic Hoses ……………………………………….189
222. Introduction ……………………………………………………………………………….189
223. Connecting the Hydraulic Hoses ………………………………………………….189
224. Disconnecting the Hydraulic Hoses ………………………………………………190
225. Quick Release Couplings ……………………………………………………………191
226. Operating the Attachments ………………………………………………………………193
227. Specifications
228. Static Dimensions …………………………………………………………………………..196
229. Dig Depth Chart ……………………………………………………………………………..197
230. Shipping Weight …………………………………………………………………………….198
231. Travel Speeds ………………………………………………………………………………..199
232. Noise Data …………………………………………………………………………………….200
233. Introduction ……………………………………………………………………………….200
234. All Machines ……………………………………………………………………………..200
235. Vibration Data ………………………………………………………………………………..201
236. Introduction ……………………………………………………………………………….201
237. Specifications ……………………………………………………………………………201
238. Lifting (Object Handling) Regulations and Safe Working Loads …………….202
239. Introduction ……………………………………………………………………………….202
240. Load Charts ………………………………………………………………………………203
241. Warranty Information
242. Machine Service Record Sheet ………………………………………………………..205
243. Registration Information ………………………………………………………………….207
244. European Community Standards
245. EC Declaration of Conformity …………………………………………………………..209
246. Introduction ……………………………………………………………………………….209
247. Explanation of the EC Declaration of Conformity …………………………… 211

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