JCB JS500 Tier 2 Operator Manual 9821-9550

JCB JS500 Tier 2 Operator Manual 9821-9550 - Image 2

JCB JS500 Tier 2 Operator Manual 9821-9550 - Image 3

JCB JS500 Tier 2 Operator Manual 9821-9550 - Image 4

JCB JS500 Tier 2 Operator Manual 9821-9550 - Image 5

jcb js500 tier 2 operator manual 9821 9550 2

jcb js500 tier 2 operator manual 9821 9550 3

JCB JS500 Tier 2 Operator Manual 9821-9550

$20.00

Type Of Manual: Operator Manual
ManualID: 9821-9550
Number of Pages: 231
Size: 18.9MB
Format: PDF

Category: JCB Operator Manual PDF

Model List:
- JS500 Tier 2

1. Safety Notices
2. Important Information ………………………………………………………………………..xii
3. The Operator Manual ……………………………………………………………………xii
4. Safety Warnings …………………………………………………………………………..xii
5. Introduction
6. About this Manual ………………………………………………………………………………1
7. Name of Manufacturer ……………………………………………………………………1
8. Product Compliance ………………………………………………………………………1
9. Machine Model and Serial Number ………………………………………………….1
10. Using this Manual ………………………………………………………………………….1
11. Left Side, Right Side ………………………………………………………………………2
12. Cross References ………………………………………………………………………….2
13. Machine Description …………………………………………………………………………..3
14. The JCB Tracked Excavator ……………………………………………………………3
15. Intended Use ………………………………………………………………………………..3
16. Component Location ……………………………………………………………………..4
17. Safety Check List ……………………………………………………………………………….6
18. Safety – Yours and Others ………………………………………………………………6
19. General Safety ……………………………………………………………………………..6
20. Operating Safety …………………………………………………………………………..8
21. Maintenance Safety …………………………………………………………………….. 11
22. Safety Labels …………………………………………………………………………………..16
23. Introduction …………………………………………………………………………………16
24. Safety Label Identification …………………………………………………………….17
25. Part Numbers and Description …………………………………………………….19
26. Identifying Your Machine …………………………………………………………………..21
27. Machine Identification Plate ………………………………………………………….21
28. Typical Product Identification Number …………………………………………….21
29. Component Identification Plates …………………………………………………….22
30. FOPS Data Plate ………………………………………………………………………22
31. ROPS Data Plate ………………………………………………………………………22
32. Engine Identification Plate ………………………………………………………….23
33. Machine Security ……………………………………………………………………………..24
34. Introduction …………………………………………………………………………………24
35. JCB Plantguard …………………………………………………………………………..24
36. Construction Equipment Security And Registration Scheme (CESAR) .24
37. LiveLink ……………………………………………………………………………………..24
38. Immobiliser …………………………………………………………………………………24
39. Operation
40. Introduction ……………………………………………………………………………………..25
41. Before Entering the Cab ……………………………………………………………………26
42. Entering and Leaving the Cab ……………………………………………………………27
43. Standard Cab Machines ……………………………………………………………….27
44. Entering the Cab ……………………………………………………………………….27
45. Leaving the Cab ………………………………………………………………………..27
46. Emergency Exit …………………………………………………………………………..28
47. Doors and Windows …………………………………………………………………………29
48. Opening and Closing the Door ………………………………………………………29
49. Opening and Closing the Front Upper Window ………………………………..29
50. Opening …………………………………………………………………………………..29
51. Closing …………………………………………………………………………………….29
52. Opening and Closing The Front Lower Window ……………………………….30
53. Door Sliding Window ……………………………………………………………………31
54. Opening and Closing the Sunblind …………………………………………………31
55. Standard Sun Blind ……………………………………………………………………31
56. Optional Sun Blind – Type 1 ………………………………………………………..32
57. Optional Sun Blind – Type 2 ………………………………………………………..32
58. Access to the Upper Structure ……………………………………………………………33
59. Standard Machines ………………………………………………………………………33
60. Seat Controls …………………………………………………………………………………..34
61. Introduction …………………………………………………………………………………34
62. Operators Seat-Console ……………………………………………………………….34
63. Operators Seat – Standard-Heated …………………………………………………34
64. Fore-Aft ……………………………………………………………………………………34
65. Weight ……………………………………………………………………………………..34
66. Cushion Height-Angle ………………………………………………………………..34
67. Backrest …………………………………………………………………………………..34
68. Headrest (if fitted) ……………………………………………………………………..34
69. Armrest ……………………………………………………………………………………34
70. The Operator Manual …………………………………………………………………34
71. Heated Seat (if fitted) …………………………………………………………………34
72. Air Suspension Seat …………………………………………………………………….35
73. Raising-Lowering the Seat ………………………………………………………….35
74. Seat Belts (if fitted) …………………………………………………………………………..36
75. Static Seat Belt ……………………………………………………………………………36
76. Fasten the Seat Belt ………………………………………………………………….36
77. Release the Seat Belt ………………………………………………………………..36
78. Adjusting the Seat Belt ………………………………………………………………36
79. Visibility Aids ……………………………………………………………………………………37
80. Mirrors ……………………………………………………………………………………….37
81. Introduction ………………………………………………………………………………37
82. Installation ………………………………………………………………………………..37
83. Adjusting the Mirrors ………………………………………………………………….38
84. Checking the Field of Vision ……………………………………………………….39
85. Cab Layout ……………………………………………………………………………………..40
86. Components Key …………………………………………………………………………40
87. Drive Controls, Switches and Instruments ……………………………………………42
88. Drive Controls ……………………………………………………………………………..42
89. Track Controls …………………………………………………………………………..42
90. Switches …………………………………………………………………………………….43
91. Console Switches ……………………………………………………………………..43
92. Starter Switch ……………………………………………………………………………46
93. Cab Interior Lights …………………………………………………………………….46
94. Courtesy Light …………………………………………………………………………..46
95. Fascia Panel …………………………………………………………………………….47
96. Emergency Back-up Switch ………………………………………………………..48
97. Instruments …………………………………………………………………………………49
98. Monitor Panel ……………………………………………………………………………49
99. Heater-Air Conditioning Controls ……………………………………………………54
100. Heater Controls …………………………………………………………………………54
101. Using the Air Conditioning ………………………………………………………….54
102. Operating Levers-Pedals …………………………………………………………………..55
103. Excavating Controls …………………………………………………………………….55
104. ISO-SAE Controls ……………………………………………………………………..55
105. Boom and Bucket ……………………………………………………………………..57
106. Superstructure and Dipper ………………………………………………………….58
107. One Touch – Automatic Idle Switch ………………………………………………59
108. Travel Speed Change Button ………………………………………………………..59
109. Operation Levers …………………………………………………………………………60
110. Slewing ……………………………………………………………………………………60
111. Optional Circuit Pedal (if fitted) ………………………………………………………61
112. Locking Pedal …………………………………………………………………………..61
113. ISO Operating Method …………………………………………………………………61
114. Safety Equipment …………………………………………………………………………….62
115. Control Locks ……………………………………………………………………………..62
116. Servo Controls Immobilisation …………………………………………………….62
117. Enable the Controls …………………………………………………………………..62
118. Controls Isolation Lever ……………………………………………………………..62
119. Dipper Stroke Limiter (If fitted) ……………………………………………………….63
120. Operation …………………………………………………………………………………63
121. Adjust the Clearance …………………………………………………………………64
122. Check the Clearance …………………………………………………………………65
123. Overload Warning System …………………………………………………………….65
124. Before Starting the Engine …………………………………………………………………66
125. Starting the Engine …………………………………………………………………………..67
126. Warming-Up ……………………………………………………………………………….68
127. JCB Immobiliser System ………………………………………………………………68
128. Disarm the Immobiliser ………………………………………………………………68
129. Immobiliser Configuration …………………………………………………………..69
130. Getting the Machine Moving ………………………………………………………………71
131. Stopping and Parking the Machine ……………………………………………………..72
132. Stopping and Parking …………………………………………………………………..72
133. Engine Shutdown ………………………………………………………………………..72
134. Working with your Machine ……………………………………………………………….73
135. Undercarriage ……………………………………………………………………………..73
136. Extending the Undercarriage into the Working Position ………………….73
137. Retracting the Undercarriage into the Transport Position ………………..75
138. Operating Practices and Site Safety ………………………………………………77
139. Clothing and Safety Equipment ……………………………………………………..77
140. Danger Zone ………………………………………………………………………………77
141. Log Moving-Handling ……………………………………………………………………77
142. Safety Practices ………………………………………………………………………….77
143. Working With the Excavator ………………………………………………………….79
144. Digging …………………………………………………………………………………….79
145. Bucket ……………………………………………………………………………………..80
146. Backfilling …………………………………………………………………………………84
147. Travelling with a Load (Pick and Carry) ………………………………………..84
148. Dumping into a Truck …………………………………………………………………85
149. Lifting (Object Handling) ……………………………………………………………….86
150. Introduction ………………………………………………………………………………86
151. Lifting With the Excavator …………………………………………………………..86
152. Load Charts ……………………………………………………………………………..88
153. Use of Machines on Gradients and Slopes ……………………………………..89
154. Travelling on Slopes ………………………………………………………………….89
155. Working on Slopes …………………………………………………………………….90
156. Getting Out of Soft Ground ……………………………………………………………92
157. Water …………………………………………………………………………………………93
158. Towing Other Equipment ………………………………………………………………93
159. Machine Stability …………………………………………………………………………94
160. Reducing Wear ……………………………………………………………………………95
161. Operating Environment ……………………………………………………………………..98
162. Maintenance in Cold Climates ……………………………………………………….98
163. On Completion of Work ………………………………………………………………98
164. Operating in a Cold Climate (Below 0°C) ………………………………………..98
165. Operating in a Hot Climate (Above 35°C) ……………………………………….98
166. Operating in Dusty or Sandy Areas ………………………………………………..99
167. Operating in Coastal Regions ……………………………………………………….99
168. Operating on Wet or Soft Ground …………………………………………………..99
169. Cab Filters ………………………………………………………………………………….99
170. Refuelling the Machine ……………………………………………………………………100
171. Low Fuel Levels ………………………………………………………………………..100
172. Filling the Tank ………………………………………………………………………….100
173. Fuel Level …………………………………………………………………………………101
174. Refuelling Pump ………………………………………………………………………..102
175. Auto mode ……………………………………………………………………………..102
176. Manual mode ………………………………………………………………………….102
177. Moving a Disabled Machine …………………………………………………………….103
178. Lowering the Boom in an Emergency …………………………………………..103
179. Retrieval …………………………………………………………………………………..103
180. Limp Mode ………………………………………………………………………………..104
181. Mechanical Engine RPM Override ……………………………………………….104
182. Transporting the Machine ………………………………………………………………..105
183. Lifting the Machine …………………………………………………………………………108
184. Storage of the Machine ………………………………………………………………….. 110
185. Introduction ………………………………………………………………………………. 110
186. Storage Area ……………………………………………………………………………. 110
187. Prepare the Machine for Storage ………………………………………………… 110
188. Put the Machine into Storage ……………………………………………………… 110
189. During Storage …………………………………………………………………………. 110
190. Take the Machine Out of Storage ………………………………………………… 111
191. Anti-Vandalism Guards (option) ……………………………………………………….. 112
192. Unpacking the Guards ……………………………………………………………….. 112
193. Fitting the Guards ……………………………………………………………………… 112
194. Guard 7 (7), Front top panel – position A ……………………………………. 112
195. Guard 6 (3), Front bottom panel – position B ………………………………. 112
196. Guard 1 (4), Door front panel – position C …………………………………… 112
197. Guard 5 (1), Door rear panel – position D …………………………………… 112
198. Guard 2 (5) and 3 (6) (Hinged), Boom side panels – position E and F …..
199. 112
200. Guard 4 (2), Rear window panel – position G ………………………………. 113
201. Removing the Guards ……………………………………………………………….. 113
202. Storing the Guards ……………………………………………………………………. 113
203. Guards ………………………………………………………………………………….. 113
204. Older guards ………………………………………………………………………….. 113
205. Routine Maintenance
206. Service Requirements ……………………………………………………………………. 115
207. Introduction ………………………………………………………………………………. 115
208. Owner-Operator Support ……………………………………………………………. 115
209. Service-Maintenance Agreements ………………………………………………. 115
210. Fit for Purpose Tests for Lifting Equipment ……………………………………. 116
211. Obtaining Replacement Parts ……………………………………………………… 116
212. Health and Safety ………………………………………………………………………….. 117
213. Lubricants ………………………………………………………………………………… 117
214. Introduction ……………………………………………………………………………. 117
215. Hygiene …………………………………………………………………………………. 117
216. Storage …………………………………………………………………………………. 117
217. Waste Disposal ………………………………………………………………………. 117
218. Handling ………………………………………………………………………………… 117
219. First Aid – Oil ………………………………………………………………………….. 118
220. Spillage …………………………………………………………………………………. 118
221. Fires ……………………………………………………………………………………… 118
222. Battery …………………………………………………………………………………….. 119
223. Warning Symbols …………………………………………………………………….120
224. First Aid – Electrolyte ………………………………………………………………..120
225. Service Schedules ………………………………………………………………………….121
226. Introduction ……………………………………………………………………………….121
227. How to Use the Service Schedules ………………………………………………121
228. Calendar Equivalents …………………………………………………………………121
229. Pre Start Cold Checks, Service Points and Fluid Levels ………………….122
230. Functional Test and Final Inspection …………………………………………….126
231. Service Intervals for Attachments …………………………………………………128
232. Periodic Replacement of Safety Related Components ……………………129
233. Fluids, Lubricants and Capacities ……………………………………………………..130
234. Specifications ……………………………………………………………………………130
235. Typical Lubrication Chart …………………………………………………………….131
236. Coolant Mixtures ……………………………………………………………………….132
237. Fuel …………………………………………………………………………………………133
238. Acceptable and Unacceptable Fuels ………………………………………….133
239. Cleanliness …………………………………………………………………………….135
240. Fuel Bulk Storage ……………………………………………………………………135
241. Fuel Analysis ………………………………………………………………………….135
242. Tools …………………………………………………………………………………………….136
243. Carrying Tools onto the Machine ………………………………………………….136
244. Location ……………………………………………………………………………………136
245. Prepare the Machine for Maintenance ………………………………………………137
246. Introduction ……………………………………………………………………………….137
247. How to Make the Machine Safe (Excavator Lowered) …………………….137
248. Cleaning the Machine ……………………………………………………………………..138
249. Introduction ……………………………………………………………………………….138
250. Detergents ……………………………………………………………………………..138
251. Pressure Washing and Steam Cleaning ……………………………………..138
252. Preparing the Machine for Cleaning ……………………………………………..138
253. Cleaning the Machine …………………………………………………………………139
254. Exterior ………………………………………………………………………………….139
255. Interior ……………………………………………………………………………………139
256. Cleaning the Tracks ……………………………………………………………………139
257. Cleaning the Radiator and Oil Cooler ……………………………………………139
258. Checking for Damage ……………………………………………………………………..140
259. Check the Machine Body and Structure ………………………………………..140
260. Check the Seat and Seat Belt ……………………………………………………..140
261. Check the Tyres ………………………………………………………………………..140
262. Check the Electrical Circuits ………………………………………………………..140
263. Checking the FOPS Structure ……………………………………………………..141
264. Introduction …………………………………………………………………………….141
265. Frame Mounted ………………………………………………………………………141
266. Cab Mounted ………………………………………………………………………….141
267. Daily Checking ……………………………………………………………………………….142
268. Greasing ……………………………………………………………………………………….144
269. Introduction ……………………………………………………………………………….144
270. Slew Ring Bearing ……………………………………………………………………..144
271. Slew Ring Teeth and Slew Pinion …………………………………………………144
272. Greasing Points …………………………………………………………………………145
273. Electrical System ……………………………………………………………………………147
274. Battery ……………………………………………………………………………………..147
275. Battery Isolator ………………………………………………………………………..147
276. Battery Disconnection-Connection ……………………………………………..148
277. Terminal Cleaning ……………………………………………………………………148
278. Checking the Electrolyte Level – Low Maintenance Batteries …………149
279. Breather Cleaning – Low Maintenance Batteries ………………………….150
280. Battery Inspection – Maintenance Free Batteries ………………………….150
281. Jump-Starting the Engine ……………………………………………………………151
282. Fuses – Cab ………………………………………………………………………………152
283. Fuses and Relays – Battery Compartment …………………………………….153
284. Bolt and Nut Torque Specifications ……………………………………………………154
285. JS500 ………………………………………………………………………………………154
286. Engine ………………………………………………………………………………………….157
287. Oil and Filter ……………………………………………………………….

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