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 01 - Machine

 03 - Safety

 09 - General Safety

01 - 5

9813/9600-2

01 - 5

09 - General Safety
Introduction

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. Ensure that you receive the correct training

before operating any machinery. Failing to do so will

result in incorrect operation of the machine and you

will be putting yourself and others at risk. 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.

Summary of Contents for 210X

Page 1: ...e 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...

Page 2: ...9813 9600 2 Notes Find manuals at https best manuals com...

Page 3: ...ERVICE MANUAL Volume 1 210X 220X EN 9813 9600 SERVICE MANUAL Volume 2 210X 220X EN 9813 9600 SERVICE MANUAL Volume 3 210X 220X EN 9813 9600 SERVICE MANUAL Volume 4 210X 220X EN 9813 9600 Find manuals...

Page 4: ...Notes 9813 9600 2 Find manuals at https best manuals com...

Page 5: ...ety 01 6 01 03 18 Operating Safety 01 8 01 03 21 Worksite Safety 01 10 01 03 24 Risk Assessment 01 11 01 03 27 Maintenance Positions 01 12 01 06 About this Manual 01 06 03 Model and Serial Number 01 1...

Page 6: ...er DEF Diesel Exhaust Fluid ECU Electronic Control Unit FEAD Front End Accessory Drive HVAC Heating Ventilation Air Conditioning MRV Main Relief Valve PIL Parts Identification List PPE Personal Protec...

Page 7: ...y Yours and Others 01 3 01 03 06 Safety Warnings 01 4 01 03 09 General Safety 01 5 01 03 12 Maintenance Safety 01 6 01 03 18 Operating Safety 01 8 01 03 21 Worksite Safety 01 10 01 03 24 Risk Assessme...

Page 8: ...Notes 01 2 9813 9600 2 01 2 Find manuals at https best manuals com...

Page 9: ...ial 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...

Page 10: ...dous 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 si...

Page 11: ...e 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 Ph...

Page 12: ...ulic Pressure Hydraulic fluid at system pressure can injure you Before connecting or removing any hydraulic hose residual hydraulic pressure trapped in the service hose line must be vented Make sure t...

Page 13: ...composition e g charring is found refer to the next paragraph for safety instructions Do not touch component or surrounding area Used fluoroelastomeric components subjected to temperatures greater tha...

Page 14: ...y kill you or bystanders if they are inhaled Do not operate the machine in closed spaces without making sure there is good ventilation If possible install an exhaust extractor If you begin to feel dro...

Page 15: ...ee clearly Modification of the machine s configuration by the user e g the fitting of large and non approved attachments may result in a restriction of the machine visibility Hands and Feet Keep your...

Page 16: ...leak is suspected contact the local gas company immediately and warn all personnel on the site Ban smoking make sure that all naked lights are extinguished and switch off any engines which may be runn...

Page 17: ...nd is there sufficient fuel to complete the job if applicable The Load How heavy is it Is it within the capabilities of the machine How bulky is it The greater the surface area the more affected it wi...

Page 18: ...el ground with the upper structure parallel to the undercarriage 2 If applicable lower the dozer blade 3 Lower the excavator so the dipper is flat on the ground Refer to Figure 2 Figure 2 4 Stop the e...

Page 19: ...01 Machine 06 About this Manual 01 13 9813 9600 2 01 13 06 About this Manual Contents Page No 01 06 03 Model and Serial Number 01 15 01 06 06 Using the Manual 01 16...

Page 20: ...Notes 01 14 9813 9600 2 01 14...

Page 21: ...s Manual 03 Model and Serial Number 01 15 9813 9600 2 01 15 03 Model and Serial Number Introduction This manual provides information for the following model s in the JCB machine range Model From To 21...

Page 22: ...able information sets are included within the same PIL reference Headings are included to identify which information is for which variant Make sure you use the correct information Systems Descriptions...

Page 23: ...If necessary replace them with new ones During assembly use new sealing elements such as gaskets and O rings Torque Tightening Use the torque tightening values contained in the individual procedures R...

Page 24: ...e control system fault Refer to Throttle Control System PIL 18 00 30 Variable displacement hydraulic pump fault Refer to Fault Finding PIL 30 12 00 Fuel pump fault Refer to Check Operation PIL 18 21 0...

Page 25: ...ndition PIL 06 24 03 1 Check the slew service cycle times Refer to Check Operation PIL 30 00 15 2 Check the applicable service spools Table 8 Travel service does not operate as expected 1 2 Cause Reme...

Page 26: ...01 Machine 09 Description 01 20 9813 9600 2 01 20 09 Description Contents Page No 01 09 12 Main Component Locations 01 21 01 09 15 Service Point Locations 01 22...

Page 27: ...01 21 12 Main Component Locations Introduction Main Assemblies Figure 3 A B C D F G H J K M L E A Bucket attachment B Tipping link C Bucket ram D Dipper E Tipping lever F Dipper ram G Boom H Boom ram...

Page 28: ...r structure A C J H G F E D B A Breather hydraulic tank B Cover suction strainer C Cover drain line filter D Cover main filter E Oil drain plug slew motor gearbox access from below the machine F Oil f...

Page 29: ...23 9813 9600 2 01 23 Figure 5 Hydraulic compartment B C A A Hydraulic pump compartment B Servo filter element C Level gauge hydraulic oil tank Figure 6 Cooling bay C B A A Cooling bay B Hydraulic oil...

Page 30: ...y module inside toolbox C Filler port DEF tank inside toolbox D Exhaust clamp DEF dosing module E Exhaust clamp SCR Selective Catalytic Reduction catalyst F Exhaust silencer G Exhaust clamp turbocharg...

Page 31: ...C D E G K J L H F A B A Battery compartment B Cooling compartment C Induction air filter outer D Induction air filter inner E Induction inlet grill F Scavenge intake G CAC Charge Air Cooler cooling p...

Page 32: ...ure 9 Hydraulic compartment B G F E D C A H A Hydraulic pump compartment B Fuel lubricity filter if installed C Fuel pre filter and water separator D Fuel line isolator valve E Water separator if inst...

Page 33: ...ervice Points Heating and Ventilation System Figure 10 F E D A C B A Cooling compartment B High pressure recharge point air conditioning only C Low pressure recharge point air conditioning only D Cond...

Page 34: ...01 Machine 33 Cleaning 01 28 9813 9600 2 01 28 33 Cleaning Contents Page No 01 33 00 General 01 29...

Page 35: ...ender the machine inoperable Remove dirt using a brush or damp cloth Clean the product with water and or steam Do not let mud debris etc to collect on the product Before you do any service procedures...

Page 36: ...aim the water jet directly at bearings oil seals or the engine air induction system Use a low pressure water jet and brush to remove dried mud or dirt Use a pressure washer to remove soft dirt and oi...

Page 37: ...9813 9600 2 2017 10 02 03 Attachments Couplings and Load Handling Contents Page No 03 00 Attachments 03 00 00 General 03 3 03 10 Excavator End Quickhitch 03 10 06 Hydraulic Quickhitch 03 7...

Page 38: ...Notes 9813 9600 2 2017 10 02...

Page 39: ...03 Attachments Couplings and Load Handling 00 Attachments 03 1 9813 9600 2 03 1 00 Attachments Contents Page No 03 00 00 General 03 3...

Page 40: ...Notes 03 2 9813 9600 2 03 2...

Page 41: ...y the gradients on which it is safe to operate or the safe distance from power lines Practice using attachments off the job before working with them for the first time JCB attachments are designed and...

Page 42: ...ad and unload on firm level ground Always be alert for possible hazards Take special care when turning or reversing DANGER Before lowering the attachments to the ground make sure that the machine and...

Page 43: ...03 Attachments Couplings and Load Handling 10 Excavator End Quickhitch 03 5 9813 9600 2 03 5 10 Excavator End Quickhitch Contents Page No 03 10 06 Hydraulic Quickhitch 03 7...

Page 44: ...Notes 03 6 9813 9600 2 03 6...

Page 45: ...the dipper and tipping link A hydraulically operated latch mechanism enables quickhitch compatible attachments to be installed and removed without the need to leave the cab The electro hydraulic contr...

Page 46: ...ure ensures that the latch defaults to the locked position A remote solenoid control valve is energised by the electronic control system when the quickhitch is set to unlock The lock ram operates agai...

Page 47: ...cavator End 06 15 00 General 06 15 06 15 03 Boom 06 17 06 15 06 Dipper 06 21 06 15 15 Tipping Linkage 06 25 06 15 30 Dipper Stroke Limiter 06 29 06 24 Slew Ring 06 24 00 General 06 37 06 24 03 Bearing...

Page 48: ...F Diesel Exhaust Fluid DTI Dial Test Indicator FOPS Falling Object Protective Structure LED Light Emitting Diode MECU Machine Electronic Control Unit PCB Printed Circuit Board PIN Product Identificati...

Page 49: ...1 9813 9600 2 06 1 06 Moveable Panel and Cover Contents Page No 06 06 00 General 06 3 06 06 03 Battery Compartment 06 4 06 06 06 Engine Compartment 06 6 06 06 07 Cooling Compartment 06 8 06 06 09 Hyd...

Page 50: ...Notes 06 2 9813 9600 2 06 2...

Page 51: ...This as a preview PDF file from best manuals com Download full PDF manual at best manuals com...

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