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 01 - Machine

 03 - Safety

 18 - Operating Safety

01 - 8

9813/9600-2

01 - 8

18 - Operating Safety
Introduction

Training

Make sure that you have had adequate training and

that you are confident in your ability to operate the

machine safely before you use it. Practice using the

machine and its attachments until you are completely

familiar  with  the  controls  and  what  they  do.  With

a  careful,  well  trained  and  experienced  operator,

your machine is a safe and efficient machine. With

an  inexperienced  or  careless  operator,  it  can  be

dangerous. Do not put your life, or the lives of others,

at risk by using the machine irresponsibly. Before you

start to work, tell your colleagues what you will be

doing and where you will be working. On a busy site,

use a signalman.
Before doing any job not covered in this manual, find

out the correct procedure. Your local JCB distributor

will be glad to advise you.

Fuel

Fuel is flammable, keep naked flames away from the

fuel  system.  Stop  the  engine  immediately  if  a  fuel

leak is suspected. Do not smoke while refuelling or

working on the fuel system. Do not refuel with the

engine  running.  Completely  wipe  off  any  spilt  fuel

which could cause a fire. There could be a fire and

injury if you do not follow these precautions.

Machine Condition

A defective machine can injure you or others. Do not

operate a machine which is defective or has missing

parts. Make sure the maintenance procedures in this

manual are completed before using the machine.

Machine Limits

Operating the machine beyond its design limits can

damage  the  machine,  it  can  also  be  dangerous.

Do  not  operate  the  machine  outside  its  limits.  Do

not  try  to  upgrade  the  machine  performance  with

unapproved modifications or additional equipment.

Engine/Steering Failure

If the engine or steering fails, stop the machine as

quickly as possible. Do not operate the machine until

the fault has been corrected.

Exhaust Gases

Machine exhaust gases can harm and possibly 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 drowsy, stop

the machine at once and get into fresh air.

Worksites

Worksites  can  be  hazardous.  Examine  the  site

before working on it. You could be killed or injured

if  the  ground  gives  way  under  your  machine  or  if

piled material collapses onto it. Check for potholes

and hidden debris, logs, ironwork etc. Any of these

could  cause  you  to  lose  control  of  your  machine.

Check for utilities such as electric cables (overhead

and  underground),  gas  and  water  pipes  etc.  Mark

the positions of the underground cables and pipes.

Make sure that you have enough clearance beneath

overhead cables and structures.

Communications

Bad  communications  can  cause  accidents.  Keep

people  around  you  informed  of  what  you  will  be

doing.  If  you  will  be  working  with  other  people,

make sure any hand signals that may be used are

understood by everybody. Worksites can be noisy, do

not rely on spoken commands.

Parking

An incorrectly parked machine can move without an

operator.  Follow  the  instructions  in  the  Operator's

Manual to park the machine correctly.

Banks and Trenches

Banked material and trenches can collapse. Do not

work or drive too close to banks and trenches where

there is danger of collapse.

Safety Barriers

Unguarded  machines  in  public  places  can  be

dangerous. In public places, or where your visibility

is reduced, place barriers around the work area to

keep people away.

Sparks

Explosions and fire can be caused by sparks from

the exhaust or the electrical system. Do not use the

machine in closed areas where there is flammable

material, vapour or dust.

Hazardous Atmospheres

This  machine  is  designed  for  use  in  normal  out

door  atmospheric  conditions.  It  must  not  be  used

in  an  enclosed  area  without  adequate  ventilation.

Do  not  use  the  machine  in  a  potentially  explosive

atmosphere, i.e. combustible vapours, gas or dust,

without first consulting your JCB dealer.

Regulations

Obey all laws, worksite and local regulations which

affect you and your machine.

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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