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 01 - Machine

 03 - Safety

 18 - Operating Safety

01 - 8

9813/8000-1

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.

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 JS210

Page 1: ...the 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 machi...

Page 2: ...9813 8000 1 Notes Find manuals at https best manuals com...

Page 3: ...CE MANUAL Volume 1 JS210 JS230 EN 9813 8000 SERVICE MANUAL Volume 2 JS210 JS230 EN 9813 8000 SERVICE MANUAL Volume 3 JS210 JS230 EN 9813 8000 SERVICE MANUAL Volume 4 JS210 JS230 EN 9813 8000 Find manu...

Page 4: ...Notes 9813 8000 1 Find manuals at https best manuals com...

Page 5: ...al 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 Assessment 01 11 01 03 27 Maintenance Positions 01 12 01 06 About this Manua...

Page 6: ...2016 10 18 Acronyms Glossary ARV Auxiliary Relief Valve FEAD Front End Accessory Drive MRV Main Relief Valve PIL Parts Identification List PPE Personal Protective Equipment Find manuals at https best...

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 8000 1 01 2 Find manuals at https best manuals com...

Page 9: ...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 time...

Page 10: ...ion 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 signal word N...

Page 11: ...are 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...

Page 12: ...er Hydraulic 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 Mak...

Page 13: ...dence of decomposition 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...

Page 14: ...r 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...

Page 15: ...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 hands and feet inside the machine When...

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: ...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 engine 5 Remove the ignition key 6 D...

Page 19: ...01 Machine 06 About this Manual 01 13 9813 8000 1 01 13 06 About this Manual Contents Page No 01 06 06 Using the Manual 01 15...

Page 20: ...Notes 01 14 9813 8000 1 01 14...

Page 21: ...variant the applicable 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 Di...

Page 22: ...components or assemblies clean the applicable parts of the machine After removal cap open ports and hoses to prevent contamination Use new sealing elements such as gaskets and O rings Do not install...

Page 23: ...01 Machine 06 About this Manual 06 Using the Manual 01 17 9813 8000 1 01 17 refer to PIL 78 00 Use the correct PPE to comply with local and employer regulations...

Page 24: ...01 Machine 09 Description 01 18 9813 8000 1 01 18 09 Description Contents Page No 01 09 12 Main Component Locations 01 19 01 09 15 Service Point Locations 01 20...

Page 25: ...9813 8000 1 01 19 12 Main Component Locations Introduction Main Assemblies Figure 3 M A Bucket attachment B Tipping link C Bucket ram D Dipper E Tipping lever F Dipper ram G Boom H Boom ram J Operator...

Page 26: ...Figure 4 Upper structure A D B C E F H G A Cover suction strainer B Breather hydraulic tank C Cover main filter D In line filter cushion valve E Oil filler port slew motor gearbox if applicable F Oil...

Page 27: ...01 Machine 09 Description 15 Service Point Locations 01 21 9813 8000 1 01 21 Figure 5 Hydraulic compartment A B A Servo filter element B In line drain filter element...

Page 28: ...Upper structure A B E H C D F G A Exhaust system B Engine oil level dip stick C Crankcase ventilation filter D Fan belt and FEAD Front End Accessory Drive belt E Engine oil filler port F Coolant expan...

Page 29: ...int Locations 01 23 9813 8000 1 01 23 Figure 7 Battery cooling compartment A C D E B A Induction air filter outer B Induction air filter inner C Air filter dust valve D Cooling pack E Engine coolant d...

Page 30: ...ription 15 Service Point Locations 01 24 9813 8000 1 01 24 Figure 8 Hydraulic compartment A B C E D A Main fuel filter B Engine fuel filter C Primary fuel filters two filters D Engine oil filter E Fue...

Page 31: ...000 1 2016 10 06 03 Attachments Couplings and Load Handling Contents Page No Acronyms Glossary 03 2 03 00 Attachments 03 00 00 General 03 3 03 10 Excavator Arm Quickhitch 03 10 06 Hydraulic Quickhitch...

Page 32: ...9813 8000 1 2016 10 06 Acronyms Glossary CAN Controller Area Network DECU Display Electronic Control Unit HECU Hydraulics Electronic Control Unit LED Light Emitting Diode...

Page 33: ...03 Attachments Couplings and Load Handling 00 Attachments 03 1 9813 8000 1 03 1 00 Attachments Contents Page No 03 00 00 General 03 3...

Page 34: ...Notes 03 2 9813 8000 1 03 2...

Page 35: ...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 36: ...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 37: ...03 Attachments Couplings and Load Handling 10 Excavator Arm Quickhitch 03 5 9813 8000 1 03 5 10 Excavator Arm Quickhitch Contents Page No 03 10 06 Hydraulic Quickhitch 03 7...

Page 38: ...Notes 03 6 9813 8000 1 03 6...

Page 39: ...normal attachment at 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 e...

Page 40: ...ure 10 A A B B C A Dipper position sensor switch housing B Boom position sensor switch housing C LED Light Emitting Diode indicator Figure 11 A A A Solenoid valve located in the hydraulic compartment...

Page 41: ...15 to cancel the request When the HECU receives the input from the switch it will inform the DECU Display Electronic Control Unit via the CAN Controller Area Network bus of a quickhitch unlock request...

Page 42: ...INT INT EP07 ECU HYDRAULIC CONTROL ECU J2 SENSOR ALIGNMENT ARM C154 C158 SENSOR ALIGNMENT BOOM C157 SENSOR PRESSURE QUICK HITCH C156 BUCKET CROWD SELECTED REVOLVER EARTH STUD EP03 REVOLVER EARTH STUD...

Page 43: ...J2 C154 ECU HYDRAULIC CONTROL ECU J1 C153 JOYSTICK RH HANDLE C095 SOLENOID QUICK HITCH C155 LIGHT QUICK HITCH BOOM STATUS C085 Q H BUTTON PRESSED CAB BASE EARTH POINT INT EP07 REVOLVER EARTH STUD EP0...

Page 44: ...Notes 03 12 9813 8000 1 03 12...

Page 45: ...General 06 13 06 15 03 Boom 06 15 06 15 06 Dipper 06 19 06 15 15 Tipping Linkage 06 23 06 15 30 Dipper Stroke Limiter 06 27 06 24 Slew Ring 06 24 00 General 06 35 06 24 03 Bearing 06 36 06 24 06 Gear...

Page 46: ...Control Unit DTI Dial Test Indicator FOGS Falling Object Guard System HECU Hydraulics Electronic Control Unit LED Light Emitting Diode PCB Printed Circuit Board PIN Product Identification Number ROPS...

Page 47: ...e Panel and Cover 06 1 9813 8000 1 06 1 06 Moveable Panel and Cover Contents Page No 06 06 00 General 06 3 06 06 03 Battery 06 4 06 06 06 Engine Compartment 06 6 06 06 07 Cooling Compartment 06 7 06 0...

Page 48: ...Notes 06 2 9813 8000 1 06 2...

Page 49: ...Introduction When moved to their maintenance position the access panels give you access to parts or areas of the machine that are not required during machine operation Before you operate the machine...

Page 50: ...Battery 06 4 9813 8000 1 06 4 03 Battery Open and Close Open 1 Make the machine safe 2 Use the ignition key to unlock the cover 3 Pull the handle to release the latch 4 Open the cover until it latches...

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

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