background image

 01 - Machine

 03 - Safety

 12 - Maintenance Safety

01 - 6

9813/7350-1

01 - 6

12 - Maintenance Safety
Introduction

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.

Air Conditioning Maintenance

The air conditioning system is a closed loop system

and contains pressurised refrigerant. No part of the

system  should  be  disconnected  until  the  system

has  been  discharged  by  a  refrigeration  engineer

or  a  suitably  trained  person.  You  can  be  severely

frostbitten or injured by escaping refrigerant.

Compressed Air

Compressed  air  is  dangerous.  Wear  personal

protective equipment. Never point a compressed air

jet at yourself or others.

Springs

Always  wear  personal  protective  equipment  when

dismantling  assemblies  containing  components

under pressure from springs. This will protect against

eye injury from components accidentally flying out.

Metal Splinters

You  can  be  injured  by  flying  metal  splinters  when

driving metal pins in or out. Use a soft faced hammer

or  copper  drift  to  remove  and  install  metal  pins.

Always wear personal protective equipment.

Communications

Bad  communications  can  cause  accidents.  If  two

or more people are working on the machine, make

sure  each  is  aware  of  what  the  others  are  doing.

Before starting the engine make sure the others are

clear of the danger areas. Examples of danger areas

are: the rotating blades and belt on the engine, the

attachments and linkages, and anywhere beneath or

behind the machine. People can be killed or injured

if these precautions are not taken.

Repairs

If  your  machine  does  not  function  correctly  in

any  way,  get  it  repaired  straight  away.  Neglect  of

necessary repairs could result in an accident or affect

your  health.  Do  not  try  to  do  repairs  or  any  other

type of maintenance work you do not understand. To

avoid injury and/or damage get the work done by a

specialist engineer.

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.  Make  sure  the  hose

service line has been vented before connecting or

removing  hoses.  Make  sure  the  engine  cannot  be

started while the hoses are open.

'O' rings, Seals and Gaskets

Badly  installed,  damaged  or  rotted  'O'  rings,  seals

and  gaskets  can  cause  leakages  and  possible

accidents.  Renew  whenever  disturbed  unless

otherwise instructed. Do not use Triochloroethane or

paint thinners near 'O' rings and seals.

Arc Welding

To  prevent  the  possibility  of  damage  to  electronic

components,  disconnect  the  battery  and  the

alternator  before  arc-welding  on  the  machine  or

attached implements.
If the machine is equipped with sensitive electrical

equipment,  i.e.  amplifier  drivers,  electronic  control

units (ECUs), monitor displays, etc., then disconnect

them  before  welding.  Failure  to  disconnect  the

sensitive  electrical  equipment  could  result  in

irreparable damage to these components.
Parts of the machine are made from cast iron, welds

on cast iron can weaken the structure and break. Do

not weld cast iron. Do not connect the welder cable

or apply any weld to any part of the engine.
Always connect the welder earth (ground) cable to

the same component that is being welded to avoid

damage to pivot pins, bearings and bushes. Attach

the welder earth (ground) cable a distance from the

part being welded no more than 0.6m.

Counterweights

Your machine may be installed with counterweights.

They are extremely heavy. Do not attempt to remove

them.

Accumulators

The accumulators contain hydraulic fluid and gas at

high  pressure.  Prior  to  any  work  being  carried  out

on systems incorporating accumulators, the system

pressure  must  be  discharged  by  a  JCB  dealer,  as

the sudden release of the hydraulic fluid or gas may

cause injury.

Hot Components

Touching hot surfaces can burn skin. The engine and

machine components will be hot after the unit has

been running. Allow the engine and components to

cool before servicing the unit.

Soft Ground

A  machine  can  sink  into  soft  ground.  Never  work

under a machine on soft ground.

Summary of Contents for JS220

Page 1: ...rst studying 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 opera...

Page 2: ...9813 7350 1 Notes Find manuals at https best manuals com...

Page 3: ...JS210 JS220 JS235 EN 9813 7350 SERVICE MANUAL Volume 2 JS200 JS210 JS220 JS235 EN 9813 7350 SERVICE MANUAL Volume 3 JS200 JS210 JS220 JS235 EN 9813 7350 SERVICE MANUAL Volume 4 JS200 JS210 JS220 JS23...

Page 4: ...Notes 9813 7350 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: ...50 1 2016 04 22 Acronyms Glossary ARV Auxiliary Relief Valve DEF Diesel Exhaust Fluid FEAD Front End Accessory Drive MRV Main Relief Valve PIL Parts Identification List Find manuals at https best manu...

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 7350 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: ...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 Figure 2 A A Excavator lowered with the dipper f...

Page 19: ...01 Machine 06 About this Manual 01 13 9813 7350 1 01 13 06 About this Manual Contents Page No 01 06 06 Using the Manual 01 15...

Page 20: ...Notes 01 14 9813 7350 1 01 14...

Page 21: ...machine 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 infor...

Page 22: ...s do not operate as expected 30 00 15 Parallel Open Centre System FF 1 09 27 09 Controls Excavator Arm 30 50 00 Excavator Control Valve Block 30 50 06 ARV Auxiliary Relief Valve FF 1 30 15 00 Cylinder...

Page 23: ...01 Machine 09 Description 01 17 9813 7350 1 01 17 09 Description Contents Page No 01 09 12 Main Component Locations 01 19 01 09 15 Service Point Locations 01 20...

Page 24: ...Notes 01 18 9813 7350 1 01 18...

Page 25: ...9813 7350 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: ...cription 15 Service Point Locations 01 21 9813 7350 1 01 21 Figure 5 Hydraulic compartment A C B D A Servo filter element T2 T4i B In line drain filter element C Servo filter element T4f D Plexus filt...

Page 28: ...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 expansion bottle G Indu...

Page 29: ...int Locations 01 23 9813 7350 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: ...e 09 Description 15 Service Point Locations 01 24 9813 7350 1 01 24 Figure 8 Hydraulic compartment T2 T4i A B C D A Main fuel filter B Engine fuel filter C Primary fuel filters two filters D Engine oi...

Page 31: ...01 Machine 09 Description 15 Service Point Locations 01 25 9813 7350 1 01 25 Figure 9 Hydraulic compartment T4f B A C A Engine fuel filter B Main fuel filter C Engine oil filter...

Page 32: ...Notes 01 26 9813 7350 1 01 26...

Page 33: ...9813 7350 1 2016 03 22 03 Attachments and Options Contents Page No Acronyms Glossary 03 2 03 00 General 03 00 00 General 03 3 03 10 Excavator Arm Quickhitch 03 10 06 Hydraulic Quickhitch 03 7...

Page 34: ...9813 7350 1 2016 03 22 Acronyms Glossary CAN Controller Area Network DECU Display Electronic Control Unit HECU Hydraulics Electronic Control Unit LED Light Emitting Diode...

Page 35: ...03 Attachments and Options 00 General 03 1 9813 7350 1 03 1 00 General Contents Page No 03 00 00 General 03 3...

Page 36: ...Notes 03 2 9813 7350 1 03 2...

Page 37: ...ents 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 manufactur...

Page 38: ...oad 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 the area a...

Page 39: ...03 Attachments and Options 10 Excavator Arm Quickhitch 03 5 9813 7350 1 03 5 10 Excavator Arm Quickhitch Contents Page No 03 10 06 Hydraulic Quickhitch 03 7...

Page 40: ...Notes 03 6 9813 7350 1 03 6...

Page 41: ...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 electro h...

Page 42: ...er position sensor housing B Boom position sensor housing C LED Light Emitting Diode indicator D Position sensing switch located inside housings A and B E Solenoid valve located in the hydraulic compa...

Page 43: ...ncel 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 The DEC...

Page 44: ...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 EP03 A Q...

Page 45: ...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 EP03 REVOLV...

Page 46: ...Notes 03 12 9813 7350 1 03 12...

Page 47: ...15 00 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 03 Bearing 06 37 06 24 06 Gear 06 41 06 30 Pivot...

Page 48: ...TI Dial Test Indicator FOGS Falling Object Guard System HECU Hydraulics Electronic Control Unit LED Light Emitting Diode LH Left Hand PCB Printed Circuit Board PIN Product Identification Number RH Rig...

Page 49: ...k 06 Access Cover 06 1 9813 7350 1 06 1 06 Access 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 06 09 Hydraul...

Page 50: ...Notes 06 2 9813 7350 1 06 2...

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

Reviews: