JCB EXCAVATOR

Contents

1. An Introduction to Hydraulic Excavators. Excavators.

2. Product Range. - Wheeled. - Tracked.

3. Key Feature Summary XO Tracked Series.

4. Features and Benefits. - JS Tracked Excavator, XO Range. - JS Wheeled Excavator XO Range. - JS Tracked Tracked Excavator Auto Range.

5. Walk Around.

6. Demonstration Notes.

7. Productivity and Machine Sizing.

8. Comparative Evaluation. - The New Generation vs XO Range. - JS 220L Auto vs Komatsu PC210-7. - JS 220L vs Caterpillar 320C. - JS 220L vs Hitachi Zaxis 210LC. - JS 220L/JS 210L/ JS220L Auto vs Case CX Range.

9. Material Densities, Volumes and Weights.

10. Additional Information.

11. Tender and Quotation Data.

12. JS Options Explained.

Contents

Section 1. AN INTROD INTRODUCTI UCTION ON TO HYDR HYDRAUL AULIC IC EXCA EXCAV VATORS

1. Background, History of JCB 360° Excavators.

2. Key Components.

3. Key Components – continued.

An Introduction to Hydraulic Excavators

BACKGROUND

INTRO0001 Hydraulic excavators were introduced in the mid 1950’s and rapidly became very popular due to their low weight compared to rope excavators of similar capacity capacity.. JCB excavators are classified by weight and the range stretches from 7 to 46 tonnes. Both tracked and wheeled excavators are available and they are used in a wide range o f applications. Many options are available to allow machines to be tailored for the required application.

HIST HI STO ORY OF JC JCB B 36 360 0O EXCAVATORS 1945

JCB founded by Joseph Cyril Bamford.

1965

JCB enters a new market when its first 360 o crawler excavator, the JCB 7, goes on sale.

1966

Introduction of the JCB 6, 6C and 7C strengthens the JCB product range.

1971

The JCB 8C, the biggest 360 o tracked excavator to that d ate, is introduced.

1973

JCB 806 and 807, a completely new range of tracked excavators with dual hydraulics launched and high percentage of parts interchangeability. interchangeability. Range expanded to include JCB 808 and 805.

1974 - 78

Updated 800 series tracked excavators introduced.

1984

811,812,814,818 and 820 introduced with servo controls.

1988 - 89

Launch of 812, 814, 816, 818 and 820 Super hydraulic excavators.

1989

The 281,750 sq.ft. site at Uttoxeter was bought to house JCB Special Products. Products. The building was originally owned by Bamfords Limited, who manufactured agricultural machinery. This communication and the information within is intended for JCB and JCB dealer personnel only, for information purposes, is confidential and may not be communicated to any third party. Whilst the information is believed to be correct, no guarantee is given by JCB as to its accuracy and its use may not be attributed to JCB.

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HIST HI STO ORY OF JC JCB B 360O EXCAVATORS 1991

(cont)

Launch of the JCB JS range of excavators (R3 series) in a joint venture with Sumitomo Construction Machinery (SCM) of Japan. JCB SCM based at Bamford Works, Uttoxeter. Uttoxeter.

1994

Launch of the first JCB wheeled excavators, the 13 tonne JS130W and the 15 tonne JS150W.

1995

Special Products moved to a new facility in Cheadle leaving JCB Heavy Products the space required required to continue its impressive growth.

Sept. 1995 May 1996

Launch of the XO series JS200 and JS240, replacing the R3 models. Launch of XO JS220 XD and JS260 XD demolition machines. Launch of XO JS220 and JS260 JS260 additional models to the range.

Sept. 1996

Launch of XO JS130 and JS160 replacing the original R3 models (JS130 and JS150).

1997

Launch of XO range of wheeled excavators. JS130W and JS160W to replace replace the original (R3) models. Launch of the JS130HD, a heavy duty forestry machine. Launch of XO JS330 to replace the JS300 model. Launch of the XO JS70. JS70.

O R T N I 3 0 / 7 0

1998

1,000th JS130 and JS200 tracked tracked excavators produced. Introduction of JS tracked excavators to US market.

2000

AMS (Advanced Management System) and new JZ70 introduced. JCB Heavy Products wins the Queen’s Award for Export Achievement.

2001

Two new wheeled excavators - the JS145W and JS175W are launched. The new JS460 is launched - this is the heaviest machine manufactured by JCB to date.

2003

The ‘New Generation’ JS200, JS210 and JS220, JCB’s most advanced excavators ever are launched at Intermat. The improvements on these machines will be cascaded down the range in the coming years.

KEY COM COMPON PONENTS ENTS The Undercarriage This consists of a track frame and tracks or axles and wheels, hydraulic drive motors, reduction gears and slewing ring. Wheeled excavators often also have stabilisers fitted at either the front, the rear or sometimes both.

INTRO0002

2

INTRO0003

This communication and the information within is intended for JCB and JCB dealer personnel only, for information purposes, is confidential and may not be communicated to any third party. Whilst the information is believed to be correct, no guarantee is given by JCB as to its accuracy and its use may not be attributed to JCB.


KEY COM COMPON PONENT ENTS S

(cont)

The Upperstructure This consists of a rotating superstructure mounted onto the slewing ring incorporating the power unit, hydraulic pumps, valves, slewing motor motor,, fuel tank, hydraulic tank and the operators cab.

Engine All JS excavators are are fitted with Isusu diesel diesel engines. engines. They vary in specification and capacity but all have mechanically governed

INTRO0004

injection pumps.

Fuel System The fuel system in all JS excavators works in essentially the same way. A supply of fuel is kept in the fuel tank from which it passes through a separator, removing any water or large debris. From there it flows on to the main fuel filter where it passes through a paper membrane removing very fine particles in order to prevent damage to the fuel pump. The fuel lift pump supplies clean fuel to the fuel injection pump which pressurises the fuel and distributes it to injectors within the combustion chambers.

Turbo Charger

Slew Ring

JCB excavators, with the exception of the JZ70, have

This component allows the upper structure to slew (rotate)

turbocharged engines. A turbocharger is designed to gain extra

about the undercarriage while still carrying the loads imposed

power from an engine without significantly increasing its weight

during use. It is made of two parts held apart by lubricated

or size. This is achieved by using energy from the exhaust gases

ball bearings spread around the circumference of the ring. All

to force air into the pistons. The exhaust exhaust gases are used to drive

JCB excavators have internal gear teeth which mesh with the

a turbine at very high speed and the energy developed drives an

slew motor to allow controlled rotation.

impeller which forces air into the engine at a raised pressure. As more air is forced into the combustion chamber more fuel can be added and hence more power is developed.

Rotary Coupling This device is mounted in the centre of the slew ring and enables

Intercooler

the excavator to slew continuously whilst still allowing the

The pressure developed by the turbocharger causes the

track motors or do zer blades).

hydraulic oil to flow to components in the undercarriage (i.e.

temperature of the air intake to increase slightly slightly.. When gases heat up they expand and subsequently less air is forced into the combustion chamber. As the turbocharger works by forcing extra air into the engine this expansion decreases the power gained by using the turbocharger turbocharger.. A solution to this problem is the addition of an intercooler to the system.

The Front End This comprises the main boom, dipper arm and bucket or other attachment.

An intercooler works in the same way as a radiator, radiator, the air from the intake, once compressed by the turbocharger is passed through a series of narrow pipes on its way to the combustion chamber. A fan blows air over the pipes causing the air within them to cool cool down down and contra contract. ct. Hence more air air is driven driven into into the combustion chamber and more power is developed upon ignition. Some of the excavators in the JS range use intercooled engines. INTRO0005 This communication and the information within is intended for JCB and JCB dealer personnel only, for information purposes, is confidential and may not be communicated to any third party. Whilst the information is believed to be correct, no guarantee is given by JCB as to its accuracy and its use may not be attributed to JCB.

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Contents

Section 2. PRODUCT RANGE

1. JS 130W - JS 145W - JS 160W.

2. JS 175W - JS 200W.

3. JZ 70 - JS 130 - JS 130HD - JS 160 L/NL.

4. JS 180 L/NL - JS 200 L/S/N - JS 210L - JS 220 L/S/N.

5. JS 220 LR - JS 220 XD L/S/N – JS 240 L/S/NL JS 260 L/S/NL.

6. JS 260 XD L/S/N – JS 330 L/NL – JS 330 XD L/NL – JS 460.

Product Range (Wheeled)

JS130 W

1 0 0 0 E G R O R P

Nominal Weight

13 tonnes

Operating Weight

12.7 - 14.96 tonnes

Engine

Isuzu

Net Power (80/1269/EC)

63 kW (85 hp)

Max. Dig Depth

5.93 m

Max Reach at Grou nd Level

9. 0 m

Maximum Loa dover Heigh t

7. 95 m

Travel Speed (high)

27 km/h (16.8 mph)

Slew Speed

13.4 rpm

Max. Bucket Capacity

0.80 cu.m (1.05 cu.yd)

(SAE heaped)

JS145 W

2 0 0 0 E G R O R P

Nominal Weight

14.5 tonnes

Operating Weight

12.7 - 14.96 tonnes

Engine

Isuzu


72 kW (96 hp)

Max. Dig Depth

5.93 m

Max Reach at Ground Level

9.0 m


7. 95 m

Travel Speed (high)

30 km/h (18.6 mph)

Slew Speed

13.4 rpm


0.80 cu.m (1.05 cu.yd)

0 7 / 0 3 P R O R G E

(SAE heaped)

JS160 W

3 0 0 0 E G R O R P

Nominal Weight

16 tonnes

Operating Weight

15.41 - 17.77 tonnes

Engine

Isuzu


72 kW (96 hp)

Max. Dig Depth

6.23 m


9.28 m


7. 58 m

Travel Speed (high)

25 km/h (15.5 mph)

Slew Speed

11.3 rpm


0.90 cu.m (1.18 cu.yd)

(SAE heaped)


1

Product Range (Wheeled)

JS175 W

4 0 0 0 E G R O R P

Nominal Weight

17.5 tonnes

Operating Weight

15.6 - 18.0 tonnes

Engine

Isuzu Tier II compliant

Net Po wer (80/ 1269/EC)

102 kW (135 hp )

Max. Dig Depth

6.23 m


9.28 m

Maxim um Lo ado ver Height

7.58 m

Travel Speed (high)

30 km/h (18.6 mph)

Slew Speed

11.3 rpm


0.90 cu.m (1.18 cu.yd)

(SAE heaped)

JS200 W

5 0 0 0 E G R O R P

E G R O R P 3 0 / 7 0

Nominal Weight

20 tonnes

Operating Weight

18.8 – 21.4 tonnes

Engine



102 kW (135 hp )

Max. Dig Depth

6.48 m


9.85 m

Maxim um Lo ado ver Height

7.3 m

Travel Speed (high)

30 km/h (18.6 mph)

Slew Speed

10 rpm


1.19 cu.m (1.56 cu.yd)

(SAE heaped)

2


Product Range (Tracked)

JZ70 Nominal Weight

7 tonnes

Operating Weight

7 - 8 tonnes

Engine



44 kW (58 hp)

Max. Dig Depth

4.57 m


6.68 m

Tracking Speed (high)

5 km/h (3.1 mph)

Slew Speed

9.5 rpm


0.30 cu.m (0.39 cu.yd)

6 0 0 0 E G R O R P

(SAE heaped) Lift Capacity at 4m Front/Rear

1901/1464 kg

JS130 Nominal Weight

13 tonnes

Operating Weight

13.2 - 13.9 tonnes

Engine

Isuzu


63 kW (85 hp)

Max. Dig Depth

6.05 m


8.66 m


5.5 km/h (3.4 mph)

Slew Speed

13.4 rpm


0.80 cu.m (1.05 cu.yd)

7 0 0 0 E G R O R P

(SAE heaped)

JS130 HD Nominal Weight

13 tonnes

Operating Weight

16.6 tonnes

Engine

Isuzu


65 kW (87 hp)

Max. Dig Depth

6.05 m


8.79 m


5.5 km/h (3.4 mph)

Slew Speed

13.4 rpm


0.80 cu.m (1.05 cu.yd)

8 0 0 0 E G R O R P

(SAE heaped)

JS160 L/NL Nominal Weight

16 tonnes

Operating Weight

16.0 - 16.9 tonnes

Engine

Isuzu


72 kW (96 hp)

Max. Dig Depth

6.46 m


9.32 m


5.5 km/h (3.4 mph)

Slew Speed

11.3 rpm


0.90 cu.m (1.18 cu.yd)

9 0 0 0 E G R O R P

(SAE heaped)


3

0 7 / 0 3 P R O R G E


JS180 L/NL

0 1 0 0 E G R O R P

Nominal Weight

18 tonnes

Operating Weight

18.12 - 18.48 tonnes

Engine

Isuzu


72 kW (96 hp)

Max. Dig Depth

6.45 m


9.32 m


5.5 km/h (3.4 mph)

Slew Speed

11.3 rpm


0.90 cu.m (1.18 cu.yd)

(SAE heaped)

JS200 L/S/N

1 1 0 0 E G R O R P E G R O R P 3 0 / 7 0

Nominal Weight

20 tonnes

Operating Weight

19.85 - 21.2 tonnes

Engine



102 kW (138h p)

Max. Dig Depth

6.60 m


9.70 m


5.5 km/h (3.4 mph)

Slew Speed

12.9 rpm


1.19 cu.m (1.56 cu.yd)

(SAE heaped)

JS210 L

2 1 0 0 E G R O R P

Nominal Weight

21 tonnes

Operating Weight

21.1 - 21.7 tonnes

Engine



102 kW (138h p)

Max. Dig Depth

6.60 m


9.70 m


5.5 km/h (3.4 mph)

Slew Speed

12.9 rpm


1.19 cu.m (1.56 cu.yd)

(SAE heaped)

JS220 L/S/N

3 1 0 0 E G R O R P

Nominal Weight

22 tonnes

Operating Weight

21.1 - 23.5 tonnes

Engine



102 kW (138h p)

Max. Dig Depth

6.60 m


9.81 m


5.5 km/h (3.4 mph)

Slew Speed

12.9 rpm


1.19 cu.m (1.56 cu.yd)

(SAE heaped)

4



JS220 LR Nominal Weight

22 tonnes

Operating Weight

21.57 - 22.1 tonnes

Engine

Isuzu

Net Po wer (80/1269/EC)

102 kW (138h p)

Max. Dig Depth

11.99 m


15.49 m


5.5 km/h (3.4 mph)

Slew Speed

12.9 rpm


0.55 cu.m (0.72 cu.yd)

(SAE heaped)

JS220 XD L/S/N Nominal Weight

22 tonnes

Operating Weight

23.069 tonnes

Engine

Isuzu


102 kW (138h p)

Max. Dig Depth

6.60 m


9.81 m


5.5 km/h (3.4 mph)

Slew Speed

12.9 rpm


1.19 cu.m (1.56 cu.yd)

(SAE heaped)

JS240 L/S/NL Nominal Weight

24 tonnes

Operating Weight

23.75 - 24.62 tonnes

Engine

Isuzu


115 kW (154h p)

Max. Dig Depth

7.32 m


10.60 m


5.5 km/h (3.4 mph)

Slew Speed

10.4 rpm


1.46 cu.m (1.91 cu.yd)

4 1 0 0 E G R O R P

(SAE heaped)

JS260 L/S/NL Nominal Weight

26 tonnes

Operating Weight

24.92 - 27.19 tonnes

Engine

Isuzu


115 kW (154h p)

Max. Dig Depth

7.40 m


11.13 m


5.5 km/h (3.4 mph)

Slew Speed

10.4 rpm


1.46 cu.m (1.91 cu.yd)

5 1 0 0 E G R O R P

(SAE heaped)


5

0 7 / 0 3 P R O R G E


JS260 XD L/S/N

6 1 0 0 E G R O R P

Nominal Weight

26 tonnes

Operating Weight

26.23 - 26.29 tonnes

Engine

Isuzu


115 kW (154h p)

Max. Dig Depth

7.40 m


11.13 m


5.5 km/h (3.4 mph)

Slew Speed

10.4 rpm


1.46 cu.m (1.91 cu.yd)

(SAE heaped)

JS330 L/NL

7 1 0 0 E G R O R P E G R O R P 3 0 / 7 0

Nominal Weight

33 tonnes

Operating Weight

31.9 - 32.6 tonnes

Engine



178 kW (239 hp )

Max. Dig Depth

8.19 m


11.68 m


5 km/h (3 mph)

Slew Speed

9.5 rpm


1.85 cu.m (2.41 cu.yd)

(SAE heaped)

JS330 XD L/NL

8 1 0 0 E G R O R P

Nominal Weight

33 tonnes

Operating Weight

32.5 - 32.9 tonnes

Engine



178 kW (239 hp )

Max. Dig Depth

8.19 m


11.68 m


5 km/h (3 mph)

Slew Speed

9.5 rpm


1.85 cu.m (2.41 cu.yd)

(SAE heaped)

JS460

9 1 0 0 E G R O R P

Nominal Weight

46 tonnes

Operating Weight

45.05 - 46.8 tonnes

Engine



228 kW (305h p)

Max. Dig Depth

9.00 m


12.91 m


5 km/h (3 mph)

Slew Speed

9.2 rpm


2.25 cu.m (2.94 cu.yd)

(SAE heaped)

6


Contents

Section 3. KEY FEATURE SUMMARY, XO TRACKED SERIES

1. The JS Range of Tracked Excavators - JZ 70 XO.

2. Machine Models. – JS 130, JS 160 & JS 180 XO – JS 240/260 XO – JS 330 & JS 460 XO.

3. Description. - Attachments, Tipping Links, Boom.

4. Description. - Dipper, Lubrication, Rams, Hose Burst Check Valves, Auxiliary Service.

5. Undercarriage - Construction, Tracking Performance.

6. Track Chain & Rollers, Track Adjustment, Motors, Braking. – Superstructure - Construction, Single key Locking, Tanks.

7. Slewing Gear, Cooling System, Engines.

8. Exhaust System, Fuelling, Noise Levels, Electrical System, Hydraulics, Pumps.

9. Pump Control/Work Modes/AMS, Power Boost, Engine Speed, Additional Features of AMS, Electrical Control System.

Contents

10. Flow on Demand, Excavator Valve Block, Cushion Control, Servo System, Swing Brakes, Hydraulic Tank, Filtration.

11. Cab & Controls, cab Construction, Windows, Comfort, Servo Controls, Switches, Monitor.

12. Service and Maintenance, Low Maintenance Requirements.

Key Feature Summary, XO Tracked Series

KEYFE0001

THE JS RANGE OF TRACKED EXCAVATORS OFFERS :• Proven Japanese components, delivering great productivity, reliability and economy. • The renowned Isuzu engine offering efficiency, power and performance. • Advanced hydraulic control systems for ease of use with Plexus filtration. • The JCB cab is one of the largest and most comfortable available. • Advanced Management System (AMS) gives exceptional control and ergonomics (simplified version on JZ70). • Uprated fabrications and structures to cope with arduous European conditions. • The JCB distribution and service network. The products themselves have a number of technological features designed to make life easier and more comfortable for the machine operator, and more cost effective for the machine owner. Nor has the ‘green’ issue been overlooked. High efficiency engines have ‘clean’ exhaust emissions, giving pollution levels well within anticipated European legislative standards; and quiet operation minimises invasive noise, both at the operators’ position and in the immediate vicinity of the machine. And of course all XO machines have the unique Plexus filter system which cleans oil down to 1.5 microns and extends hydraulic oil changes to 5000 hours and hydraulic filter changes to 1000 hours.

JZ70 XO A ‘compact’ excavator, with a nominal 7.0 tonnes operating weight,

A feature which further increases the machines’ manoeuvrability in

the JZ70 is a new “zero-tailswing” excavator (on 600mm shoes).

confined spaces is the double pivoted ‘offset’ boom option which

This allows the JZ70 to access small, restricted sites without fear of

can be moved to give a parallel digging line outside the tracks.

collision damage to the counterweight. Examples include working

Another item fitted as standard is a dozer blade, extending machine

within part of the carriageway width of ordinary roads, between

versatility to site stripping and levelling as well as rapid backfilling of

existing buildings or actually inside buildings. The compact

previously dug trenches. Rubber tracks are available in place of the

dimensions have been achieved without sacrificing any lift capacity

standard triple grouser type for operation on easily damaged

or breakout performance, whilst a large size cab makes the JZ70

surfaces. The machine has an Isuzu 4 cylinder naturally

stand out from the compact cabs of the Japanese competition.

aspirated engine.


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MACHINE MODELS

JS130, JS160 & JS180 XO Mid-range machines with nominal weights from 13 to 18 tonnes, Isuzu 4 cylinder turbocharged engines, power ‘open centre’ hydraulic systems using twin, variable displacement piston pumps, load sensed to develop flow or pressure as the dig cycle demands. Excavator control is enhanced by the AMS (Advanced Management System) which is able to define the pump operating power band to provide high productivity, or precise control with maximum fuel economy according to the prevailing work conditions. The pressed and rolled frame steel cab is acoustically isolated for quietness, has a high quality paint finish, and is designed to ISO dimensional stand ards. Equipment includes tinted glass, opening front screen (bottom screen slides into the top for easy overhead storage); radio and personal item stowage positions.

JS240/260 XO

Machines with nominal weights from 24 to 26 tonnes powered by 6 cylinder turbocharged Isuzu engines. To meet customer preference and regional regulations, the undercarriages are available in three different lengths and widths, and the heavy duty excavator ends are available with Monoboom, or Triple Articulation Boom (T.A.B.) on the JS260. These machines have ‘open centre’ flow on demand hydraulics protected by the JCB Plexus filter system. The Plexus constantly filters the oil to 1.5 microns and allows longer intervals between major services and enhances machine reliability. AMS gives four work modes to match the machine to prevailing job conditions and a one-touch power boost button gives extra digging power when required. The fully adjustable suspension seat can be moved independently or in conjunction with the control levers to ensure operator comfort. E F Y E K 3 0 / 7 0

JS330 & JS460 XO Top of the range machines with breakout power and lift cap acity to make easy work of tough digging and high productivity bulk earthmoving. Machine nominal weights are 33 and 46 tonnes respectively, depending on machine specification. JS460 is built to ‘heavy duty’ specification allowing working on tough extraction duties. Long undercarriages again offer maximum stability ‘under power’ and on adverse gradients. Other quality features are those common to other machines in the range and include high specification cabs, extensive electronic control of pump and engine power (AMS) and full servo operation of all controls. Air conditioning is also fitted as standard on both of these models. Noise levels are again well below legislative standard requirements for maximum operator comfort and environmental acceptance. Power is again provided by 6 cylinder turbocharged Isuzu engines, developing power to spare an d with exhaust gas emissions meeting the requirements of European Community ‘low emission’ standards.

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DESCRIPTION (TRACKED) , EXCAVATOR UNIT Attachments Powerful breakout forces contribute towards the versatility of the excavator end and standard excavating buckets and extra wide ditching / grading buckets are available in a range of sizes and capacities to suit the various machine groupings. Both general purpose and heavy duty buckets are available for reliable service in a variety of excavating conditions. All are fitted with hardened steel pivot pins and bearings, fully sealed to exclude dirt. See Attachments & Options chapter for the range of buckets available. Pivot centres are ‘individual’ on all machines. Buckets can also be reverse mounted at the dipper arm end for face shovel duty. JS range machines are also fully capable of driving rock breaker hammers and have the necessary auxiliary valve spool and excavator end pipework bracketry already in place. Hammers are available for all machines. See Attachments & Options chapter.

Tipping Links Machines equipped with Hose Burst Protection Valves (see Hydraulics section) can also be provided with link mounted lifting shackles or hooks. JZ70 and JS130 can be equipped with a 1 tonne capacity lift point and shackle to comply with the UK and EU ‘one tonne’ rule.

Boom Monoboom construction is used for all machines in the range. High quality steel is used and extensive use is made of robot welding. Welds are ultrasonically tested for integrity. Stress relieving and final shotblasting before painting reduce stresses

0 7 / 0 3 K E Y F E

induced during construction to ensure problem free service for the life of the machi ne (shotb lastin g also provid es an excellent ‘key’ for the paint, helping to maintain the appearance of the machine). Monoboom geometry combines good loadover height particularly useful when loading high sided vehicles - with high

MONOBOOM

lift capacity, valuable when extracting trench boxes etc. On the JS130, JS220 and JS260 models, an optional hydraulically adjustable two-piece boom (T.A.B. -Triple Articulated Boom) allows the effective boom length to be adjusted for applications which require greater flexibility such as working within trench boxes. Also, (XD) Xtra Duty builds available on the JS330, JS260 and JS220 models have reinforced dipper and bucket linkage for arduous work such as demolition.

TRIPLE ARTICULATED BOOM (TAB)


3


Dipper Dipper construction and manufacture is similar to that used for the boom and both components are designed and built with extra strength for use with breaker hammers. JS460 machines have extra reinforcement built-in to the dipper to cater for hard rock extraction duties. Each machine has a choice of d ipper arm lengths to suit the intended application. In every case, the combination is designed to ‘fold’ to give as low as possible transport height.

Lubrication On machines from JS160 upwards, boom lift and dipper ram pivot greasing points are grouped b ehind the boom for quicker routine greasing. Bucket greasing points have substantial protection against mechanical damage. All grease points are positioned to be accessible from the ground or from the top of the tracks, and pivot pin seals extend the lubrication interval to 50 hours (bucket pivots are double sealed to retain grease and to keep out dirt, and have 10 hour greasing intervals). The JS460 has chrome pins and phosphor-bronze carbon bushes for 1000 hour greasing. The bucket pins are still chrome with bronze and carbon bushes but daily greasing is recommended.

Rams Flanged hydraulic connections and bolt-on end caps are used on rams fitted to JS130 upwards (welded fittings and screwed end caps are used on JZ70). Pipework is securely clamped to prevent vibration or other mechanical damage. End damping, which ‘buffers’ the end of the ram travel to reduce shock loadings, is fitted to each end of the dipper ram, to the lift side of the boom rams and to the ram ‘open’ (bucket crowd) end of the bucket ram.

Hose Burst Check Valves (HBCV’s) E F Y E K 3 0 / 7 0

Boom lift and dipper HBCV’s are optional on all models. HBCV’s prevent gravity fall of the boom / dipper in case of hose failure and also prevent ‘ram creep’ when the machine is holding a load stationary (boom ram mounted valves are a statutory requirement in all EU countries where machines are used for lifting over 1 tonne. In addition, safety authorities in certain countries require a dipper ram mounted valve to be fitted). Where machines are not fitted with HBCV’s, then load holding valves are used to reduce ‘ram creep’. HBCV valve construction includes generously sized porting and internal galleries to maintain full flow when the machine is working.

Auxiliary Service Auxiliary hydraulic service valves, and pip ework support brackets, are fitted to all machines (except JZ70 with offset boom), making later installation of hammers etc. much simpler. The one-way flow hammer pipework installation returns oil through an in-line filter before the main hydraulic filter, then direct-to-tank to maintain oil cleanliness and to minimise back pressure. Other auxiliary service options such as auxiliary low flow and combined hammer/auxiliary circuits are also available depending on model and attachment variants.

4



UNDERCARRIAGE

Construction All undercarriages are heavy duty steel and fully welded for structural reliability. Various sizes of undercarriage are available, depending on the model, to achieve transit w idth and application requirements. These are identified after the m odel number; e.g. LC = long carriage, N = narrow etc. Track side frames are designed with sloping top faces and with relief holes below the top rollers to prevent dirt build up and to make cleaning-off easier. Other structural features include a recovery point (both front and rear) and heavy duty steps with anti-slip surfaces. The slewing turret is made as large as possible to give maximum bearing area to the superstructure. Slew bearing lubrication is via grease points on the outside of the turret. Two semi-circular plates protect the hoses and pipes inside the slewing turret and are relatively easy to remove for maintenance. XD build s have reinfo rced plate s for extra protect ion.

KEYFE0002

The JS460 uses a long heavy duty undercarriage as standard, giving extra stability and strength for tough applications. 0 7 / 0 3 K E Y F E

Tracking Performance All model s except the JZ70 have 3 track speed s and incorporate an autoshift from high to medium when tracking becomes more difficult, e.g. when turning or climbing. When tracking becomes easier, the drive motors autoshift back to the high speed for maximum operator convenience and control. The extra low speed provides fine control when required; e.g. when loading machine onto a truck. NOTE :- It is important to point out to machine users that, over long distances, machines should be driven in the ‘forward’ direction with the track sprocket to the rear. This will ensure

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maximum life from track running gear by avoiding the additional stresses and wear caused by relative movement between bush and sprocket tooth when travelling in reverse.


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Track Chain & Rollers Rollers are lubricated and sealed for long service life. Central track guides are fitted as standard to a ll but the JS70, helping to keep the chain aligned with the rollers, particularly when the machine is turning, digging over-the-side or working on sloping sites. Large pitch chains are used for strength and resistance to shock loads and with a choice of track plate widths to suit ground conditions and transportation width limits. Twin track guards a re standard on all machines from the JS180 upwa rds.

Track Adjustment Running gear is conventional in respect of track tensioning and recoil shock absorption. Spring loaded yokes carrying the idler wheel and absorb ground shock, whilst grease packed ‘hydraulic’ pistons maintain tension and provide adjustment for wear. Sprockets are bolt-on type, more easily renewed when necessary. NOTE :- Track life can be extended by ensuring that tracks are NOT run overtight and machines run in the forward direction as much as possible, enabling the recoil units to absorb shock loads most effectively.

Motors

Braking

Track motors are high efficiency variable stroke piston type, with

Two braking systems are fitted; an inbuilt ‘counterbalance valve’

pre-set swash angles for each speed. Final drive is two stage

retains hydraulic oil against a relief valve on both sides of the motor

epicyclic to bolted-on sprockets. Drive systems are contained

to prevent machine runaway on gradients. An automatic spring

within the track frame width and have heavy gauge covers for

applied, hydraulically released mechanical brake holds the machine

maximum protection.

when parked.

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Construction The superstructure is built on a substantial fabricated steel central frame, wide spaced to give maximum lateral and torsional support to the boom. Main components are arranged alongside and between the frame with a common layout between models. Deck areas formed by the components have non-slip pads and are fitted with access steps and handrails for safety. Full undercovers reduce noise emission and large clearance between tracks and mainframe reduce the likelihood of damage to internal components from site dirt, rocks and stones etc. Superstructure width is limited to 2.5m or less on models up to the JS260 for easier transportation and 3.0m on the JS330. NOTE :- The undercarriage and track plates used will obviously affect the transport width. Check in the specification sheet.

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Single Key Locking Engine and hydraulic compartments have lockable covers with, on larger machines, torsion bar assisted opening. All service door locks, caps, cab door and the starter switch use the same key for convenience.

Tanks Hydraulic tank positions are set as close as possible to the pump inlets to help ‘feed’ the pumps. Sight level gauges are provided on both fuel and hydraulic tanks. Strainers are also fitted to fill points to reduce the risk of dirt contamination, and drain taps assist on-site maintenance. Machines also have a lockable compartment for tools and equipment. When fitted, the electric refuelling pump is housed adjacent to the fuel tank. Electric refuelling is standard equipment on machines from JS200 upwards.

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Slewing gear All machines have a fixed displacement piston motor slew drive with two stage epicyclic reduction gearing. Final drive is via a spur gear and internally toothed gear ring, fully enclosed and grease bath lubricated (machines are able to work in water to the top of the tracks without detrimental effect). Greasing is simplified by a readily accessible cover between the lift rams. The large diameter ball type slewing bearing and ring gear allow high driving torque to be generated with greatest efficiency. Motors are braked hydraulically after the oil flow is shut-off and then mechanically by a disc type parking brake on the motor shaft, shortly after the superstructure has been brought to a standstill (see also Hydraulics section). For transportation, machines are fitted with a switch activated park brake which prevents slew operation.

Cooling System The cooling package, including extra large radiator, fitted to all machines is effective for all climates, allowing working in ambient temperatures of up to 46oC. A fine mesh grille in front of the radiator, easily removed for cleaning, protects the radiator and oil coolers from clogging in dirty environments. For safety, a guard is fitted over the cooling fan.

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Engines The prime mover on all machines is one of the Isuzu range of diesel engines, four cylinder on machines up to and including the JS180 and six cylinder on all others. Isuzu engines have an international reputation for sustained performance and for long term reliability. For full details for JS engines see Tender and Quotation Data section. Engines are power matched to the hydraulic requirement of the machine, for

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maximum efficiency. Turbocharging is used on JS130 to JS460

machines, giving all-climate operation and automatic compensation for altitude. The engine on the JZ70 is naturally aspirated. A glow plug in each cylinder with 20 second automatic pre-heat at engine temperatures below 10°C (50°F) ensures quick starting from cold and minimises start-up smoke. All models have the latest Isuzu engine which meets current European Low Emission Regulations. Air induction systems incorporate twin element filtration for greater engine security in dusty conditions. On the JZ70 and JS330 there is a single filter fitted, all other machines have an extra bypass filter, increasing the engine oil and filter change period from 250 hours to 500 hours. An electric motor driven throttle regulates engine speed via the AMS system.


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Exhaust System Exhaust systems are drained to below the engine compartment; this b oth prevents water build-up in the exhaust system (w hich could damage the turbocharger) and also avoids exhaust blown soot contaminating the engine compartment.

Fuelling Bosch type in-line fuel injection pump s ensure efficient engine performance and low maintenance. Twin filtering is adopted on the fuel system, with a spin-on main filter and red-line float agglomerator. The float alerts the operator to the need to drain-off water. A strainer fitted to the fuel tank inlet also acts as ‘preventative maintenance’.

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Efficient running and a large bore exhaust also reduce operational noise and, in conjunction with careful routing of intake air, keeps machine ‘bystander’ noise to low levels. All machines have in-cab and external noise levels below the new dynamic EU standards. For full details of noise levels see Tender and Quotation Data section.

Electrical System The batteries are housed out of the way of dirt, water and other site debris and are close enough to the engine to minimise voltage drop. E F Y E K 3 0 / 7 0

Heavy duty batteries and 40 Amp alternator supply a 24 Volt electrical system providing an extra margin for easier starting in cold conditions and reliable power and back-up for engine pre-heat, lighting, control systems and auxiliaries. An isolator cuts off the electrical supply to all services for extra safety wh en the engine is stopped from the keyswitch. Working lights, fitted at the top of the boom and on the right hand front of the superstructure are standard fitment, along with a socket for an inspection lamp or warning beacon. For nigh t time working, additional cab mounted and rear m ounted work lights are available as an option.

Hydraulics JCB tracked excavators use only the finest Japanese hydraulic components, and this is a big selling point with customers. A table of the suppliers and components used is in the Tender and Quotation Data section.

Pumps Variable flow twin piston pumps are used throughout the range with

The power input requirement (work rate) of the pump is a function

pressure sensing and electronic / servo control systems to ensure

of both volume flow and effort needed to overcome ground

maximum efficiency. ‘Load sensing’ from the digging unit

resistance. To maintain a constant engine load, flow reduces as

automatically sets pump output for power or speed and the system

pressure increases and vice versa. This work rate can be shown as a

provides both ‘flow on demand’ (pump output proportional to

powerband curve (or series of curves) which represent engine

control lever movement) and precise regulation of pump output for

output when flow is plotted against pressure.

fine control over the excavator and for minimum fuel usage. AMS stands for Advanced Management System, the name given

Piston pumps develop varying rates of flow by varying the angle of

to the electrical / electronic system which controls the engine and

the driving swash plate. Piston stroke - and therefore flow rate -

hydraulics speeds and power outputs, and also monitors the status

increase with increasing angle. Conversely, reducing the angle

(e.g. temperatures, work mode etc.) at which the machine is operating.

shortens the stroke and reduces the flow. Pressure is created as flow

AMS is fitted to all the XO models, with the exception of the JZ70

attempts to overcome ground resistance at the bu cket cutting edge.

which has a simplified variant of AMS.

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Pump Control / Work Modes / AMS (Not JZ70) Primary control is by pressure sensing directly from the excavator circuit in use at the time. Swash angle is au tomatically reduced to develop greater pressure against ground resistance or increased to give a faster work rate as the load reduces. By controlling the range of movement of the swash plate, the powerband of the pump can be precisely controlled to maintain constant engine load and thereby operational economy. This control is the function of AMS which maintains hydraulic power output at 100%, 90% or 70% of available engine power as set by the operator on H, S, L control. H, S and L refer generally to the digging conditions :-(H) equates to Heavy digging or High production rates and, in this mode, engine speed sensing is used to allow the pumps to take 100% of available engine power up to the maximum engine speed setting. This provides maximum output for jobs such as continuous truck loading. (S) is for standard - ideal for the majority of general excavation and loading work. This is less demanding and the pumps are able to meet the digging requirement using only 90% engine power and at reduced engine speed, saving fuel in the process. (L) is for light duties such as finishing and grading work. Pump output under these conditions is restricted to 70% of available power which reduces fuel consumption and provides reduced boom d own speed for extra control while maintaining sufficient speed of operation to carry out tight (e.g. grading) duties quickly. (F) is for fine duties such as precision lifting / positioning of material and items such as pipes, and for heavy object handling work e.g. trench box extraction. Power usage is limited to 70%, also pump swash angle is limited reducing flow and speed for precision control but with extra pressure available for difficult, heavy work.

Power Boost (Not JZ70) When either the H or S mode is being used, extra tearout can be applied w hen digging becomes difficult by a ‘one-touch’ press of the front right hand lever mounted switch. For eight seconds, a 10% pressure increase is available, enabling the bucket to overcome resistance caused by harder ground conditions. In F mode this increased pressure is perminately activated.

Engine Speed The selected engine speed (set by the rotary throttle dial) can be instantly reduced to idle speed by pressing the top right hand lever mounted switch. Another ‘one-touch’ of this button brings the engine back up to speed, giving the fastest and most convenient engine speed possible. In addition to the one-touch control, there is a selectable auto-idle feature which automatically cuts the engine speed down to idle a short period after track or excavator controls have been released, giving consequent fuel savings. Importantly, engine speed can only be regained by intentional selection of the one-touch button, avoiding accidental increases in operational speed.

Additional Features Of AMS (Not JZ70) The AMS system has a self diagnostic system in-built for use by the service engineer to interrogate and check the machine’s electrical control system settings for optimum performance, for fast fault diagnosis and for maximum up-time. Providing written information to the operator is an LCD (liquid crystal display) message monitor panel giving clear information of the machine’s operating condition. Any of 12 different languages can be set for this message monitor plus; automatic speed settings can be input to avoid overspeeding of hydraulic hammers; adjustable auto-idle delay to suit operators’ preference; auto selection of S mode and medium track speed; engine shut down if oil pressure drops and automatic engine warm up are additional features to be found in the latest generation Advanced Management System (AMS).

Electronic Control Systems Electronics provide the degree of flexibility inherent in the control of JCB excavators, particularly on engine m anagement and hydraulic flow and pressure. However, for the customers peace of mind, the control panels carry an override switch which bypasses the AMS system in the unlikely event of failure, allowing the machine to be operated in the ‘standard’ mode to get out of trouble.


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Flow On Demand The servo operated ‘flow on demand’ function works in conjunction with the primary control. It limits the pump flow rate to that called for by the degree of lever movement. Excavator operating speed is then proportional to lever movement for greater machine control. Another part of the ‘flow on demand’ system returns the pump an gle to minimum when the controls are released. This reduces the amount of oil flowing in the circuit, reducing friction losses and heat build up, again saving on fuel.

Excavator Valve Block The valve system is ‘open centre’ with ‘multi-function’ flow distribution. When no service is selected, an open gallery allows free passage of oil from pump to tank, minimising resistance to flow in the circuit. Combined pump flow operation is available on boom, dipper and bucket. This gives extra fast operation on these services when operated ‘solo’ for fast excavating cycles. On some models, the auxiliary service can be fed with this combined (or merged) pump flow to give rapid operation of large attachments such as demolition cutters / crushers. ‘Multi-function’ ensures that several services can operate simultaneously. In practice this means, for example, straight line tracking even with excavator services operated at the same time - for complete machine control and effective ‘de-bogging’.

Cushion Control (Not JZ70) An add itional valve in the servo system slows engagement / disengagement of boom and dip per services when the control lever is moved suddenly. This has the effect of cushioning the ram action, reducing the shock load on the excavator (and on the operator), and gives a smooth ‘feel’ to the controls (for the skilled operator who wants the fastest response time from the controls - or to shake free sticky material from the bucket - it can be deselected). It is a utomatically re-selected after an engine key sw itch stop / re-start - but not if other engine stop systems are used. Quick warm-up for the servo services is provided by the cushion control valve. Oil flows around the valve on the heat exchanger principle, achieving faster control response and maximum operating efficiency in the system much more quickly than allowing the E F Y E K 3 0 / 7 0

oil to warm up naturally.

Servo System Independently fed from its’ own pump, the servo system is responsible for easing control lever operation and also for regulating the main pump in response to signals from the electronic system. Servo pressure is applied to the valve spools themselves to take the effort out of excavator operation, and also to the control circuitry within the pump casing to regulate flow and pressure as the digging cycle demands.

Swing Brakes Motors are braked hydraulically after the oil flow is shut off by ‘locking up’ the fluid between control valve and motor. This builds up pressure which absorbs energy, rapidly bringing the superstructure to a stop with minimal overrun. Cross line relief valves progressively release the pressure, the mechanical parking brake then takes over automatically, preventing superstructure movement when working on slopes etc. This brake can be switch selected to prevent slewing and then becomes the slew ‘lock’ in place of a mechanical pin.

Hydraulic Tank This is self pressurised by the movement of oil as the system is operated (a non-return valve allows air to enter the tank as the oil level falls). On the JS330, an engine driven compressor is used. Both systems prevent pump cavitation.

Filtration Comprehensive filtering includes suction strainers on all pump suction lines and full-flow replaceable element types on main return, servo and motor drain lines. All contribute to a high degree of oil cleanliness and, therefore, operational reliability. The JCB Plexus bypass type filter which cleans oil down to 1.5 microns (normal is 10 microns), increasing reliability, extending hydraulic component life and hydraulic oil life to 5,000 hours. Also, hammer pipework has an in-line filter which prevents external dirt from the attachment entering the machine’s system.

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CAB & CONTROLS

Cab Construction Machines have a cab with curved and contoured shape to complete the modern machine look. The large, spacious frame is a pressed steel unit for the high quality necessary for strength and well fitting doors and windows. The large door opens and locks back with an easy to release catch. Access into the cab is made easy by the wide entrance and the two grab rails - one at either side. The controls are isolated by lever at the cab door and, for safety, also acts as an exit barrier without having to touch the arm rest.

Windows With large window areas, particularly down to the left a nd right and the low bonnet for a clear view over the back, the visibility all round is second to none. The opening door window and opening front windscreen all give ventilation. The JS330 and JS460 also have the benefit of an air conditioning unit fitted as standard. The front screen has easy to release catches - it is spring assisted taking the weight out of it and locks back automatically. The bottom screen is stowable inside the main screen when retracted into its roof space.

Comfort From the operator comfort point of view, there is a deluxe suspension seat which adjusts up and down, forward and back relative to the controls and has full recline as well as adjustable arm rests and head rest. There is a digital radio cassette player as standard. Other items for the operators’ comfort are a cigarette lighter, clock, fresh air heater/demister with fan forced air circulation and a storage area behind the seat.

Servo Controls The seat not only adjusts independently of the controls but combined adjustment is also possible because of the way the seat and controls are trolley mounted. This means the whole operator station can be moved a long way forward for those deep dig applications. Or it can be moved right back for those repetitive, truck loading type applications suiting the larger operator particularly.

Switches The console mounted switches are located either side of the operator within easy reach. They are flat membrane type switches which can be easily wiped off and are dust and waterproof. They have backlighting - like car switches - for night time use and make a clear sound when operated.

Monitor The frame mounted monitor uses the latest technology with all LCD (liquid crystal display), like a pocket calculator, but with a contrast control to ensure visibility in strong sunlight. The main display gives clear written messages to the operator on the machine’s status, whether it is the hydraulics on warm-up or the fuel level low, or power boost engaged. Included in the monitor are three bar type gauges - fuel, engine temperature and also hydraulic oil temperature, particularly useful when working with attachments like hydraulic h ammers. The AMS computer self-checks and measures 28 critical machine functions automatically alerting the operator to an electrical / electronic malfunction by a flashing indicator (with b uzzer) and a clear written message in the m onitor.


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Service and Maintenance The JS range of machines ha s been well thought out in terms of maintenance. Pivot bearings and pins are sealed to keep dirt out, and grease in, saving time by extending lubrication intervals from daily to weekly (bucket pins are greased daily). All ‘difficult to reach’ lubrications points (boom lift and dipper ram bearings) are either grouped on the back of the boom or brought down to a point accessible from ground level. Dipper and bucket pivot lubrication points are all accessible, with the boom and dipper lowered, from ground or tracks level. These same grease points are shielded by heavy gauge steel rings to protect them from ground contact damage. Slew gear greasing is simplified and made a much cleaner operation by having a covered access port near the boom base. A single grease type is used for all points on the machine, including slew drive. Fine mesh radiator/cooler grille prevents/reduces cleaning needs. A ‘red line’ indicator in the fuel system agglomerator clearly shows when water needs to be drained off, and the fuel system is also provided with a ‘spin- on’ filter. Fuel and hydraulic tanks have drain tap s for greater convenience. For operators a level cab floor with removable floor mat makes ‘housekeeping’ easier. Self sealing pressure check points are fitted to all pumps for easier relief pressure checking. Relief valves are fitted at each valve spool in the hydraulics bay. Easy clean undercarriages. Electric refuel pump - reduces time and simp lifies and refuelling, is standard on 20 tonne and larger machines.

Low Maintenance Requirements Due To :• 500 hour engine oil and filter changes. • 250 hour on JZ70. • 1,000 hour hydraulic filter changes and 5,000 hour hydraulic oil changes due to extra fine JCB Plexus filter system. • Hydraulic bay layout extra neat for access and components such as hoses identified for easier servicing. • AMS self-diagnostic system for quick and easier identification of system malfunction. • For use by a trained Service Engineer, pressing the buttons in order activates the monitor to display the function being checked E F Y E K 3 0 / 7 0

whilst the clock displays the actual readings taken. • Servicing can be carried out without the use of a laptop.

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Contents

Section 4. FEATURES AND BENEFITS JS TRACKED EXCAVATOR – XO RANGE

1. Features and Benefits.

2. Undercarriage.

3. Undercarriage (continued).

4. Superstructure.

5. Superstructure (continued).

6. Engines.

7. Hydraulics.

8. Hydraulics (continued).

9. Excavator End.

10. Cab and Controls.

11. Cab and Controls (continued).


Features and Benefits. JS Tracked Excavator, XO Range

FEATURES AND BENEFITS The following section aims to highlight the key features and benefits of the JS Excavator range, to raise the awareness of important features and technology. • Extensive use of high performance Japanese components from Kayaba, Kawasaki, Toshiba and Isuzu. • Modern styling and high quality components. • Advanced hydraulic control systems (AMS) ensuring high, efficient output. • High reliability and long service life. • Low service requirements and downtime. • Exceptional operator comfort and ease of use. • Established JCB distribution and service network.

For JS Auto machines please see later section.

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UNDERCARRIAGE

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• FEATURE

• BENEFIT

• Range of undercarriage sizes: S - Standard. N - Narrow. NLC - Narrow long carriage. LC - Long carriage.

Enables the machine undercarriage to be matched according to service requirements. Ground conditions. Cost restraints. Transportation regulations.

• Extensive range of track shoes.

Narrow shoes for: Easier transport. Reduced track wear on hard ground. Wider shoes for: Lower ground bearing pressure. (especially NLC and LC builds)

• Apex design side frames with large dirt relief holes below the top rollers.

Minimises dirt build up. Easier cleaning. Reduced the risk of top rollers seizing.

• 3 speed tracking 2.3 to 5.5 km/h with auto-shift. 2 speed on the JZ70.

Autoshift for: Fast across the site. Autoshift to Medium for high tractive effort. Special low speed for precise positioning when site access is restrictive.

• High tractive efforts.

Excellent mobility/ versatility. Enables manoeuvring and climbing in difficult ground conditions.

• Scalloped drive sprockets.

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Aids dirt relief around the sprocket teeth. Minimises wear.

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UNDERCARRIAGE (cont)

• FEATURE

• BENEFIT

• Track guides standard on all machines over 18 tonnes.

Support the track chain: Extra security to tracks when digging across or when turning.

• Large diameter slew ring and turret.

High strength with high swing force. Reduced stresses. Long life reliability.

• Track motor guards standard and pipe-work built within the undercarriage framework.

Shields undercarriage hydraulics from debris. Avoids damage on ro ugh ground.

• Two piece central under-guards fitted as standard.

Shields hydraulic lines to rotary coupling. Easy to remove / re-fit. Avoids damage from debris.

• Large recovery points on front and back (rear only on JZ70).

Enables easier machine recovery.

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SUPERSTRUCTURE

B D N A F C O X 3 0 / 7 0

• FEATURE

• BENEFIT

• Modern styling, pre-painted components and zinc plated fasteners. Major components such as slew ring and rotary coupling fitted before machine is painted.

Attractive, latest design look. Enhanced quality appearance. Increased durability. Improved re-sale value.

• Zero Tail swing on JZ70 (fitted on 600mm tracks).

Keeps rear of machine within track spread. Safe working on tight, confined job sites.

• Low bonnet and curved counterweight.

Good visibility to the rear. Safe working on site.

• Curved valances and large clearance over tracks.

Avoids material jamming between tracks / upper structure. Prevents / minimises damage to upper structure.

• Fully enclosed lockable engine and hydraulic bays.

Enclosed from harmful surroundings. Protection from damage. Security from theft. Reduces noise emissions.

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SUPERSTRUCTURE (cont)

• FEATURE

• BENEFIT

• Piston motor slew drive with epicyclic reduction gearing and sealed, grease bath lubricated final drive.

Powerful controlled flow with sealed final drive. High level of control. Good acceleration. Reduced maintenance.

• Hydraulic dynamic slew brake and automatic mechanical park braking plus 100% slew locking selectable by in-cab switch.

Powerful, steady deceleration from hydraulics. Minimises overrun. Increased control. Effective holding on slopes with parking brake. Increased operator comfort. Slew locking via switch. Safer transportation. Preventing slew in safety critical applications. e.g. lifting on a slope. NO transportation locking pin and bosses.

• Slewing speeds and torques.

High torque gives fast slew acceleration. Reduced cycle times. Assists in back-filling operations and uphill slewing.

• Large tank with electric refuelling pump.

Extended intervals between refuelling. Refuelling made quick and easy with electrical pump (optional extra on JZ70, JS130, JS160, JS180).

• Neat & tidy hydraulic layout with grouped solenoid valve and hoses colour coding identification.

Layout logical and appealing to the eye Easy and quick service access Easy identification.

• Handrails, steps and non-slip pads as standard.

Easy and safe access.

• Large, low maintenance heavy duty batteries and 40amp alternator.

Reliability and extra electrical capacity for additional equipment such as work lights.

• ‘Single Key’ for engine start/stop, cab door and all cover locking.

Greater convenience and security.

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ENGINES

B D N A F C O X 3 0 / 7 0

• FEATURE

• BENEFIT

• Isuzu engine (low emission).

Accepted as the industry standard for ‘quality and efficiency’. Long life. Stage 1I of the European Emission Laws for the JS330, JS460 and the JZ70.

• Turbo charged, ‘Bosch type’ in-line fuel injection and water separator.

Injection Turbo charged engines (not JZ70). Improves engine comb ustion efficiency. Maintains power at high altitudes.

• Bypass & standard filter with 500 hour oil and filter change (250 hours on JZ70).

Superior filtering and longer intervals between engine services. Decreases non-productive time. Reduces servicing costs. Ensures oil is always filtered, even when cold starting.

• Single filter on the JS330 with 500 hours.

• Glow plug in each cylinder.

Automatically activated by keystart switch Easy starting down to -20 oC.

• Automatic warm-up procedure on start-up in cold conditions (not on JZ70).

Ensures engine is correctly warmed-up before being put under load. Extends engine’s life

• ‘World-wide’ climate cooling package.

Standard cooling package for efficient working.

• Easily removed fine mesh grille on radiator and open matrix radiator.

Cleaner radiator and easier maintenance. Reduces downtime.

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HYDRAULICS

• FEATURE

• BENEFIT

• All major hydraulic components are Japanese supply.

World’s leading suppliers of excavator hydraulics. Assured performance and reliability.

• Load sensed system.

Automatically adjusts pump stroke for flow or pressure depending on ground conditions. Maintains constant power demand on engine. More efficient running.

• ‘Flow on demand’ controlled piston pumps, lower flow, high pressure system.

Gives flow output proportional to lever movement. Minimal energy usage. Easier control. Increased efficiency with lower flow. Higher forces from increased pressure.

• AMS control (Advanced Management System) giving high efficiency and maximum control.

Pre-set modes and user friendly interfaces which allows the machine to be suited to the driver. More efficient. Better operator comfort.

• Main control valve with multi-function ability on all services.

Allow s simul taneo us opera tion excavator, swing and tracks.

• Auxiliary hydraulic service spool, merged pump facility and pipework mounting brackets as standard.

Simplifies later fitting of hammer / auxiliary pipework and merge pump facility. 1.5 times pump flow available. Easy installation of large demolition cutters / crushers.

• Pressure test points as standard.

Simplifies pressure checking without oil loss or dirt ingress into hydraulic system. Protects system. Easy to check.

• Large purpose designed hose burst check valves, option for boom rams only, boom and dipper rams or without any (not available on JZ70).

To meet different regions regulations on craning duties. The non-hose burst check valves option for non-lifting duties. Reduces cost.

• Flow from both pumps is combined with individually operating boom, dipper and bucket services.

Increased speed of operation when one service only is being used. e.g. Fast boom up out of deep trenches.

• Regenerative circuit on dipper adds returning oil from the ram to the opposite ‘feed’ side of the ram (not JZ70).

Increases ram speed for faster transfer grading. Better flow efficiency. Better fuel consumption.

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HYDRAULICS

B D N A F C O X 3 0 / 7 0

(cont)

• FEATURE

• BENEFIT

• Ram end damping on boom, dipper rams and bucket crowd. No bucket damping on JZ70.

Reduces the effect of inertia shock at end of ram travel. Protects machine. Protects operator. Protects when large heavy attachments used.

• Boom holding valve as standard.

Minimises ‘boom creep’ when hose burst check valves not fitted. Better control.

• Plexus filter system unique to JCB (down to 1.5 microns versus normal 10 micron filtration).

Hydraulic oil is kept cleaner extending service intervals and reducing maintenance. Hydraulic filter changes at 1,000 hrs. Doubles the life of the hydraulic oil to 5,000 hrs. Extends life of components Increased reliability due to cleaner oil.

• Cushion control fitted on boom & dipper services.

Smoother controlled operation of rams. Reduces shock to both operator and machine.

• Hammer in-line filter with blockage indicator.

Extra security for hydraulic system by filtering dirt in hammer line. Protects main filter and machine hydraulics.

• Change-over valves in mainframe for optional combined auxiliary circuits (no change-over on JZ70).

Enables one way (hammer) flow, two-way flow or merged flow to be directed down the one set of excavator end auxiliary pipework. Minimal hose and pipe runs. Maximum machine versatility.

• Power boost facility (not JZ 70) for 8 seconds in ‘H’ & ‘S’ mode, permanently engaged when in ‘F’ mode.

Raises pressure an extra 10%. Increases tearouts in ‘H’ and ‘S’ modes. Increases lift capacity in ‘F’ mode.

•Boom down speed reduction on ‘L’ & ‘F’ modes (not JZ70).

Gives greater control of boom down when grading or lifting.

• Boom priority selection standard on JS330 and JS460.

Gives priority oil flow to boom. Speeds up truck loading operations.

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EXCAVATOR END

• FEATURE

• BENEFIT

• Choice of Monoboom or Triple Articulation Boom (T.A.B.) on JS130 and JS260, both built to Northern Europe heavy duty specification. Offset boom available on JZ70.

Choice of boom and heavy duty specifications. Can match to customer requirements. Longer life in heavier work, E.g. hydraulic hammer duties.

• High strength steel, robotic welding and ultrasonic testing used on all booms and dippers.

Quality assured fabrications. Long service life. Extended warranty given as standard.

• Wide choice of dipper lengths.

Machine can be matched to a wide range of applications Shorter dippers for higher tear-outs. Longer dippers for more reach, dig depth and easier grading / levelling ability.

• High bucket rotation angles.

Good material retention. Easier ‘square hole’ digging (no need to move pivot pin).

• Optional lifting point and ‘D’ shackle or hook-type lifting point.

Tested, certified and permanently available. Safer lifting of slung loads (hook not approved by HSE for UK).

• Auxiliary service / hammer pipework brackets welded to boom and dipper as standard.

Easier fitting of pipework ‘in the field’. Low cost and easy installation. (no welding or damage to paintwork)

• Sealed pivots with 50 hour greasing except bucket pivots that are double sealed and require 10 hour greasing intervals. (Extended life bushing on JS 460 increasing intervals to 1000 hours).

Keeps dirt out and grease in. Reduces operator maintenance requirements. Extends pivot / bearing life.

• Optional general purpose and heavy duty Esco buckets with ‘Super V’ wear parts. JZ70 uses general purpose buckets and wear parts.

Strong buckets, designed to suit most European customers in ‘shape’ and type of work. Secure but easy to change tooth system. High resistance to wear for long life. Wide range of tooth types to match applications.


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9


CAB AND CONTROLS

B D N A F C O X 3 0 / 7 0

• FEATURE

• BENEFIT

• Euro Cab, automotive quality pressed steel construction and interior mouldings, designed to ISO standards.

High quality ‘look and feel’, modern styling and plenty of interior space. Comfortable for the biggest operator. Enhances resale value.

• Gas strut assisted front window with integral lower section allowing storage within the main screen.

Safe, flexible and simple stowage. Greater operator comfort.

• Large glass areas on all sides with windscreen de-mister / defroster as standard.

Provides excellent all-round visibility. Safer working. Easier working.

• Tinted glass, opening side windows.

Excellent natural ventilation control and easy, convenient operator communication with site personnel. Easier and more comfortable working.

• Optional rain guard.

Shields the operator from rain when front screen is open. Fresh air when its raining.

• Rail mounted seat and control arrangement (not JZ70).

The whole control / seat assembly can be moved without disturbing the seat to-control relationship. Greater convenience when moving the operating position.

• Standard air conditioning on JS330 and JS460. Optional on all other models.

Gives fresh environment for the operator whatever the weather. Increasess operator output. Maximises operator comfort.

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CAB AND CONTROLS

(cont)

• FEATURE

• BENEFIT

• Large rear shelf & roof stowage areas.

More room to stow larger items e.g. flasks etc. High operator convenience.

• Standard stereo radio / cassette player with twin speakers, cigarette lighter, coat hook and interior light.

Full range of appointments. Maximises operator comfort and satisfaction.

• Selectable cushion control on boom and dipper services (automatically selected when machine started) unique to JCB (JZ70 has permanent cushion control).

Ensures ‘controlled return’ of valve spool to neutral position if the controls are suddenly released, Smoother machine operation. (Easily overridden for shaking bucket clear of sticky material or for a ‘sharper’ machine response).

• Automatic engine speed control for hammer operation. Fully adjustable to match hydraulic flow to the hammer fitted via AMS control panel (not JZ70).

Engine speed reduces when hammer mode engaged. Protects hammer and pumps from damage due to over-speeding.

• Dial-up throttle control and selectable one-touch engine idle or automatic / one-touch engine idle. Automatic engine idle delay can be fully adjusted on AMS control panel.

Quick and positive engine speed control. Engine put to idling during periods of non-production, i.e. waiting for trucks. Improves fuel econo my. Optimises operator control.

• Servo cut-off.

Isolates all excavator and track controls. Barrier restricts operator exit until raised to the ‘isolate position’. Maximum safety.

• Cab is acoustically isolated from the super structure using 6 damped viscous mountings.

Flexible but strong mountings. Reduces noise and vibration transmission to cab a nd operator. Cab sideways movement is minimised when tracking over rough ground at speed.

• Short stroke, ISO pattern, servo excavator controls.

Industry norm for ready European operator acceptance. Minimal operator effort.

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CAB AND CONTROLS

B D N A F C O X 3 0 / 7 0

(cont)

• FEATURE

• BENEFIT

• Track & auxiliary service foot controls, all servo operated.

For both foot and hand operation. To suit o perator style and level of control required.

Combined pedal / lever track controls (with removable levers).

‘Metered’ feed available for progressive controls. NO maintenance required.

• Three-speed track selection floor mounted with auto-shift option.

Convenient speed change, auto-shift between three speeds. Flexible and individually selectable. Simple to control.

• Large display console ergonomically positioned in interior moulding; displaying warning messages, time, total hours, fuel, engine temperature, hydraulic reservoir level, working mode and tracking speed. 12 languages optionally available.

Logical operation and clear indication of main machine controls. Easy reach of any operator position. Enhances operator control.

• Flush mounted membrane switch panel on interior moulding clearly laid out with bright LED switch lights. Operates main machine functions in conjunction with the display console.

In line of sight but not obstructing the operators view. Provides direct communication to the operator via clear messages, including machine warnings and action confirmation. Displays service history records, error logs and service due reminders. Enhances machine controllability

• Computer self-diagnostics on critical machine functions.

Automatically alerts operator to an electrical / electronic malfunction with history log. Assures machine is maintained in good condition.

• Overload warning system fitted as standard with optional HBCV’s.

Warns the operator if machine reaches maximum SWL when on lifting duties. Increases operator awareness. Enhances machine feed back.

• Two or three way switch for combined hammer / auxiliary of merged pipework circuits - if fitted.

Allows full engine speed for nonhammer attachment operation plus merged circuit selection (if fitted).

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Contents

Section 4. FEATURES AND BENEFITS JS WHEELED EXCAVATOR - XO RANGE

1. JS 130W, JS 145W XO - JS 160W XO, JS 200W XO.

2. Chassis and Transmission.

3. Chassis and Transmission (continued).

4. Chassis and Transmission (continued).

5. Excavator End.

6. Engine.

7. Superstructure.

8. Hydraulics.





Features and Benefits. JS Wheeled Excavator XO range

JS130W, JS145W XO Dependant on specification these machines weigh between 13 and 15 tonnes, placing them in one of the key categories for wheeled machines. Both machines use 4 cylinder turbo charged Isuzu engines, open centre hydraulic systems with twin variable displacement piston pumps, all controlled by the AMS (Advanced Management System) to give the power and controllability demanded for this type of machine. The machines can be specified with mono or triple articulated booms, a choice of dippers and stabilizers, dozer or wheel only options, making it easy to match the machine to the application. The greater power on the JS145W ensures a higher road speed and greater hill climbing ability from this version.

JS160W XO Nominal weights of between 15.5 and 18 tonne, these machines compete in a key European sector. Using a 4 cylinder turbo charged Isuzu engine and open centre hydraulic system allows good control of all excavator functions. A choice of booms, dippers and chassis options allow the machine to be specified to suit the application, while the spacious, comfortable cab ensures the operator can work for long periods.

JS175W XO This model is based on the JS160W but uses the 6 cylinder Turbo charged Isuzu engine to give higher road speed and greater hill climbing ability, making it a good choice for machines which are driven long distances.

JS200W XO With a weight range of 19 to 21 tonnes this machine competes in the heavy end of the wheeled excavator market. This weight machine is becoming increasingly popular in the re-handling industry and is the machine of choice in Southern Europe. Using a 6 cylinder turbo charged Isuzu engine, closed centre single hydraulic pump and AMS control, and available with a choice of booms, dippers and undercarriage options.

WHFANDB0001 This communication and the information within is intended for JCB and JCB dealer personnel only, for information purposes, is confidential and may not be communicated to any third party. Whilst the information is believed to be correct, no guarantee is given by JCB as to its accuracy and its use may not be attributed to JCB.

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CHASSIS AND TRANSMISSION

• FEATURE

• BENEFIT

• ‘U’ section construction.

Durability and reliability, resulting in longer life.

• Choice of twin or single tyres.

Twins are used for stability. Super Singles are used under poorer ground conditions and extra traction. They also have the additional benefit of the ease of replacement. Flotation tyres are used for poor ground conditions.

• Lockable front axle.

Increased stability.

See JS Options Explained for details.

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• Tapered chassis allowing increased steering lock angle.

Tightest turning circle in class, giving the best manoeuvrability and easier operation in confined sites.

• Enclosed 'balanced' steering ram.

Protected with equal lock angles. Not prone to damage from material, and gives accurate control.

• Lockable toolbox as standard. Extra toolbox optional.

2

Allows operator to carry all necessary tools. Greater convenience and security.

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• FEATURE

(cont)

• BENEFIT

• Pin-on chassis options (Dozer blade front or rear, 2 or 4 stabilisers front or rear, grab stowage bar).

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• Independent stabiliser operation.

Allows machine to be configured to suit job. Maximises machine utilisation.

• Stabiliser ram check valves.

High lift, levelling and stabilisation in restricted or uneven job areas. Aids wheel changing operations. Improved stability and allows access to a broader range of working sites. Prevents downward creep when lifting, and provides hose burst protection. Increased safety.

• Curved dozer blade.

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Aids material flow.

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• Flat dozer blade base; twin ram parallel linkage.

Effective site levelling and site stripping.

• Dozer ram check valves.

Gives hose burst protection and prevents dozer blade creep when roading. Ensures safety and operator confidence.

• JCB / ZF axles and transmission.

Well-known manufacturers and proven reliability.

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3



B D N A F H W 3 0 / 7 0

(cont)

• FEATURE

• BENEFIT

• Plantary hub reduction with compact differential casing.

Good ground clearance and smooth running. Lower noise levels and good site mobility.

• Enclosed oil immersed brakes.

Effective braking under all site conditions. No adjustment requirement and unaffected by water/dirt ingress. Safer, reduced maintenance and service.

• Dual circuit brakes.

Safe and reliable.

• All hydraulic brakes.

No air reservoir to drain. Reliable and will not freeze up. Low maintenance.

• Transmission brake.

Independent parking brake for extra security and operator confidence.

• Auto-speed (range) change transmission motor.

Automatically varies speed within power band range depending on gradient/site conditions. Increased site mobility and simple control.

• Manual override on range change.

Allows operator to limit speed for travelling across rough sites. Easier operation/greater comfort. Precise control. Safer downhill travel.

• Hydrostatic braking via motor.

Reduces need to use foot brake. Minimises brake wear. Lowers maintenance costs. Lower operator effort.

• Downhill over speed valve.

Limits downhill speed, preventing machine runaway. Safer machine operation.

• Two speed ‘powershift’ unit.

Easy gear-shifting on the move. Not available on competitive machines.

• Creep speed setting.

Maintains engine speed for maximum hydraulic effort when precision placing or carrying loads over rough sites. Increased control.

4



EXCAVATOR END

• FEATURE

• BENEFIT

• Monoboom.

Proven, durable design, already in use on equivalent tracked machines. Good load-over height in arm-out and arm vertical positions. Offers easy loading of high-sided trucks for easier operation and small front swing radius. Faster cycle times, increased output, easy confined space working. Good lift capacity (stabilisers increase over side lift capacity) and low transportation height.

• Triple Articulated Boom (TAB).

Good load over height. Easy loading of high-sided trucks, short forward projection in travel position (legal requirement in some territories). Variable geometry allows working around objects in tight areas. Easy confined space working. Easier and safer roading. Greater convenience and utilisation. Good lift capacity (stabilisers increase over side lift capacity).

• Choice of dipper arm lengths utilising tracked excavator ram design.

Structurally and performance proven components.

• Optional tipping link point and stowage lock.

Approved lift point. Lock (where fitted) retains link securely when not in use (e.g. when a grab is fitted). Safer craning.

• High bucket rotation angle.

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Good square holing and material retention. Effective operation gives maximum output. No need to move pivot pin.

• Optional hydraulic circuits. Bucket / Grab changeover. Hammer. Grab rotation. Auxiliary (2 way).

Any combination of circuits can be fitted. Maximum versatility and maximum machine availability.

• All pivots are sealed, allowing 50 hour service interval; except bucket pivots which have a double seal arrangement and 10 hour greasing intervals.

Keeps dirt out and grease in. Reduces operator maintenance requirements and extends pivot / bearing life.

• Pipework mounting brackets fitted as standard.

Simplifies 'field fix' of auxiliary services. Reduces installation cost and no welding required (so no paint work damage).

• Choice of 2,3 or 4 hose burst check valves (HBCV's).

Meet lifting regulations in various countries. Safer lifting and prevents 'load creep'.

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ENGINE

B D N A F H W 3 0 / 7 0

• FEATURE

• BENEFIT

• Isuzu engine.

All engines are turbo-charged and have in-line direct injection fuelling. Automatic preheat in each cylinder. High performance engines with proven long service reliability and fuel efficiency. Pre-heat gives first time starting even in the coldest conditions. Accepted as the industry standard for quality and efficiency. Long life and meets current European Emission Laws.

• Glow plug in each cylinder and 24 Volt electrical system.

Automatically activated by key-start switch. Easy starting at all temperatures.

• Large efficient exhaust and well designed cooling air flow (and soundproofing).

Very low noise emissions (well below European Regulatory requirements).

• Large heavy duty batteries, 24 Volt with 40A alternator.

Extra power. Easier starting in cold conditions.

• Large radiator with removable fine mesh radiator grille.

Efficient cooling in all conditions. Grille keeps debris out of radiator. Easy to clean and protects radiator.

• Fully enclosed engine and hydraulics bays.

Protects components from damage, and reduces noise emissions.

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SUPERSTRUCTURE

• FEATURE

• BENEFIT

• Large slew ring.

Generous bearing capacity reduces stresses. Increased reliability and durability.

• Internally toothed slew ring and grease bath lubrication.

Maximum protection from dirt. Retains lubricant for reliability.

• Automatic slew braking.

Smooth action, powerful and easy to use (no separate pedal to operate). Ensures accurate 'spotting' over trenches or trucks. Safe handling and no 'creep' on side slopes.

• Slew park brake.

Automatically engages after slewing operation. Prevents slew 'drift' on inclines. Safer operation in precision jobs.

• Slew lock pin.

Ensures upper-structure is in line with chassis, and ensures safer transportation.

• Handrails, footsteps and non-slip pads.

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Easy, safe access onto the machine whichever way it is parked.


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HYDRAULICS

B D N A F H W 3 0 / 7 0

• FEATURE

• BENEFIT

• Main hydraulic components are of Japanese origin to maintain proven performance. JS200W incorporates Rexroth components, proven on competitive machines.

Proven track record and reliable. High performance and smooth.

• Plexus filter usage unique to JCB (down to 1.5 microns versus normal 10 micron filtration).

Hydraulic oil is kept cleaner than new, extending service intervals and reducing maintenance. Hydraulic filter changes at 1,000 hrs. Doubles the life of the hydraulic oil to 5,000 hrs. Increased reliability due to cleaner oil.

• Pressure test on pumps points fitted as standard.

Simplifies pressure checking without oil loss or dirt ingress into hydraulic system. Protects system and easy to check.

• End cushioning on boom lift and dipper rams.

Smoother operation of rams. Reduces shock to both operator and machine.

• Load sensing hydraulic system on the JS200W.

Automatically adjusts pump stroke for flow or pressure depending on ground conditions. Maintains constant power demand on engine. More efficient running.

• Flow sensing on all other machines.

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HYDRAULICS

(cont)

• FEATURE

• BENEFIT

• Advanced Management System (AMS).

Pre-set modes and user friendly interfaces which allows the machine to be suited to the driver. More efficient, better operator comfort and better machine control.

• Four work modes: S, H, L and F.

S - Standard mode for g eneral excavating or trenching. H - Heavy mode for continuous high performance. L - Light mode for precise light duty work, e.g. grading. F - Fine mode for operations requiring maximum accuracy and lifting power.

• Multi-function hydraulics. Easy to access hydraulic filters.

Makes servicing of machine easier for fitter.

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CAB AND CONTROLS

B D N A F H W 3 0 / 7 0

• FEATURE

• BENEFIT

• High quality steel construction, designed to ISO standards.

Pressed and rolled frame and door gives high quality feel. 'Clean' lines and excellent modern appearance for the latest in design, and plenty of room for even the biggest operator to work in comfort.

• Gas strut assisted front window with integral lower section allowing storage within the main screen.

Easy and quick removal of the entire front screen area. Integral lower section means safe and simple stowage.

• Tinted glass, opening side window.

Excellent natural ventilation control and easy, convenient operator communication with site personnel.

• Air conditioning (optional).

Gives fresh, comfortable environment for the operator whatever the weather, maximising operator output.

• Optional rain guard.

Shields the operator from rain when the front screen is open.

• Rail mounted seat and control arrangement.

For greater convenience when moving the operating position (to suit the machine application), the whole control / seat assembly can be moved without disturbing the seat-to-control relationship.

• Large rear shelf and stowage areas.

Gives operator more convenience to stow larger items, bags, flasks etc.

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CAB AND CONTROLS (cont)

• FEATURE

• BENEFIT

• Standard stereo radio / cassette player with twin speakers, cigarette lighter, coat hook and interior light.

Full range of appointments for maximum operator comfort and satisfaction.

• Selectable cushion control on boom and dipper services (automatically selected when machine started) unique to JCB on wheeled machines.

Ensures 'controlled return' of valve spool to neutral position if the controls are suddenly released, for smoother machine operation. This can be overridden by the operator e.g. to shake the bucket clear of sticky material of or for a 'sharper' machine response).

• Automatic engine control for hammer operation. Adjustable to match the hydraulic flow to the hammer fitted.

Engine speed reduces when hammer mode engaged. Protects hammer and pumps from damage due to over-speeding (fully adjustable using AMS control panel).

• Dial-up throttle control and selectable one-touch engine idle or automatic / one-touch engine idle. Automatic engine idle delay can be fully adjusted on AMS control panel.

Quick and positive engine speed control. Engine put to idling during periods of non-production, i.e. waiting for trucks. Improves fuel economy. Delay fully adjustable to suit conditions and operator style. Engine automatically returns to original speed with controls activated.

• Servo cut-off.

Isolates all excavator and track controls for maximum safety. Barrier restricts operator exit until raised to the ‘isolate position’.

• Cab is acoustically isolated from the super structure using 6 damped viscous mountings.

Flexible but strong mountings. Reduce noise and vibration transmission to cab and operator. Cab sideways movement is minimised when tracking over rough ground at speed.

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11


CAB CA B AN AND D CO CONT NTRO ROLS LS (cont)

B D N A F H W 3 0 / 7 0

• FEATURE

• BENEFIT

• Short stroke, ISO pattern, servo excavator controls by Kawasaki.

Industry norm for ready European operator acceptance. Minimal operator effort.

• Triple Articulated Boom positional ram adjustment via floor mounted pedal.

‘Hands free’ operation of T.A.B. allows all other controls including travel to be operated simultaneously.

• Large display console ergonomically positioned in interior moulding; displaying warning messages, time, total hours, fuel, engine temperature, temperature, hydraulic reservoir level, working mode and travel gear.

In line of sight but not obstructing the operators view. view. Provides direct communication communicat ion to the operator via clear written messages, including including machine warnings and action confirmation. confirmation. Displays service history records, error logs and service due reminders.

• Flush mounted membrane switch panels on interior moulding clearly laid out with bright LED switch lights. Operates main machine functions in conjunction with the display console.

Logical operation and clear indication of main machine controls within easy reach of any operator position.

• Computer self-diagnostics on critical machine functions.

Automatically alerts operator to an Automatically electrical / electronic malfunction with history log.

• Overload warning system fitted as standard with optional HBCV’s.

Warns the operator operator if machine reaches maximum SWL when on lifting duties.

• Two or three way switch for combined hammer / auxiliary of merged pipework circuits – if fitted.

Allows full engine speed for nonhammer attachment operation plus merged circuit selection (if fitted).

12

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This communication and the information within is intended for JCB and JCB dealer personnel only, for information purposes, is confidential and may not be communicated to any third party party.. Whilst the information on is believed to be correct, correct, no guarantee is given given by JCB as to its accuracy and its use may may not be attributed to JCB. JCB.

Contents

Section 4. FEATURES AND BENEFITS JS TRACKED EXCAVATOR AUTO RANGE

1. JS 20 Ton Tracked Excavators. - Introduction.

2. Excavator End.

3. Hydraulics.


5. Engines.

6. Superstructur Superstructure. e.


8. Undercarriage.





Features and Benefits. JS Tracked Excavator Auto Range

JS 20 TON CLASS TRACKED EXCAVATORS

INTRODUCING THE NEW JS200 JS200 / JS210 / JS220 TRACKED EXCAVA EXCAVATOR TOR

The following section aims to highlight the key features and benefits of the new 19.5 ton – 23.00 ton class JS Excavators, to raise the awareness of the latest important features and technology. • Engine power 102kw, 102kw, tier II emissions compliant. compliant. • Excelle Excellent nt power. Bucket tearout, 15800 kgf. Dipper tearout, 14610 kgf. • Fast cycle cycle times. • Proven high performance Japanese component s from Kayaba, Kawasaki, Toshiba and Isuzu. • Modern styling and high high quality components. components. • Intelligent, Advanced Management Systems (AMS). Automatic digging mode selection delivering great productivity and economy. • Low operating costs. Low fuel consumption. consumption. 1000 hour greasing intervals and no 100-hour first service. • Built in reliability. reliability. IP69 electrics, mechanically mechanically governed engine for simplicity simplicity.. Superior filtration providing providing long service life. • Excellent operator comfort, comfort, visibility and ease of of use.

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FANDB0001


1


EXCAV EXCA VATOR END

• FEATURE

• BENEFIT

• Fast cycle times times on all services. services.

Increased performance gives high output of material. material. Services are well balanced.

Bucket in 2.8 seconds out 2.2 second Dipper in 3.1 seconds out 2.6 second Boo m in 3.7 3.7 seco second ndss out 3.2 second Slew speed 12.9 rpm

B D N A F C X E 3 0 / 7 0

• Powerful performance. - Dipper tearout 12550 kgf (2.4m Arm) - Bucket tearout 15800 kgf

Good performance in all conditions. Plenty of power to complement the speed of the attachment.

• Choice of Monoboom or Triple Articulation Boom. Boom.

Can match to customer requirements. TAB - Close digging / grading. TAB - Close / confined lifting.

• Choice of dipper lengths. lengths. - 1.9M arm - 2.4M arm - 3.00M arm

Machine can be matched to a wide range of applications – Shorter dippers for higher tear-outs tear-outs.. Longer dippers for more reach, dig depth and easier grading / levelling ability.

• Optional lifting point point and ‘D’ shackle shackle or hook-type lifting point.

Tested, certified and permanently available. Safer lifting of slung loads (hook not approved by HSE for UK).

• 1000 hrs greasing greasing on boom foot foot and boom dipper, by use of bushes with graphite plugs. Remainin Remainingg pivots are sealed pivots with 50 hour greasing.

Keeps dirt out and grease in. Reduces operator maintenance requirements. Extends pivot / bearing life.

• Option of general general purpose, heavy heavy duty and ‘Scoop’ buckets with ‘Super V’ wear parts.

Strong buckets, designed to suit most European customers in ‘shape’ and type of work. Secure but easy to change tooth system. High resistance to wear for long life. Wide range of tooth types to match applications. Scoop buckets designed to operate operate with scoop quick-hitch. quick-hitch. No bucket or dipper de-ration in tearout force.

2

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HYDRAULICS

• FEATURE

• BENEFIT

• All major hydraulic hydraulic components components are Japanese supply. • Main hyd pump: Kawasaki variable axle piston. • Max flow: 214 x 2 lpm. lpm. • Max pressure: 373 bar.

World’s leading suppliers of World’s excavator hydraulics. Assured performance performance and reliability. reliability.

• ‘Flow on demand’ demand’ controlled controlled piston pumps, lower flow, and highpressure system.

Gives flow output proportional to lever movement. Minimal energy usage. Easier control. Increased efficiency with lower flow. Higher forces from increased pressure.

• AMS control (Advanced (Advanced Management Management System) giving high efficiency and maximum control.

Pre-set modes and user friendly interfaces which allows the machine performance to match the operation.

• Work modes: - Auto 100% hyd flow. 343 bar – 373 bar. 1950 rpm max. 99kW hyd HP.

Maximum productivity and efficiency in heavy conditions. (Auto digging mode senses the load and adjusts the engine and hydraulics to suit).

- Economy 100% hyd flow. Hyd pressure 343 bar. 1850 rpm max. 77kW hyd HP.

Maximum efficiency working in medium digging conditions, minimising running costs.

- Precision 100% hyd flow. Hyd pressure 343 bar. 1750 rpm max. 53kW hyd HP.

Precision grading application applications. s.

- Lifting 70% hyd flow. 1750 rpm max. Hyd pressure 373bar. 53kW hyd HP.

Maximum lift capability with excellent precision controllability.

• Auxiliary hydraulic hydraulic service spool, merged pump facility.

Up to 75% ot the total hydraulic oil flow available.Easy installation of large demolition cutters / crushers.

• Pipe-work mounting mounting brackets brackets as standard.

Simplifies later fitting of hammer / auxiliary pipework.

• Quickhitch electric electric harness, in cab switch and dipper mounting brackets all fitted as standard.

Easy and high quality fitment of quickhitch by dealers. (no welding or electrical work required).

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3


HYDRAULICS (cont)

B D N A F C X E 3 0 / 7 0

• FEATURE

• BENEFIT

• Pressure test points as standard.

Simplifies pressure checking without oil loss or dirt ingress into hydraulic system. Protects system. Easy to check.

• Hose burst check valves, option for boom rams only or boom and dipper rams.

To meet different region’s regulations on craning duties.

• Regenerative circuit on the boom down, dipper in and bucket crowd. Adds returning oil from the ram to the opposite ‘feed’ side of the ram.

Increases ram speed for faster transfer grading. Better flow efficiency. Better fuel consumption.

• Ram end damping on boom, dipper rams and bucket crowd.

Reduces the effect of inertia shock at end of ram travel. Protects machine and operator. Protects when large heavy attachments used.

• Cushion control fitted on boom and dipper services.

Smoother controlled operation of rams. Protects the machine i.e. reduces wear and tear on pins, bushes and under carriage etc. Reduces shock to both operator and machine.

• Plexus filter system unique to JCB (down to 1.5 microns versus normal 10 micron filtration).

Hydraulic oil is kept cleaner allowing service intervals to 5000 hrs. Increased reliability due to cleaner oil. Extends life of components. Hydraulic filter changes at 1,000 hrs.

• Hammer in-line filter with blockage indicator.

Extra security for hydraulic system by filtering hammer line. Protects main machine hydraulics.

• Change-over valves in mainframe for optional combined auxiliary circuits.

Enables one way (hammer) flow, two way flow or merged flow to be directed down the one set of excavator end auxiliary pipework. Minimal hose and pipe runs. Maximum machine versatility.

• Boom / slew priority, standard.

Gives priority oil flow to boom or slew. Speeds up truck loading operations.

4

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ENGINES

• FEATURE

• BENEFIT

• Isuzu engine BB-6BG1T. • Stage II emission compatible. • Engine rated power (138hp) 102kW @1950rpm. • Displacement 6.494cc.

Accepted as the industry standard for ‘quality and efficiency’. Complies with Stage II of the European Emission Laws.

• Turbo charged, ‘Bosch type’ in-line fuel injection (Mechanically fuelled) and water separator.

Injection Turbo charged engines. Improves engine combustion efficiency. Maintains power at high altitudes. Injection equipment ‘tolerant’ to dirt / water ingress.

• Single filter with 500-hour oil and filter change.

Superior filtering and long intervals between engine services. Decreases non-productive time. Reduces servicing costs.

• Hinged plate to access filter and screw on type oil drain plug.

Easily located and clean for the machine and the enviroment. 8 0 0 0 B D N A F

• Automatic warm-up procedure on start-up in cold conditions. (Note auto warm-up is cancelled if any hydraulic service is used during the warm-up period).

Ensures machine is correctly warmedup before being put under load. Extends engine’s life.

• ‘ World-wide’ climate cooling package.

Standard cooling package for efficient working. Reliable performance up to 45 C.

0 7 / 0 3 E X C F A N D B

O

• 2 easily removed fine mesh grilles on radiator and open matrix radiator.

Cleaner radiator and easier maintenance. Reduces downtime. 9 0 0 0 B D N A F


5


SUPERSTRUCTURE

• FEATURE

• BENEFIT

• Modern styling.

Attractive, latest design look. 1 0 0 0 B D N A F

• Pre-painted components and zinc plated fasteners. Major components such as slew ring and rotary coupling fitted before machine is painted.

Enhanced quality appearance. Increased durability. Improved re-sale value.

• Low level bonnet design.

Modern and strong appearance. Excellent visibility to rear. Lighter and easier to open. Single latch mounted on front face which is easy to reach.

B D N A F C X E 3 0 / 7 0

• Heavy duty steel walkway gripper plates. • Plates phosphate dipped.

6

4 0 0 0 B D N A F

0 1 0 0 B D N A F

Extremely durable, offers good grip in all weather conditions. 1 1 0 0 B D N A F



SUPERSTRUCTURE (cont)

• FEATURE

• BENEFIT

• Curved side skirts and large clearance over tracks.

Avoids material jamming between tracks / upper structure. Reduces damage to upper structure.

• Fully enclosed lockable engine and hydraulic bays.

• Slew speed, 12.9rpm.

Protection from damage. Security from theft. Reduces noise emissions.

2 1 0 0 B D N A F

3 1 0 0 B D N A F

Good acceleration, reduced cycle times.

• Slew Torque, 62900Nm.

0 7 / 0 3 E X C F A N D B

4 1 0 0 B D N A F

• Hydraulic slew brake and automatic mechanical park braking plus 100% slew locking selectable by in-cab switch.

Powerful, steady deceleration, minimising overrun and increasing control. Effective holding on slopes with parking brake. Increased operator comfort. Locking via in cab switch, preventing slew in critical applications. e.g. lifting on a slope. NO transportation locking pin and bosses required as slew lock defaults to on.

• Fuel tank capacity, 343 ltrs with electric refuelling pump.

Extended intervals between refuelling. Refuelling quick and easy with electrical pump.

• Hydraulic layout with grouped solenoid valve and hose colour coding identification.

Layout logical and appealing to the eye Easy and quick service access Easy identification.

5 1 0 0 B D N A F


7


UNDERCARRIAGE

B D N A F C X E 3 0 / 7 0

• FEATURE

• BENEFIT

• Range of undercarriage sizes for each model: Available on JS200,JS220. • SC – Standard. (46 links / 2200mm track gauge). • NC – Narrow. (46 links / 1990mm track gauge). • LC – Long carriage. (49 links / 2390mm track gauge). Available on JS210. • LC – Standard Long. (49 links / 2200mm track gauge).

Enables the machine undercarriage to be matched according to service requirements. Ground conditions. Cost restraints. Transportation regulations. LC - Improved stability.

• Extensive range of track shoes: 500mm 600mm 700mm 800mm 900mm

Narrow shoes for: Easier transport and where transport width restrictions are enforced. Reduced track wear on hard ground. Wider shoes for: Lower ground bearing pressure. (especially LC builds)

• Apex design side frames with large dirt relief holes below the top rollers.

Minimises dirt build up. Easier cleaning. Reduced the risk of top rollers seizing.

• 3 speed tracking 2.3 to 5.5 km/h with auto-shift. (Tracking speed now controlled by switch located on the right hand side joystick hydraulic control lever).

Fast across the site. Auto-shift from high to medium for increased tractive effort when needed. Special low speed for precise positioning.

• Sealed and greased track chain pins / bushes.

Lubricates the pins and bushes. Minimises pin and bush wear, extends life of the components.

• Sealed for life link. Bushes typically retain grease for 1000 hrs which reduces wear in early life, when most chain wear occurs.

• Scalloped drive sprockets.

• Heavy duty track gear box.

8

Aids dirt relief around the sprocket teeth. Minimises wear. High torque enables manoeuvring and climbing in difficult ground conditions.

6 1 0 0 B D N A F

7 1 0 0 B D N A F

8 1 0 0 B D N A F

9 1 0 0 B D N A F

0 2 0 0 B D N A F



UNDERCARRIAGE (cont)

• FEATURE

• BENEFIT

• Twin track guides standard.

Supports the track chains: Extra security to tracks when digging across or when turning.

• Large diameter slew ring and turret.

1 2 0 0 B D N A F

High strength with high swing force. Long life reliability. 2 2 0 0 B D N A F

• Track motor guards standard and pipe-work built within the undercarriage framework.

Shields undercarriage hydraulics from debris. Avoids damage on rough ground.

• Two-piece central under-guards fitted as standard.

Shields hydraulic lines to rotary coupling. Easy to remove / re-fit. Avoids damage from debris.

• Large recovery points on front and back.

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3 2 0 0 B D N A F

4 2 0 0 B D N A F

Enables easier machine recovery. 5 2 0 0 B D N A F


9


CAB AND AND CON CONTRO TROLS LS

B D N A F C X E 3 0 / 7 0

• FEATURE

• BENEFIT

• Automotive quality pressed pressed steel construction and interior finish. • Improved storage space. space. • Smaller door, easier closing - no decrease in entrance size.

High quality ‘look and feel’, modern styling and plenty of interior space. Comfortable for the biggest operator. Improved rear visibility from bonnet less design. Improved visibility to the tracks.

• Large glass areas areas on all sides with with windscreen de-mister de-mister / defroster as standard.

Provides excellent all-round visibility.

• Large roof window. • Wiper motor positioned on left side of the roof window.

Excellent visibility of attachmen attachmentt at height or overhead obstacles. Bucket is visible to full height allowing easy loading operations.

• Low line superstructur superstructure. e.

Rear visibility is very good, making operating easier.

6 2 0 0 B D N A F

7 2 0 0 B D N A F

8 2 0 0 B D N A F

9 2 0 0 B D N A F

• Vision to right hand side is excellent excellent due to large window.

Front of right track is fully visible making machine placement easy. 0 3 0 0 B D N A F

• Gas strut assisted assisted front window window with integral lower section allowing storage within the main screen.

10

Easy, flexible and simple stowage. Greater operator comfort.



CAB AND AND CON CONTRO TROLS LS (cont)

• FEATURE

• BENEFIT

• Tinted glass with sliding door window

Excellent natural ventilation control and easy, convenient operator communication communicat ion with site personnel. Easier and more comfortable working.

• Rail mounted seat and control arrangement arrangement..

The whole control / seat assembly can be moved without disturbing the seat to-control relationship. relationship. Greater convenience when moving the operating position.

• Air conditioning conditioning or full climate control is optional. • Improved air air conditioning conditioning performance and air distribution including integral cool box.

Gives fresh environment for the operator whatever the weather. Increasess operator output. Maximises operator comfort.

• Large rear storage storage / side pocket document holder.

More room to stow larger items e.g. flasks etc. High operator convenience.

• Standard stereo stereo radio / cassette cassette player with twin speakers and mute button.

Full range of appointments. Maximises operator comfort and satisfaction. satisfaction. Allows operator operator to switch off radio quickly to help with communication. communication.

• Moblie phone holder on 12v charger.

Makes communication easier while using the machine.

• Interior light operable from from ground level.

Easier to get into the cab during the dark.

• Selectable cushion cushion control on boom and dipper services.

Ensures ‘controlled return’ of valve spool to neutral position if the controls are suddenly released. Smoother machine operation. (Easily overridden for shaking bucket clear of sticky material or for a ‘sharper’ machine response).

• Automatic engine engine speed control control for hammer operation. operation. Fully adjustable adjustable to match hydraulic flow to the hammer fitted via AMS control panel.

Engine speed reduces when hammer mode engaged. Ensures best performance from hammers.

• Dial-up throttle throttle control and and selectable one-touch engine idle or automatic / one-touch engine idle. Automatic engine idle delay can be fully adjusted on AMS control panel.

Quick and positive engine speed control. Engine put to idling during periods of non-production, non-produc tion, i.e. waiting for trucks. Improves fuel economy. Optimises operator control.

1 3 0 0 B D N A F


0 7 / 0 3 E X C F A N D B

11


CAB AND AND CON CONTRO TROLS LS (cont)

B D N A F C X E 3 0 / 7 0

• FEATURE

• BENEFIT

• Short stroke, stroke, ISO pattern, pattern, servo excavator controls. • Light lever lever efforts. efforts.

Industry norm for European operator acceptance. Minimal operator effort. Allows the operator to use the armrest.

• Combined pedal / lever lever track controls.

‘Metered’ feed available for progressive controls. For both foot and hand operation. To suit operator style and level of control required.

• Three-speed track selection mounted on the right side hydraulic joystick, with auto shift between high and medium speeds.

Convenient speed change. Auto-shift between two speeds while creep speed is selectable for tracking machine and moving attachment. ie, pipe carrying.

• Large adjustable adjustable display display console displaying warning messages, time, total hours, fuel, engine temperature, temperature, hydraulic reservoir level, working mode and tracking speed.

Easy to see display while operating machine. In line of sight but not obstructing the operators view. view. Provides direct communication communicat ion to the operator via clear messages, including machine warnings and action confirmation.

• Flush mounted membrane switch panel on interior moulding clearly laid out with bright LED switch lights. Operates main machine functions in conjunction with the display console.

Logical operation and clear indication of main machine controls. Easy reach enhances operator control.

• Computer self-diagnostics self-diagnostics on on critical machine functions.

Automatically alerts operator to an Automatically electrical / electronic malfunction with history log. Assures machine is maintained maintained in good condition.

• Overload warning warning system fitted fitted as standard with optional HBCV’s.

Warns the operator operator if machine reaches maximum SWL when on lifting duties. Increases operator awareness.

12

2 3 0 0 B D N A F

3 3 0 0 B D N A F

4 3 0 0 B D N A F


Contents

Section 5. WALK WA LK AROUND

1. Walk around.

2. Auto tracked Excavator. - AMS and Switch panel.

3. XO Tracked Excavator. - AMS and Switch Panel.

4. XO Wheeled Excavator. - AMS and Switch Panel.

5. Pocket guide (cut out and keep).

Walk W alk Around

JS EXCAVATOR WALK AROUND The best route for a standard walk around is to start with the bucket, dipper and boom, then engine and hydraulics, undercarriage/ chassis followed by service access and finally cab and controls. controls. This leaves the customer sitting sitting in the cab so he is comfortable and taking in the cab benefits while you finish talking to him. If he gets into the cab at the beginning of the walk around you will not get your message across properly. properly.

Prior to Giving a Walk Around Find the information on the key details of the machine being discussed. Depending on the depth of the information required you can use the pocket card found in this section, a spec sheet or information contained in the features and benefits section. The correct level of information to include will on ly be apparent by knowing your customer and the situation in which the w alk around takes place. Make sure the machine is clean and unlocked.

Areas to Discuss: Bucket, Dipper and Boom

Wheeled

The bucket is a very important part o f the machine for the customer.

A selection of tyres are available to suit varying ground and site

The wrong bucket can destroy a lot of hard work in presenting

conditions. Stabilizers, dozer or a combination of these can be fitted

the machine. Discuss bucket requirements at this stage and also

to the ma chine. Discuss the app lication to ensure you get the right

check what other attachments attachments may be fitted. fitted. This is important so

spec. Point out the tight turning circle on the JS.

that the correct hydraulic circuits can be discussed. (See JS options explained section for details).

Upperstructure Open each of the service bays in turn and discuss the major

Explain that the JS machines have a range of dippers to suit different

comonents, giving you the opportunity to point out the quality of

applications, all factory fitted with pipe clamp bases to accept

finish due to the used of all pre painted components. In the pump

hydraulic pipe work.

bay explain the use of each filter, explaining the benefit these give to protecting the owners investment. investment. Also while here explain that that all

Explain the greasing intervals on the boom and dipper and point out

JS machines are quick hitch ready with all wiring in place as standard.

the grouped grease po ints for improved service access.

Get the customer up on the top of the upper structure to look at the engine access, and open the engine cover. cover. This is a lot easier on a

Engine and Hydraulics

JCB than most other excavators. Open the tool box to show the

At this stage mention the key details of the engine and h ydraulics:-

storage space and point out the refuelling pump if fitted.

make, size, aspiration, power and flow. The key message here is JCB uses Japanese core components for the engine and hydraulic

Cab and Controls

systems, in the same way that the other leading brands do. (the

When preparing the machine for demonstration demonstration make sure that both

JS200W uses a European hydraulic system in line with most other

seat runners are fully back and the seat is set in the highest position.

large wheeled excavators)

This will immediately emphases the feeling of space in the cab when the customer gets in. Also it gives a good reason to explain the seat

Undercarriage or Chassis

controls fully so he understands all the adjustments available.

Heavy duty design built for European and North American

So let the customer get in, explain the seat then work round the cab

conditions (where machines regularly track long distances).

All

making sure you cover visibility, controls and the front window

hoses are protected within the structure and have guarding fitted to

opening. Make sure that you include Cushion control (as this feature

minimise the chance of site damage. The design of the cross frame

is often ignored and so not understood by the customer) and the

offers good ground clearance and all JS tracked machines have

AMS. Use the AMS guide card to explain the operator accessible

guarding below the rotary coupling.

adjustments and the explain the diagnostic and machine history ability of the unit. It is also important to point out that although although this

Tracked

system is technically advanced it doesn’t make life more difficult as all

JCB use sealed and greased chains which give improved durability

servicing and first stage diagnostics can be carried out without the

and quieter running, they are sealed for life and so do not require any

need to down load any information.

additional servicing compared to dry chains. While the customer is sitting in the cab you can now check he is happy with every thing, before if appropriate letting him go on to operate the machine. This communication and the information within is intended for JCB and JCB dealer personnel only, for information purposes, is confidential and may not be communicated to any third party. Whilst the information is believed to be correct, no guarantee is given by JCB as to its accuracy and its use may not be attributed to JCB.

1

0 7 / 0 3 E X C W A L

Walk W alk Around

AUTO TRACKED EXCAV EXCAVATO ATORS RS

L A W C X E 3 0 / 7 0

2

EXCWALA0001

EXCWALA0002

EXCWALA0003

EXCWALA0004


Walk Around

XO TRACKED EXCAVATORS

EXCWALA0005

EXCWALA0006

EXCWALA0007

EXCWALA0008


0 7 / 0 3 E X C W A L

3

Walk Around

XO WHEELED EXCAVATORS

L A W C X E 3 0 / 7 0

4

EXCWALA0009

EXCWALA0010

EXCWALA0011

EXCWALA0012


Walk Around

POCKET GUIDE FOR JS RANGE

0 6 8 4 4 S J

8 2 2

9

1 9 . 2 1

5 2 . 2

6 1 7 . 5 1

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0 6 3 . 3 2 S 3 J

8 7 1

9 1 . 8

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0 5 6 7 . 2 7 S 2 J

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0 2 4 . 2 5 S 2 J

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0 5 2 5 . 2 2 S 2 J

2 0 1

6 . 6

0 1 2 S J

5 6 1 . 1 2

2 0 1

6 . 6

D E K C A R T

) S E N N O T ( T H G I E W G N I T A R E P O

) W K ( R E W O P E N I G N E T E N

5

2 . 9

0 5 6

6 6 . 6

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5 . 9

0 8 5

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5 , 5

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0 1 3

6 4 . 1

8 . 7

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0 1 3

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9 1 . 1

5 9 . 6

2 . 4

5 . 5

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9 1 . 1

4 5 . 7

3 4 . 4

6 . 5

9 . 2 1

3 4 3

L E V E L D N U O R G T A H C A E R

3 m Y T I C A P A C T E K C U B

S / O M 6 T A Y T I C A P A C T F I L

) h / m k ( D E E P S L E V A R T

m p r D E E P S W E L S

) S E R T I L ( K N A T L E U F

E / O H M T 6 P E T A D Y G T I N I C G A P G I A D C X X X T A A A F I M M M L

These charts have been laid out so they can be cut out, folde d and laminated to make a quick pocket summary for the range.

FOLD

0 0 2 S J

9 1 . 1 2

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8 4 . 3

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2 3 . 9

9 . 0

1 1 . 5

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2 0 1

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5 7 2 . 9

9 . 0

1 1 . 5

5 2 8 . 3

0 3

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2 7

6 4 . 6

2 3 . 9

9 . 0

7 9 . 3

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3 . 1 1

0 4 2

W 0 6 1 S J

7 7 7 . 7 1

2 7

5 2 2 . 6

5 7 2 . 9

9 . 0

1 1 . 5

5 2 8 . 3

5 2

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0 9 3 . 1 3 S 1 J

3 6

5 0 . 6

6 6 . 8

8 . 0

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W 5 4 1 S J

6 9 . 4 1

2 7

3 9 . 5

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8 . 0

6 8 . 3

2 4 . 3

0 3

4 . 3 1

0 4 2

0 7 8 Z J

4 4

7 5 . 4

8 6 . 6

3 . 0

) m 4 ( 1 0 9 . 1

) m 4 ( 4 5 6 4 . 1

5 . 9

0 2 1

W 0 3 1 S J

6 9 . 4 1

3 6

3 9 . 5

9

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H T P E D G N I G G I D X A M

L E V E L D N U O R G T A H C A E R X A M

3 m Y T I C A P A C T E K C U B X A M

L E V E L D N U O R G T A H C A E R X A M

3 m Y T I C A P A C T E K C U B X A M

E / O M 6 T A Y T I C A P A C T F I L



m p r D E E P S W E L S

) S E R T I L ( K N A T L E U F

D E K C A R T

) S E N N O T ( T H G I E W G N I T A R E P O


E / O M 6 T A Y T I C A P A C T F I L



) S E m R T p r I L ( D K E E N P S A T W L E E L U S F

) S E N N O T ( T H G I E W G D I E N L T E A E R H E P W O


H T P E D G N I G G I D X A M


0 7 / 0 3 E X C W A L

5

Contents

Section 6. DEMONSTRATION NOTES

1. Why Demonstrate? - Preparation. - Guide to Demonstrating.

2. The Demonstration. - The Basics. - Typical Sequence of Events.

3. Follow-Up/ The Demonstration Report. - The Objectives. - The Presentation. - Standard Demonstration Report.

4. Demonstration Guide. - Full Scale Demonstration/Presentation Report. - General Considerations.

5. Minimum Content of a Demonstration Report.

Demonstration Notes

INTRODUCTION - WHY DEMONSTRATE? The demonstration provides two major aids to the selling process: • A means of confirming the suitability of the product for the customer’s application. • A graphic way of showing all of the features and benefits of the product, i.e. performance, operator conditions, service access and manufacturing quality. A properly conducted and reported demonstration will ensure that these items are thoroughly exploited. Conversely, a poorly organised and executed demonstration can turn your customer off for a very long time.

PREPARATION - PRIOR TO THE DEMONSTRATION Visit the site on wh ich the demonstration is to be held. Check the ground conditions a nd the type and weight of material to be handled. Verify the distances to be travelled during lo ading exercises. Ensure that the machine to be demonstrated can handle the prevailing conditions and achieve the desired results. Take notice of competitor’s machines doing the same job. This is always an indication of what size machine is required. On NO account should the machine to be demonstrated be asked to achieve more than it is capable of doing. Check for tight corners, low buildings, overhead cables etc. which may cause problems. Specifically ask if underground utilities have been or will be clearly marked. Check the access to the site and note any details which may be useful to the driver who will be delivering the machine. Ensure that the correct build of machine is available for the application. For example: Ensure correct specification of machine i.e. length of dipper, size of bucket and teeth etc. Never assume that the standard build of the m achine will be satisfactory. YOU must be sure that the equipment to be demonstrated will give long term high performance for your customer. If it is possible and acceptable to your customer, take maximum advantage of the situation by inviting other customers to the demonstration. Always check if other demonstrations are required in the area. A demonstration tour, or ‘Round Robin’ demonstration, is more cost effective than a one- off event.

GUIDE TO DEMONSTRATING (continued) PREPARATION - ON THE DAY (On an extended demonstration we recommend that these procedures are followed for at least one of the days.) Check that all parties involved in the demonstration are going to attend. Ensure that transportation arrangements are satisfactory. Make sure you have your: • Up-to-Date Sales Literature/Specification Sheet(s). • Stop Watch. • Camera. • Writing Material. • Tape Measure. Ensure that the machine and driver arrive early. Brief the demonstrator (when available) of the demonstration required and give him time to get acquainted with the surroundings. Remember, the demonstrator is in charge of the machine, but YOU are in charge of the demonstration. Get to know the demonstrator and give him a full briefing on wh at the customer wants to see. Listen to his comments and do not ask him to do things that are unreasonable.


1

0 7 / 0 3 E X C D E M O

Demonstration Notes

THE DEMONSTRATION At the start of the demonstration you sho uld have a clear understanding o f the customer’s requirements, i.e. machine build, attachments, operating conditions, output, noise levels, serviceability, productivity etc., which must be covered during the demonstration and on the written demonstration report.

The Basics First, sell to all those persons involved in the decision making process, not just the owner. Every demonstration must involve all those people who could influence the purchasing decision - the operators, mechanics, foreman, supervisor etc. If possible, arrange the day so that all concerned can be involved. Second, the machine must be demonstrated in the application that it would normally work.

Typical Sequence of Events Before the ‘VIP’s’ arrive, have the demonstrator and operator discuss and walk through the job to identify the requirements. The demonstrator should have ample opportunity to familiarise himself with the site. When the ‘ VIP’s’ arrive, the machine should be parked on a clear, level part of the site ready for inspection and walk a round. The demonstrator is ready to begin the demonstration. Point out the features and benefits of the machine. Begin the demonstration. As the machine is working, point out what the demonstrator is doing and make features/benefits comments. Write notes, take measurements or take cycle times that you consider necessary to enter into your demonstration report or be used for future negotiations. Record any complimentary quotes for inclusion into the report. For example: Truck Loading • Truck size. • Truck-to-machine position. • Number of passes to load truck.

O M E D C X E 3 0 / 7 0

• Ground conditions. • Material type and density. • Cycle times. When photographs are b eing taken, include people as well as machines. If you intend to publish pictures with people included, you must get a photographic release signed by the customer. Whenever possible, photograph the machine working and get a picture of the operator. Write down the operator ’s name and address and send him a picture. After the demonstration, talk with the demonstrator. Find out if he has any specific comments or information that will affect the sale. Before leaving the demonstration, ensure that you have the following information: • Correct title and address of the company. • Names and titles of all people in attendance. • Full specification of the machine being considered, together with any attachments. • Details of competitors and machines involved. • Productivity figures. • Photographs. • Records of comments. • Particular jobs the machine performed well.

2


Demonstration Notes

FOLLOW-UP/THE DEMONSTRATION REPORT The Objectives • Confirm the suitability of the JCB product demonstrated in the application. • Provide an opportunity for further negotiation and contact with the customer. Ideally the customer should be persuaded to commit to a satisfactory demonstration - the report is proof. Deliver the reports personally. • Promote the image of both the dealer and the customer. • Add a personal touch to the deal. The demonstration report tells the customer that the salesperson has taken the time and trouble to give personal attention to the customer and his personal need.

The Presentation Two levels of demonstration report are possible: • Standard Demonstration Report. • Full Scale Demonstration/Presentation Report.

A. Standard Demonstration Report This report is applicable to the small business where the owner plays the major role in the decision making process and is well known by the salesperson. It should consist of: • Presentation Folder. • Product Literature. • Demonstration photographs. • Standard JCB demonstration report. • Formal quotation. Either you or your office staff should assemble the copy(s) and get them ready for your personal delivery to the customer. Always retain a copy of the complete report for yourself as a reference. File the report neatly in yo ur Sales Quotation Log.

0 7 / 0 3 E X C D E M O

Demonstration Guide B. Full Scale Demonstration/Presentation Report This is applicable if the following conditions apply: • Demonstration has been performed to a large company and there are a number of people involved in the purchasing decision. • Everyone involved in the purchasing decision does not attend the demonstration. • A number of machines, including the competitors, are to be demonstrated over a period of time. • The decision to purchase is to be made later.

General Considerations • The report should be concise and businesslike - keep it simple - remember, a photograph can be worth a thousand words. • The report must always relate to a customer’s needs. • All copies of the report should be personalised with the name and title of the recipient. • Write the report as early as possible after the demonstration while the facts are fresh in your mind. • As with the standard report, retain a copy for your records.


3

Demonstration Notes

Minimum Content of a Demonstration Report Title Page: Machine demonstrated: Model: Serial Number: Specification: (Build, shovel size, attachments, tyre specifications etc.) Prepared for: (Name and company address) Demonstration Site: (Name and address of location.) Persons Present at the Demonstration: (Names and titles.) Duration of the demonstration: (From - day/date - to)

Subsequent pages: Objective of Demonstration: (Work requirement of the demonstration.) Customer requirements: (Application) Site conditions: (Soil type, climatic conditions, etc.) Special equipment: (Non-standard items) Machine performance Quotes

O M E D C X E 3 0 / 7 0

4


Contents

Section 8. COMPARATIVE EVALUATION – JS 200L/210 L/220L AUTO VS CASE CX RANGE

1. JS 200L/JS 210L/JS220L Auto vs Case CX Range.

2. Introduction and Overview.

3. Introduction and Overview(continued).

4. The Evaluation.

5. Lifting Performance.

6. Engines.

7. Cabs.

8. Cab Overview.

9. Cab (continued).

10. Cab/Seat Controls.

11. Cab Design/Vision.

12. Cab Visibility.

13. System Display and Control Panel.

14. Power Work Modes.

Contents

15. Power Work Modes (continued).

16. AMS.


18. Storage.

19. Track Pedals.

20. Superstructure.


22. Visibility And Access.

23. Visibility And Access (continued).

24. Walkway And Service Issues.


26. Service Issues.


28. Service Access.




32. Undercarriage Overview.

Contents

33. Undercarriage Overview (continued).



36. Excavator End.

37. Excavator End (continued).




JCB Product Information - Comparative Evaluation

JS200L/JS210L/JS220L AUTO vs CASE CX RANGE, MAY 2003

THE NEW GENERATION 0 7 / 0 3 J S V C A S E

CX210

CX225R-SR


1


INTRODUCTION AND OVERVIEW Comparison between the JS and Case 19-23.0 tonne class tracked excavators. Case has a joint venture with Sumitomo Construction Machinery. Case machines for the European market, are manufactured by Sumitomo in Japan. Reports show that just over 5000 units were sold last year and this includes machines for Case and Link Belt. Although the product from Sumitomo is good, they don’t offer a mini excavator within their product range. Case has gone through trauma over the years by offering mini excavators from Kubota, then Kobelco and now Schaff. This report primarily focuses on the JS220L auto and the latest CX210LC, although other offerings from Case, such as the CX225-SR is covered but to a lesser degree. The objective of this document is to establish the differences between the JCB and Case excavators. The following tables show the operating weight and track gauge etc. This will help to establish the direct competitor to the relevant JS machine. A more detailed comparison is included later.

JS vs CASE (all 2390mm track gauge)

E S A C V S J 3 0 / 7 0

JS200L

JS220L

CX210LC

CX225SR

20,870kg

22,172kg

20,100kg

22,700kg

No

No

No

Yes

3700kg

5000kg

REAR SWING RADIUS

2825mm

2825mm

2720mm

1680mm

MINIMUM SWING RADIUS

3710mm

3710mm

3670mm

2550mm

TRACK GAUGE

2390mm

2390mm

2390mm

2390mm

LIFT CAPACITY @ 6M

4430kg

5220kg

4300kg

4450kg

OVER-SIDE/FRONT

7030kg

8040kg

6686kg

7150kg

TRACK PLATE WIDTH

700mm

700mm

600mm

600mm

OPERATING WEIGHT REDUCED TAIL SWING COUNTER WEIGHT

JS vs CASE (case do not offer a 2200mm track gauge)

JS200S

JS210L

JS220S

20,430kg

21,355kg

21.731kg

No

No

No

3700kg

4350kg

5000kg

REAR SWING RADIUS

2825mm

2825mm

2825mm


3710mm

3710mm

3710mm

TRACK GAUGE

2200mm

2170mm

2200mm

LIFT CAPACITY @ 6M

3920kg

4420kg

4670kg

OVER-SIDE/FRONT

6090kg

7540kg

7040kg

TRACK PLATE WIDTH

700mm

700mm

600mm


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JS vs CASE (1990mm narrow track gauge)

JS200N

JS220N

CX210NLC

20,095kg

21,396kg

19,900kg

No

No

No

3700kg

5000kg

REAR SWING RADIUS

2825mm

2825mm


3710mm

3710mm

TRACK GAUGE

1990mm

1990mm

1990mm

PLATE WIDTH

600mm

600mm

500mm

LIFT CAPACITY @ 6M

3480kg

4190kg

3680kg

OVER-SIDE/FRONT

6000kg

6940kg

6990kg


2830mm

TRACK LENGTH

Note some track plate widths vary, although the width of the track plates makes little difference when comparing stability over the side. Note, lifting numbers are shown with no bucket, and either at 87% hydraulically limited or 75% stability limited which ever is relevant.

Other Information The CX210C is available with : - Long Reach. JCB offer: - 600mm track plates with 50mm offset. The offset allows 600mm plates to be fitted to the JS N machines and stay within the 2.55m maximum width which is specified in some countries. Wider plates enhance the machines perception and lowers the ground bearing pressures considerably. - Long Reach.


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THE EVALUATION

The evaluations included productivity and efficiency tests, quality comparisons, service access and product specifications etc.

Key advantages of the JS range and features to consider on Case machines.

• Customer Perception. Fiat own 70% of CNH and the rest is publicly owned. Under the CNH umbrella is O&K, Case, NH and Fiat / Kobelco. CNH and Kobelco Japan have a financial interest in each other i.e both companies’ own shares with each other. Case has a joint venture with Sumitomo (OEM) i.e. Sumitomo supply Case with equipment but have no financial ties with each other.

• Operating Weight. The demise of the joint venture between JCB and Sumitomo gave Case the opportunity to distribute Sumitomo machines in Europe and Middle East etc. All Case / Sumitomo tracked excavators are exported from Japan and are built to the Asian specification i.e. a lighter duty machine, designed for the Asian market.

E S A C V S J 3 0 / 7 0

Where possible, the table below compares the weights in a like for like situation. KG

KG

JS200L

20,870

JS210LC

21,355

CX210LC

20,100

CX210NLC

19,900

JS DIFFERENCE

+ 3.8%

JS DIFFERENCE

+ 7.3%

JS220LC

22,172

JS220L

22,172

CX210LC

20,100

CX225SR

22,700

JS DIFFERENCE

+2.3%

JS DIFFERENCE

+10.3%

KG

TRACK PLATES MM

JS220N

21,396

600 Off-set

CX210NLC

19,900

500

JS DIFFERENCE

+ 7.5%

Primarily the extra weight of the JS machines is built into the undercarriage, boom / dipper and counter weight. The JS machine is designed for heavier / harder applications. The CX225SR is slightly heavier than the JS220L. Reduced tail swing machines rely on a huge counter weight for stability / performance.

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• Lifting Performance. JS220L The Case range of machines is no match for the JS new generation machines. The JS220L at 6m has over 21% more lift capacity over side and 20% more over the front than the Case 210LC. This degree of advantage is significant when bulk muck shifting and heavy lifting duties i.e. trench boxes where the weight of the box and ground suction becomes an issue. The 220L also out lifts the CX225R (Zero Tail Swing) by 17% over the side and over 12% over the front. (The CX225R has the same width undercarriage as the JS220L). JS200L The JS200L also out lifts the CX210LC by 6% and equals the CX225R over the side. Over the front the JS200L is better than the CX210LC and has only 120kg less capacity than the CX225R over the front. JS210L Case does not offer a machine with a 2200mm track gauge option. (Sumitomo offer 2200mm track gauge therefore Case must have chosen not to include the 2200mm track gauge in their range. This could be due to the fact that the Sumitomo 2200mm undercarriage is only offered as standard length, unlike the JS210L). JS advantage: Over the side the JS210L with it’s 2200mm track gauge out lifts the CX210LC and equals the CX225R, both the case machines have 2390mm track gauge. Over the front the JS210LC out lifts the CX210LC by nearly 13% and the Cx225R by over 5%. JS220N The JS220N has a 1900mm track gauge and standard length undercarriage. The Case 210NLC has the same width track gauge but has a LC fitted. Over the side the JS220N out lifts the CX210NLC by nearly 14%. Lifting over the front both machines lift just under the 7 tonnes @ 6 metre.

• JS Narrow machines. Track Plates: Machines with a 1990mm track gauge require 500mm track plates to be under the maximum overall width of 2.55m. JCB offer 600mm offset tracks. The offset keeps the machine under the maximum width and lowers the ground bearing pressure. Perception is also an important issue, 600mm plates look good and offer reduced ground bearing pressure. Advantages / disadvantages: - The JS220N with the 600mm offset track plates is within the 2.55 maximum width. - Ground bearing pressure. The JS220N with 600mm plates has over 10% more track area on the ground. However, the JS is heavier than the CX and this gives both machines virtually the same ground bearing pressures. - Turning / counter rotating. Whilst long carriages have their advantages in certain situations, counter rotating or turning is generally a disadvantage when compared to turning with a standard length undercarriage. - The JS220N has nearly 14% more lift capacity over the side and virtually equal lift over the front. - The JS200N has slightly less lift capacity over the side than the CX210N and 16% lift capacity over the front.


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• Engines Both the JS and Case machines have the same Isuzu BB-6BGIT engine. (Neither unit is aftercooled) The JS units have a 102 kW engine and the Case CX210 units have 105kW motor. (CX225R has a 103kW motor) Considering both engines are identical we should consider the following: - Engines in both the JS and Case have the same Specific Fuel Consumption (SFC) when tested in bench conditions. - Case must be giving the motor more fuel to gain the extra kW! - Do Case maintain the hyd flow longer or generate higher breakout forces etc, therefore improving the machines overall performance! (Tests done by JCB show no advantages). • Excellent all round visibility from JS Cab. The high bonnet and old design cab on the CX machines proved to be the main dis-advantage when compared to the JS auto. • Hydraulic flow- The new generation JS machines have 6.5% more hyd flow than the CX210 machine and 12.6% more than the CX225R. • The plexus filter on the JS machines needs to be replaced every 1000 hours and the hydraulic oil at 5000-hours. Case offer a similar system called Ultra Clean and the service intervals are the same as the JS. Both systems reduce service costs and enhance reliability. However, Case fit the Ultra Clean filter from Sumitomo and our own experience with the filters from Japan, tells us it could be very expensive when compared to the JCB filter. • Isuzu has deleted the first 100-hour service, and the double engine oil filter has been replaced with an improved single filter on the JS new generation machines. The improvements made by Isuzu are designed to reduce service costs and eliminate unnecessary down time for the customer. E S A C V S J 3 0 / 7 0

• The new low-level bonnet on the JS Auto machine is lighter and easier to open. JCB is not recommending the mounting of a vandal guard on top of the engine cover due to restricting the rear vision. (The cab roof has provision for optional cab guard storage). • Drawbar pull - The JS Auto has 191.9kN Vs the Case 210LC which has 183.4kN (4.6% less than the JS Auto). • Slew torque – The CX has 61.0kN Vs 73.11kN on the JS auto. JS has 19.8% more slew torque. • The JS has 3 speed tracking versus 2 speed on the case machines. Creep speed is the advantage for the JS. Both machines offer auto speed change. • Creep speed tracking is standard on JS machines, it is designed to give the ultimate hydraulic control by reducing the hydraulic flow and engine rpm. Case products don’t offer this feature. • The upper-structure width is 2.5m on all the JS 20 class machines. Case, like some other none European designed machines, build a special narrow upper-structure to comply with the maximum width of 2.55m required in some countries. CX210LC superstructure is 2.8m wide. Whilst we believe this is a small issue, Case will need to stock parts to suit both structures. • Swing Speed – JS Auto 12.9 rpm and Case CX 210LC 12.0 rpm (JS 7.5% faster) and the CX225SR is 11.5 rpm (17% slower than the JS Auto). The JS new generation machine has over 3% more slew torque than the Case CX210LC. The JS advantages help provide faster cycle times. • JCB offer 3 different sizes of counterweights i.e. 3.7T JS200L, 4.35T JS210L and 5.0T for the JS220L machine. Working on slopes / inclines etc, the larger counter weight provides even better slewing performance.

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• Cab - JS Short joystick controllers – more precise and lighter to use. - JS Cab front windows – Integral 2 piece on the JS. (Case bottom front window stored separate behind the seat). - The JS has excellent all round visibility, whilst the CX has poor upward vision, poor vision to the right side track and restricted vision over the rear. - The re-designed JS door is easier to close from operators’ seat. - The adjustable AMS monitor, switch / control panels are better located for vision and ease of use.

• Performance. - Unfortunately the tests conducted were done at different times and in some instances the tests were constructed totally differently therefore this makes it difficult to give an accurate performance analysis. However we should consider the following:

• Supporting information: - Hydraulic speeds. With the exception of boom down the JS Auto is faster in all other services. - Breakout force. Both machines have equal dipper breakout force and the JS has 12% more bucket breakout force. - Hydraulic flow. The JS has 6.4% more hydraulic flow. - The JS has a better lift performance. - Harder and heavier ground condition would have favoured the JS machine with its higher hydraulic flow, higher bucket tearout and heavier lifting performance.

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- Case does not offer a short 1900mm dipper. - Draw bar pull, the JS has nearly 5% more kgf. - The JS200, 210 and 220 machines offer counter weights to assure maximum performance.


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CAB Cab Overview The JS cab is manufactured by a company called TIM and they are located in France. Whilst the Case cab is built to a good standard. Visibility is not as good as the new JS auto. The JS cab has the same high quality finish but incorporates a modern design, excellent visibility and user-friendly controls etc. The cab for the new Auto machine is probably the best excavator cab that JCB has produced. JCB fulfiled all their objectives in the design. JCB has taken particular care when designing the cab and its controls. The focus has been on improving the following: visibility, quality / durability, operator comfort, control layout and ease of use etc.

CASE CX210LC

JS 220L AUTO

Air-conditioning with climate control as standard.

The cab for the new Auto machine includes: Unmatched all round visibility, the control and cab layout is excellent for simplicity and ease of use. Air-conditioning or climate control incorporating chilled cool box is an option.

E S A C V S J 3 0 / 7 0

JSVCAS0001

8

JSVCAS0002



CAB

(cont)

CASE CX210LC

JS 220L AUTO

The cab has a roof hatch. The design sacrifices visibility to

The JS roof window wiper motor has moved to the side for

the attachment at height when the hatch is closed.

better visibility. A roller blind is standard and it protects operators from direct sun either from above or from the front of the cab.

Case offers a 2 piece front window as standard but cannot be integrated in the raised position. The lower screen can be

The 2-piece window is easy to open with gas strut assistance

removed and stowed in the storage compartment behind

using well-positioned handles. Lower section of front window

the seat. This is not ideal due to breakages etc.

is an integral part of the front window and held in top section. The door window also incorporates a sliding window. There is no better design.

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JSVCAS0003

JSVCAS0004

The Case cab door is similar in size to the JS XO door.

Both JCB and Case have a sliding window in the door.

The width of the JS XO door was always an issue with

The door on the auto machine has reduced in width when

operators. Closing / opening the door from the operators seat

compared to the previous XO machine. This was done to

was seen as a problem, particularly if the wind was blowing.

make it easier to close the door when inside the cab. Probably more important to the larger or older operator, the actual access width in to the cab has not reduced i.e. front of the joystick base to front of in-side cabin.

1070mm

JSVCAS0005

980mm

JSVCAS0006


9


Cab / Seat / Controls

CASE CX210LC

JS 220L AUTO

The Case CX cabin is functional and well put together.

Modern and ergonomically designed.

- Case claim to have a 1mtr wide cabin.

Switch and control panel easier to see and use.

The widest point measured on the JS machines is 920mm and this is wider than Case cabin which was measured at 910mm.

- Large cab designed to accommodate the largest and smallest of operators.

- Air-conditioning and climate control is standard.

- Smaller door for easier closing.

- Anti-theft device standard. Each machine has an individual

- The new heater and air-conditioning unit develops 56%

code. The code must be entered on the computer to allow the machine to be started. - Like the majority of excavators, Case machines are

more airflow. - Optional full climate control air-conditioning. - Interior lamp with timer switch aids easier access to the cab.

controlled by electronic management systems and an LCD

- Flat floor with no door lip – easy clean.

monitor to show the relevant functions / features offered.

- Document storage pocket. - Mobile telephone holder and 12v charger point.

The LCD monitor is side mounted, not ideal in sun light (This design is similar to the LCD monitor used on the first JS R3 machines). E S A C V S J 3 0 / 4 0

- Optional deluxe air suspension seat with heated pod and adjustable lumber support. - Radio mute switch, cuts off radio to improve communication.

- Long joystick control levers. Long levers require the operator to use their arm

- Adjustable LCD monitor directly facing the operator. - Short joystick control levers.

wrists together. Also due to the excessive movement of the joysticks, the seat armrests become useless. Many European

The short joystick controls require less effort and are easier to

customers will not accept these long movement controls i.e.

use for the operator, particularly when fine precise work is

JCB previously fitted the same levers and was subjected to

required. Short levers have a distinct advantage when used in

strong criticism.

conjunction with seat armrests.

XXXXXX

JSVCAS0007

10

JSVCAS0008



Cab Design / Vision

CASE CX210LC

JS 220L AUTO

Dated design, wider pillars and higher bonnet all contribute to

Modern designs with excellent all round visibility.

poor visibility to the rear, both sides and upwards. Forward vision is acceptable.

JSVCAS0009 The Case workstation feels closed in compared to the JS.

JSVCAS0010 0 7 / 0 3 J S V C A S E

The JS has better vision, particularly with the door closed.

Smaller glass area to both sides compounds the feeling.

Vision to left side.

Excellent all round vision.

JSVCAS0011

JSVCAS0012


11


CASE CX210LC

JS 220L AUTO

Rear vision.

Excellent rear vision.

JSVCAS0013 Vision through the roof hatch when open.

JSVCAS0014 Excellent vision through the roof light. The roller blind seen here can be used to deflect the sun from the roof or front window.

E S A C V S J 3 0 / 7 0

JSVCAS0015

JSVCAS0016

JSVCAS0017

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System Display and Control Panel

CASE CX210LC

JS 220L AUTO

Monitor is mounted with side panel.

Modern and all within easy reach of the operator. Work modes selected on the AMS monitor.

Tracking speeds x 2 and the hydraulic work modes are

Tracking speeds are selected from a button located on the

selected from this panel.

right side joystick. The operator can shift through the 3 speeds without removing his hands from the joysticks.

The throttle dial is within easy reach and located next to the

The throttle control is easy to reach. Hydraulic work modes

ignition key.

are selected independently from the AMS monitor.

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JSVCAS0018

JSVCAS0019


13


POWER WORK MODES

JS Auto The AMS on the auto machine has been improved to make life easier and more efficient for the operator. With Auto mode selected, power boost is automatically activated, and the AMS regulates whether the machine needs maximum power and speed or economy ensuring maximum efficiency. The remaining 3 work modes are E – Economy (lowest fuel consumption), P - Precision mode (fine grading duties) and L – Lifting mode (Lifting duties). In L mode the hydraulic pressure increases automatically by 10% for maximum power. Note, when starting the JS Auto machines the work mode selected will be the mode previously used prior to stopping the machine.

Case CX210LC The Case CX series machines have a choice of 3 traditional work modes plus 1 automatic mode. The first switch marked Auto, simplifies the machine operation and it works not unlike the JS new generation machine with Auto mode selected. The difference between the 2 Auto modes is that the Case appears to work in Economy mode and selects Heavy mode i.e. as and when necessary. (In Auto mode the JS works in heavy mode and drops to economy when maximum power is not required). The CX has a second work mode switch, H – heavy mode (Maximum production), S – Standard mode (Similar to economy on the JS) and L – Lifting mode. Case does not appear to be offering a precision / fine work mode. The Case selects power boost automatically. E S A C V S J 3 0 / 7 0

Note, Auto is the default. When starting the CX machines Auto will be automatically selected. When Auto mode is off the machine goes to H mode. The following explains how both systems work and compare with each other.

CASE MANAGEMENT SYSTEM

JCB ADVANCED MANAGEMENT SYSTEM

Fixed EMS monitor mounted side on – Difficult to view in

Adjustable AMS Monitor gives improved external visibility.

bright sun light.

Hydraulic Work Modes:

Hydraulic Work Modes:

Auto

A – Auto

H – Heavy

E – Economy

S – Standard

P - Precision

L - Lifting

L – Lifting

Diagnostic work can be done without the aid of a Laptop.

14



POWER WORK MODES

(cont)


JCB ADVANCED MANAGEMENT SYSTEM

Auto Mode

Auto Mode

- 100% hyd flow Available (402ltr 1/min).

- 100% hyd flow (428ltr 1/min).

- 1950rpm.

- 1950rpm.

- Hyd power - unknown.

- Hyd power 95kW.

- Power Boost automatic.

- Power Boost automatic.

- Automatically selects Heavy mode when necessary,

- Automatically select Economy mode if joystick is less that

i.e. full hyd flow etc. - Maximum hyd pressure 373bar.

75% open. - Maximum hyd pressure 373bar.

Heavy Mode - 100% hyd flow. - (402ltr 1/min). - 1950 rpm. - Hyd power - unknown. - Maximum hyd pressure 373 bar.

Standard Mode

Economy Mode

- 90% hyd flow.

- 95% hyd flow.

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- 1850rpm. - Hyd power 77kW. - Maximum hyd pressure 343bar (No pressure boost).

Precision Mode - 90% hyd flow. - 1750rpm. - Hyd power 53kW. - Maximum hyd pressure 343bar.

Lifting Mode

Lifting Mode

- flow - unknown.

- 63% hyd flow.

- rpm - unknown.

- 1750rpm.

- Maximum pressure 373 bar.

- Hyd power 53kW. - Maximum pressure 373 bar.

Tracking

Tracking

- Maximum hyd pressure 343bar.

- Maximum hyd pressure 343bar-.

- Maximum drawbar pull 183.4KN.

- Maximum drawbar pull 191.9KN.

- 2 speed.

- 3 speed – 2 speed motors and creep standard.


15



ADVANCED MANAGEMENT SYSTEM

Regenerated hydraulics Standard (Prevents cavitations and increases boom down, arm in and bucket in speed).

Boom / Slew Priority


- Automatic.

- Standard and selectable.

- Slew torque = 61.0kN.

- Slew torque = 73.11kN.

Cushion Control

Cushion Control

Standard.

Standard.

Free swing

Free Swing

Standard.

Not available.

Case Management System - Side mounted.

AMS - Front mounted and clearly visible. - AMS has 1 pre-set setting and for further attachments the operator selects the correct rpm via the AMS monitor.

E S A C V S J 3 0 / 7 0

- Work modes selected on the monitor.

- Work modes selected on the monitor.

- Tracking speed selected on the monitor.

- Tracking speed selected on right-hand joystick.

- Modern design and simple to use.

JSVCAS0020/1

16

JSVCAS0022



POWER WORK MODES

(cont)

CASE CX210LC

JS 220L AUTO

The AMS monitor gives virtually unrestricted vision through both the front and side windows while ensuring operating information is in the operators line of sight.

JSVCAS0023 Radio cassette? player

Radio cassette player

- Located low and on the right side to the operator, ideal place

- Mounted high and at the rear of the cab, free from dirt and

for dirt and dust to rest! - No mute button.

dust etc. - Radio mute button located next to the right side mute button.

JSVCAS0024 Case 210 right side consul. - Climate control / air-conditioner standard.

JSVCAS0025 - Optional air-conditioner or climate control including integral cooling box.

- Rear air vents located next to rear window.

- Rear air vents located each side of the storage box.

- Large storage shelf located behind the seat below the air vents.

- Large storage box with lid and latch to keep closed. - Mobile telephone holder and charger located next to the cooler.


17

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CASE CX210LC

JS 220L AUTO

JSVCAS0026

JSVCAS0027

Cab storage.

Cab storage.

Case also offer a storage box with a lid.

Storage box closed.

E S A C V S J 3 0 / 7 0

JSVCAS0028 JCB has a document storage sleeve located below the cup holder in the front on the right side. Also storage sleeve behind the operators seat.

JSVCAS0029

18



Track Pedals

CASE CX210LC

JS 220L AUTO

The floor design eliminates the need for foot rests. Hammer and TAB pedals are better-located leaving room for the feet to rest.

Tracking speed is selected from the control panel next to the

The track speed control selector has moved from the floor

right joystick.

position and is located on the right side joystick. Easier to operate and better controllability for the operator. The Auto speed change

The Case CX210LC has 2-speed travel. With high selected,

between high, medium and creep speed is manually selected.

auto speed change is activated. The JS has 191.9kN drawbar pull 4.9% more than the The Case CX210LC has 183kN drawbar pull.

Case CX210LC.

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JSVCAS0030 - Case has a 2 piece front window. The bar dividing the window is 45mm wide.

JSVCAS0031 - The bar dividing the top and bottom windows is kept to a minimum (10mm).

- The lower window is separate from the top section. The lower section can be removed and stored behind the

- The lower window is an integral part of the top section, therefore can be opened together i.e. as one piece.

seat. (You will often s ee these lower windows either broken or missing.

JSVCAS0032

JSVCAS0033


19


SUPERSTRUCTURE OVERVIEW

JCB has made some significant changes to the Superstructure. JCB’s objective was to build a machine with improved access to all compartments, reduce service costs, provide improved visibility, improve quality / durability and improve performance. Sumitomo first launched the Case CX series design in Japan around 5 years ago. Sumitomo started to supply Case with the SH machines in 1998. Whilst the engine and hydraulic systems have been continually updated, the tinwork including the cab has changed little.

Reduced Tail Swing Machines The CX225R has also been around in Asia for 5/6 years. Case is offering the reduced tail swing machines in Europe etc. Note: it is not our intention to focus on the CX225R. However it is possible that the CX225R will be offered to your customers, therefore you will find some details outlining the fundamental differences between the 2 designs. Note, the track gauge for JS NC and CX210N is 1990mm. The CX210N is the only model being offered by Case with a maximum width of less than 2.55m.

E S A C V S J 3 0 / 7 0

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CASE CX210LC

JS NEW GENERATION

The Case machines are all post painted.

All JS machines are pre-painted to provide the following: - Better visual finish. - Better residual value. - Easier/user friendly for the service engineers, i.e. tracing electrical and hydraulic faults etc.

JSVCAS0034

JSVCAS0035

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CX225R Reduced tail swing.

JSVCAS0036


21


VISIBILITY AND ACCESS

The most noticeable improvement on the JS machines is the introduction of the flat bonnet. Vision to the rear is improved dramatically.

CASE CX210LC

JS 220L AUTO

Vision is restricted with the high bonnet.

Vision over the bonnet is excellent.

The bonnet has no negative effect on visibility.

The bonnet is light to open and close.

E S A C V S J 3 0 / 7 0

JSVCAS0037

JSVCAS0014

CX225R - Rear vision is extremely poor when compared to any traditionally designed superstructure.

Reduced tail swing maybe important in some situations, but this all-round vision for site work is poor.

JSVCAS0039

22



VISIBILITY AND ACCESS (cont)

CASE CX210LC

JS 220L AUTO

- The bonnet restricts rear vision.

- Decal design gives room for sign writing.

- The Superstructure width is 2.75m on the CX210L.

- At close proximity the machine vision is obviously better.

- The CX210NLC has a purpose built 2.5m superstructure.

- The superstructure width is 2.549m on the JS200,210 and 220 machines. Parts stocking is an obvious advantage over the Case.

JSVCAS0040

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JSVCAS0041

CX225R - Case is keen to show in their CX225R brochure that the cab is below 3m height, but omit to show the height of the superstructure!!!

- The superstructure width is 2.80m.

JSVCAS0042


23


WALKWAY AND SERVICE ISSUES

CASE CX210LC

JS 220L AUTO

Case use similar none slip grippers as the JCB XO machines.

The Auto machines have perforated plate steel covering the

Whilst the grippers do their job they are not seen to be as

majority of the upper structure. The plate is Phosphate

durable as the perforated plate now used on the JS auto.

dipped for durability.

The walkway and working area is wider for easy access.

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JSVCAS0043

24

JSVCAS0044




CASE CX225R

JS 220L AUTO

CX225R

The valve block is located behind the slew motor and under

- Access on to the CX225R is narrow and needs more care

the walkway cover on the JS machines. Excellent access to

when climbing on or off the superstructure.

both the valve block and slew motor.

- No storage box. The hyd valve block is housed in the compartment along side the steps.

- Access to the valve block is not ideal and due to the location requires long hose runs between the joysticks etc.

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JSVCAS0045

JSVCAS0046

The Case CX210LC is not too dissimilar to the XO.

Excellent grip, durable and a large wide area, ideal platform to

(the image below shows the top plate removed).

carry out daily checks etc.

JSVCAS0047

JSVCAS0048


25


SERVICE ISSUES

CASE CX210LC

JS 220L AUTO

- Servo.

- Case drain / leakage line.

- Main Hyd return.

- Servo / pilot line.

- Suction strainer.

- Main hyd return.

- Ultra Clean bypass.

- Suction strainer. - Plexus bypass.

- The CX main return filter is a 10 micron.

The JS main return line filters down to 10 micron.

- The main hydraulic filter needs changing every 2000 hours.

- The main hydraulic filter is located inside the hydraulic tank

The hyd oil is replaced every 5000 hours.

and it should be changed every 1000 hours. The hyd oil needs replacing every 5000 hours. The main hyd filter cleans all oil before returning to tank.

- The bypass filter (Ultra Clean) is located in the hydraulic

E S A C V S J 3 0 / 7 0

- The bypass filter (Plexus) is situated in the hydraulic pump bay.

pump bay. The filter needs replacing every 5000 hours.

The filter needs replacing every 5000 hours. To ensure

The Ultra Clean filter does the same as the JCB Plexus filter.

ultimate performance and reliability a bypass filter (Plexus) filters the oil down to 1.5 microns. Cleaner oil breed’s reliability.

- None fitted.

- The pump case drain filter needs replacing every 1000 hours. The filter for the case drain is designed to ensure that no unused oil from the valve block returns to tank without being filtered.

- Hydraulic pressure test points are located inside the pump bay. Easy for the service engineer to reach and, using calibrated gauges, should always give an accurate reading.

- Suction strainer needs replacing every 5000 hours.

- The suction strainer needs to be replaced every 2000 hours. The strainer is designed to filter any unwanted larger particles entering the main hyd pump.

- Case do not state whether the auxiliary filter is fitted.

- Hammer return line filter is fitted as standard if pipework is ordered.

The hammer return filter is extremely important. Attachments are probably the worst offenders for contaminating the hydraulic oil and this filter takes care of such contamination. Also in the event of any damage occurring with breakers etc, the filter prevents debris from entering the system.

- Servo filter needs replacing every 1000 hours.

- The servo filter needs replacing every 1000 hours.

The filter takes care of the oil entering the valves and hoses ensuring ultimate fine controllability. 26




CASE CX210LC

JS 220L AUTO

- The grey paintwork looks dark and dull.

- Yellow paintwork is bright and ideal from a visual point of view and good for service engineers.

JSVCAS0049

JSVCAS0050

Case CX225-SR 0 7 / 0 3 J S V C A S E

Pump bay overview. - Poor access. - Confined space. - The hydraulic filtration system is the same as the CX210 machine.

JSVCAS0051 Hydraulic valve block located at the front right side. Reduced tail swing machines have less room available in all compartments. - Poor access.


27


CASE CX210LC

JS 220L AUTO

Access to:

Access to:

- Radiator.

- Radiator and quick release fine mesh grill.

- Hydraulic swing out cooler.

- Air-conditioner condenser if fitted. - Air filter. - Batteries. - Servo hoses.

JSVCAS0052 E S A C V S J 3 0 / 7 0

JSVCAS0053

Attention to detail.

Attention to detail.

- The CX is untidy compared to the JS auto machine.

- The picture tells the story, hose runs are particularly tidy and colour coded on JS auto machines.

JSVCAS0054

28

JSVCAS0055




CASE CX210LC

JS 220L AUTO

Sound proofing - this is not a good picture but it is sufficient to

Sound proofing - JCB now clip and stick soundproofing to the

see that soundproofing is only glued on.

swing out doors etc. The improvement is designed to be more durable, visually it looks more finished.

JSVCAS0049

JSVCAS0057

Case use the Isuzu 105kW BB-6GIT engine. Maximum speed

Isuzu 102kW BB-6GIT engine (No Aftercooled) The Isuzu is a

is 1950rpm.

6.494 litre turbocharged motor. Maximum 1950 rpm.

The Case has a side-opening bonnet which is much heavier

Front opening bonnet on the JS. Gas strut assistance makes

than the JCB bonnet, requiring a mechanical spring to assist

the bonnet easy to open and catch on front face means

the operator.

operator stays in the middle of the top walkway plate.

First 100 hour service removed.

JSVCAS0058

JSVCAS0059


29

0 7 / 0 3 J S V C A S E


CASE CX225R

JS 220L AUTO

CX225R

Engine access JS auto machines.

Engine access CX225R

- Conventional tail swing machines have the luxury of more

- Clearly access to the engine is difficult. The tall

available space compared to reduced tail swing machines.

superstructure design places the engine low down in its compartment and difficult to reach for maintenance checks. The basic design clearly restricts overall access.

JSVCAS0060 E S A C V S J 3 0 / 7 0

JSVCAS0059

CX225R

Engine access JS auto machines.

- Access to the engine air filter and coolers is equally difficult.

- Conventional tail swing machines have the luxury of more

These areas need regular access for cleaning the filters and

available space compared to reduced tail swing machines.

coolers. (If it is difficult, it seldom gets done!).

JSVCAS0062

30




CASE CX210LC

JS 220L AUTO

Engine oil / filter access.

Engine oil / filter access.

To drain the engine oil, a plate needs to be removed from

The JS Auto has a quick release flap to access the engine

under the upper structure. The hydraulic filter is the twin

drain point. A long quick release drainpipe is supplied in the

type similar to the XO JS200.

toolbox with all Auto machines.

JSVCAS0063

0 7 / 0 3 J S V C A S E

JSVCAS0064


31


UNDERCARRIAGE AND OVERVIEW

The JS undercarriage design is basically the same as the XO machine, although a number of improvements were made i.e. the drawbar pull is greater on the JS Auto by nearly 7%. This has been achieved by increasing the displacement size of the track motors. Drawbar pull on the JS Auto is 191.9kN and the Case has 183.4kN 4.6% less than the JS Auto machine. The JS machine offers 3 speed tracking (Creep speed fitted as standard) whilst the Case has only 2 speeds. Construction and the remaining components on the JS auto have not changed from the XO machine although the main hydraulic pressure (Maximum) has increased from 343 bar to 373 bar. When tracking the hydraulic pressure on the JS Auto machine remains at 343 bar i.e. same as the XO units with pressure boost activated.

Case machine operates on the same hydraulic pressures as the JS Auto machines.

CASE CX210LC

JS 220L AUTO

Construction of the JS undercarriage is regarded as being heavy-duty compared to the majority of the competition. Clearly both JCB and Sumitomo gained experience and have adopted similar build standards to meet the demands of the

E S A C V S J 3 0 / 7 0

European market.

The JS and Case have 8 bottom rollers and 2 top rollers for the European market.

Case have chosen to offer a limited range of models and

JCB offer a wide range of undercarriages to suit the JS200,

undercarriage options.

210 and 220 machines. The options are as follows:

The options are as follows:

- JS200 S-Standard, N-Narrow, and L-Long Carriage.

- CX210 LC-Long Carriage.

- JS210 L-Long Carriage.

- CX210N LC-Narrow Long Carriage.

- JS220 S-Standard, N-Narrow and L-Long Carriage.

CX225R - CX225R LC-Long Carriage.

Note, Sumitomo offer other undercarriage options. Case must

A wide range of options allows the JCB dealer and end user

have taken the decision to restrict customer choice.

to select the model and appropriate undercarriage to suit their needs / applications.

Sealed and greased Tracks:

Sealed and greased Tracks:

- Standard.

- Standard.

32



UNDERCARRIAGE AND OVERVIEW (cont)

CASE CX210LC

JS 220L AUTO

Sealed and greased track chain gives quieter, smoother running and extended track life. Track performance and durability is good, JCB offer 1000 hours warranty on track component failure. Track Chain:

Track Chain:

- Standard duty chains only.

- Standard chains. - Optional heavy-duty chains. - Offset (50mm) chains for the narrow carriage machines (Allows 600mm track chains to be fitted to a 1990mm track gauge machine and remain under 2.55mm restricted maximum width).

Track Guides:

Track Guides:

- 1 standard on long carriages.

- 2 standard on long carriages.

0 7 / 0 3 J S V C A S E

- 2 optional.

JSVCAS0065

JSVCAS0066


33


CASE CX210LC

JS 220L AUTO

Upper structure protection.

Track clearance between the tracks and the upper structure has always been better than the majority of the competition. The latest curved design has further enhanced the clearance/protection from site damage.

E S A C V S J 3 0 / 7 0

JSVCAS0067

JSVCAS0065 The Case undercarriage frame is similar to the JS undercarriage.

Large top roller relief hole size 250 x 155 allows dirt to fall away from the top rollers reducing wear on the roller and track chain.

Cold climate- The apex design is easy to clean. In freezing conditions this is extremely important to the operator.

JSVCAS0068

34

JSVCAS0069



UNDERCARRIAGE AND OVERVIEW (cont)

CASE CX210LC

JS 220L AUTO

The layout of footrest restricts floor space for the feet when

The layout of footrest restricts floor space for the feet when

auxiliary pedals are fitted.

auxiliary pedals are fitted.



right joystick.

right joystick.



auto speed change is activated.

auto speed change is activated.

The Case CX210LC has 183kN drawbar pull.

The Case CX210LC has 183kN drawbar pull.

JSVCAS0070 Ground clearance 490mm.

JSVCAS0071 Ground clearance 486mm.

0 7 / 0 3 J S V C A S E


35


EXCAVATOR END

CASE CX210LC

JS 220L AUTO

Boom and dipper:

Boom and dipper: - The design of the boom and dipper on the JS is similar to the Case.

JSVCAS0010 E S A C V S J 3 0 / 7 0

Boom End Nose:

Boom End Nose: The most significant difference between the 2 constructions is the boom end design. The JS design incorporates a fabricated boom nose unlike the Case which has a forged nose.

With regard to which is best, there is no reason to doubt the integrity of either design. (Caterpillar fabricate the nose end as JCB).

JSVCAS0073

36

JSVCAS0074



CASE CX210LC

JS 220L AUTO

Hydraulic pressures:

Hydraulic pressures:

- Maximum hydraulic pressure 373bar.

- Maximum hydraulic pressure 373bar.

Dipper Options:

Dipper Options:

- Case only offer either a medium or long dipper. This limits

JCB offer a short, medium and long dipper. All dippers are

the Case machines performance in heavy muck shifting

designed to work in the hardest applications.

applications etc.

Power Boost:

Power Boost:

Standard and automatic activated in all modes.

Automatic activated in Auto and Lifting mode.

Lifting mode:

Lifting mode:

Increased hyd pressure, reduces flow and rpm.

- Increased hyd pressure, reduces flow and rpm.

Lift mode is designed to be user-friendly i.e. maximum performance in a controlled manor.

Boom / Slew priority:


Not shown as an option.

- Standard and selectable.

0 7 / 0 3 J S V C A S E

Priority boom is generally selected in a deep dig situation. The boom rises faster, hence faster cycle times.

Slew Cycle Speed: - Slew speed is faster on the JS 12.9rpm versus 12rpm on the Case (7.5% faster).

Slew torque: - JS has 73.4kn Vs 61.0kN on the Case (JS has 19.8% more slew torque).

Note, as the hydraulic system includes an automatic work

Dipper Tearout:

mode pressure boost is automatically selected. The Case

- The JS and Case have a similar performance when either the

brochure reflects this information and shows only one set of

medium or long dipper is fitted. With the short dipper fitted

results for tearout.

this is not so.

Bucket Tearout: - The JS has around 15,800kgf versus 13,842kgf on the CX210 i.e. the JS has 12% more bucket tearout than the Case CX machines.

Note, the JS brochures will show 2 sets of results, for tearout. Auto and lift mode will show 373bar and working in economy or precession will show 343bar i.e. no pressure boost.


37


EXCAVATOR END

(cont)

CASE CX210LC

JS 220L AUTO

Boom End Nose:

Pipework options: All pipework brackets for both low flow and high flow are factory welded on as standard on JS machines. Therefore eliminating the need for any welding outside of the factory.

E S A C V S J 3 0 / 7 0

JSVCAS0075

JSVCAS0076

Regenerated Hydraulics:

Regenerated Hydraulics:

- Sales material does not state if the hydraulics are regenerated.

The JS Auto machine has boom, dipper and bucket

We suspect the dipper ram is the only service with

regeneration circuits. (As the oil is being pushed out of the

regenerated hydraulics.

ram it gets diverted to the opposite side of the ram and increases the cycle speeds).

Cushion Control:

Cushion Control:

Same as JCB.

Cushion control is standard on all JS tracked excavators. Cushion control can be deselected at any time. The feature is designed to protect the machine and give a smoother operation. In some applications cushion control should be switched off i.e. lifting duties or sticky conditions. Note with cushion control switched on some operators consider the machine to be slower! This is not so, same oil flow and same working pressure. It is only the stopping that is controlled and the smoothness misleads operators into thinking it’s slower.

38



EXCAVATOR END

(cont)

CASE CX210LC

JS 220L AUTO

Controllability / grading: High on the agenda generated from customer evaluations was grading capability. Customers compared the XO machine to the new Auto and without exception all agreed that the auto machine is much smoother and quicker.

Lift Performance: - Comparing the JS220LC against the CX210LC, the 220 is capable of lifting 21% more weight over the side and 20% more over the front.

The advantage – more output, more stability, both enhance versatility.

0 7 / 0 3 J S V C A S E

JSVCASE0079

JSVCASE0078


39


EXCAVATOR END

(cont)

CASE CX210LC

JS 220L AUTO

Extended Greasing Interval:

Extended Greasing interval:

Case offer extended greasing for the same pins / bushes as

Carbon bushes and chrome pins extend greasing intervals to

JCB. The remaining grease points are every 50 hours.

1000 hours. (Boom base and boom to dipper).

The main reason for introducing carbon bushes is to build durability and reduce service costs.

E S A C V S J 3 0 / 7 0

JSVCASE0080

40


Contents

Section 8. COMPARATIVE EVALUATION – JS 220L VS CATERPILLAR 320C

1. JS 220L vs Caterpillar 320C.

2. Introduction And Overview.

3. Introduction and Overview (continued).

4. Key Advantages Of The JS Range And Features To Consider On The Caterpillar – JS 220 – JS 210L.

5. JS 200N & JS 220N.

6. Cab.

7. Cab (continued).

8. Cab – Design Layout.

9. Cab Visibility.

10. Switch Panel – Power Work Modes.


12. AMS.

Contents

13. Air Conditioning And Storage.

14. Track Pedals.

15. Visibility.

16. Superstructure And Layout.



19. Walkway And Service Issues.

20. Hydraulic Filtration.

21. Service Access.

22. Service Access (continued).

23. Service Access (continued).

24. Undercarriage Overview.


26. Excavator End.



Contents

29. Bush Service.

30. Machine Excavation Performance.

31. Fuel Comparison.

32. Specification Comparison.



JS 220L vs CATERPILLAR 320C, (APRIL 2003)

JSVCAT0001

JSVCAT0002

0 7 / 0 3 J S V C A T


1


INTRODUCTION AND OVERVIEW

Comparison between the JS and Caterpillar 19 – 23.0 tonne class tracked excavators. Competing with the world’s largest excavator manufacturer is no easy task. Caterpillar claim that the 300 family of excavators gives the customer the choice of booms, dipper and undercarriages that best meets their requirements. Without being too critical of their products, it is Cat branding and their experience in all territories that often gives them a foothold ahead of their competitors. This report shows the new auto machine is at least equal, and in many instances a better product. This report primarily compares the JS220L Auto with the latest Caterpillar 320CL, and is designed to be equally informative and comparative. Caterpillar has a range of machines and offers various boom options etc. To ensue that we clearly understand the Cat 20 tonne class range and where they compete with the new JS Auto machines, the tables below show the operating weight and track gauge etc. This will help to establish the direct competitor to the relevant JS Auto machine. A more detailed comparison is included at the end of the evaluation.

JS Vs Caterpillar (All 2390mm track gauge) JS200L

JS220L

320CL

320CL (ME)

Operating Weight

20,870kg

22,172kg

21,430kg

21,715kg

ReducedTail Swing

No

No

No

No

3700kg

5000kg

4120kg

4120kg

Rear Swing Radius

2825mm

2825mm

2770mm

2770mm

Min Swing Radius

3710mm

3710mm

Track Gauge

2390mm

2390mm

2390mm

2390mm

4430kg

5220kg

4719kg

4669kg

7030kg

8040kg

7529

7489kg

700mm

700mm

600mm

600mm

Counter Weight T A C V S J 3 0 / 7 0

Lift Capacity @ 6m over-side / front

Track Plate Width

JS Vs Caterpillar (All 2200mm track gauge) JS200S

JS210L

JS220S

320C

320C (ME)

20,430kg

21,355kg

22.172kg

20,880kg

21,170kg

Zero Tail Swing

No

No

No

No

No

Counter Weight

3700kg

4350kg

5000kg

4120kg

4120kg

Rear Swing Radius

2825mm

2825mm

2825mm

2770mm

2770mm

Min Swing Radius

3710mm

3710mm

3710mm

Track Gauge

2200mm

2170mm

2200mm

2200mm

2200mm

4430kg

4430kg

4670kg

4249kg

4296mm

7030kg

7540kg

7040kg

6369kg

6436mm

600mm

700mm

600mm

600mm

600mm

Operating Weight


Track Plate width

2



JS Vs Caterpillar (All under 1990mm track gauge) JS200N

JS220N

320CLN

320CLN (ME)

320CS

320CS (ME)

20,095kg

21,396kg

21,395kg

21,685kg

22,715kg

23,005kg

Zero Tail Swing

No

No

No

No

No

No

Counter Weight

3700kg

5000kg

4420kg

4420kg

4420kg

4420kg

Rear Swing Radius

2825mm

2825mm

2770mm

2770mm

2770mm

2770mm

Min Swing Radius

3710mm

3710mm

Track Gauge

1990mm

1990mm

1990mm

1990mm

1990mm

1990mm

Plate Width

500mm

500mm

500mm

500mm

500mm

500mm


3480kg

4190kg

4039kg

4086kg

4216kg

4156kg

6000kg

6940kg

7659

7726kg

7749kg

7706kg

Operating Weight

Note; some track plate widths vary, although the width of the track plates makes little difference when comparing stability over the side. Lifting numbers are shown with no bucket, and either at 87% hydraulically limited or 75% stability limited which ever is relevant.

Other Information Caterpillar’s range includes 3 types of booms: - Reach boom - Competes with JS standard mono boom. Four dippers offered, 1,9m, 2.5m, 2.9m and 2.9m heavy duty. - Mass Excavation (ME) – Shorter boom (5.2m long) for mass excavations i.e. increased forces and bigger buckets etc. Three dippers are offered 1.9m, 2.4m and 2.9m. Caterpillar claim that the 2 smaller dippers are designed for larger bucket and the larger dipper is for demolition etc. - Variable Adjustable (VA) – Similar to the JS TAB, Triple Articulated Boom.

Other features offered by Caterpillar: - SmartBoom – Basically the boom has a float position. This can be used for scraping hard surfaces, with grapples / bucket grabs etc. The op erator only needs to control the bucket and dipper, the boom raises or lowers accordingly. - Multipro Monitor (Similar to AMS Monitor).

The Caterpillar 320CS machines: Within the 320 family Caterpillar offer a 320CS, either with the standard Reach or ME boom. The 320CS has a narrow track gauge and is the heaviest model within their range. The upper structure is the same as the rest of the 320C model range. The Undercarriage is where the difference appears, it is a heavy-duty frame with heavy-duty running gear.


3

0 4 / 0 3 J S V C A T


Other Information The evaluations included productivity and efficiency tests, quality comparisons, service access and product specifications etc. Also high on the agenda, was an evaluation of Caterpillars ability to present a machine, that is not necessarily any better than some of their competitors, but always leaves customers with the perception that it’s heavier and perhaps stronger than others.

Key advantages of the JS range and features to consider on the Caterpillar • OperatingWeight. Perception is that the 320CL is a heavier machine than the JS machines. The table below compares like for like specifications.

KG

KG

JS200L

20,870

JS210LC

21,355

Cat 320LC

21,430

Cat 320C

20,880

JS Difference

+ 475

JS Difference

- 560

JS220L

22,172

JS220L

22,172

Cat 320CL

21,430

Cat 320CL ME

21,715

JS Difference

+ 742

JS Difference

+457

• The JCB Advanced Management System is easier to use and has more defined benefits. T A C V S J 3 0 / 7 0

A 10-position throttle dial controls the Caterpillar management system and it is un clear where the dial sho uld be positioned to gain maximum benefit. • Opening front window is standard. Optional on the Cat. • Lifting Performance.

JS220 JS machines prove to be exceptionally stable when compared to the Cat. Taking the JS220L and the Cat 320CL at 6m, the JS has over 10% more lift capacity over side and nearly 7% more over the front.

JS210L The JS210L Vs Cat320C (both with 2200mm track gauge). The JS210L has a 14% advantage over the side and 18.4% over the front. To put things into perspective, the JS210 (with 2200mm track gauge and standard length carriage) out lifts the Cat320CL with its 2390mm track gauge and long carriage. The JS advantage is 2.1% over the side and equal lift performance over the front.

4



JS200N & JS220N Both the JS Narrow (1990mm track gauge) machines match any of the Cat 320CLN machines over the side. Over the front the JS has 10% less lift. This is due to the Cat 320CLN having a long carriage whilst the JS has a standard length carriage. • JS machines have a 102 kW turbocharged Isuzu engine Vs 103kW Caterpillar engine. Both motors are Tier II and have a similar displacement i.e. 6.494ltr in the JS and 6.4ltr in the Cat. • Excellent all round visibility from cab. Caterpillar’s high bonnet proves to be one of Caterpillar’s main disadvantage compared to the JS auto. • Superior hydraulic filtration system. The plexus filter allows 5000-hour oil change. The big issue is reliability. • The JS Auto engine cover is much lighter to open. • Drawbar pull - The JS Auto and the Cat have virtually equal tractive effort. • JS Access on to the top of the superstructure is easier and the walkway / work platform is much larger than on the caterpillar. (Probably more important, the Cat 320 is short of space on top of the superstructure). • Swing Speed – JS Auto 12.9 rpm and Cat 320 11.5 rpm (12% slower than the JS Auto). The JS Auto has nearly 2% more slew torque than the Cat. Slew torque gives fast acceleration through 0-90 degree and 0-180 degree, hence faster cycle times. The JS220 machine has a 5000kg counter weight compared to 4120kg on the Cat320C. Working on slopes / inclines etc, the extra counter weight provides extra slewing force. • Similar excavating output (tonnes per hour). Under strict test condition both machines load a similar amount of material. Due to the higher tearout forces, it’s believed, if working in harder ground conditions, the JS would have significant advantages over the Cat. (Supporting Information) - The JS has 12,550kgf dipper tearout (Medium dipper) compared with 11,526 (8.8% less) on the standard 320C machines and 12,750kgf 320C ME machine. Bucket tearout on the JS Auto is 15,800kgf compared with 13,646 (15.8% less) on the standard 320C and 15,606kgf on the 320C ME machine. For Caterpillar to compete with the JS Auto machine, they need to offer their ME version of the 320C with its higher breakout forces. In a no load situation the Caterpillar boom down and dipper in speeds proved to be slightly quicker, but the higher performance i.e. increased slew speed and slew torque, increased bucket and dipper tearouts, and the auto select has given the JS Auto some distinct advantages in an actual working situation. • Lower fuel consumption (Tonnes per litres) Fuel consumption is extremely important. Tests were done until consistent report results were achieved from bo th machines. The JS proved to be 2.3% more fuel-efficient loa ding at 180 degree and nearly 11% better when loading at 90 degree. Both machines were working to max capacity. • Undercarriage – If any machines are a match for each other it’s the JS and the Cat. Both are built to a heavier standard than most of the other competition. • JCB offers 3 different weight counter weights – 3.70t, 4.35t and 5.0t. The counter weight is matched to the relevant JS machine to ensure maximum performance. Caterpillar has a standard weight 4.12t and a second option 4.42t designed for the narrow track gauge machines.


5

0 7 / 0 3 J S V C A T


CAB

The JS cab is manufactured by a company called TIM and they are located in France. Caterpillar use the same company to produce their cabins, therefore you will notice the same high quality finish and some similar features. The cab for the new Auto machine is probably the best excavator cabin that JCB has produced. JCB fulfilled all their objectives in the design, having taken particular care when designing the cabin and it’s controls. The focus has been on improving the following: visibility, quality / durability, operator comfort, control layout and ease of use etc.

CATERPILLAR 320C

JS220L AUTO

Air-conditioning with climate control is standard. Whilst

The cab for the new Auto machine includes: Unmatched all

operators like having the A/C etc, they often prefer to work

round visibility, the control and cab layout is excellent for

with the door open and w ith the front window open.

simplicity and ease of use.

T A C V S J 3 0 / 7 0

JSVCAT0003 Cat fixed 1 piece window with twin window wiper blades.

JSVCAT0004 Air-conditioning or climate control incorporating chilled cool box is an option.

Caterpillar is offering a 1 piece front window as standard. The

JS and Cat cab is a similar design. JCB window wiper motor

2-piece 50/50 split front window is an option. The fixed 1

has moved to the side for better visibility.

piece window has been greeted with mixed feelings, operators like the split window for better vision and verbal contact with

Window easy to open with gas strut assistance using well

other ground-men.

positioned handles. Lower section of front window is an integral part of the front window and held in top section. The door window also incorporates a sliding window.

6



CATERPILLAR 320C

JS220L AUTO

JSVCAT0005

JSVCAT0006 Both JCB and Cat have a sliding window in the door.

Note, the door on the auto machine has reduced in width compared the previous XO machine. This was done to make it easier to close the door when inside the cabin. (The actual access in to the cab has not reduced i.e. front of the joystick base to front of in-side cabin.) Caterpillar’s door is 950mm wide, slightly smaller than

The JCB's door is 980mm wide which gives good access to

the JS door.

the cab. Probably more important than the door width is the distance from the front of the seat to the front of the inside of the cab.

950mm

980mm

\

JSVCAT0003

JSVCAT0007


7

0 7 / 0 3 J S V C A T


Cab Design / Seat

CATERPILLAR 320C

JS220L AUTO

The C series cabin is a great improvement over their B series.

Modern and ergonomically designed.

However, the interior looks dated compared to the JS.

Switch and control panel easier to see and use. - Large cab designed to accommodate the wide

The AEC computer system is located behind the cab as

range of operator sizes.

opposed to inside the cab. This is exposed if washing the

- Smaller door for easier closing.

machine under the canopies.

- The new heater and air-conditioning unit develop 56% more a irflow.

AEC redundancy switch is located under the right armrest.

- Optional full climate control air-conditioning. - Interior lamp with timer switch aids easier access to the cab. - Flat floor with no door lip – easy clean. - Document storage pocket. - Mobile telephone holder and 12v charger point. - Optional deluxe air suspension seat with heated pod and adjustable lumber support. - Radio mute switch cuts off radio to improve communication.

T A C V S J 3 0 / 7 0

JSVCAT0008

8



CATERPILLAR 320C

JS220L AUTO CAB

The cab exterior design is similar to the JS cabin.

Modern design with excellent all round visibility.

JSVCAT0003 The Cat workstation is much the same as the JS with the

JSVCAT0009 The JS has better vision, particularly with the door closed.

exception of when the door is closed. (This photo is with the door open on the Cat).

0 7 / 0 3 J S V C A T

JSVCAT0010

JSVCAT0011 The JS joysticks control levers required only 2.1 Nm giving easy smooth control of the excavator.


9


Switch Panel

CATERPILLAR 320C

JS220L AUTO

Although functional the design looks dated.

Modern and all in easy reach of the operator. The work modes are selected on the AMS monitor.

The 10-position throttle dial is located behind the joystick. The dial selects the relevant hydraulic work mode and it’s the

The throttle control is easy to reach. The hydraulic work

amount of rpm selected by the operator that determines the

modes are selected independently from the AMS monitor.

work mode.

T A C V S J 3 0 / 7 0

JSVCAT0012

JSVCAT0013

Power Work Modes

JS Auto The AMS on the auto machine has been improved to make life easier for the operator and more efficient. With Auto mode selected, power boost is automatically activated, and the AMS senses the conditions and adjusts the hydraulic power accordingly. Economy mode is ideal for normal dig applications. Precision mode is for fine grading duties and the L mode is for lifting duties. In L mode the hydraulic pressure increases automatically by 10% for maximum power.

Cat 320C The Cat C series machines have no selectable work modes. The brochure and operator handbook gives no direction on how best to prepare the machine for the various applications etc. The hydraulic system is managed in much the same way as the JS XO machines, the Cat system is called ‘’Auto Engine Control’’. AEC (Automatic Engine Control) has a 3-stage system / 3 work modes, and a 10-position throttle dial controls the system, there is no facility to adjust the work modes without using the throttle. The fundamentals i.e. hyd flows, hyd pressure and rpm etc operate similar to the XO Advanced Management System. Th e new Auto system h as moved on a stage further from the XO AMS system. The following explains how both systems work and compare with each other.

10



CATERPILLAR 320C AUTO ENGINE CONTROL

JS220L AUTO AMS MONITOR

Adjustable Monitor.

Adjustable AMS Monitor gives improved external visibility.

Hydraulic work modes:


-3

A – Auto

- Caterpillar claim to have made life easier for the operator!

E – Economy P - Precision

- The Cat has a switch designated ‘’Automatic Engine

L – Lifting

Control’’, which is similar to the auto idle feature on the JS XO, machines. The switch can be switched on or off.

Diagnostic work can be done without the aid of a Laptop.

First Stage.

Auto Mode

When AEC is off, the engine speed drops by 100rpm from its

- 100% hyd flow

setting 3 seconds after the joystick levers return to neutral.

- 1950rpm

The benefit of this is unknown.

- Hyd power 95kW - Power Boost automatic

Second Stage When the AEC is on, the engine speed drops to 1300 rpm

- Automatically senses conditions and adjusts hydraulic power accordingly

3 seconds after the joysticks return to neutral.

- Maximum hyd pressure 373bar

A 10 speed rotary dial controls the engine speed, a LCD on

Economy Mode

the monitor displays the dial position. In position 10 the pum p

- 95% hyd flow

torque is calculated according to the engine speed, as H mode

- 1850rpm

does on the XO machines.

- Hyd power 77kW

In position 5 to 9 the pump torque is constant, as the JS XO in

- Maximum hyd pressure 343bar (No pressure boost)

0 7 / 0 3 J S V C A T

S mode and in position 1 to 4 the pump torque is reduced as L mode on the JS XO machines.

Precision Mode - 90% hyd flow

Manual Stage

- 1750rpm

With the AEC on or off and in position 3 –10 on the rotary

- Hyd power 53kW

dial, the engine drops to approximately 950 rpm i.e. in the


same way as the JS manual / redundant position. Lifting Mode There is no lifting mode on the cat (where pressure is

- 63% hyd flow

increased and hydraulic flow reduced) or power boost.

- 1750rpm - Hyd power 53kW

The C series Cat machines look as if they have done away

- Maximum pressure 373 bar

with work mod es, they haven’t, the selection is now done on the throttle setting. Not only is the Cat limited on selective

Tracking

functions it is unclear to operators as to which throttle

- Maximum hyd pressure 343bar-

position would benefit them most.

- Maximum drawbar pull 221.3KN


11


CATERPILLAR 320C

JS220L AUTO

Regenerated hydraulics


Standard – depends on joystick movement.

Standard (Prevents cavitations and increases boom down, arm in and bucket in speed).



Automatic.

Standard and selectable.

Cushion Control

Cushion Control

Not available.

Standard.

Multipro / Attachment

AMS / Attachments

AEC allows 5 pre-set settings for different attachments.

AMS has 1 pre-set setting and for further attachments the operator selects the correct rpm via the AMS monitor.

Modern design and simple to use.

Virtually no vision restriction caused by the AMS mo nitor.

T A C V S J 3 0 / 7 0

12

JSVCAT0014

JSVCAT0015

JSVCAT0016

JSVCAT0017



CATERPILLAR 320C

JS220L AUTO

Climate control / air-conditioner standard.

Optional air-conditioner or climate control including integral

Rear air vents located next to rear window.

cooling box.

Large storage self located behind the seat below the air vents.

Rear air vents located each side of the storage box. Large storage box with lid and latch to keep closed.

JSVCAT0018

JSVCAT0019

Cab Storage

Cab Storage

Under the right side armrest is a small storage box.

Storage box closed. 0 7 / 0 3 J S V C A T

JSVCAT0020

JSVCAT0021


13


CATERPILLAR 320C

JS220L AUTO

JSVCAT0020 Cab Storage.

JSVCAT0022 Cab Storage. JCB has a document storage sleeve located below the cup holder in the front on the right side. Also storage sleeve behind the operators seat.

Track Pedals.

Track Pedals.

The layout of foot pedals restricts floor space for the feet T A C V S J 3 0 / 4 0

when auxiliary pedals are fitted.

Cleaner floor space. Hammer and TAB pedals are betterlocated leaving room for the feet to rests.

Tracking speed is selected from the control panel next to the right joystick.

Track speed control is moved from floor position and relocated in the right side joystick. Easier to operate and

The Cat has 2 speed travel. With high selected, auto speed

better controllability for the operator. The Auto speed change

change is activated.

between high, medium and creep speed is manually selected.

196kN drawbar pull.

The JS has 221.3kN drawbar pull 13% more than the Cat 320C.

JSVCAT0023

14

JSVCAT0024



CATERPILLAR 320C

JS220L AUTO

JSVCAT0005

JSVCAT0017

The fixed window in the front of the cab is standard and the

JCB received negative feedback when considering fully

split window is an option.

fixed windows.

The bar dividing the top and bottom windows in kept to a minimum 10mm.

0 7 / 0 3 J S V C A T

JSVCAT0025 Upward vision, JCB and Cat have the same cab manufacturer,

The JS Auto machine has excellent vision to the attachment at

visability levels are similar for both Machines.

full height.


15


SUPERSTRUCTURE AND LAYOUT ETC

JCB has made some significant changes to the Superstructure. JCB’s objective was to build a machine with improved access to all components, reduce service costs, improve visibility, improve quality / durability and performance. The Caterpillar B series machines were looking dated and they were less than impressive with regard to performance. Hence Cat was one of the first to introduce their latest machine and this included the introduction of the Tier II engine. They focused on reducing service costs, improving performance, service access and operator comfort etc.

CATERPILLAR 320C

JS AUTO

T A C V S J 3 0 / 7 0

JSVCAT0026

16

JSVCAT0027



Visibility and Access JCB has taken particular care when designing the cabin and it’s controls. The focus has been on improving the following: visibility, quality / durability, operator comfort, control layout and control simplicity and ease of use etc.

CATERPILLAR 320C

JS 220L

The first Cat C series machines to be launched were

The JS superstructure is less than 2550mm wide and the low

designed for the Japanese and American markets. The

bonnet remains.

superstructure widths for these markets are generally around 2700mm wide. However, some countries within Europe implement maximum width restrictions i.e. the overall width of the machine must not exceed 2550mm if you wish to transport or use the machines on the highways etc without Police / Highways permission etc.

The Cat C series was originally designed with a virtually zero height bonnet, but with the narrow European version Cat were unable to ma intain the original height of the bonnet. The European version 320C has a bonnet height similar to the 0 7 / 0 3 J S V C A T

XO JS200 machine, hence restricting rear vision.

JSVCAT0028

JSVCAT0029 The step design gives easy access on to the walkway. Better visibility to the right side.


17


CATERPILLAR 320C

JS 220L

JSVCAT0030

JSVCAT0031

High-level bonnet similar to JS XO. Unlike the JS machine, the bonnet on the Cat reduces visibility over the rear.

This particular Cat customer has fitted a concave mirror to improve rear vision.

T A C V S J 3 0 / 7 0

Vision over the bonn et is excellent.

The overall height to the top of the superstructure in slightly less that the Cat 320C. The bonnet has no negative effect on visibility.

JSVCAT0032 The bonnet restricts rear vision.

JSVCAT0033 Decal design gives room for sign writing. At close proximity rear vision is noticeably better.

JSVCAT0034

18

JSVCAT0035



Walkway and Service Issues

CATERPILLAR 320C

JS 220L

Whilst the Cat walk way is made from similar material to the

The Auto machines has a perforated plate steel covering the

auto machine, it’s narrow access is not ideal, particularly in


poor weather conditions.


The walkway and working area is wide for easy access.

0 7 / 0 3 J S V C A T

JSVCAT0036 Compared to the JS Auto, the Cat walk area is narrow and is

JSVCAT0031 Excellent grip, durable and a large wide working platform.

not ideal for service engineers or operators to perform the daily checks etc.

JSVCAT0037

JSVCAT0038


19


Filtration and Location

CATERPILLAR 320C

JS 220L

Hydraulic filtration:

Hydraulic filtration:

- Case drain / leakage drain

- Case drain / leakage line

- Servo

- Servo

- Main Hyd return

- Main hyd return

- Suction strainer

- Suction strainer - Plexus


To ensure ultimate performance and reliability a bypass filter (Plexus) filters the oil down to 1.5 microns. Cleaner oil breed’s reliability.

Below you will see the main hydraulic filter, which requires

The main hydraulic filter is located inside the hydraulic tank

changing every 1000 hours. The hyd oil is replaced every

and the Plexus filter is situated in the hydraulic pump bay.

2000 hours. Both the main hyd filter and the plexus filters need changing

T A C V S J 3 0 / 7 0

every 1000 hours. The hyd oil needs to be replaced every 5000 hours.

Hydraulic pressure measurement is done via the AEC monitor,

Hydraulic pressure test points are located inside the pump bay.

however this method is not always the most accurate and

Easy for the service engineers to reach, and using calibrated

reliable method.

gauges, should always give an accurate reading.

Bleed points for oil sampling are standard.

JSVCAT0039

20

JSVCAT0040



CATERPILLAR 320C

JS 220L

Access to:

Access to:

- Radiator

- Radiator and quick release fine mesh grill

- Hydraulic swing out cooler

- Air-conditioner condenser if fitted - Air filter - Batteries - Servo hoses

JSVCAT0041

JSVCAT0042

Access to:

0 7 / 0 3 J S V C A T

- Case drain filter - Air filter - Fuses and electric’s isolator - Batteries - AEC computer

JSVCAT0043


21


CATERPILLAR 320C

JS 220L

The Cat engine is a 103kW turbocharged unit. (No

Isuzu 102kW engine (No Aftercooler) The Isuzu is a 6.494 litre

aftercooler) The engine displacement is 6.4 litres. Maximum

turbocharged motor. (No aftercooler) Maximum 1950 rpm.

rpm is 1800 versus 1950 on the JS auto machine. Front opening bonnet on the JS. Gas strut assistance makes Cat has a rear-opening bonnet but is much heavier than the

the bonnet easy to open and catch on front face means

JCB, therefore has a mechanical spring to assist the operator.

operator can stay in the middle of the top plate.

First 100 hour service removed.

T A C V S J 3 0 / 7 0

JSVCAT0044

JSVCAT0045

Access to the engine oil filter is via the engine cover. The filter is mounted upside down, this is a messy job when replacing.

JSVCAT0046

22



Engine Oil

CATERPILLAR 320C

JS 220L

Caterpillar has a quick release plate to access the engine drain

The JS Auto has a quick release flap to access the engine oil

plug and pipe.

filter and engine drain point. A long quick release drainpipe is supplied in the toolbox with all Auto machines.

JSVCAT0047

JSVCAT0048 0 7 / 0 3 J S V C A T


23


UNDERCARRIAGE AND OVERVIEW

The JS undercarriage design is basically the same as the XO machine, although a number of improvements were made i.e. the drawbar pull is greater on the JS Auto by nearly 7%. This has been achieved by increasing the displacement size of the track motors. Drawbar pull on the JS Auto is 191.9 kN and the Cat320C has 196kN. With regard to the construction and the rest of the components on the JS auto, they have not changed from the XO machine. Be aware that as the main hydraulic pressure (Maximum) has increased from 343 bar to 373 bar on the JS Auto machine. When tracking the JS Auto machine the pressure remains at 343 bar i.e. same as XO.

CATERPILLAR 320C

JS 220L

Lubricated Tracks:

The construction of the JS undercarriage is regarded as being

Standard

heavy-duty when compared to the majority of the competition. The Caterpillar design is probably the closest to

T A C V S J 3 0 / 7 0

Track Chain:

the JCB, the metal thickness etc is similar. Both undercarriages

Standard and optional heavy duty chains

suit heavy European conditions.

Track Guides:

The JS and Cat have 8 bottom rollers and 2 top rollers.

- 2 standard - Optional full guard

Lubricated Tracks:

- Optional sprocket guarding

Standard.

Track Chain: Standard and optional heavy-duty chains.

Track Guides: 2 standard.

JSVCAT0049

24

JSVCAT0050



CATERPILLAR 320C

JS 220L

Dirt release hole 170 x 200

Large top roller relief hole size 250 x 155 which allows dirt to fall away from the top rollers reducing wear on the roller and

Single slope frame holds the dirt. This can accelerate track

track chain.

component wear. Cold climate – The JS apex design is easier to clean. In freezing conditions this is extremely important for the operator.

JSVCAT0051 Ground Clearance 460mm

JSVCAT0052

0 7 / 0 3 J S V C A T

Ground Clearance 486mm

The Cat has 2 tow points front and rear. Whether facing the front or the rear, one hole will be inline with the centre of the boom. This is often used as a guide to line up for trenching.

JSVCAT0053 Caterpillar machines all have a sealed lubricated track chain.

Sealed and lubricated track chain gives quieter, smoother running and extended track life. Track performance so good JCB offer 1000 hours warranty on tracks.


25


EXCAVATOR END

CATERPILLAR 320CL

JS 220 L The JS and Cat boom and dipper fabrications are similar. At the dipper end bo th booms have fabricated ends i.e. no t cast.

Maximum hyd pressure 343bar.

Maximum hyd pressure 373bar.

Booms offered:

Boom offered:

- Standard

- Standard

- ME (Mass Excavation designed

- TAB

for bulk excavations) - VA (Same as TAB)

T A C V S J 3 0 / 7 0

Caterpillar offer the ME machine. The shorter boom and

JCB offer short, medium and long dippers. All dippers are

increased tearout forces on the bucket and dipper require

designed to work in the hardest applications. Remember, the

stronger dippers. Cat supply a different / stronger range of

JS dipper tearout is similar to the ME and bucket tearout is

dippers for the ME machine.

higher on the JS.

Light and heavy-duty dippers!!!

Heavy duty o nly.

Power Boost:

Power Boost:

Not available.

Standard and automatic activated in Auto mode.

Lifting mode:

Lifting mode:

Only by reducing the throttle dial i.e. reduced rpm gives less

Increased pressure, reduced flow and reduced rpm.

hyd flow but does not offer increased hyd pressure.



Standard and is automatically activated by the position

Standard and selectable.

of the joysticks.

JSVCAT0054

26

JSVCAT0055



CATERPILLAR 320C

JS 220 L All pipe work brackets for both low flow and h igh flow are factory welded on as standard on JS machines. Therefore eliminating the need for any welding outside of the factory.

JSVCAT0056 Caterpillar offer boom, bucket and dipper

The JS Auto machine has boom, dipper and bucket

regenerated circuits.

regeneration circuits. As the oil is being pushed out of the ram it gets diverted to the opposite side of the ram and increases the cycle speeds.

Cushion control is standard on all the JS tracked excavators.

Cushion Control - not Available.

Cushion control can be deselected at any time. The feature is designed to protect the machine and give a smoother operation. In some applications cushion control should be switched off i.e. lifting duties or sticky conditions. (Note with cushion control switched on some operators consider the machine to be slower!. This is not the case, same oil flow and same working pressure. It is only the stopping that’s controlled and the smoothness misleads operators into thinking it’s slower.

7 5 0 0 T A C V S J


27

0 7 / 0 3 J S V C A T


CATERPILLAR 320C

JS 220 L

SmartBoom

JS - no offering

The SmartBoom is basically an excavator with a float position

Controllability / grading.

i.e. the boom is allowed to move up and down according to

High on the agenda from the customer evaluations were

the application.

grading capabilities. Customer’s compared the XO machine to the new Auto and without exception all agreed that the auto

Caterpillar claim that the benefits are:

machine is much smoother and quicker.

- Scraping rock (the operators has no need to lift the boom) - Hammer work (the weight of the boom is sufficient downward pressure) - Grab applications (with a grab and working off firm ground, the operator has no need to simultaneously lift and close the grab)

T A C V S J 3 0 / 7 0

JSVCAT0058 Although the Cat brochure does not show extended greasing

The boom base and boom to dipper pins are now 1000 hours

intervals, the operator’s manual does indicate 1000 hour

between greasing.

greasing on some bushes etc.

28



CATERPILLAR 320C

JS 220 L

JSVCAT0059

JSVCAT0002

Cat claim extended greasing, however it is unclear which pins

The carbon bushes and chrome pins extend greasing intervals

and bushes have the extended greasing intervals.

to 1000 hours. (Bo om base and boom to dipper).

0 7 / 0 3 J S V C A T

JSVCAT0060


29


MACHINE EXCAVATION PERFORMANCE

JSVCAT0001

T A C V S J 3 0 / 7 0

JSVCAT0002

Caterpillar proved to be very competitive with regard to actual productivity but proved to be less efficient in the overall test. The test was done by excavating between 2 and 3 m deep. The spoil excavated was loaded on to a dump truck (both at 90 and 180 degree) and weighed. Both machines were equipped with fuel consumption meters and the loading cycles were timed. The results are shown in the table below: The ground was an easy dig but heavy conditions.

Trench Output (tonnes/hr)

Fuel Efficiency (tonnes/litre)

JS 220 L 180 degree

547

22

Caterpillar 320CL 180 degree

591

21.5

JS220L 90 degree

719

29

Caterpillar 320CL 90 degree

718

26

Both machines performed well, the Cat was slightly quicker at loading through 180 and both m achines were equal loading through 90 degree. With the JS having more bucket and dipper tearout harder ground would have suited the JS better. Fuel consumption was the main difference between the 2 machines, particularly through short cycles. The Cat was using nearly 11% more fuel than the JS Auto.

All tests are done based on a 60-minute hour and in test condition. The main objective was to establish the difference between the two machines. All test were done un der test conditions i.e. at the JCB testing ground, with only 1 Caterpillar machine and with JCB’s own test drivers.

30



Fuel Comparison JS Auto Working in Auto Mode Vs Economy Mode. Bulk handing in heavy wet sand and gravel and slewing through 90 degrees the JS Auto was put to the test. The aim was to compare the fuel consumption when working in Auto Mode as opposed to Economy Mode. Each test was done over a 1-hour (60min) period and fuel was measured. Note, the test was purely a fuel test comparing the fuel used between the 2 work modes and not productivity test i.e. the weight of the material moved was not calculated.

Fuel Used JS in Auto mode – 25.2 litre per hour. JS in Economy mode – 21.6 litre per hour. Economy mode proved to use 16.6% less fuel in the hour. This shows the benefit of offering mode selection independent of the throttle dial.

0 4 / 0 3 J S V C A T


31


SPECIFICATION COMPARISON

B C J

T A C V S J 3 0 / 7 0

N O S I R A P M O C N O I T A C I F I C E P S C I S A B S R O T A V A C X E R E L W A R C 32

R A L L I P R E T A C

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T I G B 6 6 B B

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0 7 7 , 2

0 0 5 , 2

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) E M ( L C 0 2 3 ) E M ( N L C 0 2 3

r t l

S N O I T A C I r F I e r u C t s r E E c e a l I P l N d S f e e n u d e i d G n k Y a o l E N a o y K M M E M M C

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g m h / N m m m k e m m k m m m d i k s r e p s r s e l l e S t o w M d h r h N o o g E t l i f E m d O T m e i . I . s S e e x G o S d w w t l d a M Y A t s t I t N S b s e E u o a o m r h s t r E i e R g d C t R b u i / s T d f c m S d o u M t a e r I e I p A e e e r f c q Y g l p e e L h l m S e r C o u e e D g t u w e p r r p b o w U s t a g n n t s e a u e i g l G s t R C o A f t f s E p t v I R i r g g p e o s o w n k e t N l e n I i n i n D . c v c T s u i t D . j u l i l A i a a e Y o d a W w w N o a o a a p T u r r r N H N A M S S S U N T T T S T T S C

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B C J

R A L L I P R E T A C

L 0 2 2 S J

3 4 3

0 1 3 9 1 / -

L 0 1 2 S J

3 4 3

0 1 3 9 1 / -

L 0 0 2 S J

3 4 3

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) E M ( S C 0 2 3

0 2 3

0 0 2 9 1 / -

S C 0 2 3

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0 2 3

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0 2 3

0 0 3 9 1 / -

L C 0 2 3

0 2 3

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r t l ) t n o c ( S N O I T A C I r S F I e E r I u C t T I E c a P C l S f e A u d n Y a o P A E K M M C

l e u F

0 0 0 3 / 0 0 4 2 0 0 0 3 / 0 0 4 2 0 0 0 3 / 0 0 4 2 / 0 0 4 2 0 0 9 2 / 0 0 5 2 0 0 9 2 / 0 0 4 2 0 0 9 2 / 0 0 4 2 0 0 9 2 / 0 0 5 2 0 0 9 2 / 0 0 5 2 0 0 9 2 / 0 0 4 2 0 0 9 2 / 0 0 5 2

m m m m

5 5 5 5 5 5 1 1 1

2 7 1 , 2 2

7 0 6 4 5 o . 0 n 2 1 o / 0 M 7 . O S 5 I

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7 6 o 0 4 5 . 0 n 2 1 o / 0 M 2 . O S 5 I

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- / / 3 3 1

2 7 5 4 1 1

5 0 0 , 3 2

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/ 6 0 1

2 7 9 5 2 1 1 1 1

5 1 7 , 2 2

7 6 o 0 5 5 . 0 n / 2 1 o 8 M 6 . O S 5 I

0 8 8 6

0 5 3 3

/ 4 4 1

/ 5 2 1

/ 6 1 1

3 3 2 5 5 3 1 1 1

5 1 7 , 1 2

7 6 o 0 4 5 . 0 n 2 1 o / 0 M 2 . O S 5 I

0 3 7 6

0 1 9 3

/ 4 4 1

/ 5 2 1

/ 6 1 1

3 3 2 5 5 3 1 1 1

5 8 6 , 1 2

7 0 6 5 o 4 . 0 n 2 1 o / 0 M 2 . O S 5 I

0 6 8 6

0 2 2 3

/ 4 4 1

/ 3 1 1

/ 9 9

3 2 2 5 3 3 1 1 1

0 3 4 , 1 2

7 0 6 5 o 5 . 0 n 2 1 o / 6 M 6 . O S 5 I

0 7 7 6

0 6 9 3

/ 4 4 1

/ 3 1 1

/ 9 9

3 2 2 5 3 3 1 1 1

5 9 3 , 1 2

7 0 6 5 o 5 . 2 0 n / 1 o 8 M 6 . O S 5 I

0 0 9 6

0 8 2 3

/ 4 4 1

/ 5 2 1

/ 6 1 1

3 3 2 5 5 3 1 1 1

0 7 1 , 1 2

7 0 6 5 o 4 . 0 n 2 1 o / 0 M 2 . O S 5 I

0 7 5 5

0 3 4 3

/ 4 4 1

/ 3 1 1

/ 9 9

3 2 2 5 3 3 1 1 1

0 8 8 , 0 2

7 0 6 5 5 o . 0 n 2 1 o / 8 M 6 . O S 5 I

0 1 6 5

0 9 4 3

N k N k N k

N N N k k k

g k

g k

g k

h c a e r l e v e l d n u o r g m 0 . 6 t a t f i L


S M L - - r t e s t s t s p o o o p i o o o d b b b T / / / S S L d U S t d t T d S s r / s t s O S / U s N e - R p X M O t t t O p h h R u u u A I i E T d t t o o A o T r r g P f g E r a a a n n o O r l e t e t e S e l e T t T R e r r R r r r E E b e e E e e e K P m p p P p p p C P p i p P p i p i p U I u i I i D N D D D D D D B

r e r p e p p i p d i d S M L T - - H G I t d E h r g a W i e d E w n a N d G t I s r a N H d g n C n I i T t A t a I F a M S L R

r e p p i d d r a d n a t s / 1 m o o b o n o M

d n e r e v O

e l c r i c l l u F


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33

Contents

Section 8. COMPARATIVE EVALUATION – JS 220L AUTO VS HITACHI ZAXIS 210LC

1. The New Generation vs Komatsu PC210-7.

2. Key Advantages Of The JS Auto.

3. Introduction And Overview.

4. Introduction And Overview (continued).

5. Cab and Controls - Design/Vision.

6. Seat.

7. Roof Hatch/Skylight.

8. Joystick And Controls.

9. AMS.

10. Visibility.

11. Cab Floor and Track Controls.

12. Cab Storage And Air Conditioning.

13. Superstructure.

14. Cooling.

Contents

15. Storage and Access.

16. Hydraulic Pump Bay.

17. Engine Access – Walkway Grippers.

18. Upper Structure Undercarriage.



21. Excavator End.

22. Performance Overview.

23. JS And Hitachi Basic Specification Comparison.

24. JS And Hitachi Basic Specification Comparison.


JS220L AUTO vs HITACHI ZAXIS 210LC, APRIL 2003

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1


KEY ADVANTAGES OF THE JS 220 AUTO

• Opening of front window well designed and easy to use. The bottom window is integral with the top window. (Not stowed separate). • None of the ZX 20 tonne class machines come anywhere near the lifting performance of the JS220LC. Comparing the JS220LC and ZX210LC, lifting over the front the JS220LC has 19% more lift capacity and 24% more over the side. • Hitachi offer reduced (Not zero) tail swing machines – ZX225USR / ZX225US, and they have some obvious advantages. However in many instances the advantages are out-weighed by the disadvantages i.e. poor vision, poor service access, increased operating weight, and reduced performance etc. The JS220LC has a 76% advantage on the ZX225USLC when lifting over the front and 17.8% over the side. • Gas assisted front opening bonnet – safe and easy. • Simple to use and understand hydraulic work modes. • 3 speed tracking (Creep speed is the difference). • Three centrally placed slew ring grease nipples. • Cushion control is standard providing a smoother operation, and can be switched off when necessary i.e. for lifting duties, working in sticky conditions etc. Used in the right situations, cushion control protects the customer’s investment. • Two track guards as standard. A T I H V S J 3 0 / 7 0

• Superior hydraulic filtration system. The Plexus and hyd leakage line filters are standard on the JS machines. Cleaner oil breed’s reliability. • Sealed and greased track chain with 1000 hour tracking warranty. • The standard undercarriage is a heavy-duty construction compared to the ZX machines. The JS220L is over 2 tonne heavier than the ZX210LC and the JS undercarriage accounts for a large proportion of the extra weight. • The JS machines (JS200,210 &220) have 19.7% more bucket tearout than the ZX210, 225USR & 225US machines. • With a short dipper fitted the JS has 4% more breakout force. With the medium dipper the ZX (ZX210 only) has 3% more than the JS220 and with the long dipper fitted, all the JCB and Hitachi machines are equal to each other. • JCB offer both the JS200 and JS220 with a narrow carriage i.e. less than 2.55m overall width. The ZX210N has a dedicated superstructure to comply with the width restrictions. The ZX210S and ZX210LC superstructure is wider than 2.55m. • To improve the ZX machines relatively poor lifting performance, Hitachi offer an optional 1000kg extra counterweight on the ZX210. • The JS Auto has 8.6% higher excavating output (tonnes per hour). • Lower fuel consumption, 11% more efficient than the Hitachi (litres per tonne).

2



INTRODUCTION AND OVERVIEW Comparison between the JS 19 – 23.0 tonne class tracked excavators. Over a number of weeks JCB undertook to benchmark the new auto machine against the major competition. The evaluations were done in the second half of 2002. Products / competitors included were: JS220L (XO), Hitachi, Komatsu, Caterpillar, Daewoo, Volvo and Case. The evaluations included productivity and efficiency tests, quality comparisons, service access and product specifications.

JCB Vs Hitachi

JSVHITARGE

The following comparison is designed to give JCB and it’s distribution network an understanding of the Zaxis excavators. The Hitachi Zaxis machines are excellent and have a good reputation in the market. However, development of the new JS Auto range has given the machine many visual and functional advantages when compared directly to the Zaxis machine. We are competing with the world’s best excavator m anufactures and it is down to us to present the new JCB excavators to the customer. However large or small we perceive the advantage to be it is the customer that ultimately puts a values on the feature! The table below shows the operating weight, the weight of the

0 4 / 0 3 J S V H I T A

counter weight and track gauge etc. This will help to establish the direct competitor to the relevant JS Auto machine.

JS200L

JS210L

JS220L

ZX210LC

ZX225USRLC

EX225USLC

20,870kg

21,355kg

22,172kg

20,400kg

22,500

23,500kg

Zero Tail Swing

No

No

No

No

No

Yes

Counter Weight

3700kg

4350kg

5000kg

4250kg

6710kg

7300kg

Rear Swing Radius

2825mm

2825mm

2825

2750

1990mm

1680mm

Track Gauge

2390mm

2170mm

2390mm

2390mm

2390mm

2390mm

Lift Capacity

4430kg

4420kg

5220kg

4210kg

4560kg

4430kg

@ 6m

7030kg

7540kg

8040kg

6750kg

7090kg

4560kg

Operating Weight

over-side / front

(Both Stability Limited)

Note, the track gauge for JS NC and ZX210N is 1990mm. The ZX210N is the only model being offered with a maximum width of less than 2.55m.


3


To compete with the JS210LC Hitachi offer a 2200mm track gauge on their ZX210, ZX225US and ZX225USR. Note the ZX225USR has a reduced tail swing (1990mm) and the ZX225US has a further reduced tail swing (1680mm). Minimum swing radius i.e. front and rear. The ZX225US boasts a minimum swing radius of 2300mm - medium dipper. Clearly the boom design is an urban swing type, this gives a greater lift height and a shorter front swing radius. The JS220, ZX210 and ZX225USR all have a similar minimum swing radius i.e. around 3600mm / 3700mm. Hitachi nomenclature that finishes with a K (K Series) indicates that it is designed for demolition. JCB offer the JS220LC XD for demolition etc.

Machine Comparison The following detail is specific to the JS220L Auto versus Hitachi Zaxis 210LC. However many of the comparisons are reflected throughout the JS Auto and ZX range. The un dercarriage options and the weight of the counter weight are probably the most significant items that change when comparing the JS200, JS210 & JS220 machines. We should also note that the machine being marketed in Europe is a ZX210 as opposed to a ZX200. Fundamentally both the ZX200 / ZX210 are the same machine i.e. hydraulics, engine, structures etc. The results in this comparison are generally focused on the ZX210LC.

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4



CAB AND CONTROLS

Both the JCB and Hitachi produce excellent quality cabins. The difference between the two cabins is the JS has a larger cabin, hence more room for the European size operator, better all-round visibility, controls and switches designed for simplicity and function. It is modern and particular attention has been given to the operator’s needs i.e. mobile telephone holder / charger, large storage box, increased ventilation and a document holder. If an air suspension seat is ordered a back lumber support and a heated seat are included.

Cab Design / Vision

HITACHI ZAXIS 210LC

JS 220L AUTO

To open the front window on the Hitachi requires a large

Window easy to open w ith gas strut assistance using well

amount of effort. Lower window storage is on the rear side

positioned handles.

window, which means that the operator ha s to move the glass around in the cab.

Lower section of front window is an integral part of the front window and h eld in top section.

The Hitachi's door is only 850mm wide which limits access

The JCB's door is 980mm wide, which gives very good access

to the cab.

to the cab.

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5


Seat

HITACHI ZAXIS 210LC

JS 220L AUTO

Less appealing design.

Modern design seat.

Although the armrests are wide they are of little use when

The adjustable seat and control console move independently

using the long stroke joysticks.

to suit any size of operator.

The width of the seat arm-rests have been increased, making them more practical for operators who w ish to use the joystick with wrist action only.

Once the door is open, the interior light can be switched on from ground level and this makes accessing the can in the dark easier.

A T I H V S J 3 0 / 7 0

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6

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Roof Hatch / Skylight

HITACHI ZAXIS 210LC

JS 220L AUTO

Hitachi offers a metal opening roof hatch. This is not ideal for

Excellent vision at height, particularly for lifting duties and

vision at height and it also give a feeling of being closed in.

working in confined restricted overhead spa ces.

Roof hatch is made from steel.



7


Joystick and Controls

HITACHI ZAXIS 210LC

JS 220L AUTO

Long levers with limited auxiliary buttons within the joystick.

Short multi function levers with built in switches. The new auto machine, tracking speeds are controlled by a

A rotary switch, located on a panel next to the right side

switch mounted to the front of the right side joystick. This allows

joystick, controls the tracking speed.

the operator to change between the 3 speeds without interrupting

When changing tracking speed the operator must release the

other services. Multi function is also made easier by the auto

joystick to select the desired speed i.e. high / low. (No creep

speed change between high and low speed. (Creep needs to

speed available).

be selected by the operator via the switch on the joystick).

Power Boost is selected from a button located on top of the

Power boost is applied automatically in Auto and Lifting modes.

right side joystick.

A T I H V S J 3 0 / 7 0

JSVHITA0008 The layout of the Hitachi controls is at hand and functional.

JSVHITA0009 Switches and controls positioned for ease of use and functional. The inside of the cabin is stylish, modern and durable.

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8



E-P CONTROL

ADVANCED MANAGEMENT SYSTEM

Hitachi's monitor is quite basic and displays minimal

The AMS display on the JS is well laid out with all information

information with only the hour meter being digital. The

digitally displayed.

differences in the digging modes are unclear and the modes are selected by turn switches.

The AMS monitor is adjustable to suit the brightest conditions. Visibility past the monitor was a major factor when designing

The hydraulic work modes are as follows:

the new monitor.

- Digging Mode - Attachment Mode

The hydraulic work modes are as follows: - A – Auto

Also offered on the Hitachi is a Power Mode Switch. This

- E – Economy

allows the operator to switch between E – Economy, P -

- P – Precision

Power Mode (General excavations) & H/P Mode (When extra

- L - Lifting

horsepower is needed). In HP mode the engine rpm speeds change depending on the load required.

The Auto Mode is designed to produce maximum efficiency without the operator having to choose the correct work

Power Boost is selected by pressing a button on top of the

mode. The Auto mode selects power boost automatically

right side joystick.

when necessary. Also if the joysticks are less than 75% open the machine automatically reverts to the economy mode.

The brochure and the operator’s manual are unclear when explaining the benefit of the different work modes.

Whilst the JS AMS is equipped to ensure maximum efficiency, store data and to assist service engineers with potential

The Hitachi boasts it’s 108kw engine, this is only when in H/P

problems etc, a major advantage is that it can be used to

Mode. The engine increases from 1900 – 2100rpm. Clearly

diagnose problems and log service data, which can be

this will not be the most efficient work mode.

downloaded onto a laptop computer.

Working in P - Power Mode the engine develops 101kw, slightly less that the JS Auto.

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9

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Visibility

HITACHI ZAXIS 210LC

JS 220L AUTO

The joint between top and bottom window is 45mm.

The joint between top and bottom window is only 10mm.

This gives reduced vision to the front.

This gives excellent visibility to the front with hardly any blind spot.

The bottom window on the Hitachi is removable and can be

The bottom window is integral part of the total window.

stored in the rear of the cabin. Re-moveable windows

Window stowage is second to none. It’s easy to operate

often break.

and durable.

A T I H V S J 3 0 / 4 0

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Refuelling

HITACHI ZAXIS 210LC

JS 220L AUTO

No fuel sight gauge on the Hitachi. This will make it difficult to

JS has a fuel level gauge and hydraulic level gauge which can

fill without over spilling.

both been seen from the outside while filling.

10



Cab Floor and Track Controls

HITACHI ZAXIS 210LC

JS 220L AUTO

The floor is flat therefore needs foot rest. This can be a

The floor is flat and no door lip for easy cleaning.

problem when fitting optional auxiliary pedals. The floor is designed not to need foot rests unlike it’s competitors. The extra floor space easily allow fitment of any optional hydraulic auxiliary pedals.

The ZX has 2- speed tracking only.

The JS machines offer 3 speed tracking including creep speed for difficult confined conditions.

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11


Cab Storage and Air-conditioner

HITACHI ZAXIS 210LC

JS 220L AUTO

Hitachi offers air-conditioning, platform for storage and a small

JS has optional air-conditioning. Large stowage box standard

storage box shown here with the red cross on top.

and with AC fitted the box is cooled.

Airflow for both the heater and AC increased by 56% on the JS auto machine (from the XO model).

A T I H V S J 3 0 / 7 0

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Visibility Rear

HITACHI ZAXIS 210LC

JS 220L AUTO

The virtually zero height bonnet gives excellent rear vision. 36% improvement when compared to the XO machine. Although no static test was d one on the Hitachi. The JS has a clear advantage in rear visibility.

JSVHITA0019

12

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SUPERSTRUCTURE

Generally the overall layout of JS is similar to the ZX, the hydraulic valves / pumps, engine, cooling etc. are housed in similar location. However, the new auto machine has a number of clear advantages, and they are as follows:

HITACHI ZAXIS 210LC

JS 220L AUTO

JSVHITA0021


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13


Cooling

HITACHI ZAXIS 210LC

JS 220L AUTO

The water radiator, hydraulic cooler, A/C condenser and after-

With the exception of the after-cooler, the JS layout is similar

cooler are all housed in this area.

to the ZX machine. The JS220 does not require an aftercooler, therefore it is easier to clean the other cooler.

Hitachi used wet batteries, these need checking and are expensive to replace.

JCB use dry type maintenance free batteries.

Engineers all agree, visibility is reduced when working on

JCB yellow is designed to be bright and light, and this

machines with dark painted compartments, particularly in the

improves the working environment for the engineers.

winter months. The two images below identify the difference even in good light.

A T I H V S J 3 0 / 7 0

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14

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Storage and Access

HITACHI ZAXIS 210LC

JS 220L AUTO

Hitachi promote this area as a storage compartment, their

The servo hose layout is neat, visible and easy to access.

storage box located on the opposite side is very small.

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15


Hydraulic Pump Bay

HITACHI ZAXIS 210LC

JS 220L AUTO

Similar access to JCB. The hydraulic pumps are marked

Good access with plenty of space around the Kawasaki pumps.

as Hitachi? Filters located in the pump bay: These pumps have separate lubricating oil, which also needs changing every 1000 hours.

- Plexus hyd filter - Servo filter

Filters located in the pump bay:

- Pump / valve block leakage line filter

- Servo filter

The main hydraulic filter and suction strainer are located inside

- No leakage line filter

the hydraulic tank.

- No Plexus type filter

The main hydraulic filter and suction strainer is located inside the hydraulic tank.

A T I H V S J 3 0 / 7 0

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16

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Engine Access

HITACHI ZAXIS 210LC

JS 220L AUTO

The bonnet is higher and heavier than the JS design.

The low or no bonnet design is light and easy to open.

It is hinged on one side and more difficult to open. Hitachi has

The rear hinges also add to the easiness and excellent access.

attached a mechanical spring to assist the operator when opening the bonnet.

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Walkway grippers

HITACHI ZAXIS 210LC

JS 220L AUTO

Grippers used on the ZX machines are similar to those used


on the JS XO machines. Whilst they are effective, customer


perception is that the stick-on type is temporary.


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17


UPPERSTRUCTURE

HITACHI ZAXIS 210LC

JS 220L AUTO

The nomenclature is designed to leave enough room for customers to sign-write their names etc. above the JCB decals.

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UNDERCARRIAGE

HITACHI ZAXIS 210LC

JS 220L AUTO

JSVHITA0002 The Hitachi has only one-track guide on each side.

JSVHITA0038 The JS has two track guides per side giving greater security to the tracks. Two track guides on each side are standard on all JS machines over 20 tonne.

18



HITACHI ZAXIS 210LC

JS 220L AUTO

Two speed tracking at 5.3 and 3.3 kph.

Three speed tracking at 5.5, 3.5, 2.6 kmph. Slower option for greater control than the Hitachi.

The cross frame on the Hitachi undercarriage joins onto the

The cross frame on the JS is welded into track beam, which is

side of the tunnel, which is only 8mm thick.

30mm thick, making a very strong undercarriage. This 30mm track beam ensures a strong durable undercarriage to suit European conditions.

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Recessed grease nipple on front and rear of slew ring making

Centralised greasing. Three grease nipples all grouped

greasing awkward. Th e operator has to grease one side and

together giving easy central access for greasing.

then slew the machine 180 degrees in order to grease the other side.

JSVHITA0041

JSVHITA0042

The Hitachi has no turret guard which exposes the rotary

Two piece turret g uard recessed ensures protection of rotary

coupling to site debris.

joint from site debris. The two-piece design allows easy removal in the field.


19


HITACHI ZAXIS 210LC

JS 220L AUTO

Dirt release hole 140mm x 190mm If rollers stop turning it

Large top roller relief hole of 250mm x 155mm. This allows

costs money!

dirt to fall away from the top rollers, therefore reducing wear.

Sealed and greased track chain gives quieter, smoother running and extended track life. Track performance is so good JCB offer 1000 hours warranty on tracks.

Probably the most significant feature of the JS undercarriage is the design of the track tunnel. The apex shape helps dirt fall away, hence less build-up and less undercarriage wear. In an JCB is aware that the Hitachi ZX design track tunnel is similar

extreme cold climate this feature is excellent. Frozen dirt is

to the JS330. However, we should be aware of the pit falls

difficult for the operators to remove, therefore less cleaning

when in extremely cold conditions. The long slope attracts a

work for the operator at the end of each da y.

build-up of dirt and is difficult to remove, compared to the JS apex design. Frozen tracks can lead to major repair costs etc.

A T I H V S J 3 0 / 7 0

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20

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EXCAVATOR END

HITACHI ZAXIS 210LC

JS 220L AUTO

The Hitachi's top and bottom wrappers on the boom are

The JS boom is made with a one-piece top and

made with 3 pieces of steel.

bottom wrapper.

With regard to the construction of the excavator end, perception is probably the strongest selling point. The JS220LC is over 2 tonnes heavier than the ZX210LC, and the majority of the extra weight is in the undercarriage and the excavator end.

Hammer pipe work welded on by dealer.

All pipe work brackets both low flow, high flow and quick hitch are factory welded on as standard on JS machines. Therefore eliminating the need for any welding outside of the factory.

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Excavator

The boom base and boom to dipper pins are now 1000 hour

Hitachi is promoting HN Bushing. This allows extended

between greasing.

greasing interval - 500 h our. The brochure indicates 500 hour interval greasing on the bucket and front section.


21


PERFORMANCE OVERVIEW

To test the Hitachi’s excavating performance against the JCB, a production test was carried out. Prior to testing, tractive effort, dipper and bucket tearout were confirmed. This was done by excavating a trench at one bucket depth. The spoil from this trench was used to fill a JCB dumper truck. The excavator had to slew 90o from the trench to the truck. The truck was always filled with 4-bucket loads. This spoil was then weighed to give a figure of the output. Both the Hitachi and JCB repeated the test until the results were consistent. Both machines were wired up with fuel consumption meters and the loading cycle of the dump truck was timed. The results are shown in the table below:

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Trench Output (tonnes/hr)

Fuel Efficiency (tonnes/litre)

JS 220 L Auto

716

26.3

Hitachi Zaxis 200

659

23.67

The results show the following points: • The JS 220 L excavated 57 tonnes more in one hour. • The JS220 L is 11% more fuel efficient per tonne of spoil moved.

Lifting Test No actual lifting tests were done with the ZX machine. However comparing the lift charts in the relevant brochure, the JS machines are in a class above the Hitachi machines. Zero or reduced tail swing are shown to be restricted when it comes to heavy lifting duties.

The following specification chart shows JS machines clear advantage and in the summary it ‘s shown in percentage terms.

22

This communication and the information within is intended for JCB and JCB dealer personnel only, for information purposes, is confidential and may not be communicated to any third party. Whilst the information i s believed to be correct, no guarantee is given by JCB as to its accuracy and its use may not be a ttributed to JCB.


JS AND HITACHI TRACKED EXCAVATOR BASIC SPECIFICATION COMPARISON

KEY SPECIFICATIONS Manufacturer

JCB

JCB

JCB

Hitachi

Hitachi

Model

JS200L

JS2l0L

JS220L

ZX210LC

ZX225USRLC ZX225USLC

Operating weight class

20870

21,355

22,172

20,000

22,900

23,900

3700

4350

5000

4250

6710

7300

Make

Isuzu

Isuzu

Isuzu

Isuzu

Isuzu

Isuzu

Model

BB-6BGIT

BB-6BGIT

BB-6BGIT

AA-6BG1T

AA-6BG1T

AA-6BG1T

6.494

6.494

6.494

6.494

6.494

6.494

Aspiration

Turbo.

Turbo.

Turbo.

Turbo.

Turbo.

Turbo.

Aftercooled

No

No

No

Yes

Yes

Yes

(700mmPlates)

kg

Counter weight

kg

Hitachi

ENGINE

Displacement

ltr

Rated speed

rpm

1950

1950

1950

2100

2100

2100

Net power

kW / hp

102 / 138

102 / 138

102 / 138

108 / 147

108 / 147

108 / 147

SAE J1349

SAE J1349

SAE J1349

SAE J1349

SAE J1349

SAE J1349

Main pump type

Var. piston

Var. piston

Var. piston

Var. piston

Var. piston

Var. piston

No. of main pumps

2

2

2

2

2

2

2 x 214

2 x 214

2 x 214

2 x 194

2 x 194

2 x 194

95

95

95

Hydraulic

Hydraulic

Hydraulic

Hydraulic

Hydraulic

Hydraulic

13.3

13.3

13.3

Rating standard HYDRAULIC SYSTEM

Main pumps-max. flow

ltr/min

Hydraulic horsepower (Auto mode)

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kW

SWING SYSTEM Slew brake - dynamic Swing speed

rpm

12.9

12.9

12.9

Swing torque

Nm

62908

62908

62908

Yes

Yes

Yes

No

No

No

No. of top /bottom rollers per side

2/8

2/8

2/8

2/8

2/8

2/8

No. of shoes

49

49

49

49

49

49

2,390

2,170

2,390

2,390

2,390

2,390

Automatic

Automatic

Automatic

UNDERCARRIAGE Sealed track

Track gauge - std.

mm

TRACK DRIVE Service brake actuation Travel speeds

km/h

2.3 / 3.3 / 5.6

2.3 / 3.3 / 5.6

2.3 / 3.3 / 5.6

3.3 / 5.3

3.3 / 5.3

3.3 / 5.3

Gradeability

°/%

35 / 78

35 / 75

35 / 75

35 / 70

35 / 70

35 / 70

Tractive effort

kN

191.9

191.9

191.9

184

200

200

Power to weight

kN / Ton 8.99

8.99

8.66

9.2

8.73

8.37

Superstructure width

mm

2,500

2,500

2,500

2,710

2,860

2,810

Ground clearance

mm 2,990

2,800

2,990

2,990

2,990

2,990

STATIC DIMENSIONS

Width over std. Tracks (600mm)

mm


23


CAPACITIES Fuel

ltr

343

343

343

360

320

270

3

3

3

4

3

3

2.03 / 2.42

- / 2.22

- / 2.22

DIPPER OPTIONS Number of dippers Dipper length XS / S

mm

- / 1910

- / 1910

- / 1910

Dipper length M / L

mm

2400 / 3000

2400 / 3000

2400 / 3000

2.91 / 3.51

2.91 - 4.41

2.91 - 4.41

10410

10410

10410

10400

10400

10400

12550

12550

12550

13000

?

?

14610

14610

14610

14050

13400

13400

15800

15800

15800

13200

13200

13200

ISO 10567

ISO 10567

ISO 10567

ISO 10576

ISO 10576

ISO 10576

7030

7540

8040

6750

7090

4560

4430

4420

5220

4210

4560

4430

DIPPER TEAROUTS Dipper tearout Maximum - L (SAE)

kgf

Dipper tearout Maximum - M (SAE)

kgf

Dipper tearout Maximum - S (SAE)

kgf

BUCKETS Bucket breakout (SAE)

kgf

LIFTING Rating standard Monoboom 1 / standard dipper Over end Lift at 6.0m ground level reach A T I H V S J 3 0 / 7 0

Full circle

kg

Lift at 6.0m ground level reach kg

24


Contents

Section 8. COMPARATIVE EVALUATION – JS 220L AUTO VS KOMATSU PC210-7

1. The New Generation vs Komatsu PC210-7.

2. Introduction – Overview.

3. JS vs Conventional Counter weight. - JS vs Reduced Tail Swing. - JS vs Komatsu Narrow.

4. The Evaluation. - Key advantages of the JS 220 and features to consider on the Komatsu.

5. Cab Overview.

6. Cab Layout. - Cab Visibility. - Cab Controls.

7. Cab Design/Vision.

8. Switch Panel.

9. Power Work Modes.

10. Air Conditioning – Storage.

11. Track Pedals.

Contents

12. Loadover visibility.

13. Superstructure And Layout.


15. Walkway And Service Platform.

16. Hydraulic Pressure testing – Access.

17. Engine Access and Detail.

18. Guarding and Lubrication.

19. Undercarriage.

20. Ground Clearance.

21. Excavator end.

22. Machine Excavation Performance.

23. Fuel Comparison.


25. Specification Comparison (continued).



JS 220L AUTO vs KOMATSU PC210-7 (APRIL 2003)

PC210-7 / PC210LC-7 / PC210NLC-7

JCB0192 0 7 / 0 3 J S V K O M A T


1


INTRODUCTION AND OVERVIEW Comparison between the JS and Komatsu 19 – 23.0 tonne class tracked excavators. Competing with the world’s best manufacturers will never be an easy task and Komatsu is no exception. Their excavator business is considered be one of the most important product lines within the Komatsu organisation and their products are very good. This guide aims to show where JCB are strongest in the machine range. This report is primarily comparing the JS220L Auto with the latest Komatsu PC210LC-7. However we should be aware of the overall situation with the Komatsu excavator range. Currently the PC210-7, PC230NHD, PC240-7, PC290-7 and PC340-7 have the Tier II engines. The rest of their range is still either a Dash 3 if it’s a reduced tail swing machine, or a Dash 6 if it has a conventional counterweight etc. Note the Dash 3 reduced tail swing machines have Tier II engines. Komatsu claim that the new Dash 7 machines are designed with the European market in-mind and the following improvement apply: - Higher productivity. - Low fuel consumption. - Easier maintenance and serviceability. - Improved operator comfort. - Lower noise. - Meets Stage II emissions regulations. - Advanced Attachment Control. - Multi –function colour monitor. T A M O K V S J 3 0 / 7 0

- PC210NLC has transport width 2.55m (Only with 500mm track plates).

The 3 tables below show the operating weight and track gauge etc. This will help to establish the direct competitor to the relevant JS200L, JS210L & JS220L Auto machines. A more detailed comparison is included at the end of the presentation. Obviously with regard to the reduced tail swing machines, the table will give you an overview of the main difference. Note, lifting numbers are shown with no bucket fitted, and either as 87% hydraulically limited or 75% stability limited.

2



JS Vs Conventional Counter Weight JS200L

JS210L

JS220L

PC210-7

PC210LC-7

20,870kg

21,355kg

22,172kg

20,575kg

21,575kg

Reduced Tail Swing

No

No

No

No

No

Rear Swing Radius

2825mm

2825mm

2825mm

2800mm

2800mm

Min Swing Radius

3710mm

3710mm

3710mm

3010mm

3090mm

Track Gauge

2390mm

2170mm

2390mm

2200mm

2380mm

4430kg

4420kg

5220kg

4160kg

4710kg

7030kg

7540kg

8040kg

6110kg

7360kg

JS200L

JS210L

JS220L

PC228US-3

PC228USLC-3

20,870kg

21,355kg

22,172kg

21,980kg

23,280kg

Zero Tail Swing

No

No

No

Yes!

Yes!

Counter Weight

3700kg

4350kg

5000kg

6335kg

6335kg

Rear Swing Radius

2825mm

2825mm

2825mm

1680mm

1680mm

Min Swing Radius

3710mm

3710mm

3710mm

2310mm

2310mm

Track Gauge

2390mm

2170mm

2390mm

2200mm

2380mm

Lift Capacity @ 6m

4430kg

4420kg

5220kg

3810kg

4460kg

over-side / front

7030kg

7540kg

8040kg

5960kg

7360kg

JS220N

PC210NLC

PC230NHD

21,355kg

21,075kg

22,600kg

No

No

No

Rear Swing Radius

2825mm

2800mm

2770mm

Min Swing Radius

3710mm

3040

3010mm

Track Gauge

1990mm

2040mm

1990mm

Plate Width

500mm

700mm

700mm

Lift Capacity @ 6m

4190kg

4060kg

4310kg

over-side / front

6940kg

7360kg

7360kg

Operating Weight


JS Vs Reduced Tail Swing

Operating Weight

0 7 / 0 3 J S V K O M A T

JS Narrow Vs Komatsu Narrow.

Operating Weight Zero Tail Swing

You will notice that the lift capacities shown for the PC210N and PC230N are with 700mm track plates. The use of wider track plates does increase over side lift capacity, but defeats the object when working within a maximum width of less than 2.55m.

The PC230NHD The undercarriage is the main area of difference when comparing the PC210N and the JS220N. The PC230N has larger heavy-duty undercarriage and running gear, which includes larger rollers, heavier, larger bushes, deeper and wider track links, and 8 bottom rollers as opposed to 7 on the JS220N. In some areas the JS track frame is constructed from heavier material than on the PC230N frame. However, Komatsu has focused on the wear parts and customer perception, bigger is better. This version allows Komatsu to have a model where width restrictions are an issue i.e. Italy.


3


THE EVALUATION

Over a number of weeks JCB undertook to benchmark the new auto machine against the major competition. The evaluations were done in the second half of 2002. Products / competitors included were: JS220L (XO), Hitachi, Komatsu, Caterpillar, Daewoo, Volvo and Case. The evaluations included productivity and efficiency tests, quality comparisons, service access and product specifications etc.

Key advantages of the JS 220 and features to consider on the Komatsu JSVJOKAMATRGE • Opening of front window well designed and easy to use. The lower front window is an integral part of the upper window. • JS Narrow carriage machines have 1990mm track gauge and with 600mm plates is still within the maximum width of 2.55m. (The PC210N (2040mm gauge) will only comply with 500mm track plates therefore Komatsu must offer the PC230N (1990mm gauge) to comply with 600mm tracking plates. • In virtually all instances the JS machines have a much better lifting performance i.e. over the front and over the side. The JS220L and the PC210LC, at 6m the JS has over 10% more lift capacity over T A M O K V S J 3 0 / 7 0

side and over 9% more over the front. • To put things into perspective, the JS210L out lifts the PC210-7,

• Excellent all round visibility from the JS cab, including vision over

both with 2200mm track gauge, by over 6% over the side and

the bonnet area. Komatsu boast a large cabin but visibility appears

2.5% over the front. Comparing the JS210L wih the PC210LC

to be restricted by the large cab frame design.

with its 2390mm track gauge and long carriage, the JS advantage is 2.5% over the front and only over the side the JS advantage is

• Superior filtration system including case drain filters. (Komatsu has

only 6% less. These advantages are significant in the day to day

introduced a 6 micron hydraulic filter and is promoting a 5000 hr

operation of 20 tonne class excavators.

oil change).

• Reduced tail swing machines have their advantages but lifting is not

• Gas assisted front opening bonnet – safe and easy.

one of them. The JS 220LC has 17% more lift capacity over the side and over 9% over the front than th PC 228USLC.

• Drawbar pull - The JS Auto has 191.1kN Vs the Komatsu PC210LC which has 179kN (6.8% less than the JS Auto).

• The JS210 and the PC228US-3 both have a track gauge width of 2200mm. The JS has 26% better stability over the front and 16% over the side.

• Swing Speed – JS Auto 12.9 rpm and PC210 12.4 rpm (4% slower than the JS Auto). The JS Auto has high slew torque and gives fast acceleration through 0-90 degree and 0-180 degree.

• The JS machines have a 102 kW engine Vs 107kW (4.9% greater) on the Komatsu machines. However the Isuzu has a larger

• Undercarriage, overall JS machines are heavier and the heavier

displacement 6.494ltr compared to the Komatsu that has a 5.88ltr

construction of the undercarriage accounts for the majority of the

motor i.e. the Isuzu displacement is 10.4% greater. From a

weight i.e. 20% thicker steel in the track beam, 25% thicker

perception point of view a larger displacement is better and

material in the tunnel plate and 33% thicker cross frame plate.

increase in kW is only good if the hydraulic power follows accordingly. (The PC210LC has 9 rollers Vs 8 on the JS machine. However both • JS Joystick lever effort is significantly less. Lever effort on the JS

undercarriages are virtually the same length.)

machine is 2.1Nm making the machine light and precise to operate. The Komatsu lever effort was 4.9Nm, extremely heavy over twice the effort is required to operate these.

4



CAB Cab Overview JCB has taken particular care when designing the cabin and it’s controls. The focus has been on improving the following: visibility, quality / durability, operator comfort, control layout and control simplicity and ease of use etc.

KOMATSU PC210LC-7

JS220L AUTO

JSVKOMAT0001 The front window on the Komatsu is awkward to open.

JSVKOMAT0002

0 7 / 0 3 J S V K O M A T

Window easy to open with gas strut assistance using well positioned handles.

The lower window storage is on rear window, which means that the operator has to move the glass around in the cab. This is certainly

Lower section of front window is an integral part of the front

not ideal and the windows are often broken in the process.

window and held in top section.

The Komatsu's door is only 850mm wide which reduces access

The JCB's door is 980mm wide which g ives good access to

to the cab.

the cab.

Note, the door has reduced in width compared the previous XO machine. This has improved the closing of the door when inside the cabin. (The actual access in to the cab has not reduced i.e. front of the joystick base to front of in-side cabin.)

850mm

JSVKOMAT0003

980mm

JSVKOMAT0004


5


KOMATSU PC210LC-7

JS220L AUTO

JSVKOMAT0005 T A M O K V S J 3 0 / 7 0

JSVKOMAT0006 Modern and ergonomically designed. Switch and control panel easier to see and use. - Cab designed to accommodate the wide range of operator sizes. - Small door for easier closing. - The new heater and air-conditioning unit develops 56% more airflow. - Optional full climate control air-conditioning. - Interior lamp with timer switch aids easier access to the cab. - Flat floor with no door lip – easy clean. - Document storage pocket. - Mobile telephone holder and 12v charger point. - Optional deluxe air suspension seat with heated pod and adjustable lumber support. - Radio mute switch cuts off radio to improve communication.

6



Cab Design / Vision

KOMATSU PC210LC-7

JS220L AUTO

JSVKOMAT0007 Although the cab is large, the square design with large posts

JSVKOMAT0008 Modern designs with excellent all round visibility.

does restrict vision to the side, front and rear.

0 7 / 0 3 J S V K O M A T

Joystick Controls

KOMATSU PC210LC-7

JSVKOMAT0009

JS220L AUTO

JSVKOMAT0010

The Komatsu control lever effort was 4.9Nm. This is over

The JS control levers required only 2.1 Nm giving easy

double that of the JS.

smooth control of the excavator. In real terms the Komatsu controls are 2.3 times heavier to pull than the JS controls.


7


Switch Panel

KOMATSU PC210LC-7

JSVKOMAT0011 Right hand side switches.

JS220L AUTO

JSVKOMAT0012 Modern and all in easy reach of the operator.

T A M O K V S J 3 0 / 7 0

JSVKOMAT0013 Left hand side switches.

8



Power Work Modes JS Auto The AMS on the auto machine has been improved to make life easier for the operator. With Auto (A) mode selected, power boost is automatically activated, the AMS ensures maximum efficiency. Economy (E) mode is ideal for normal digging operations and is particularly fuel efficient. Precision mode is for fine grading duties and the lifting (L) mode is for lifting duties. In L mode the hydraulic pressure increases automatically by 10% for maximum power.

PC-7 EMMS has 4 work modes, Active is used for maximum performance, and Economy for efficiency, Breaker for rock breaking and L is for lifting. Komatsu also offer pressure boost, it’s known as Power Max, but only a 7% increase in hydraulic pressure. The EMMS controls RPM, Hyd Pressure and hyd pump flow in a similar way to the JS AMS system. KOMATSU PC210LC-7

JS220L AUTO

EMMS Monitor

AMS Monitor

Fixed Monitor

Adjustable AMS Monitor



A – Active

A – Auto

E – Economy

E – Economy

B – Breaker

P - Precision

L - Lifting

L – Lifting

Compared to the JS Auto monitor vision is restricted on

0 7 / 0 3 J S V K O M A T

Improved visibility.

the Komatsu. Diagnostic work can be done without the aid of a Laptop.

JSVKOMAT0009

JSVKOMAT0014


9


KOMATSU PC210LC-7

JS220L AUTO

Climate control / air-conditioner standard.

Optional air-conditioner or climate control.

Rear air vents located next to the storage tray.

Rear air vents located each side of the storage box.

JSVKOMAT0015

T A M O K V S J 3 0 / 7 0

JSVKOMAT0016

Cab Storage

Cab Storage

Open tray for storage and small box to the left of the tray for

Improved in-cab storage box with latch to keep closed.

cooling drink etc.

- Air conditioning vents included to cool contents i.e. drinks etc.

JSVKOMAT0017

JSVKOMAT0018

Cab Storage

Cab Storage

Komatsu has in-cab storage behind the seat.

JCB has a document storage sleeve located below the cup holder in the front on the right side and in the rear of seat.

10



Track Pedals KOMATSU PC210LC-7

S220L AUTO

JSVKOMAT0019

JSVKOMAT0020

Cab floor has limited foot space which is further reduced if a

Cleaner floor space.

hammer is fitted.

Track speeds control removed from floor position and relocated in the right side joystick. Easier to operate and better

Tracking speeds are selected from the EMMS monitor But also

controllability for the operator. Auto speed change between

note Dash 7 machines include auto speed change.

high and medium and creep speed is manually selected.

Hammer and TAB pedals are better located leaving room for the feet to rest.

The joint between top and bottom window is 45mm. This

The joint between top and bottom window is only 10mm.

gives a blind spot to the front.

This gives excellent visibility to the front with a much-reduced blind spot.

JSVKOMAT0001

JSVKOMAT0014


11

0 7 / 0 3 J S V K O M A T


Loadover visibility KOMATSU PC210LC-7

JSVKOMAT0021

S220L AUTO

JSVKOMAT0022

The PC210-7 has a better loadover height than it’s

The JS Auto machines have slightly less loadover height but

predecessor Dash 6. However the vision at height is poor.

vision is excellent to full height.

The roof hatch can be raised to help the situation.

With the sunblind down (as shown above) operators are protected from direct sunlight and heat.

T A M O K V S J 3 0 / 4 0

12



SUPERSTRUCTURE AND LAYOUT ETC Superstructure Overview Whilst introducing the Tier II engine to the JCB 20 tonne class machines, JCB made some significant changes to the Superstructure. JCB’s objective was to build a machine with improved access to all compartments, reduce service costs, provide improved visibility, improve quality / durability and improve performance. Komatsu also took advantage of the introduction of the Tier II engine. They focused on reducing service costs, improving performance and service access etc. Visually the Komatsu has not changed as much as the JCB.

KOMATSU PC210LC-7

JS 220L

0 7 / 0 3 J S V K O M A T

JSVKOMAT0023

JSVKOMAT0024


13


Visibility and Access The most noticeable improvement on the JS machines is the introduction of the flat bonnet. Vision to the rear has improved dramatically.

KOMATSU PC210LC-7

JSVKOMAT0025 High level bonnet.

JS AUTO

JSVKOMAT0026 Vision over the bonnet is excellent.

T A M O K V S J 3 0 / 7 0

JSVKOMAT0027 The bonnet restricts rear vision.

JSVKOMAT0028 Decal design gives room for sign writing. At close proximity the machine vision is obviously better.

14



Walkway and Service Platform KOMATSU PC210LC-7

JS AUTO

JSVKOMAT0029

JSVKOMAT0030

Grippers used on the PC machines are similar to those used


on the JS XO machines. Whilst they are effective, customer


perception is that the stick-on type is temporary.


0 7 / 0 3 J S V K O M A T

JSVJOKAMAT0031 Hydraulic filtration:

JSVJOKAMAT0032 Hydraulic filtration:

- No case drain

- Case drain / leakage line

- Servo

- Servo

- Main Hyd return

- Main hyd return

- Suction strainer

- Suction strainer - Plexus

Komatsu has introduced a 6-micron main hydraulic return line filter. This has extended the hyd change to 5000hr.


Clearly Komatsu feel a 6 micron filter is adequate to allow the extended oil change!

To ensure ultimate performance and reliability a bypass filter (Plexus) filters the oil down to 1.5 microns. Cleaner oil

The main hydraulic filter is located behind the cab.

breed’s reliability.


15


KOMATSU PC210LC-7

KOMATSU PC210-7

Hydraulic pressure measurement is done via the EMMS

The main hydraulic filter is located inside the hydraulic tank

monitor, however this method is not always the most accurate

and the Plexus filter is situated in the hydraulic pump bay.

and reliable method. Hydraulic pressure test points are located inside the pump bay. Easy for the service engineers to reach and using calibrated gauges should always give an accurate reading.

Access to:

Access to: - Radiator

- Radiator and fine mesh grill

- Aftercooler

- Air-conditioner condenser if fitted

- Air-conditioner condenser if fitted

- Air filter

- Air filter

- Batteries

- Main hydraulic filter

- Servo hoses

T A M O K V S J 3 0 / 4 0

JSVJOKAMAT0033

16

JSVJOKAMAT0034



Engine Access and Details KOMATSU PC210LC-7

JS AUTO

JSVJOKAMAT0035

JSVJOKAMAT0036

Komatsu and Cummins have a joint venture. The base engine

Isuzu 102kW engine (No Aftercooler) The Isuzu is a 6.494 litre

is a 107kW Cummins with some improvements made by

motor (10% larger than the Cummins) does not required an

the Japanese. The engine is a 5.88ltr motor and is aftercooled.

aftercooler.

The Komatsu has a side-opening bonnet. This is heavy to open and operator must go to edge of top plate to open catches.

0 7 / 0 3 J S V K O M A T

Front opening bonnet on the JS. Gas strut assistance makes the bonnet easy to open and catch on front face means

Uses mechanical type spring to assist with the weight opening

operator can stay in the middle of the top plate.

and closing. First 100 hour service removed.

Engine Oil

Engine Oil

Komatsu offer a remote engine oil drain and remote filters. To

The JS Auto has a quick release flap to access the engine oil

drain the engine oil you still need to be under the machine to

drain point, and a long quick release drainpipe is supplied.

access the drain plug.

JSVJOKAMAT0037

JSVJOKAMAT0038


17


KOMATSU PC210LC-7

JS AUTO

Under guarding not under the fuel tank leaving fuel hose

Under side completely protected.

exposed to damage.

JSVJOKAMAT0039

JSVJOKAMAT0040

Grease points located at the front and rear.

Centralised greasing at the front.

There are only two grease nipples on the slew ring, which makes

Three grease nipples all grouped together give easy central

it harder for the grease to penetrate the entire slew ring.

access for greasing.

T A M O K V S J 3 0 / 7 0

JSVJOKAMAT0041

18

JSVJOKAMAT0042



UNDERCARRIAGE Although the design is basically the same as the XO machine, the drawbar pull is greater on the JS Auto by nearly 7%. This has been achieved by increasing the displacement size of the track motors. Drawbar pull on the JS Auto is 191.1 kN and the Komatsu has 179kN (6.8% less). With a long undercarriage fitted, the Komatsu will have noticeably less power when trying to counter rotate the tracks etc. Construction and the remainder of the components have not changed from the XO machine. Main hydraulic pressure (Maximum) has increased from 343 bar to 373 bar on the JS Auto machine. When tracking the JS Auto machine the pressure remains at 343 bar i.e. same as XO.

KOMATSU PC210LC-7

JS AUTO

The cross frame on the Komatsu undercarriage joins on the

The cross frame on the JS is welded into track beam which is

side of the tunnel, which is only 8mm thick. The track beam

30mm thick making a very strong undercarriage. This 30mm

itself is only 25mm, 5mm less than the JCB.

track beam ensures strong durable undercarriage to suit European conditions.

The tunnel plate is 10mm thick, 2mm thicker than the Komatsu and the cross frame plate is 20mm thick versus 15mm on the Komatsu.

0 7 / 0 3 J S V K O M A T

The JS has 8 bottom rollers and the PC210LC has 9. The undercarriage length is virtually the same on both machines.

JSVJOKAMAT0043 Dirt release hole 170 x 200.

JSVJOKAMAT0044 Large top roller relief hole size 250 x 155 which allows dirt to fall away from the top rollers reducing wear on the roller and track chain.


19


KOMATSU PC210LC-7

JS AUTO

Ground Clearance 460mm less than JS 220L.

Ground clearance 486mm.

JSVJOKAMAT0045 Komatsu machines all have a sealed track chain.

JSVJOKAMAT0046 Sealed and greased track chain gives quieter, smooth running and extended track life. Track performance so good JCB offer 1000 hours warrenty on tracks.

T A M O K V S J 3 0 / 7 0

20



EXCAVATOR END With regard to the construction of the excavator end, perception is probable the strongest selling point. The JS220LC is around 600kg heavier than the PC210LC, with the majority of the extra weight in the undercarriage and the excavator end.

The JS and Komatsu have a boom made with a one-piece top and bottom wrapper.

All pipe work brackets for both low flow and high flow are factory welded on as standard on JS machines. Therefore eliminating the need for any welding outside of the factory.

The JS Auto machine has boom, dipper and bucket regeneration circuits. As the oil is being pushed out of the ram it gets diverted to the opposite side of the ram and increases the cycle speeds.

Cushion control is standard on all the JS tracked excavators. Cushion control can be deselected at any time. The feature is designed to protect the machine and give a smoother operation. In some applications cushion control should be switched off i.e. lifting duties or sticky conditions. (Note with cushion control switched on some operators consider the machine to be slower!. This is not the case, same oil flow and same working pressure. It is only the stopping that’s controlled and the smoothness misleads operators thinking it’s slower).

KOMATSU PC210LC-7

JS AUTO 0 7 / 0 3 J S V K O M A T

The shape of the Komatsu's boom is straight with a casting at the boom base.

JSVJOKAMAT0047

JSVJOKAMAT0048

Komatsu is promoting SCSH Bushing. This allows extended

The boom base and boom to dipper pins are now a 1000

greasing interval - 500 hour. The brochure advises that it is

between greasing.

only on some pins, but does not specify which pins.

9 4 0 0 T A M A K O J V S J


21


MACHINE EXCAVATION PERFORMANCE

JSVJOKAMAT0050 T A M O K V S J 3 0 / 7 0

JSVJOKAMAT0051

To test the Komatsu’s excavating performance against the JCB, a production test was carried out. Prior to the testing, tractive effort, dipper and bucket tearout were confirmed. The test was done by excavating a trench between 2 and 3 m deep. The spoil from this trench was used to fill a JCB dump truck. The excavator had to slew 90 o from the trench to the truck. The truck was always filled with 4-bucket loads. This spoil was then weighed to give a figure of the output. Both machines were wired up with fuel consumption meters and the loading cycle of the dump truck was timed. The results are shown in the table below: The ground was an easy dig but heavy conditions.

Trench Output

Fuel Efficiency

(tonnes/hr)

(tonnes/litre)

JS 220 L

689

25.9

Komatsu PC 210-7

631

24.52

The results show the following points: • The JS 220 L Auto excavated 58 tonnes more in one hour. • The JS220 L Auto is 5.6% more fuel efficient per tonne of spoil moved. Observation from the test: • JS were faster on the slew. • The JS was quicker on the dipper and bucket. • The JS looked smooth compared to the Komatsu. All tests are done based on a 60-minute hour and in test condition. The main objective was to establish the difference between the two machines. All test were done under test conditions i. e. at the JCB tes ting ground, with only 1 Komatsu machine and with JCB’s own tes t drivers.

22



Fuel Comparison JS Auto Working in Auto Mode Vs Economy Mode. Bulk handing in heavy wet sand and gravel and slewing through 90 degrees the JS Auto was put to the test. The aim was to compare the fuel consumption when working in Auto Mode as opposed to Economy Mode. Each test was done over a 1-hour (60min) period and fuel was measured. Note, the test was purely a fuel test comparing the fuel used between the 2 work modes and not productivity test i.e. the weight of the material moved was not calculated.

Fuel Used JS in Auto mode – 25.2 litre per hour. JS in Economy mode – 21.6 litre per hour. Economy mode proved to use 16.6% less fuel in the hour.

0 7 / 0 3 J S V K O M A T


23



U S T A M O K

T A M O K V S J 3 0 / 7 0

N O I S I R A P M O C N O I T A C I F I C E P S C I S A B R O T A V A C X E D E K C A R T U S T A M O K D N A S J 24

B C J

3 C L S U 8 2 2 C P

u s t a m o K

E 3 9 2 4 4 0 o s 0 1 3 1 8 b 1 5 e r Y 9 / J D 8 . u 6 5 T 1 7 E 0 A 1 A A S S

4 5 2 3

8 2 4

1 1

0 s 9 8 e / 9 3 , Y 2 4 2

7 D H N 0 3 2 C P

u s t a m o K

2 E 5 . 2 3 0 8 o 0 4 1 8 b s 1 5 r e 9 / . u Y D 5 1 7 T 6 0 A 1 A S

4 0 2 6

4 1 4 4 2 x 2

9 . 1 1

0 8 s e / 7 9 , Y 2 4 9 1

3 S U 8 2 2 C P

u s t a m o K

E 2 0 o s 1 8 b e D 8 . r u Y 6 5 T A A S

9 4 3 1 J E A S

4 5 2 3

8 4 4 2 4

1 1

0 7 s 0 e / 5 2 , Y 2 4 2

7 C L 0 1 2 C P

u s t a m o K

2 E 3 9 2 o 4 4 0 8 b 1 2 1 8 s 0 r 5 . / 9 e D 5 T u Y 9 6 1 7 0 O A I 1 S A S

4 0 2 6

4 1 4 4 2 x 2

4 . 2 1

0 9 s 8 e / 9 3 , Y 2 4 2

7 0 1 2 C P

u s t a m o K

2 E 2 3 9 o 0 8 b 1 8 0 4 r 1 4 2 . s D 5 T u e 5 / 9 6 Y 9 1 7 A 0 O A I 1 S S

4 0 2 6

4 1 4 4 2 x 2

4 . 2 1

0 s 7 0 e / 5 2 4 , Y 2 2

L 0 2 2 S J

T I 8 9 4 o u 3 4 b z G B 9 0 1 3 r 4 u 1 o 6 . 5 u s I B 6 T N 9 / J 2 E 1 0 A B 1 S

4 0 2 4

4 1 4 4 2 x 2

9 . 2 1

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25


U S T A M O K

) t n o c (

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N O I S I R A P M O C N O I T A C I F I C E P S C I S A B R O T A V A C X E D E K C A R T U S T A M O K D N A S J 26

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h c a e r l e v e l d n u o r g m 0 . 6 e l t c a r i t c f i l l L u F


Contents

Section 8. COMPARATIVE EVALUATION – NEW GENERATION VS XO RANGE

1. The New Generation vs XO Range.

2. Introduction. - Overview.

3. Performance Overview. - Engine. - Dig end Speed.

4. Slew Performance. - Productivity Overview. - Trenching Overview. - Truck Loading Overview. - Truck Loading Productivity.

5. Hydraulic Overview. - Hydraulic Work Modes.

6. Hydraulic Performance Specification. and Comparison.

7. Undercarriage Overview. - Excavator Overview.

8. Cab and Controls. - AMS.

Contents

9. Cab and Controls. - Layout.

10. Tracking Control. - Visibility.

11. In Cab Storage.

12. Visibility. - Through The Skylight.

13. Visibility. - Through The Rear. - Serviceability.

14. Serviceability (continued).




THE NEW GENERATION vs XO RANGE

NEWVOLD0001 0 7 / 0 3 N E W V O L D

NEWVOLD0002


1


INTRODUCTION

The new ‘Auto’ range of JS excavators replaces the old JS200, JS210, JS220 (including TAB), XD and LR machines. Undercarriage options (NC, SC, LC ) remain the same. Before launching the new ‘Auto’, customers from mainland Europe and the UK w ere invited to evaluate and compare the new machines and their input was u sed in the final product. Improved reliability, performance, operator acceptance and serviceability have resulted from the introduction of state-of-the-art technology and design. Enhanced performance and reliability will strengthen JCB’s position in the market and improve product value. Improved features include: • Performance and efficiency • Durability • Operator Comfort and Ease of Operation • Serviceability • Visibility

D L O V W E N 3 0 / 7 0

OVERVIEW

Performance / Efficiency

Productivity

- Performance has improved giving

- Auto power mode automatically

higher productivity.

Versatility - The range of undercarriage options,

regulates the amount of hydraulic

together with a wide variety of excavator

horsepower needed to achieve

end attachments, enables JCB to offer

maximum productivity. Improved

high efficiency levels in many applications.

controllability, h igher tearout forces, increased hydraulic oil flow, and a more comfortable cab increase productivity and reduce operating costs.

Ease of Operation

Operator Comfort

Serviceability

- The latest improved Advanced

- Cab provides greater operator comfort

- Simplified service and maintenance

Management System simplifies the

for higher efficiency a nd productivity.

operation and controls for operators.

features save the customer time and money.

- Improved all round visibility. - Switches and dials are well positioned for operator comfort.

- Increased heating and cooling. - Instrument panel relocated for easier reach and use.

- Improved grading and multi functioning.

- 100-hour first service deleted.

- Flat spacious floor makes it easy to clean. - Improved in cab storage

2

- Increased greasing intervals.

- IP69 electrics for increased reliability.



PERFORMANCE OVERVIEW

Auto machine performance has been improved from the XO 20 tonne class machines to provide higher productivity on truck loading, trenching, and grading. Increased dipper, bucket and boom speed has improved the overall efficiency of the machine. Operators who evaluated the new auto machine regarded it as very quick and smooth to operate.

ENGINE

Auto

XO

Engine Model

Isuxu BB-6BG1T

Isuxu A-6BG1TQB

Rated Power

102kW(138hp) 1950rpm

95kW(128hp) 1950rpm

Piston Displacement

6.494 ltrs

6.494 ltrs

Emissions Compliant

Tier 11

Tier 1

Over the last decade the Isuzu engine has become a key feature of JS excavators. The new auto JS 20 tonne machines are fitted with the latest Tier II Isuzu 102kW engine, giving 7% more power than the outgoing XO machines. Isuzu is probably best known for it’s reliability, durability and fuel efficiency and throughout testing the new engine combined with the high performance hydraulics provided exceptionally high fuel efficiencies. The simplicity of the mechanically fuelled system, is seen as an advantage in the industry where users already understand the system.

DIG END SPEED

The auto machine is faster than it’s predecessor. The hydraulic pressure and flow have increased, giving faster boom up and dipper in/out movements without sacrificing breakout forces which have also increased. The excavator is also faster and more powerful.

% Improvement

Excavator End Speed

Bucket

Dipper

Boom

JS Auto

JS XO

In

(crowd)

2.8 seconds

2.8 seconds

0%

Out

(Dump)

2.2 seconds

2.2 seconds

0%

In

3.1 seconds

3.6 seconds

14%

Out

2.6 seconds

2.9 seconds

10%

Up

3.7 seconds

3.9 seconds

5%

Down

3.2 seconds

2.5 seconds

-21%

Note: The lift ram size (diameter) on both the JS auto and JSXO are the same. However, the hydraulic flow and hydraulic pressure increase by around 8.5% on the new generation machines.


3

0 4 / 0 3 N E W V O L D


SLEW PERFORMANCE

Slew performance on the JS auto has been substantially improved over the JS XO. Speed has increased by 7.5% and slew torque is 3.5% higher. JS XO machines were always known to have high performance. The latest improvements increase productivity and give greater slew slope capability.

JS Auto

JS XO

Slew motor displacement

151 cc/rev

151 cc/rev

Slew speed

12.9 rpm

12.0 rpm

Slew pressure

289.4 bar

279.4 bar

Slew torque

62908Nm

60778Nm

PRODUCTIVITY OVERVIEW

Performance of the JS auto machine range has improved dramatically, due to higher hydraulic flows and pressures, a more powerful engine and the latest improved intelligent Advanced Management System. Auto digging mode selects power boost automatically and the amount of movement on the hydraulic joysticks the power from pumps and engine. The auto system is simple to use and ensures maximum efficiency. D L O V W E N 3 0 / 7 0

Trenching Overview Comparisons between the Auto and XO machines have been conducted. Ground condition on the test site proved difficult to accurately assess the actual productivity, however the overall perception of the new machine from customer evaluations and JCB’s own operators is that it is much quicker and easier to bottom the trench.

Truck Loading Overview The results for this test were obtained by each machine loading 4 trucks with sand / gravel material on level ground. The average results between the 4 loads were used to evaluate machine loading performance. Both machines were loading from a 2/3 meter depth and slewing through 180 degrees. Results were all based on a 100% fill factor and a 60min hour.

Tonnes per Hour (JS Auto)

Productivity (JS XO)

% Improvement

547

492

11.0%

20.5 t/ltrs

7.5%

Tonnes Moved per Litre

22 t/ltrs

Truck Loading Productivity The Auto machine’s hourly production was 55t/hr more that the XO machine. The auto machine’s overall efficiency i.e. tons p er litre proved to be higher by over 7%.

4



HYDRAULIC OVERVIEW

Clearly the auto machine has improved visually and cosmetically. Another significant improvement is on the hydraulic system. The way the Advanced Management System controls the system has been improved to m ake the machine more efficient. The following information highlights the changes made to the hydraulics and compares the changes between the JS Auto and the JS XO. Focus on the following:

- Hydraulic flow increased all work modes. - Hydraulic power increased all work modes. - Hydraulic pressure increased. - Hydraulic draw-bar pull.

Hydraulic Work Modes Auto Range

- 100% hyd flow

A - Auto

XO Range H - Heavy

- 1950rpm

- 1950rpm

- Hyd power 95kW

- Hyd power 90kW

- Power Boost automatic

- Power boost,- manual

- Senses power requirement and adjusts


engine and hydraulic power accordingly.

- 95% hyd flow

boost 314bar) S – Standard

- 80% hyd flow

- 1850rpm

- 1850rpm

- Hyd power 77kW

- Hyd power 73kW



(No pressure boost) - 90% hyd flow

P - Precision

0 7 / 0 3 N E W V O L D

with pressure boost (No power

- Maximum hyd pressure 373bar E - Economy

- 100% hyd flow

with pressure boost L – Light

- 58% hyd flow

- 1750rpm

- 1750rpm

- Hyd power 53kW

- Hyd power 43kW

- Maximum hyd pressure 343bar - 63% hyd flow

L - Lifting

F - Fine ( For Lifting)

58% hyd flow

- 1750rpm

- 1750rpm

- Hyd power 53kW

- Hyd power 43kW

- Maximum pressure 373bar

- Maximum pressure 343bar

- Maximum hyd pressure 343bar-




Track motor displacement

153.4cc/rev

143.5cc/rev


Bucket, dipper and boom

Dipper

Boom / slew priority

Standard

Optional

Cushion control

Standard

Standard

Tracking

(Prevents cavitations and increases boom down, arm in and bucket in speed)


5


Hydraulic Performance Specification & Comparison

D L O V W E N 3 0 / 7 0

New

Old

% Improve

Dipper arm cylinder diameter

130mm

135mm

Pressure

373 bar

343 bar

Breakout Arm force (Medium)

12550kg

12045kg

Bucket cylinder diameter

115mm

120mm

Pressure

380 bar

350 bar

Tearout Force

15800kg

12710kg

Swing flow

214 lpm

200 lpm

Swing motor displacement

151cc/rev

151 cc/rev

Swing speed

12.9 rpm

12.00 rpm

7.5%

Swing pressure

289.4 bar

279.6 bar

3.5%

Swing torque

62908Nm

60778Nm

3.5%

Track motor displacement

153.4 cc/rev

143.5 cc/rev

6.9%

Track pressure

343 bar

343 bar

Gearbox ratio

49.5

49.5

Tractive effort

191.1 KN

185.7KN

3%

Engine power

102 Kw

95 Kw

7.3%

Max pump flow

428 lpm

392 lpm

7%

Max pressure

373 bar

343 bar

8.7%

Dipper arm in time

3.4s

4.0s

15%

Dipper arm out time

2.6s

2.9s

10%

Boom up time

3.7s

3.9s

5%

Boom down time

3.2s

2.5s

Bucket dig time

2.8s

2.8s

0%

Bucket open time

2.2s

2.2s

0%

SFC

235 g/KW.h

243 g/KW.h

3.3%

SFC x power

23.970

23.085

(102Kw)

(95Kw)

4.1%

24.3%

Production

Fuel consumption

lower

Note - Fuel consumption. The auto machine engine uses slightly less fuel under test bench conditions. However, due to the increase in power output, the engine uses slightly more than the 95kw motors. Therefore the only true a nalysis for fuel consumption is by measuring tonnes moved by litres used. The new auto machine is more powerful and more fuel efficient in a real working environment.

6



UNDERCARRIAGE OVERVIEW

Larger displacement track motors on the new auto machine, result in 7% more drawbar pull. Narrow & Long undercarriages continue to be available. All JCB’s undercarriages are built to a heavy duty European specification. The running gear and hydraulic motors are of the finest quality, built with durability and reliability in-mind.

Undercarriage Options 3 track gauge options continue to be available:

JS200 JS220

JS210

– NC = 1990mm, – SC = 2200mm. – LC = 2390mm. – LC = 2200mm.

EXCAVATOR OVERVIEW

Structurally the boom and dippers remain the same. Significant improvements have been made to the boom base bushes and boom to dipper bushes. Bronze alloy bushes with graphite plugs are used allowing greasing interval to increase from 50 hours to 1000 hours. Choice of Monoboom or Triple Articulation Boom (T.A.B.) heavy-duty specification.

0 7 / 0 3 N E W V O L D

Choice of dipper lengths: - 1.9M arm - 2.4M arm - 3.00M arm All hydraulic auxiliary circuits – hammer auxiliary, low flow, etc remain available. All dippers are fitted with quick hitch pipework clamp bases as standard.


7


CAB AND CONTROLS OVERVIEW - EASE OF USE AND OPERATOR COMFORT

When designing the latest excavators, performance, reliability and operator comfort were three key priorities. The operator’s perception and acceptance of any machine is fundamental in achieving the key objectives. Different working condition demand different features i.e. cold, heat, rain, dirt, dust, corrosive substances, noise and lighting conditions are just a few examples that need to be considered to minimise operator fatigue and maximise safety and productivity. The following improved features have been designed to benefit all working environments. All the controls are functional and designed for simplicity.

Advanced Management System JS AUTO AMS

JS XO AMS

D L O V W E N 3 0 / 7 0

NEWVOLD0004

NEWVOLD0003 Adjustable AMS Monitor

Fixed AMS monitor



A – Auto

H – Heavy

E – Economy

S – Standard

P - Precision

L - Light

L – Lifting

F - Lifting

The AMS has been improved to make life easier for the operator and increase efficiency. In auto mode, the system selects the engine and pump output to match conditions.

8



Cabin and Controls

JS AUTO CABIN AND CONTROLS

JS XO CABIN AND CONTROLS

NEWVOLD0005

NEWVOLD0006

- Improved cab layout. - Switches and control panel are easier to see and use. - Smaller door for easier closing. - New heater and air-conditioning unit developing 56% more airflow.

0 7 / 0 3 N E W V O L D

- Optional full climate control air-conditioning. - Interior lamp with timer switch assists access to the cab. - Flat floor with no door lip – easy clean. - Document storage pocket. - Mobile telephone holder and 12v charger point. - Optional deluxe air suspension seat with heated pod and adjustable lumber support. - Radio mute switch cuts off radio to improve communication.

J S AUTO AMS

JS XO AMS

NEWVOLD0007

NEWVOLD0008

All switches are at ha nd and can be seen and controlled with the arms rest down. This communication and the information within is intended for JCB and JCB dealer personnel only, for information purposes, is confidential and may not be communicated to any third party. Whilst the information is believed to be correct, no guarantee is given by JCB as to its accuracy and its use may not be attributed to JCB.

9


Tracking Control JS AUTO TRACK CONTROL

NEWVOLD0009

JS XO TRACK CONTROLS

NEWVOLD0010

Improved footrest position.

Track speed control located on the floor – left side.

Cleaner floor space.

Operator often needs to change from foot to hands when

Track speed control removed from floor position and relocated

tracking to enable track speed to be changed.

in the right side joystick. Easier to operate and D L O V W E N 3 0 / 7 0

better controllability. Hammer and TAB pedals are better located - close to the track pedals.

Visibility - right side window JS AUTO VISIBILITY (RIGHT SIDE WINDOW)

NEWVOLD0011

JS XO VISIBILITY (RIGHT SIDE WINDOW)

NEWVOLD0012

The visibility from the cabin to the right side track has improved d ramatically.

10



In-cab Storage JS AUTO IN-CAB STORAGE

NEWVOLD0013

JS XO IN-CAB STORAGE

NEWVOLD0014

- Improved in-cab storage box with latch to keep closed. - Air conditioning vents included to cool contents i.e. drinks etc

0 7 / 0 3 N E W V O L D


11


Visibility through the skylight JS AUTO SKYLIGHT

JS XO SKYLIGHT

NEWVOLD0015

NEWVOLD0016

Vision to the excavator / attachment has been improved. Larger glass area.

D L O V W E N 3 0 / 7 0

NEWVOLD0017

NEWVOLD0018

NEWVOLD0019

NEWVOLD0020

The wiper motor is now mounted on the left side as opposed to the centre of the screen.

12



Visibility through the rear JS AUTO REAR VISIBILITY

JS XO REAR VISIBILITY

NEWVOLD0021

NEWVOLD0022

The new low-level bonnet provides excellent visibility to the rear. Rear vision has improved by 36% when viewing 1mtr obstacle.

Serviceability JS AUTO ENGINE ACCESS

0 7 / 0 3 N E W V O L D

JS XO ENGINE ACCESS

NEWVOLD0023

NEWVOLD0024

- Light and easy to open / close.

IP67 electrics.

- Excellent service access.

Twin oil filter.

- IP69 electrics - more durable / reliable.

Require 100-hour first service.

- Single oil filter. - 100-hour first service removed.


13


JS AUTO OIL CHANGE

JS XO OIL CHANGE

NEWVOLD0025

NEWVOLD0026

- Swing down plate to access oil drain.

Bolt on cover plate to remove.

- Single filter to replace.

Twin filters to replace.

- Oil drainpipe supplied and stored in the toolbox. Screwing the

No oil drainpipe.

pipe to drain hole allows the oil to flow without spillage.

D L O V W E N 3 0 / 7 0

NEWVOLD0027 JS Auto Walkway Grippers

NEWVOLD0028

JS XO Walkway Grippers

NEWVOLD0029

Durable and functional in all weather conditions. (Electro phosphate dipped) 14




CRAWLER EXCAVATORS BASIC SPECIFICATION COMPARISON

JS200L XO

JS200L AUTO

JS220L XO

JS220L AUTO

JCB

JCB

JCB

JCB

JS 200 L

JS200L

JS 220 L

JS220L

Make

Isuzu

Isuzu

Isuzu

Isuzu

Model

A-6BG1TQB-04

BB-6BGIT

A-6BG1TQB-04

BB-6BGIT

6.494

6.494

6.494

6.494

Turbo.

Turbo.

Turbo.

Turbo.

No

No

No

No

KEY SPECIFICATIONS Manufacturer Model ENGINE

Displacement

ltr

Aspiration Aftercooled Rated speed

rpm

1950

1950

1950

1950

Net power

kW / hp

95 / 128

102 / 138

95 / 128

102 / 138

SAE J1349

SAE J1349

SAE J1349

SAE J1349

Var. piston

Var. piston

Var. piston

Var. piston

2

2

2

2

ltr/min

2 x 196

2 x 214

2 x 196

2 x 214

Hydraulic Pressure (Max)

Bar

343

373

343

373

Hydraulic power (Auto mode)

kW

90

95

90

95

Hydraulic power (Economy mode)

kW

73

77

73

77

Hydraulic power (Precision mode)

kW

43

53

43

53

Hydraulic power (Lifting mode)

kW

43

53

43

53

ltr/min

20

20

20

20

Hydraulic

Hydraulic

Hydraulic

Hydraulic

Rating standard HYDRAULIC SYSTEM Main pump type No. of main pumps Main pumps-max. flow

Pilot pump - flow

0 7 / 0 3 N E W V O L D

SWING SYSTEM Slew brake - dynamic Swing speed

rpm

11.9

12.9

11.9

12.9

Swing torque

Nm

60778

62908

60778

62908

Yes

Yes

Yes

Yes

2/8

2/8

2/8

2/8

49

49

49

49

2,390

2,390

2,390

2,390

Automatic

Automatic

Automatic

Automatic

UNDERCARRIAGE Sealed track No. of top /bottom rollers per side No. of shoes Track gauge - std.

mm

TRACK DRIVE Service brake actuation Travel speeds

km/h

2.3 / 3.3 / 5.5

2.3 / 3.3 / 5.6

2.3 / 3.3 / 5.5

2.3 / 3.3 / 5.6

Gradeability

°/%

35 / 78

35 / 78

35 / 75

35 / 75

kN

185.7

191.9

185.7

191.9

Tractive effort


15


JS200L XO

JS200L AUTO

JS220L XO

JS220L AUTO

STATIC DIMENSIONS Superstructure width

mm

2,500

2,500

2,500

2,500

Ground clearance

mm

486

486

486

486

Track gauge

mm

2,390

2,390

2,390

2,390

Width over std. Tracks (600mm)

mm

3,090

3,090

3,090

3,090

Fuel

ltr

310

343

310

343

Engine oil

ltr

19.5

21.51

19.5

21.51

Hyd. tank / system capacity

ltr

120 / 200

120 / 200

120 / 200

120 / 200

3

3

3

3

CAPACITIES

DIPPER OPTIONS Number of dippers Dipper length XS / S

mm

- / 1910

- / 1910

- / 1910

- / 1910

Dipper length M / L

mm

2400 / 3000

2400 / 3000

2400 / 3000

2400 / 3000

kgf

12040

12550

12040

12550

kgf

12710

15800

12710

15800

Mono 5.70 / 2.40

Mono 5.70 / 2.40

Mono 5.70 / 2.40

Mono 5.70 / 2.40

DIPPER TEAROUTS Dipper tearout - std/boost - M (ISO) BUCKETS Bucket breakout (ISO) TRANSPORT DIMENSIONS Monoboom / standard dipper D L O V W E N 3 0 / 7 0

Transport length

mm

9560

9560

9560

9560

Transport height

mm

3060

3060

3060

3060

Standard weight

kg

20,690

20,870

22,155

22,172

Counter weight

kg

3700

3700

5000

5000

ISO 10567

ISO 10567

ISO 10567

ISO 10567

Mono 5.70 / 2.40

Mono 5.70 / 2.40

Mono 5.70 / 2.40

Mono 5.70 / 2.40

kg

6906

7040

8039

8040

kg

4489

4430

5219

5220

MACHINE WEIGHTS

LIFTING Rating standard Monoboom 1 / standard dipper Over end (No bucket) Lift at 6.0m ground level reach Full circle (No bucket) Lift at 6.0m ground level reach

16


Contents

Section 7. PRODUCTIVITY AND MACHINE SIZING

1. Introduction. - The Basics.

2. Selecting A Machine. - Machine Bucket Productivity. - Estimating Production Rate.

3. Standard Cycles Per Hour. - Standard Cycle Times. - Operating Efficiency.

4. Conversion For Slew Angle and Dig Depth. - Production Rate A Worked Example.

5 Summary of Formulae.

6. Maximising Production. - Optimum B ench Height And Truck distance. - Optimum Work Zone and Slew Angle. - Optimum Distance From Edge.

Productivity and Machine Sizing

MACHINE BUCKET PRODUCTIVITY

INTRODUCTION The purpose of this section is to help you select the most effective combination of machine and bucket for a particular earthmoving task. First, it is worth remembering what is meant by 'earthmoving'. To begin with, let's look at 'earth'. It could actually be topsoil, gravel, clay, sand, slag, iron ore... in fact any (mostly natural) material situated in or on the ground. The material could be 'banked' (i.e. in its natural state as part of the earth's surface), 'swelled' (its state after it has been disturbed from the earth and loosened) or compacted. Each of these states gives a different density to the material and therefore affects the amount which can be carried by a machine/bucket combination. So what about 'moving'? Well, this could involve either digging the material out of the ground or gathering it from a pile, and then depositing it in another place. The 'other place' could itself be a hole or a p ile or some kind of vehicle (truck, railway w agon etc.) to transport the material further afield. Due to its relatively low travel speed, an excavator is not realy suitable for transporting excavated material over any great distance. In fact it is specifically designed to work best within its own 'arm's length'. An excavator, of course, is only an y use once it has been equipped with a bucket, or some other device such as a grab or rockbreaker. We are concerned in this section only with buckets. There are different buckets to suit different situations; wide buckets, narrow buckets, light duty buckets, heavy duty buckets, buckets for soft materials, buckets for hard materials and so on. It is important that the most appropriate bucket is chosen for the job in hand. The choice of machine and bucket is determined by the exact nature of the job. But whatever the job, the objective must always be to select the combination which gives the greatest hourly production rate. In other words, you must find the combination which can move the most earth in the fastest time. And in the rest of this section you will find guidance on how to do just that.

A Note about Compacted Materials: Due to the variety of densities that can occur through compaction, no data is shown in this section for Compacted materials. To find the density etc. of compacted materials the ground should be tested as indicated in "Unlisted Materials".

THE BASICS The aim of this section is to help guide your customer towards the most cost effective JS machine/bucket combination for a particular application. At first glance the following pages may seem a little daunting; but it is basically only a matter of selecting the appropriate data from the tables then using that data in a few simple calculations.

Method 1. Assuming you know roughly the nature of the proposed application you will almost certainly be able to produce a shortlist of probable machines, using the information in the Specification Sheet. 2. Then you will need to look in more detail at the job itself: e.g. the type of material, the amount of material, the state of the material, the timescales, site conditions, truck sizes and so on. Your client may well have this information to hand, or you may need to help him obtain it using information from Machine/Bucket Productivity using the form and explanatory notes given.


1

0 7 / 0 3 E X C P R O D


SELECTING A MACHINE

In one sense, selecting a machine for a given job is more straighforward than selecting the bucket itself. After all, while there are literally hundreds of buckets to choose from, the choice of machines is far less. It's not quite as simple as that of course, because for most JCB machines you can select different dipper lengths. Obviously, bucket capacity range, dig depth and reach will be the main determining factors here. The JZ70 is also available with an Offset Boom, while the JCB wheeled excavators, the JS130, the JS220 and the JS260 with a Triple Articulated Boom (TAB). These options may be desirable where access to the actual digging area is restricted. The JCB JS220LR is available as a 'river rig'. IMPORTANT: When selecting a machine you must ensure that it can safely handle the maximum Filled Bucket Weight likely to be encountered during the job. This will reduce the risk of 'overbucketing' the machine. Overbucketing can cause overstressing of components, increased cycle times (see later) and machine instability. 'Underbucketing' - selecting a larger than necessary machine for the Filled Bucket Weight - will on the other hand result in an expensive offer to your customer. You will need to study the machine recommended bucket sizes and maximum lift capacities before making a choice.

2 - MACHINE / BUCKET PRODUCTIVITY D O R P C X E 3 0 / 7 0

ESTIMATING PRODUCTION RATE Once you have selected a machine/bucket combination you can set about estimating the production rate. Production rate depends on:

A

Bucket Capacity

B

Fill Factor

C

Standard Cycles per Hour

D

Operating Efficiency

E

Conversion for Slew Angle and Dig Depth

The production rate is determined by multiplying the Bucket Capacity, Fill Factor, Work Cycle Time and Operating Efficiency together then dividing the result by the Conversion Factor for Slew Angle. In other words:

Production rate (m 3 /hr) = A x B x C x D E

We have already dealt with items A and B in the formula; so now we need to understand the other factors.

2


Productivity Producti vity and Machine Sizing

STANDARD CYCLES PER HOUR Every excavator has what is known as a Standard Cycle Time. This is the time taken to complete one cycle of machine operation, i.e. the time it takes to excavate one bucket load then slew the machine round, discharge the load and slew back ready to gather the next load.

Cycle Time = Excavating time + Slew time (loaded) + Dump time + Slew time (empty) Standard Cycle Times for JCB excavators are given in the following table. The times stated in the table have been arrived at based on the following assumptions: • The machine is working under average conditions. • Slew angle is between 45° and 90°. • Dig depth is upto 75% of maximum. • Dumping at ground level.

So for a particular machine you can easily work out the Standard Cycles per Hour - e.g. for the JS200L: 0 7 / 0 3 E X C P R O D

Standard Cycles per Hour = 3600 (secs in 1 hr) 14 (from table) = 257

OPERATING EFFICIENCY

STANDARD CYCLE TIMES

MODEL

SECONDS

CYCLES/HR

The phrase 'Standard Cycles per Hour' assumes that all 3600 seconds (60 minutes) will actually be spent working. In real life,

JZ70

12

300

JS130

13

277

reduce the actual amount of time spent excavating. Weather,

JS160 / JS180

14

257

traffic holdups, bucket changes, blasting..... all these a nd other

JS200 / 210 / 220

14

257

factors can reduce the actual number of cycles which can be

JS240 / 260

16

225

achieved in an hour hour..

JS330

16

225

JS460

18

200

JS130W / JS145W

13

277

100%). Under bad conditions the work rate could drop to 45

JS160W / JS175W

14

257

minutes per hour (75%) or even less. Since this is an important

JS200W

14

257

factor in the Production calculation you will need to agree a

of course, all manner of things occur during the working day to

In normal conditions, work rate is calculated on the basis of 50 productive minutes per hour -i.e. 83% efficiency (50/60 x

figure for Operating Efficiency with your client.

This communication and the information within is intended for JCB and JCB dealer personnel only, for information purposes, is confidential and may not be communicated to any third party. Whilst the information is believed to be correct, no guarantee guarantee is given by JCB as to its accuracy and its use may not be attributed to JCB.

3


CONVERSION FOR SLEW ANGLE AND DIG DEPTH The final factor in the Production Calculation concerns the adjustment you need to make to account for the dig depth and the slew angle. The slew angle is the angle which the machine's turntable needs to traverse between gathering a load and dumping it. (Remember that the Standard Cycle Times quoted for excavators are based on assumed dig depths and slew angles. This conversion factor merely adjusts the calculation to take into account the actual figures). The conversion factors for different dig depths and slew angles are given in the table below. (Note that these figures will increase if dump height is above ground level).

SWING ANGLE ( DEG DEG ) DIG DEPTH

LESS THAN 45°

TO 90°

TO 135°

OVER 135°

Less than 40%

0.80

0.85

0.95

1.05

Less than 75%

0.95

1.00

1.10

1.20

Over 75%

1.10

1.15

1.25

1.40

Since this factor ('E' in the formula) occurs 'below the line' a lower number will give a higher production rate, while a higher number will reduce the production rate. It follows that wherever possible the excavating job should be organised to keep dig depth and slew angle to the minimum. See ' Maximising Production' at the end of this section for advice on how to do this.

D O R P C X E 3 0 / 7 0

PRODUCTION RATE - A WORKED EXAMPLE

What is the estimated output of a JS200L excavating banked dry earth into a truck positioned level with the excavator, excavator, assuming: Bucket Capacity (A)

= 1.1 m3

Fill Factor (B)

= 95% (i.e. 0.95)

Standard Cycles per Hour (C)

= 257

Operating Efficiency (D)

= 83% (i.e. 0.83)

Conversion Factor for Slew Angle and Dig Depth (E)

= 1.4

Output (m 3 /hr)

=AxBxCxD E = 1.1 x 0.95 x 257 x 0.83 1.4 = 159.2 m3 /hr

So for an eight hour working day:

Daily output = 8 x 159.2 = 1274 m3 Note that this is the Loose volume.

Banked Volume (Loose Volume/Swell Factor) = 1274 m3 1.25 (from table)

Total Weight (Volume x Density) = 1019 x 1900 (from table) = 1,936,100 kg = 1,936.1 tonnes

= 1019

4

m3


Productivity Producti vity and Machine Sizing

SUMMARY OF FORMULAE

Here is a reminder of the formulae discussed throughout this section. It is worth b ecoming familiar with each of them and, more importantly, understanding the principles behind them.

Swell Factor = Loose Volume Banked Volume

To find the Loose Density divide the Banked Density by the Swell Factor and

To find the Banked Density multiply the Loose Density by the Swell Factor

To Find the Loose Volume multiply the Banked Volume by the Swell Factor and

To find the Bank Volume divide the Loose Volume by the Swell Factor

0 7 / 0 3 E X C P R O D

Cycle Time = Excavating Time + Slew Time (loaded) + Dump Time + Slew Time (empty)

Production rate (m 3 /hr) = A x B x C x D E where:

A Bucket Capacity B Fill Factor C Standard Cycles per Hour D Operating Efficiency E Conversion for Slew Angle and Dig Depth


5


MAXIMISING PRODUCTION The following shows how production for a particular job can be maximised by positioning the excavator and truck to best effect. Job sites and work situations vary, of course, but if these principles are applied wherever possible, production will be increased.

Optimum Bench Height and Truck Distance When excavating stable Banked materials, bench height should be as close as possible to dipper length. For less stable materials it ought to be less. The most effective position for the truck is with the inside truck body rail directly below the boom/dipper pivot as shown.

Optimum Work Zone and Slew Angle Ideally, the slew angle should not be more than 15° either side of the machine centreline (or roughly equal to the width of the undercarriage). Trucks should be stationed as close as possible to the machine centreline.

D O R P C X E 3 0 / 7 0

Optimum Distance From the Edge The most effective position is when the dipper is vertical when the bucket reaches full load. This position ensures maximum breakout force and minimum time spent returning the dipper. (Of course, if the machine gets any closer to the edge there will be a risk of undercutting). For greater efficiency the operator would start raising the boom when the bucket is approx. 75% through its 'crowd' cycle - i.e. as the dipper approaches the vertical.

6


Contents

Section 9. MATERIAL DENSITIES, VOLUMES AND WEIGHTS

1. Introduction.

2. Banked Versus Loose. – The Swell Factor. - Machine And Bucket Selection.

3. Unlisted Materials.

4. Material Density.

5. Material Density (continued).

6. Bucket Productivity.

7. Types Of Bucket.

8. Fill Factor Of The Material. – Filled Bucket Weight.

9. Filled Bucket weight (continued).

Material Densities, Volumes and Weights

INTRODUCTION

Before you can choose a machine/bucket combination you will need to know, quite accurately, the volume and weight of material being 'moved'. At first glance, this might seem quite simple - just multiply the area of the site by the dig depth to find the volume, then find the weight by looking up a table of material densities. Unfortunately it is not quite as simple as that. You will find a table of material densities at the end of this section. If you study it you will see that for most materials listed there are two or perhaps three density figures. This is because most of the materials can be in any one of three states: 'Banked', 'Loose', or 'Compacted'. Banked describes the state of the material as it lies, undisturbed, as part of the earth's surface. Loose is what banked material becomes when it is disturbed from the earth's surface - i.e. when it is dug up (in the case of soils) or broken

away (in the case of rock). Compacted speaks for itself. It describes the state of the material when it has been compressed, say by a roller.

Material density and volume can increase considerably between the Banked and Loose states. Dig a 10m 3 hole and you will find that you have got somewhat more than 10m3 pile of earth beside it. What has happened, of course, is that the state of the soil has changed from Banked to Loose. And in the process it has become less dense.

0 7 / 0 3 E X C M A T

In the earthmoving industry, material quantities are generally stated in 'Bank Cubic Metres'. But since, depending on the job, the material state can shift between Banked and Loose you need to know the exact relationship between these two conditions. *In practice, mathematical 'exactness' is impossible to achieve. The materials we are dealing with are natural, rather than man-made, and are not uniform in their texture. And even if they were, other factors, especially dampness, can cause them to change density and upset the most painstaking calculations, All anyone can do is to use their knowledge, experience and available reference material to achieve as honest an estimate as possible.


1


BANKED VERSUS LOOSE - THE SWELL FACTOR If you look at the table on page 18 at say, Basalt, you will see a density for Loose, a density for Banked and a figure for 'Swell Factor'. It is the Swell Factor which defines the relationship between the two densities for that material - i.e. between Banked and Loose. Like all other similar tables the figures have been arrived at by sampling and measurement and will give a good degree of accuracy in your estimates (but please read the notes at the bottom of the table!). You can check the relationship yourself, if you've got a calculator to hand:

To find the Loose Density divide the Banked Density by the Swell Factor

and To find the Banked Density multiply the Loose Density by the Swell Factor

2 - MACHINE AND BUCKET SELECTION BANKED VERSUS LOOSE - THE SWELL FACTOR (cont'd) T A M C X E 3 0 / 7 0

Try it with the figures for Basalt (you will find that a little rounding out has been done, to keep the numbers looking sensible).

BANKED

SWELL FACTOR

LOOSE

2970 / 1.52 = 1990 and 1990 X 1.52 = 2970

LOOSE

SWELL FACTOR

BANKED

Remembering that density is the weight per unit volume you can apply the same principle to find how the volume changes between Banked and Loose. For a given weight of material:

To find the Loose Volume multiply the Bank ed Volume by the Swell Factor

conversely: To find the Banked Volume divide the Loose Volume by the Swell Factor

2



Take Sandstone for example:

BANKED

SWELL FACTOR

10 m 3 x 1.67 = 16.7 m

LOOSE

3

and 10 m 3 / 1.67 = 5.98 m

LOOSE

SWELL FACTOR

3

BANKED

UNLISTED MATERIALS If you are dealing with a material which is not listed here (or in other available density tables) you can do the following: 1 Excavate a sample from the bank. 0 7 / 0 3 E X C M A T

2 Calculate the volume of the hole. 3 Weigh the removed sample.

Banked Density

4 Calculate the Bank Density (weight / hole volume).

Loose Density

5 Determine the volume of the removed (Loose) material. 6 Calculate the Loose Density (weight / material volume).

Swell Factor

7 Calculate the Swell Factor (Loose Volume / Banked Volume). IMPORTANT: To achieve maximum accuracy you must take many samples from around the site and use the averages of all the calculated results. Also remember that results can be altered by excessive dryness or wetness of the material.


3


MATERIAL DENSITY

MATERIAL

LOOSE Kg/m

3

BANKED lb/yd

3

Kg/m

3

SWELL FACTOR lb/yd

3

Basalt

1960

3300

2970

5000

1.52

Bauxite, Kaolin

1420

2400

1900

3200

1.33

Calicho

1250

2100

2260

3800

1.82

Carnotite, uranium ore

1630

2750

2200

3700

1.35

Cinders

560

950

860

1450

1.52

Clay - Natural bed

1660

2800

2020

3400

1.22

Clay - Dry

1480

2500

1840

3100

1.23

Clay - Wet

1660

2800

2080

3500

1.25

Clay & Gravel - Dry

1420

2400

1660

2800

1.18

Clay & Gravel - Wet

1540

2600

1840

3100

1.18

Coal - Anthracite, Raw

1190

2000

1600

2700

1.35

Coal - Anthracite, Washed

1100

1850

560-650

900-110

590-890

1000-1500

1.08

75% Rock, 25% Earth

1960

3300

2790

4700

1.43

50% Rock, 50% Earth

1720

2900

2280

3850

1.33

25% Rock, 75% Earth

1570

2650

1960

3300

1.25

Earth - Dry Packed

1510

2550

1900

3200

1.25

Earth - Wet excavated

1600

2700

2020

3400

1.27

Earth - Loam

1250

2100

1540

2600

1.23

Granite - Broken

1660

2800

2730

4600

1.64

Gravel - Pitrun

1930

3250

2170

3650

1.12

Gravel - Dry

1510

2550

1690

2850

1.12

(1 /4 in - 2 in)

1690

2850

1900

3200

1.12

Gravel - Wet 6-50mm (1 /4 in - 2 in)

2020

3400

2260

3800

1.12

Gypsum - Broken

1810

3050

3170

5350

1.75

Gypsum - Crushed

1600

2700

2790

4700

1.75

1810-2450

4000-5400

2130-2900

4700-6400

1.18

Limestone - Broken

1540

2600

2610

4400

1.69

Limestone - Crushed

1540

2600

Magnetite, iron ore

2790

4700

3260

5500

1.18

Pyrite, iron ore

2580

4350

3030

5100

1.18

Sand - Dry, Loose

1420

2400

1600

2700

1.12

Sand - Damp

1690

2850

1900

3200

1.12

Sand - Wet

1840

3100

2080

3500

1.12

Sand and Clay - Loose

1600

2700

2020

3400

1.27

Sand and Clay - Compacted

2400

4050

-

-

-

Sand & gravel - Dry

1720

2900

1930

3250

1.12

Sand & gravel - Wet

2020

3400

2230

3750

1.10

Sandstone

1510

2550

2520

4250

1.67

Shale

1250

2100

1660

2800

1.33

Ash, Bituminous Coal

1.35

Decomposed rock -

T A M C X E 3 0 / 7 0

Gravel - Dry 6-50mm

Hematite, iron ore, high grade

4



MATERIAL DENSITY

(cont)

MATERIAL

LOOSE Kg/m

3

BANKED lb/yd

Slag - Broken

1750

2950

Snow - Dry

130

220

Snow - Wet

520

860

Stone - Crushed

1600

Taconite

3

Kg/m

3

SWELL FACTOR lb/yd

3

2940

4950

1.67

2700

2670

4500

1.67

1630-1900

3600-4200

2360-2700

5200-6100

1.72

Top Soil

950

1600

1370

2300

1.43

Taprock - broken

1750

2950

2610

4400

1.49

• Varies with moisture content, grain size, degree of compaction, etc. Tests must be made to determine exact material characteristics.

0 7 / 0 3 E X C M A T


5


BUCKET PRODUCTIVITY

SELECTING A BUCKET BUCKET CAPACITY RATING There are two methods of describing bucket capacity - Struck Capacity and Heaped Capacity. Struck Capacity indicates the volume capacity of the bucket when 'struck at the strike plane'. This is like levelling off a heaped teaspoonful with the back of a knife. The 'strike plane' of a bucket passes through the top back edge to the cutting edge.

T A M C X E 3 0 / 7 0

Heaped Capacity is the struck capacity plus the volume of heaped material above it, assuming a certain 'Angle of Repose' (see diagram). There are four main standards for defining Heaped Capacity. The only significant difference between them is the Angle of Repose.

Angles of Repose for Heaped Capacity Rating (Buckets) JIS

PCSA

SAE

CECE

1:2

1:1

1:1

1:2

JIS

Japanese Industrial Standard - JIS A8401 - 1976

PCSA

Power Crane and Shovel Association (USA) - PCSA No. 37-26

SAE

Society of Automotive Engineers (US) - SAE J296/J742b

CECE

Community of European Construction Equipment - CECE SECTION VI

JCB define bucket volume by Heaped Capacity, using the SAE standard.

6



TYPES OF BUCKET Bearing in mind the basic objective of moving the most material in the shortest time, you will need to consider a number of factors when selecting the most appropriate bucket: Hardness of the Material to be Excavated.* Fill Factor of the Material. Filled Bucket Weight.

*Obviously this factor only applies when Banked or Compacted material is to be excavated. If the job involves only Loose material (e.g. when loading a truck from a pile) you need only consider the other two factors.

HARDNESS OF THE MATERIAL TO BE EXCAVATED Some buckets are more suitable for hard or rocky materials, while others are best suited for softer materials. It is basically a matter of geometry, involving the bucket's width and its 'tip radius'. Common sense will tell you that narrow buckets would be best for hard materials. With a narrow bucket the excavator's digging forces are

NARROW

WIDE

(HARD MATERIALS)

(SOFT MATERIALS)

0 7 / 0 3 E X C M A T

applied over a smaller area, so the pressure applied by the bucket's teeth will be higher, giving the greater penetration force needed. Softer materials can be excavated using a wider bucket. Tip radius is another way of describing the working length of the bucket, from pivot to tooth tip. It is fairly obvious that a shorter tip radius (i.e. a shorter bucket) will create a higher digging force than one with a long tip radius. It's a matter of leverage. To summarise: For Harder materials select a narrower bucket with a shorter tip radius. For softer materials you can use a wide bucket with a longer tip radius.


7


FILL FACTOR OF THE MATERIAL The amount of material (by volume) that a bucket can carry is determined by the bucket's capacity and shape plus the Fill Factor of the material. The Fill Factor of a material is a measure of its ability to form a heap (specifically in a bucket). If you look at the table you will see that Moist Loam or Sandy Clay has a high Fill Factor. At the other extreme, Poorly Blasted Rock has a very low Fill Factor. Obviously materials with a low Fill Factor would be most efficiently handled by a larger bucket. MATERIAL

FILL FACTOR RANGE (PERCENT OF HEAPED BUCKET CAPACITY)

Moist Loam or Sandy Clay

A - 100-110%

Sand and Gravel

B - 95-110%

Hard, Tough Clay

C - 80-90%

Rock - Well Blasted

60-75%

Rock - Poorly Blasted

40-50%

FIILLED BUCKET WEIGHT

T A M C X E 3 0 / 7 0

The filled weight of the bucket is obviously the weight of the bucket plus its contents. The weight of the contents is determined by its density and Fill Factor, and so varies between materials. The weight of the bucket itself is obviously constant. As the Filled Weight of the bucket increases, the load on the machine's hydraulic system also increases. This will tend to reduce the speed of operation and therefore affect the overall efficiency of the job (more of this later). And, of course, the machine's stability will also be affected: as the filled weight increases the machine will get closer to its stability limits (see Specification Chapter).

8



For example: Take a 0.75 m3 capacity bucket with an empty weight of 555 kg, loaded with sand and gravel which has a Fill Factor of 95% and a density of 1720 kg/m3. 0.75 m3 (Heaped Capacity) multiplied by:

0.95 (Fill Factor) multiplied by:

1720 kg/m3 (Density) plus:

555 kg (Bucket Weight) equals:

1780.5 kg (Filled Bucket Weight)

OTHER FACTORS AFFECTING BUCKET SELECTION

Trench width, trench box size, the desire to minimise the amount of bedding material required...... these are typical factors which you may also need to consider when choosing a bucket. These factors, combined with the three main ones must all be weighed in the balance before selecting the most appropriate size of bucket for the job. Information on JCB buckets available for the JS excavator is on the JCB Attachments Sales file, available from JCB Service or your parts department.


9

0 7 / 0 3 E X C M A T

Contents

Section 10. ADDITIONAL INFORMATION

1. Excavator Specification Sheets. - Lift capacities. - Standard Positions And Equipment. - Lifting Standards.

2. Maximum Reach Lift Capacity.

3. Calculating Ground Bearing Pressure.

4. Exchange Dipper Scheme.

5. Conversion Factors.

6. Conversion Factors.

Additional Information

EXCAVATOR SPECIFICATION SHEETS When comparing the published performance of a machine against a competitor, it is important that the same parameters and standards be applied.

LIFT CAPACITIES 1 - "STANDARD" POSITIONS AND EQUIPMENT As the lifting performance of any excavator varies widely depending upon the position of the boom and dipper arm, the "standard" position that should be used as the starting point for any comparison is: 6m ground level (over end) Also, when comparing machines, you should check that the specification being compared is the same for both machines, i.e.: SAME BOOM SAME DIPPER (find the nearest comparable size to the JS) SAME BUCKET (Does the performance include bucket? Find the nearest comparable size to the JS - the key measurement being the weight when comparing lift charts) 0 7 / 0 3 E X C A D D

SAME TRACK SHOES (this is particularly important when comparing machine weights and ground bearing pressures) 2 - LIFTING STANDARDS Extra care is needed when comparing lift capacities of competitive excavator s. Two standards are commonly used: SAE J1097 DIN 15019 Confusion and misleading information can result if the standards are not compared on a "like-for-like" bas is. By using a different standard of lift capacity measurements a competitor can obtain an apparent superiority of lift performance, when in reality the machine may actually lift less. There are two conditions which limit an excavator's ability to lift: 1. Hydraulic limit (i.e. how powerful it is). This is usually indicated on lift charts by an asterisk *. 2. Stability limit. This is the point at which the machine starts to tip. One or other condition can apply at different points, whether lifting over the front / rear or over the side. Each standard then applies different safety margins as follows:

SAE J1097

DIN 15019

Hydraulic lift capacity

87%

(15% safety factor)

100%

(0% safety factor)

Stability - max. tipping load

75%

(33.3% safety factor)

80%

(25% safety factor)


1


Therefore, a machine with lift capacities quoted with the DIN standard will appear to have greater lift capacity than if it is quoted to the SAE standard. It should also be noted that the 25% safety factor / margin quoted with the DIN standards is NOT equal to 75% of the tipping load, as is often mistakenly assumed. To convert from DIN to SAE Stability value - Multiply DIN value by 0.937 To convert from DIN to SAE Hydraulic value - Multiply DIN value by 0.87. EC regulations for "Object Handling" (lifting) use the same parameters as the SAE standard, to which JCB published lift charts currently comply. For this reason, JCB lift charts will remain with the larger safety factors.

3 - MAXIMUM REACH LIFT CAPACITY Another anomaly can be created when specifying lift capacities at maximum reach, both by the use of different standards and also by using different points of definition for lift radius. It will be understood that as the reach increases, the amount by which the machine can lift will decrease. Therefore it is important when making comparisons, to know the actual radius of the lifting point, as well as the standard (SAE J1097 or DIN 15019) to which lift charts are being quoted. For example, the lift point could be located on the dipper, on the tipping link or on the bucket itself - varying the maximum reach radius and affecting the machine's lif t capability accordingly. As some manufacturers do not quote the radius of the lift point at maximum reach it is safer, when making comparisons, to use the lift points at specific radii, eg., 3 metres, 6 metres, 8 metres, etc. In conclusion, great care must be taken when comparing different manufacturers' specification sheets, especially as they may be based on D D A C X E 3 0 / 7 0

different standards. Always read the "small print" on the sheet to make sure which standard applies.

2



CALCULATING GROUND BEARING PRESSURE Various formulas are available to calculate the ground bearing pressure of a tracked excavator, but this is one of the most commonly used. Hard Ground =

P=

F

(P2)

L1 x B x 2

Soft Ground =

P=

F

(P1)

2 x B (L1 + 0.35D) P

=

Ground bearing pressure in bar.

F

=

Total operating weight of the machine (in kg with working attachments).

B

=

Track pad width in cm.

L1

=

Distance between idle sprocket wheel centres in cm (This corresponds to dimension A in brochure).

L2

=

Undercarriage overall length (This corresponds to dimension B in brochure).

D

=

Track height in cm.

The value obtained corresponds to an AVERAGE PRESSURE. When working, the position of the centre of gravity of the machine varies according to the direction of the upper structure, the position of the attachment, etc. The ground bearing pressure is therefore never evenly distributed under the tracks. 0 7 / 0 3 E X C A D D

Note: 1 bar = 14.50PSI As a generalisation, add or subtract 2.6kgs per shoe for every 100mm of shoe width to determine the machine weight.


3


EXCHANGE DIPPER SCHEME An exchange dipper scheme has been in operation at JCB Heavy Products for sometime. This gives the dealership flexibility on stock machines to match the end user’s ‘specification’. In essence your parts department contacts Heavy Line Marketing Department to advise that there is a dipper to be returned, orders the required dipper from JCB Service and advises the Heavy Line Markering Department when the dipper from new stock machine is going to be returned to JCB HEAVY PRODUCTS at Uttoxeter. Allow three weeks from the date of order for the replacement dipper to be delivered. Procedures for progressing the Dipper Exchange Scheme are to be found on Salesflashes HE 8/97, HE10/96, and HE 2/96.

D D A C X E 3 0 / 7 0

4



CONVERSION FACTORS FROM

TO

MULTIPLY BY

FROM

TO

MULTIPLY BY

mm

in

0.03937

in

mm

25.4

mm

ft

3.2808

ft

mm

0.3048

mm

yd

1.0936

yd

mm

0.9144

km

mile

0.6214

mile

km

1.609

mm2

in2

0.00155

in2

mm2

645.2

cm2

in2

0.155

in2

cm2

6.452

m2

in2

1.549

in2

m2

0.0006452

m2

ft2

10.764

ft2

m2

0.092903

m2

yd2

1.196

yd2

m2

0.8361

km2

mile2

0.3861

mile2

km2

2.59

ha

acre

2.471

acre

ha

0.4047

mm3

in3

0.00006102

in3

mm3

16390

cm3

in3

0.06102

in3

cm3

16.39

cm3

litre

0.001

litre

cm3

1000

m3

ft3

35.32

ft3

m3

0.02832

m3

yd3

1.308

yd3

m3

0.7646

litre

in3

61.01

in3

litre

0.01639

litre

m3

0.001

m3

litre

1000

litre

UK gal

0.22

UK gal

litre

4.546

litre

UK pt

1.76

UK pt

litre

0.5683

US gal

UK gal

0.8327

UK gal

US gal

1.201

UK gpm

0.354

UK gpm

litre/km

2.825

lb/bhp hour

0.001644

lb/bhp hour

g/kW hour

608

g

oz

0.03527

oz

g

28.35

g

lb

0.002205

lb

g

453.6

kg

lb

2.205

lb

kg

0.4536

ton

0.9842

ton

tonne

1.016

lb/yd3

1.686

lb/yd3

kg/m3

0.5933

N

lbf

0.2248

lbf

N

4.448

N

kgf

0.102

kgf

N

9.807

Length

Area

Volume

0 7 / 0 3 E X C A D D

Fuel Consumption litre/km g/kW hour

Mass (weight)

tonne

Density kg/m3

Force


5


CONVERSION FACTORS (cont) FROM

TO

MULTIPLY BY

FROM

TO

MULTIPLY BY

psi

14.5

psi

bar

0.06895

Pressure bar bar

Pa

100000

Pa

bar

2

0.00001

kg/cm

psi

14.22

psi

kg/cm

0.07032

kg/cm2

bar

0.9807

bar

kg/cm2

1.02

Nm

lbf ft

0.7376

lbf ft

Nm

1.356

kgf m

lbf ft

7.233

lbf ft

kgf m

0.1383

kW

hp

1.341

hp

kW

0.7457

CV, PS

hp

0.9863

hp

CV, PS

1.014

kW

Btu

3412

Btu

kW

0.0002931

°F

(°C x 9/5) + 32

°F

°C

(°F - 32) x 5 /9

rev/min

60

rev/min

Hz

1 / 60

%

grade °

1 in X

10

5.7

10

20

11.3

5

30

16.7

3.3

40

21.8

2.5

50

26.6

2

60

31

1.7

70

35

1.4

80

38.7

1.3

90

42

1.1

100

45

1

2

Torque

Power

Temperature °C

D D A C X E 3 0 / 7 0

Frequency Hz

GRADES

Notes millimetre

mm

Approx. 40 "thou" of an inch

centimetre

cm

10mm / Not used in S.I. Units

metre

mm

Standard S.I. Unit for length

kilometre

km

Approx. 5 /8 mile

litre

l

1/1000 m3. Approx 1 3 /4 pints

tonne

t

1000 kg. Approx. 1 ton (2240 lb)

Newton

N

S.I. Unit force. Approx. 1/10 kg force

Pascal

Pa

S.I.unit of pressure = 1 N/m2

bar

bar

100000 Pa. Approx. kgf/cm2

Hertz

Hz

Cycles (revolutions) per second

6


Contents

Section 11. TENDER AND QUOTATION DATA

1. JS Main Component Manufacturers.

2. JS Tracked Chain Dimensions.

3. Boom Lengths.

4. Dipper Lengths.

5. JS Slew Torques.

6. JS Noise Emissions.

7. Engine Specifications.

8. Engine Performance Curves.

9. JZ70 Tier II.

10. JS200/JS210/JS220 Auto Tier II + JS175W/JS200W Tier II.

11. JS330 Tier II.

12. JS 460 Tier II.

13. Bucket Mounting Detail.

Tender and Quotation Data

JS MAIN COMPONENT MANUFACTURERS Model

Pump

Control Valve

Slew Motor

Track Motor Track Gearbox

Hydraulic rams

Engine

Axles (wheeled only)

JZ70

TOSHIBA

TOSHIBA

TOSHIBA

KAYABA

TRASMITAL

KAYABA

ISUZU

-

JS130

KAWASAKI

TOSHIBA

TOSHIBA

KAYABA

TRASMITAL

KAYABA (HYDRAUTO)

ISUZU

-

JS130HD

KAWASAKI

TOSHIBA

TOSHIBA

KAYABA

TRASMITAL

KAYABA (HYDRAUTO)

ISUZU

-

JS160

KAWASAKI

TOSHIBA

TOSHIBA

KAYABA

TRASMITAL

KAYABA (HYDRAUTO)

ISUZU

-

JS180

KAWASAKI

TOSHIBA

TOSHIBA

KAYABA

TRASMITAL

KAYABA (HYDRAUTO)

ISUZU

-

JS200

KAWASAKI

KAYABA

TOSHIBA

KAYABA

TRASMITAL

KAYABA

ISUZU

-

JS210

KAWASAKI

KAYABA

TOSHIBA

KAYABA

TRASMITAL

KAYABA)

ISUZU

-

JS220

KAWASAKI

KAYABA

TOSHIBA

KAYABA

TRASMITAL

KAYABA

ISUZU

-

JS240

KAWASAKI

KAYABA

KAWASAKI

KAYABA

TRASMITAL

KAYABA (HYDRAUTO)

ISUZU

-

JS260

KAWASAKI

KAYABA

KAWASAKI

KAYABA

TRASMITAL

KAYABA (HYDRAUTO)

ISUZU

-

JS330

KAWASAKI

KAYABA

KAWASAKI

KAYABA

TRASMITAL

KAYABA (HYDRAUTO)

ISUZU

-

JS460

KAWASAKI

KAYABA

KAWASAKI

KAYABA

TRASMITAL

KOYO SEIKI

ISUZU

-

JS130W

KAYABA

TOSHIBA

TOSHIBA

-

-

KAYABA (HYDRAUTO)

ISUZU

JCB

JS145W

KAYABA

TOSHIBA

TOSHIBA

-

-

KAYABA (HYDRAUTO)

ISUZU

JCB

JS160W

KAYABA

TOSHIBA

TOSHIBA

-

-

KAYABA (HYDRAUTO)

ISUZU

JCB

JS175W

KAWASAKI

TOSHIBA

TOSHIBA

-

-

KAYABA (HYDRAUTO)

ISUZU

JCB

JS200W

REXROTH

REXROTH

TOSHIBA

-

-

KAYABA (HYDRAUTO)

ISUZU

ZF


0 7 / 0 3 E X C T E C

1


JS TRACKED CHAIN DIMENSIONS

C E T C X E 3 0 / 7 0

Model

Nearest “D” Size

A. Link Pitch mm

B. Bush Width mm

C. Pin Diameter mm

D. Rail Height mm

E. Bush Diameter mm

JZ70

NA

154

45.0

24.0

74.0

41.26

JS130

*D4

190

84.6

36.5

106.0

58.7

JS130HD

>D5

190

84.6

36.5

106.0

58.7

JS160

>D5

190

84.6

36.5

106.0

58.7

JS180

>D5

190

84.6

36.5

106.0

58.7

JS200 / 210 / 220

>D5

190

84.6

36.5

106.0

58.7

JS240 / 260

>D5

190

84.6

36.5

106.0

58.7

JS330

*D6

202.9

106.5

44.5

117.5

66.7

JS460

TBA

TBA

TBA

TBA

TBA

TBA

* = Nearest equivalent NOTE: D4, D5, D6 etc. refer to the original CAT Bulldozer model number to which that particular size of chain was fitted. These chains were subject to modification during the production life of the CAT machines, and so sizes are variable. The "D" references are to be avoided whenever possible. They have been provided as a rough guide, to be used only when customers particularly want to refer to them.

D Ref.

A. Link Pitch mm

B. Bush Width mm

C. Pin Diameter mm

D. Rail Height mm

E Bush Diameter mm

D4

171.07

75.25

33.20

93.00

50.61

D4D

171.07

75.25

33.50

85.20

53.90

D5

175.41

90.76

36.64

103.20

58.74

D6D

202.80

86.10

44.58

121.50

66.62

D6C

202.80

102.55

44.58

121.50

66.62

2



BOOM LENGTHS (M)

Machine

Monoboom

Tab

Offset

JZ70

3.7

-

3.94

JS130

4.70

5.00

-

JS130HD

4.70

-

-

JS160

5.15

-

-

JS180

5.15

-

-

JS220

5.70

5.71

JS210

5.70

5.71

JS220

5.70

5.71

JS240

5.85

-

-

JS260

5.85

6.24

-

JS260XD

5.85

-

-

JS330

6.45

-

-

JS330XD

6.45

-

-

JS460

7.1

-

-

JS130W

4.70

5.00

-

JS145W

4.70

5.00

-

JS160W

5.15

5.00

-

JS175W

5.15

5.00

-

JS200W

5.70

5.00

-

0 7 / 0 3 E X C T E C

Boom length is measured between the boom foot boss and boom to dipper boss as shown above. TAB are measurd in the fully extended position.


3


DIPPER LENGTHS (M)

Machine

Short

Medium

Long

Extra Long

JZ70

-

1.74

2.18

-

JS130

2.10

2.50

3.00

-

JS130HD

2.10

2.50

3.00

-

JS160

2.25

2.70

3.05

-

JS180

2.25

2.70

3.05

-

JS240

2.00

2.44

3.09

3.53

JS260

2.00

2.44

3.09

3.53

-

2.44

3.09

-

2.21

2.63

3.23

4.03

-

2.63

3.23

-

JS460

2.50

3.36

4.0

4.76

JS130W

2.10

2.50

3.00

-

JS145W

2.10

2.50

3.00

-

JS160W

2.25

2.70

3.05

-

JS175W

2.25

2.70

3.05

-

JS200W

1.91

2.40

3.00

-

JS260XD JS330 JS330XD

C E T C X E 3 0 / 7 0

Dipper length is measured between the boom to dipper pivot and bucket pivot as shown above.

4



JS SLEW TORQUES

MACHINE

Kgf m

Nm

JZ70

1395

13680

JS130

3368

33031

JS130HD

3368

33031

JS160

4603

45141

JS180

4603

45141

JS200

6195

60754

JS210

6195

60754

JS220

6195

60754

JS220XD

6195

60754

JS240

7625

74774

JS260

7625

74774

JS260XD

7625

74774

JS330

10433

102316

JS330XD

10433

102316

JS460

14635

143520

JS130W

3368

33031

JS145W

3368

33031

JS160W

4603

45141

JS175W

4603

45141

JS200W

6445

63200


0 7 / 0 3 E X C T E C

5


JS NOISE EMISSIONS Shown below are the noise emission for JS tracked and wheeled excavators:

C E T C X E 3 0 / 7 0

Internal (LPA)

External (LWA)

JZ70

76

101

JS130

74

103

JS160

75

103

JS180

75

103

JS200

74

102

JS210

74

102

JS220

74

102

JS240

77

106

JS260

77

106

JS330

77

108

JS460

78

109

JS130W

76

103

JS145W

77

103

JS160W

76

103

JS175W

77

102

JS200W

76

103

Explanation of the tests: INTERNAL A machine is tested whilst running (with heater and fan running) and the engine at full RPM. 2 readings are taken (one from the left and one from the right) and the highest is declared. EXTERNAL The machine is tested under dynamic conditions (i.e. "air-digging") at full power and full RPM, and the noise is measured at six points around the machine. Each point has its own "weighting" and the value is calculated using an equation. These tests conform to the following standards: 86/662/EEC, 89/514/EEC AND 95/27/EC. The displaying of external noise level is only required as part of the CE marking for EU countries. Internal noise level does not need to be displayed on the machine.

6



ENGINE SPECIFICATIONS

SUPPLIER MODEL

OUPUT (SAE NET)

JZ70 (Tier II)

JS130 JS130W (Tier I)

JS130HD (Tier I)

JS160 JS180 JS160W JS145W (Tier I)

JS200 JS210 JS220 JS220LR JS175W JS200W (Tier II)

JS240 JS260 (Tier I)

JS330 (Tier II)

JS460 (Tier II)

ISUZU

ISUZU

ISUZU

ISUZU

ISUZU

ISUZU

ISUZU

ISUZU

A-4JG1 PAW-02

A-4BG1T-S1

A-4BG1T-S1

A-4BG1 TPA-03

6BGITRB-05

A-6BG1T QB-05

6HK1X

AA-6SDiTC-S

73.5 kW / 98.5hp @ 2300 rpm

102 kW / 138 hp @ 1950 rpm

117 kW / 156 hp @ 2150 rpm

178 kW / 239hp @ 1900 rpm

228 kW / 305 hp @ 2000 rpm

44 kW / 58 hp 63 kW / 85 hp 63 kW / 85 hp @ 2300 rpm @ 2200 rpm @ 2200 rpm

MAX TORQUE (SAE NET) 192 Nm @ 1600 rpm

294 Nm @ 1600 rpm

294 Nm @ 1600 rpm

345 Nm @ 1600 rpm

532 Nm @ 1600 rpm

539 Nm @ 1700 rpm

932 Nm @ 1800 rpm

1274 Nm @ 1600 rpm

105 x 125

105 x 125

105 x 125

105 x 125

105 x 125

115 x 125

120 x 145

24 volt, 40 amp

24 volt, 40 amp

24 volt,75 amp (Heavy Duty)

24 volt, 40 amp

24 volt, 40 amp

24 volt, 40 amp

24 volt, 40 amp

24 volt, 50 amp

ZEXEL

ZEXEL

ZEXEL

ZEXEL

ZEXEL

ZEXEL

ZEXEL

ZEXEL

NATURAL

TURBO

TURBO

TURBO

TURBO

TURBO

TURBO

TURBO

NUMBER OF CYLINDERS

4

4

4

4

6

6

6

6

DISPLACEMENT (litres)

3.06

4.329

4.329

4.329

6.494

6.494

7.79

9.839

BORE x STROKE (mm)

ALTERNATOR FUEL INJECTION SYSTEM ASPIRATION

95.4 x 107


0 7 / 0 3 E X C T E C

7


ENGINE PERFORMANCE CURVES The following diagrams summarise the power,torque and specific fuel comsumption for engines used in JS machines. All graphs use engine speed as a common basis. Note: These charts are for an engine run on a test bench and not for an installed unit, therefore fuel consumption is not for a machine but for a general engine use.

C E T C X E 3 0 / 7 0

8


6 0 0 0 E F Y E K


JZ70 TIER II Performance curve 4JG1PAW-02/-30

Rated output: 42 + _ 1.3 kW / 2200 rpm

Maximum Torque: 192 +2 -17 Nm / 1800 rpm

200 180 160 140

T O R Q U E ( N m )

60

50

40

) W k ( T U P T U O R E W O P

0 7 / 0 3 E X C T E C

30

20

10

0 260 240 220 200

S F C ( g / k W .h r )

180 500

1000

1500

2000 ENGINE SPEED (rpm)

2500

3000


3500

9


JS200/JS210/JS220 AUTO TIER II + JS175W/JS200W TIER II Performance curve 6BG1TRB-05

Rated output: 102.0 kW / 1950 rpm

Maximum Torque: 532 Nm / 1600 rpm

Idle speed: 900 rpm

700 600 500 400

T O R Q U E ( N m )

120

100 C E T C X E 3 0 / 7 0


80

60

40

20

0 260 240 220 200 180 500

1000

1500

2000

2500

ENGINE SPEED (rpm)

10


S F C ( g / k W .h r )


JS330 TIER II Performance curve 6HK1XQB-01

Rated output: 182.0 + _ 3% kW / 1900 rpm

Maximum Torque: 932 Nm + _ 5% / 1800 rpm

Idle speed set: 1000 rpm

1100 1000 900 800 700 600

T O R Q U E ( N m )

500 200

180

160 0 7 / 0 3 E X C T E C

140


120

100

80

60

40

20

0 260 240 220 200

S F C ( g / k W .h r )

180 500

1000

1500

2000

2500

ENGINE SPEED (rpm)


11


JS460 TIER II Performance curve 6SD1TC-S Rated output: 240.0 kW / 2000 rpm Maximum Torque: 1274 Nm / 1600 rpm

1400 1200 1000 800

T O R Q U E ( N m )

260 240 220 C E T C X E 3 0 / 7 0

200 180


160 140 120 100 80 60 40 20 0 260 240 220 200 180 500

1000

1500

2000

2500

ENGINE SPEED (rpm)

12


S F C ( g / k W .h r )


BUCKET MOUNTING DETAIL

MACHINE

A

B

C

ØD

ØE

F

G

H

ØI

ØJ

JZ70

300

311

191

50

100

20

15

15

14

100

JS130

385

382

255

65

150

25

20

15

18

100

JS160 / 180

435

440

301

80

160

25

22

18

22

120

JS200 / 210 / 220

450

460

307

80

180

32

22

18

22

120

JS240 / 260

460

485

326

90

190

32

25

18

22

130

JS130W / 145W

385

382

255

65

150

25

20

15

18

100

JS160W / 175W

435

440

301

80

160

25

22

18

22

120

JS200W

450

460

307

80

180

32

22

18

22

120

0 7 / 0 3 E X C T E C

MACHINE

A

B

C

ØD

ØE

F

G

H

ØI

ØJ

K

ØL

JS330

565

612

401

90

200

25

25

22.5

22

160

28

130

JS460

570

702

480

100

210

25

28

30

26

190

28

155


13

Contents

Section 12. JS OPTIONS EXPLAINED

1. Hydraulic Circuit Information. - XO Tracked Hydraulic Circuit Controls.

2. JS Auto Hydraulic Circuit Controls.

3. XO Wheeled Hydraulic Circuit Controls. - JZ70 Hydraulic Circuit Controls.

4. Joystick Auxiliary Controls.

5. Hammer Flow and Pressure capacity. - JS 130. - JS 160/180.

6. Hammer Speed Settings. - JS 240/260. - JS 330.

7. Hammer Speed Settings. - JS 200/210/220 Auto. - JS 130W/145W.

8. Hammer Speed Settings. - JS 160W/175W. - JS 200W.

9. JS Wheeled Excavator Tyre Option.

JS Options Explained

JS HYDRAULIC CIRCUIT INFORMATION Below is a list of the 7 primary hydraulic pipework options for the Excavator end. They are split into two types; High flow and low flow. Only one high flow and one low flow are possible per machine. All high flow services are operated via the fo ot pedal on tracked machines. All low flow services are operated via a push button on the hand control. To change from hammer to auxiliary a manua l change over valve must be repositioned. This diverts the return line oil back into the valve block and allows it to operate a double acting system.

High Flow

Low Flow

Hammer

Low flow (20 lpm)

Single acting.

Double acting.

Oil flows in one direction only.

Oil flow can flow in both directions.

High flow and high pressure.

Oil stops immediately and holds in the desired position.

Application: Hammer/Breaker only.

Application: Tilting Bucket.

Auxiliary

Low Flow ( 27 - 45 lpm)

Double acting.

Double acting.



High flow and high pressure.

Oil runs on slightly when stopped in order to protect motor.

Hammer cannot be used with this option.

Application: Weed cutter bucket.

0 7 / 0 3 E X C O P T

Application: Sorting Grab. Hammer/Auxiliary combined Single acting or double acting. Oil flow can flow in both directions. High flow and high pressure. Application: Hammer or a Grab. Hammer/Auxiliary Merged Single acting or double acting. Oil flow can flow in both directions. Very high flow and high pressure. Application: Demolition Cutter/Crusher. Bucket to Grab Uses bucket service to operate attachment. Bucket ram and linkage cannot be used as well. Operation: Bucket service on hand control. Application: Clam shell bu cket.


1


JS AUTO HYDRAULIC CIRCUIT CONTROLS Location of Controls and Components.

FEATURE

MACHINE Auto

High flow circuit

1 1

One touch idle

2

Low flow

3

Offset boom change over

None

Dozer

None

Stabilizers

None

Track speed control

4

Quick hitch

5

Hammer/aux. change over

6

Horn

7

Boom/slew priority

8

TAB position ram

9 10 10

Auto idle T P O C X E 3 0 / 7 0

Power boost

Auto

EXCOPT0001

These features maybe fitted as option fit only.

XO TRACKED HYDRAULIC CIRCUIT CONTROLS Location of Controls and Components.

FEATURE

MACHINE XO tracked

High flow circuit

1

One touch idle

2

Low flow

3


None

Dozer

None

Stabilizers

None

Track speed control

4

Quick hitch

5


6

Horn

7

Boom/slew priority

8

TAB position ram

9

Auto idle

10

Power boost

11

EXCOPT0002


2



XO WHEELED HYDRAULIC CIRCUIT CONTROLS Location of Controls and Components.

FEATURE

MACHINE XO wheeled

High flow circuit

1 1

One touch idle

2 2

Low flow

3 3


10 1

None

13 13

Dozer change over Stabilizers

4 4

Track speed control

5 5

Quick hitch

6 6


7 7

Horn

8 8

Boom/slew priority

9 9

TAB position ram

10 10

Auto idle

11 11

Power boost

12 12

6

5

11

3

13 8

2

12

7

4

9

A335431

EXCOPT0003

0 7 / 0 3 E X C O P T


JZ70 HYDRAULIC CIRCUIT CONTROLS Location of Controls and Components.

FEATURE

MACHINE 3

JZ70 High flow circuit

1

One touch idle

4 6

55 (two way switch)

Low flow Offset boom change over

2

Dozer

3

Stabilizers

5

1

2

4

9

None

Track speed control

6

Quick hitch

7


8

Horn

9

Boom/slew priority

None

TAB position ram

None

Auto idle

None

Power boost

None

7

8

A335535

EXCOPT0004



3


JOYSTICK AUXILIARY CONTROLS The joysticks fitted to all JS products have two, one way and a single two way switch each. Any switch not used for the control of the machine is available for use on local conversions.

EXCOPT0005

EXCOPT0006

The following section shows the functions of the in cab controls affecting major machine controls. For more detail please see the relevant operator manuals. T P O C X E 3 0 / 7 0

4



HAMMER FLOW AND PRESSURE CAPACITY The following chart, taken from the operator h andbook shows the engine rpm required to a chieve specific flow and pressure settings for hammers. By setting the engine rpm on the AMS monitor and adjusting the auxiliary circuit relief valve, the desired flow and pressure for a certain hammer can be achieved. Note the JZ70 does not work in this way but instead has a preset flow of 80 ltrs/min from the hammer circuit. For more detailed information refer to the relevant service manual.

Hammer speed settings

JS 130 150

140 WORKING PRESSURE

130

BAR 120

110

1495

1660

1835

2055

-

-

1390

1545

1730

1950

-

-

1485

1650

1825

2045

2205

-

1380

1540

1725

1945

2110

-

1465

1625

1810

2030

2190

-

1370

1530

1715

1935

2100

-

1445

1605

1790

2010

2170

-

1355

1515

1700

1920

2080

-

1430

1595

1775

1990

2150

2250

1340

1500

1685

1905

2065

2115

70

80

90

100

110

115

0 7 / 0 3 E X C O P T

REQUIRED FLOW (LPM)

JS 160/180 150


130

BAR 120

110

1590

1765

1985

2140

2320

-

1480

1660

1875

2045

2210

-

1575

1750

1970

2130

2310

-

1470

1655

1870

2035

2215

-

1560

1735

1955

2115

2295

-

1460

1645

1860

2025

2205

-

1540

1720

1940

2100

2280

-

1445

1630

1850

2020

2195

-

1525

1700

1920

2080

2265

2360

1430

1615

1840

2005

2170

2265

80

90

100

110

120

125

REQUIRED FLOW (LPM) **** Upper figure = no load pressure **** Lower figure = loaded engine pressure


5



JS 240/260 220


180

BAR 160

140

120

100

80 T P O C X E 3 0 / 7 0

1360

1415

1435

1500

1620

1720

1830

1950

-

-

-

-

1170

1190

1205

1275

1400

1520

1640

1765

-

-

-

-

1275

1385

1415

1425

1535

1645

1750

1850

1965

2075

-

-

1082

1180

1200

1205

1320

1440

1555

1670

1785

1900

-

-

1180

1320

1375

1410

1450

1560

1670

1770

1870

1990

-

-

985

1140

1185

1210

1265

1370

1480

1585

1695

1815

-

-

1040

1230

1310

1380

1445

1530

1640

1730

1825

2005

2005

-

880

1045

1160

1200

1250

1335

1450

1550

1645

1840

1840

-

1130

1145

1250

1340

1395

1495

1605

1700

1790

1880

1975

2075

870

990

1110

1195

1240

1340

1445

1545

1640

1740

1830

1935

980

1085

1185

1295

1360

1460

1550

1660

1750

1850

1935

2040

840

955

1060

1175

1230

1330

1425

1525

1625

1725

1815

1920

935

1030

1120

1235

1310

1420

1525

1620

1710

1810

1920

2010

820

920

1030

1130

1220

1320

1425

1520

1610

1720

1815

1905

910

1010

1100

1195

1285

1370

1475

1590

1680

1785

1885

1970

825

920

1025

1125

1215

1300

1405

1510

1605

1710

1800

1890

80

90

100

110

120

130

140

150

160

170

180

190

REQUIRED FLOW (LPM)

JS 330 150


130

BAR 120

110

1320

1465

1620

1795

1985

-

1240

1385

1535

1705

1890

-

1300

1445

1600

1775

1965

2180

1220

1365

1515

1685

1870

2075

1280

1425

1580

1755

1945

2160

1200

1345

1495

1665

1850

2065

1260

1405

1560

1735

1925

2140

1180

1325

1475

1645

1830

2055

1240

1385

1540

1715

1905

2120

1160

1305

1455 *

1625

1810

2045

150

175

200

225

250

275


6




JS 200/210/220 AUTO 220


180

BAR 160

140

120

100

80

1345

1380

1505

1635

1765

1905

2065

-

-

-

-

-

1210

1255

1385

1525

1660

1805

1985

-

-

-

-

-

1320

1340

1410

1535

1650

1780

1925

2040

-

-

-

-

1200

1210

1290

1415

1545

1680

1830

1960

-

-

-

-

1290

1330

1335

1455

1555

1690

1805

1930

2055

-

-

-

1185

1200

1220

1345

1450

1595

1710

1845

1925

-

-

-

1255

1300

1320

1390

1490

1595

1725

1835

1965

2095

-

-

1165

1190

1205

1280

1390

1505

1635

1750

1880

2015

-

-

1135

1255

1305

1340

1440

1540

1650

1765

1880

1985

2095

-

1020

1155

1200

1235

1340

1445

1560

1680

1800

1905

2025

-

1075

1190

1290

1300

1400

1490

1590

1690

1800

1905

2015

-

970

1090

1180

1200

1305

1405

1510

1610

1720

1830

1950

-

1015

1135

1250

1295

1370

1470

1560

1670

1775

1870

1965

2055

915

1040

1160

1200

1285

1390

1480

1595

1705

1800

1900

2000

955

1070

1195

1280

1365

1460

1560

1660

1765

1860

1955

2040

860

975

1100

1200

1280

1385

1490

1595

1700

1800

1900

1990

80

90

100

110

120

130

140

150

160

170

180

190

0 7 / 0 3 E X C O P T

REQUIRED FLOW (LPM)

JS 130W/145W 150


130

BAR 120

110

1495

1660

1835

2055

-

-

1390

1545

1730

1950

-

-

1485

1650

1825

2045

2205

-

1380

1540

1725

1945

2110

-

1465

1625

1810

2030

2190

-

1370

1530

1715

1935

2100

-

1445

1605

1790

2010

2170

-

1355

1515

1700

1920

2080

-

1430

1595

1775

1990

2150

2250

1340

1500

1685

1905

2065

2115

70

80

90

100

110

115



7



JS 160W/175W 150

140

1590

1765

1985

2140

2320

-

1480

1660

1875

2045

2210

-

1575

1750

1970

2130

2310

-

1470

1655

1870

2035

2215

-

1560

1735

1955

2115

2295

-

1460

1645

1860

2025

2205

-

1540

1720

1940

2100

2280

-

1445

1630

1850

2020

2195

-

1525

1700

1920

2080

2265

2360

1430

1615

1840

2005

2170

2265

80

90

100

110

120

125

WORKING PRESSURE

130

BAR 120

110

REQUIRED FLOW (LPM)

JS 200W T P O C X E 3 0 / 7 0

220


180

BAR 160

140

120

100

80

1345

1380

1505

1635

1765

1905

2065

-

-

-

-

-

1210

1255

1385

1525

1660

1805

1985

-

-

-

-

-

1320

1340

1410

1535

1650

1780

1925

2040

-

-

-

-

1200

1210

1290

1415

1545

1680

1830

1960

-

-

-

-

1290

1330

1335

1455

1555

1690

1805

1930

2055

-

-

-

1185

1200

1220

1345

1450

1595

1710

1845

1925

-

-

-

1255

1300

1320

1390

1490

1595

1725

1835

1965

2095

-

-

1165

1190

1205

1280

1390

1505

1635

1750

1880

2015

-

-

1135

1255

1305

1340

1440

1540

1650

1765

1880

1985

2095

-

1020

1155

1200

1235

1340

1445

1560

1680

1800

1905

2025

-

1075

1190

1290

1300

1400

1490

1590

1690

1800

1905

2015

-

970

1090

1180

1200

1305

1405

1510

1610

1720

1830

1950

-

1015

1135

1250

1295

1370

1470

1560

1670

1775

1870

1965

2055

915

1040

1160

1200

1285

1390

1480

1595

1705

1800

1900

2000

955

1070

1195

1280

1365

1460

1560

1660

1765

1860

1955

2040

860

975

1100

1200

1280

1385

1490

1595

1700

1800

1900

1990

80

90

100

110

120

130

140

150

160

170

180

190


8


JCB EXCAVATOR

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