jcb 8026 CTS, Operator'S Manual

Page 1: ...rinted In England Dear JCB Customer Even if you have operated this type of equipment before it is very important that your new machines operations and functions are explained to you by a JCB Dealer Re...

Page 2: ...0 0 9811 9950 Notes E S e r v i c e s...

Page 3: ...Manual xv Safety Warnings xvi Introduction About this Manual 1 Machine Model and Serial Number 1 Using this Manual 1 Left Side Right Side 2 Cab Canopy 3 Cross References 3 Machine Description 4 The J...

Page 4: ...Labels 31 Introduction 31 Safety Label Identification 32 Identifying Your Machine 37 Machine Identification Plate 37 Component Identification Plates 39 Machine Security 42 Introduction 42 JCB Plantgu...

Page 5: ...Securing the Door in the Open Position 52 Opening and Closing the Front Window 54 Removing and Refitting the Windscreen Lower Panel 55 Opening and Closing the Side Window 57 Seat Controls 58 Introduc...

Page 6: ...fitted 79 Operating Levers Pedals 80 Introduction 80 Control Layouts 80 Excavator Controls 82 Dozer Controls 90 Auxiliary Operation 92 Safety Equipment 94 Control Locks 94 Beacon 95 Overload Warning...

Page 7: ...for Site Travel 113 Working with the Machine 115 Operating Practices and Site Safety 115 Clothing and Safety Equipment 116 Danger Zone 116 Log Moving Handling 117 Safety Practices 117 Working with the...

Page 8: ...perating in Dusty or Sandy Areas 137 Operating in Coastal Regions 137 Operating on Wet or Soft Ground 137 Getting the Machine Moving 138 Operating Practices 138 Operating Procedure 139 Refuelling the...

Page 9: ...achine onto the Transporting Vehicle 148 Securing the Machine 150 Unloading a Machine from the Transporting Vehicle 152 Lifting a Machine 154 Storage of the Machine 156 Introduction 156 Storage Area 1...

Page 10: ...ifting Equipment 161 Obtaining Replacement Parts 161 Health and Safety 162 Lubricants 162 Battery 166 Service Schedules 170 Introduction 170 How to Use the Service Schedules 171 Calendar Equivalents 1...

Page 11: ...red 193 Cleaning the Machine 194 Introduction 194 Preparing the Machine for Cleaning 195 Cleaning the Machine 196 Cleaning the Tracks 197 Checking for Damage 199 Check the Machine Body and Structure 1...

Page 12: ...s 204 Slew Ring Bearings 206 Slew Ring Gear Teeth 207 Access Panels 209 Introduction 209 Engine Cover 209 Hydraulic Bay Cover 211 Electrical System 212 Battery 212 Fuses 220 Engine 222 Oil and Filter...

Page 13: ...System 238 Hydraulic System 240 Introduction 240 Releasing the Hydraulic Pressure 242 Oil and Filter 243 Tracks and Running Gear 245 Tracks 245 Fire Extinguisher if fitted 250 Checking the Fire Exting...

Page 14: ...259 Quick Release Couplings 261 Quickhitch Assembly 265 Introduction 265 Installation 266 Removal 267 Maintenance 267 Buckets 268 Bucket Selection 268 Removing a Bucket Non Quickhitch Models 269 Insta...

Page 15: ...ickhitch Rockbreaker 281 Operation 282 Specifications Lifting Regulations and Safe Working Loads 285 Introduction 285 Static Dimensions 289 Performance Dimensions 292 Auxiliary Pressures 294 Noise Dat...

Page 16: ...Warranty Information Machine Service Record Sheet 303 Registration Information 307 European Community Standards EC Declaration of Conformity 309 Introduction 309 Explanation of the EC Declaration of...

Page 17: ...and follow the instructions in the Operator Manual If you do not understand anything ask your employer or JCB dealer to explain it INT 1 4 2 Do not operate the machine without an Operator Manual or if...

Page 18: ...iously injured INT 1 2 1 MWARNING Denotes a hazard exists If proper precautions are not taken the operator or others could be killed or seriously injured INT 1 2 2 MCAUTION Denotes a reminder of safet...

Page 19: ...Read this manual from front to back before using the machine for the first time Particular attention must be given to all the safety aspects of operating and maintaining the machine If there is anythi...

Page 20: ...on of the machine without notice is reserved No responsibility will be accepted for discrepancies which may occur between specifications of the machine and the descriptions contained in this publicati...

Page 21: ...uld be noted that these statements also apply to canopy build machines Cross References T1 004_2 In this publication page cross references are made by presenting the subject title printed in bold ital...

Page 22: ...ne Intended Use The machine is intended to be used under normal conditions for the applications described in this manual If the machine is used for other purposes or in dangerous environments for exam...

Page 23: ...Introduction Machine Description 5 5 9811 9950 1 C031400 B1 Fig 2 ZTS 8 0 3 0 1 3 2 4 7 6 5 8 E S e r v i c e s...

Page 24: ...ou of potential hazards and how to avoid them If you do not fully understand the warning messages ask your employer or JCB distributor to explain them But safety is not just a matter of responding to...

Page 25: ...are working with or on the machine take care and stay alert Always be careful Always be alert for hazards INT 1 3 5 MWARNING Clothing You can be injured if you do not wear the proper clothing Loose cl...

Page 26: ...Equipment You can be injured if you use incorrect or faulty lifting equipment You must identify the weight of the item to be lifted then choose lifting equipment that is strong enough and suitable for...

Page 27: ...d suffer serious injury or be killed INT 3 3 7_1 MDANGER Lightning Lightning can kill you Do not use the machine if there is lightning in your area 5 1 1 2 MWARNING Machine Modifications This machine...

Page 28: ...ot operate the machine outside its limits Do not try to upgrade the machine performance with unapproved modifications INT 2 1 4 MWARNING Engine Steering Failure If the engine or steering fails stop th...

Page 29: ...ter pipes etc Mark the positions of the underground cables and pipes Make sure that you have enough clearance beneath overhead cables and structures INT 2 2 1_2 MWARNING Communications Bad communicati...

Page 30: ...a to keep people away INT 2 2 8 MDANGER Sparks Explosions and fire can be caused by sparks from the exhaust or the electrical system Do not use the machine in closed areas where there is flammable mat...

Page 31: ...sure you can do them safely INT 2 1 1 MWARNING Airborne particles of light combustible material such as straw grass wood shavings etc must not be allowed to accumulate within the engine compartment or...

Page 32: ...for working beneath overhead power cables You must obtain details from your local electricity supplier 2 2 5 4 MCAUTION If you have an attachment which is not covered in the Operator Manual do not in...

Page 33: ...MWARNING Touching hot surfaces can burn skin The engine and machine components will be hot after the unit has been running Allow the engine and components to cool before servicing the unit 10 1 1 40 M...

Page 34: ...The TOPS structure is designed to give you protection in an accident If you do not wear the seat belt you could be thrown off the machine and crushed You must wear a seat belt when using the machine...

Page 35: ...when you are correctly seated 0179_2 MCAUTION Passengers Passengers in or on the machine can cause accidents Do not carry passengers INT 2 2 2_1 MWARNING Fires If your machine is equipped with a fire...

Page 36: ...angerous Before starting the engine make sure your seat belt is fastened Check the tightness and condition of the seat belt securing bolts regularly see maintenance schedules INT 2 1 8_1 MWARNING Safe...

Page 37: ...t before starting the engine 2 2 1 9 Maintenance Safety MWARNING Communications Bad communications can cause accidents If two or more people are working on the machine make sure each is aware of what...

Page 38: ...etal pins in or out Use a soft faced hammer or copper pin to remove and fit metal pins Always wear safety glasses INT 3 1 3_2 MWARNING Electrical Circuits Understand the electrical circuit before conn...

Page 39: ...letely wipe off any spilt fuel which could cause a fire There could be a fire and injury if you do not follow these precautions INT 3 2 2_3 MWARNING Oil Oil is toxic If you swallow any oil do not indu...

Page 40: ...against eye injury from components accidentally flying out GEN 6 2 MCAUTION Rams The efficiency of the rams will be affected if they are not kept free of solidified dirt Clean dirt from around the ra...

Page 41: ...aint thinners near O rings and seals INT 3 2 12 MWARNING Hydraulic Hoses Damaged hoses can cause fatal accidents Inspect the hoses regularly Do not use the machine if a hose or hose fitting is damaged...

Page 42: ...1 9950 1 MWARNING Working Under the Machine Make the machine safe before getting beneath it Ensure that any fitments on the machine are secure engage the park brake remove the starter key disconnect t...

Page 43: ...ion e g charring is found refer to the next paragraph for safety instructions DO NOT TOUCH COMPONENT OR SURROUNDING AREA Used fluoroelastomeric components subjected to temperatures greater than 300 C...

Page 44: ...fety glasses or goggles Remove or protect any combustible materials from the area which could be ignited by sparks GEN 1 12 MWARNING To avoid burning wear protective gloves when handling hot component...

Page 45: ...ne are made from cast iron welds on cast iron can weaken the structure and break Do not weld cast iron Do not connect the welder cable or apply any weld to any part of the engine Always connect the we...

Page 46: ...NG Petrol Do not use petrol in this machine Do not mix petrol with the diesel fuel in storage tanks the petrol will rise to the top and form flammable vapours INT 3 1 6 MCAUTION Do not disconnect the...

Page 47: ...toxic and corrosive Do not breathe the gases given off by the battery Keep the electrolyte away from your clothes skin mouth and eyes Wear safety glasses INT 3 2 1_3 MWARNING Battery Terminals The mac...

Page 48: ...e or exhaust system get these jobs done by a qualified person who has a copy of the engine service manual 5 1 6 1 MDANGER Before removing the boom from the machine ensure that the counterweight is ade...

Page 49: ...ding the safety labels Do not over stretch or place yourself in dangerous positions to read the safety labels If you do not understand the hazard shown on the safety label then refer to Safety Label I...

Page 50: ...ion Safety Labels 32 32 9811 9950 1 Safety Label Identification T038750 3 Fig 3 ISO 07D ISO 10A ISO 11D ISO 01A ISO 07B ISO 11E ISO 15E ISO 06D ISO 12A ISO 09C ISO 05C ISO 09A ISO 04A ISO 11A E S e r...

Page 51: ...Warning Read the operator manual before you operate the machine ISO 04A 817 70004 4 Part Number 817 70004 Description Burns to fingers and hands Stay a safe distance away ISO 05C 817 70012 2 Part Numb...

Page 52: ...tion ISO 07B 817 70018 2 Part Number 817 70018 Description Crush hazard Do not operate the controls from outside of the machine ISO 07D 817 70112 2 Part Number 817 70112 Description Crush hazard Keep...

Page 53: ...ount safely Refer to Entering and Leaving the Cab Operation Section ISO 09C 817 70102 3 Part Number 817 70102 Description Crushing of fingers or hands Remove the starter key and refer to the Service M...

Page 54: ...4581 1 Part Number 332 P4581 Description Severing of hands or fingers Keep clear of do not reach into the moving parts Stop the engine and remove the starter key before you start maintenance work Refe...

Page 55: ...model and build specification is indicated by the PIN Refer to Typical Product Identification Number PIN If the engine is replaced by a new one the serial number on the identification plate will be wr...

Page 56: ...acturer Identification 3 Digits JCB UK Build 2 Machine Type and Model 5 Digits 08025 8025 3 Random Check Letter 1 Digit The Check Letter is used to verify the authenticity of a machine s PIN 4 Machine...

Page 57: ...engine identification number A typical engine identification number is 1 Engine Type 2 Digits GJ Naturally aspirated 8026 CTS 18 4kW GJ Naturally aspirated 8025 ZTS 8030ZTS 20 9kW GJ Naturally aspirat...

Page 58: ...in death or injury to the operator 5 3 1 7_2 Machines built to ROPS and TOPS standards have an identification label fitted to the cab K Fig 6 T 40 A bolt on falling object guard is available which als...

Page 59: ...nformation contact your JCB Dealer The falling objects protection structure FOPS is fitted with a dataplate The dataplate indicates what level protection the structure provides There are two levels of...

Page 60: ...f any one of these security devices will help to minimise not only the damage or loss of your machine but also subsequent lost productivity It could also result in reduced insurance premiums Construct...

Page 61: ...AR initiative and will offer it as a factory fit option across the range The CESAR kit includes 2 Tamper proof triangular ID plates fitted on either side of the machine a unique transponder mini radio...

Page 62: ...Introduction Machine Security 44 44 9811 9950 1 Page left intentionally blank E S e r v i c e s...

Page 63: ...ere is anything you do not understand ask your JCB distributor The operator must always be aware of events happening in or around the machine Safety must always be the most important factor when you o...

Page 64: ...get caught in the linkages Lower the boom and dipper before doing these checks If you are new to this machine get an experienced operator to lower the boom and dipper for you If there is nobody to he...

Page 65: ...with damaged tracks Do not use the machine with damaged or excessively worn tracks MD 2 1 1 3 Check the tracks Rubber Check for cut rubber and penetration by sharp objects Do not use a machine with d...

Page 66: ...ved The machine must always be entered exited with the left hand isolator raised via the left hand side 8 2 9 22 MWARNING Do not enter or exit the cab unless the arm rest or lever lock is fully engage...

Page 67: ...always maintain a three point contact with the handrails and step Do not use the machine controls as handholds Emergency Exit Glazing Breaker Remove the glazing breaker B and strike the rear screen n...

Page 68: ...Operation Entering and Leaving the Cab 50 50 9811 9950 1 Fig 8 B A E S e r v i c e s...

Page 69: ...provided and press the lock barrel to release the catch Pull the handle towards you To open the door from inside push lever A forwards K Fig 9 T 51 Close the door from the inside by pulling it firmly...

Page 70: ...ured in the fully open position Swing the door fully open until the spigot A on the door locates securely in the socket B on the side of the cab K Fig 10 T 52 804110 Fig 10 To release the door when it...

Page 71: ...Operation Doors and Windows 53 53 9811 9950 1 C035100 Fig 11 E S e r v i c e s...

Page 72: ...e hydraulic controls before opening and closing the window 0120 To open the up and over window 1 Hold handles A press and hold down securing levers B 2 Lift the screen into a position parallel with th...

Page 73: ...solated Open the front window and secure it in a position parallel with the roof K Opening and Closing the Front Window T 54 MWARNING When handling the removed windscreen lower panel take care not to...

Page 74: ...een lower panel and stow it next to the rear window as shown at G Turn retainers F to secure the panel and tighten screws E To refit the windscreen lower panel reverse the removal procedure Make sure...

Page 75: ...The side window is held closed by catch A operated from inside the cab To open the window operate the catch A and slide the window to the desired position To close the window slide the window fully s...

Page 76: ...ou could have an accident if you operate the machine with the seat in the wrong position 13 1 1 9_1 The operator s seat can be adjusted for your comfort A correctly adjusted seat will reduce operator...

Page 77: ...Operation Seat Controls 59 59 9811 9950 1 Standard Seat The forward and backwards adjustment is adjusted using lever B T033180 1 Fig 16 A E S e r v i c e s...

Page 78: ...Seat If fitted The seat back rest can be adjusted by moving lever A The forward and backwards adjustment is adjusted using lever B Weight adjustment is adjusted by lever C The thigh support is adjuste...

Page 79: ...eplace it with a new one if it is damaged if the fabric is worn or if the machine has been in an accident Fit a new seat belt every three years 2 3 1 7_1 Fasten the Seat Belt 1 Sit correctly in the se...

Page 80: ...Belt MWARNING Release the seat belt only after switching off the engine 2 2 1 10 Press button C and pull the male fitting A from the buckle B Fig 18 Adjusting the Seat Belt Make sure the belt is acros...

Page 81: ...50 1 To adjust the male fitting A 1 Pull toggle D down the strap by the required distance a To make the strap longer pull end E as far as it will go b To make the strap shorter pull end F as far as it...

Page 82: ...Operation Cab Layout 64 64 9811 9950 1 Cab Layout C019600 1 Fig 20 0 1 SAE 12 4 13 2 8 1 6 5 11 9 10 7 7 3 E S e r v i c e s...

Page 83: ...Starter Switch T 72 4 K Horn T 74 5 K Auxiliary Power Socket T 73 6 K Console Switches T 70 7 K Excavator Controls T 82 8 K Instrument Panel T 75 9 K Swing Auxiliary Switch T 74 10 K Dozer Controls T...

Page 84: ...de lever controls the left track The right side lever controls the right track The two levers can be operated individually or together as necessary to move the machine as required This can be done usi...

Page 85: ...MWARNING When the cab is swung around so that it is facing the track motor end of the undercarriage the action of the tracking controls is reversed Take extra care 8 2 8 1 731911 5 Fig 22 Moving the...

Page 86: ...ft lever back to turn left This causes one of the tracks to move slower than the other The faster moving track will push the machine around Release the lever to stop 731911 8 Fig 24 Spinning the machi...

Page 87: ...e Lever A hand operated throttle lever in the cab controls the speed of the engine K Fig 25 T 69 Move the lever A to increase or B to decrease the engine speed The lever can be left in any position be...

Page 88: ...to the specification of the machine Each switch has a graphic symbol A to show the function of the switch Before you operate a switch make sure that you understand its function The rocker switches ha...

Page 89: ...ition Position 1 OFF Position 3 Boom and cab work lights ON Cab machines only Position 2 Boom work light ON Rear Window Wiper if fitted 340070 1 Three position rocker switch The switch functions opera...

Page 90: ...f the engine fails to start the switch needs to be returned to position 0 before re engaging the starter H04432 2 Fig 27 0 Turn the key to this position to stop the engine Make sure the controls are i...

Page 91: ...or a long period of time C007130 1 Fig 28 Auxiliary Power Socket The socket X supplies a 12 Volt DC power supply to electrical accessories from the battery Only connect items which are compatible with...

Page 92: ...a push button switch located in the left hand excavator control lever Press the switch to set the swing auxiliary pedal to control either swing or auxiliary services For more information refer to Exca...

Page 93: ...ted GREEN when high speed is engaged 5 SAE Controls Selected Indicator Illuminates GREEN when SAE control pattern is selected 6 Glow Plugs On Indicator Illuminates YELLOW when the Glow Plugs are energ...

Page 94: ...Operation Drive Controls Switches and Instruments 76 76 9811 9950 1 445991 B6 Fig 30 10 4 11 5 7 6 9 8 12 3 2 1 E S e r v i c e s...

Page 95: ...4 bars to Full Pump symbol illuminated All bars illuminated and reducing as level drops ie 11 bars 10 bars 9 bars etc 3 4 bars to 3 bars Buzzer gives 3 short beeps Pump symbol starts to flash 4 3 bar...

Page 96: ...the buzzer will sound continuously for 180 seconds after which it will sound intermittently one second on two seconds off Set the starter key to the off position to reset all operations 1 Charge Fault...

Page 97: ...ote The air intake filter F should be washed in warm soapy water if it becomes dirty Fig 32 Cab Heater Controls Air can be directed into the cab by selecting the required fan speed using switch A Temp...

Page 98: ...d before raising the boom Keep an adequate safe distance from all electrical power lines Contact your local power company for safety procedures 5 2 1 5_1 Control Layouts MWARNING Control lever switch...

Page 99: ...Operation Operating Levers Pedals 81 81 9811 9950 1 Page left intentionally blank E S e r v i c e s...

Page 100: ...ted The excavator levers are spring loaded to the central position In this position related services will not operate The speed and movement of the associated hydraulic function depends on how far you...

Page 101: ...Operation Operating Levers Pedals 83 83 9811 9950 1 C035010 3 Fig 34 SAE h 1 A B E S e r v i c e s...

Page 102: ...Excavator Levers ISO Control Pattern 731911 11 Fig 35 A Slew cab left B Slew cab right C Raise boom D Lower boom E Dipper in F Dipper out G Close bucket to gather a load H Open bucket to dump a load...

Page 103: ...Operation Operating Levers Pedals 85 85 9811 9950 1 731911 Fig 36 F E S e r v i c e s...

Page 104: ...Excavator Levers SAE Control Pattern 731911 2 Fig 37 A Slew cab left B Slew cab right C Raise boom D Lower boom E Dipper in F Dipper out G Close bucket to gather a load H Open bucket to dump a load J...

Page 105: ...Operation Operating Levers Pedals 87 87 9811 9950 1 731911 Fig 38 F E S e r v i c e s...

Page 106: ...he pedal when the excavator end has reached the desired position To swing the boom to your right B make sure that the swing auxiliary switch C is selected to swing press the swing auxiliary pedal D to...

Page 107: ...Operation Operating Levers Pedals 89 89 9811 9950 1 796300 B3 Fig 40 A B A B D E S e r v i c e s...

Page 108: ...by a single control lever C on the right side of the cab K Fig 41 T 91 The lever is spring loaded to the central position In this position the dozer will not move Raise Dozer A To raise the dozer pul...

Page 109: ...Operation Operating Levers Pedals 91 91 9811 9950 1 C019940 2 Fig 41 C B A A B E S e r v i c e s...

Page 110: ...ion before operating the swing auxiliary pedal 8 2 9 39 Make sure that the swing auxiliary switch C is selected to auxiliary position K Fig 43 T 93 Press the swing auxiliary pedal D to the left A or r...

Page 111: ...Operation Operating Levers Pedals 93 93 9811 9950 1 796300 B4 Fig 43 A B D E S e r v i c e s...

Page 112: ...railer otherwise the boom could swing to one side and cause injury or death 8 2 9 41 Slew Lock The slew lock is situated in the seat bulkhead K Fig 44 T 94 Lift and move to the desired position X posi...

Page 113: ...Be careful when you operate the machine with a beacon The total height of the machine is increased when the beacon is in the operating position 1 Put the beacon A on the cab roof Note The beacon is he...

Page 114: ...e buzzer sounds the operator must do the necessary corrective action to reduce the lift When this is fulfilled the buzzer is cancelled and the system resets automatically When the machine is not used...

Page 115: ...ire Extinguisher If fitted Location The fire extinguisher A is located in the front of the cab and is held in position by a stowage bracket Keep the fire extinguisher in this position until you need t...

Page 116: ...the instructions found on the fire extinguisher Only try to extinguish a fire if the circumstances permit and your safety is not endangered If necessary contact your nearest fire department Using the...

Page 117: ...Operation Safety Equipment 99 99 9811 9950 1 S170520 3 Fig 48 The fire extinguisher should be inspected daily Refer to Routine Maintenance Fire Extinguisher if fitted E S e r v i c e s...

Page 118: ...area around it are clear of other people Anyone on or close to the machine could fall and be crushed by the attachments or get caught in the linkages 2 2 3 4 1 Lower the excavator bucket and dozer to...

Page 119: ...that your hands and shoes are clean and dry MWARNING Loose articles can fall and strike you or roll on the floor You could be knocked unconscious or the controls could get jammed If that happens you c...

Page 120: ...n an accident Fit a new seat belt every three years 2 3 1 7_1 j Check that the following are in working order Lights Horn All Switches Windscreen Washer and Wipers if fitted 3 Adjust the seat so that...

Page 121: ...n you must disarm the immobiliser before you can start the engine Refer to Immobiliser if fitted 3 Start the Engine a Move the throttle lever to half speed position b Turn the starter key to the glow...

Page 122: ...come on while the engine is running stop the engine as soon as it is safe to do so Note The engine noise and or tone may be louder than usual when cold The engine will become quieter when the engine...

Page 123: ...hand lever to the left for 5 seconds Repeat for several minutes b Select dozer up by moving dozer control lever backwards keep selected for one minute 3 Warm up hydraulic circuit a Reduce engine spee...

Page 124: ...h attempt will lock the system for 30 minutes It then resets and you will have three more attempts Note If you wait more than eight seconds between button presses then the immobiliser will go into err...

Page 125: ...2 minutes the system disarms automatically To Add a New or Additional PIN Code The Keypad Immobiliser System can be programmed to accept a maximum of 14 different four digit PIN codes 1 Turn the star...

Page 126: ...T MD F1 then ENT If you have successfully deleted all the PIN codes the LED A will flash 5 times Unique Key Immobiliser System T2 029_4 Each machine is supplied with a master key red and two starter k...

Page 127: ...s automatically immediately The red LED B flashes for 60 seconds then goes OFF To Add a New or Additional Starter key Note Starter keys can be programmed to start more than one machine 1 Put the maste...

Page 128: ...ion I The LED will flash 3 times 2 Keep the starter switch in position I for 60 seconds the LED will flash 5 times The starter key codes have now been deleted from the ECU 3 Turn the starter switch to...

Page 129: ...A then push the hand throttle lever B to the idle position MWARNING Ensure that the excavator is in a safe condition 8 2 9 34 MCAUTION Before stopping the engine lower the dozer blade to the ground 8...

Page 130: ...Operation Stopping and Parking the Machine 112 112 9811 9950 1 period close and latch the window and lock the door Make sure that the fuel filler cap is locked Fig 53 C B C A E S e r v i c e s...

Page 131: ...necessarily the applied law Please make sure that before you travel on site you and your machine comply with all the relevant local laws it is your responsibility Preparing for Site Travel P11 2029_2...

Page 132: ...Operation Preparing the Machine for Travel 114 114 9811 9950 1 732010 7 Fig 54 150mm 6in E S e r v i c e s...

Page 133: ...l trained and experienced operator your machine is a safe and efficient machine With an inexperienced or careless operator it can be dangerous Do not put your life or the lives of others at risk by us...

Page 134: ...ailable JCB can accept no responsibility for the recommendations advice statements opinions and conclusions expressly or by implication and gives no warranty or representation of assurance in respect...

Page 135: ...f you uncover any containers or you see any signs of toxic waste stop the machine and advise the site manager immediately 2 2 5 5 MWARNING Water Supplies and Drains Before you start using the machine...

Page 136: ...excavation work commences Hand dig trial holes to obtain precise pipe locations Any cast iron pipes found should be assumed to be gas pipes until contrary evidence is obtained Older gas pipes can be d...

Page 137: ...ou will not do your job well and you will be a danger to yourself and others If you will be working with a labourer make sure you both understand what each other will be doing Learn and use the recogn...

Page 138: ...the machine 8 2 9 30 Preparing to Use the Excavator P11 2031 When choosing a digging position avoid digging downhill if possible Whenever possible dump the load on the uphill side of the excavation B...

Page 139: ...xcavate on hard or rocky ground with the boom positioned diagonally across the undercarriage The resulting rocking motion could cause damage to the track gearbox sprockets and tracks 8 2 2 6_2 It is p...

Page 140: ...larly do not use the side of the bucket to push soil into the excavation Both these practices will damage the machine 16 2 7 2 3 Slew the machine or swing the bucket to the dump area Start dumping as...

Page 141: ...Operation Working with the Machine 123 123 9811 9950 1 731990 2 Fig 55 1 2 3 E S e r v i c e s...

Page 142: ...longer than the excavator s reach dig to the required depth and width A until it is not possible to dig any closer without contacting the machine When this position is reached move the machine a suita...

Page 143: ...excavator you must read and understand this section Failure to take the precautions shown can result in death or injury 2 2 7 38 Before using this machine for lifting refer to Specifications Lifting...

Page 144: ...se a signalman when lifting with the excavator Make sure you both understand and use the recognized signals Keep all persons clear of the load and machine while the load is on the excavator 1 A bucket...

Page 145: ...ck the load weight before choosing the lifting chains 4 Attach a handline to the load Make sure the person holding the handline stands clear of the load and machine 5 Test the load by lifting it 25 50...

Page 146: ...t exceeded Important If a load chart is not provided in the cab the machine is not designed for lifting MCAUTION The Load Chart shown is only an example Do not use it to find the loading limits on you...

Page 147: ...ng with the Machine 129 129 9811 9950 1 Using the Load Chart A Working Height at Bucket Pivot B Distance of Bucket pivot from centre of machine metres C Weight to be lifted kgs D Safe Working Load E S...

Page 148: ...Fig 59 Example only 2 m 337 198 3 5 A 1 103m 0 5 1 301 C m 258 _ 2 5 420 397 3 _ C Kg 242 1 0 187 306 306 3 372 1 2 0 1 0 236 2 1 0 277 8025 ZTS 3 0 318 0 5 _ 0 294 332 V2521 4 0 _ 0 390 238 2 _ 453 4...

Page 149: ...machines in such applications 0017 There are a number of factors which can adversely affect the stability of the machine and the safety of the machine and operator when used on a gradient It is essen...

Page 150: ...er for maximum stability This may mean the dozer and the boom are at the same end of the machine especially if digging down hill lower the dozer sufficiently to bring the machine level If necessary to...

Page 151: ...orking with the dozer Dozing and Grading Keep the bottom of the dozer parallel to the ground When grading a site remove high spots first then use this soil to fill in troughs Do not use excessive down...

Page 152: ...ter the cut Backfilling When backfilling on a slope pile the material on the high side of the trench whenever possible Set the dozer level to the ground Work at right angles to the trench filling a do...

Page 153: ...the end of each work period This will help to prevent condensation forming on the tank walls 6 Protect the machine when not in use Park the machine inside a building or cover it with a tarpaulin 7 Ins...

Page 154: ...rm 3 If the machine is left outside for more than one day without usage remove the battery and take it indoors 4 Drain the water collected in the fuel system to prevent it freezing 5 Clean the machine...

Page 155: ...dless of the inspection interval Not the safety element 2 Securely tighten the hydraulic oil tank filler cap to prevent sand and dust from entering the hydraulic system Operating in Coastal Regions 1...

Page 156: ...When moving the machine keep it under control at all times Stay alert for obstructions and possible hazards Approach deep mud slowly MWARNING Do not dismount a moving machine 3 2 3 12 Take particular...

Page 157: ...ened b Make sure that the seat is correctly adjusted 2 Make sure that the cab slew lock is disengaged and the slew switch is pressed 3 Move off a Check that the attachments are in the travel position...

Page 158: ...or load while there is air in the fuel system then subsequent damage to the engine can occur If the fuel supply contains air you must stop the engine fill the fuel tank then bleed the fuel system to...

Page 159: ...l in this machine Do not mix petrol with the diesel fuel in storage tanks the petrol will rise to the top and form flammable vapours INT 3 1 6 MWARNING Mobile Phones Switch off your mobile phone befor...

Page 160: ...e of fuel This will prevent overnight condensation from developing in the fuel Note Do not fill the tank completely leave some space to allow the fuel to expand 1 Unlock and remove the fuel cap A 2 Ca...

Page 161: ...stores a limited amount of hydraulic pressure for use in an emergency engine failure for example This hydraulic pressure should be used to position the dipper and lower the boom into a safe position D...

Page 162: ...ne should be made safe lifted onto a transporter and moved to a location where is can be repaired K Lifting a Machine T 154 In the event that towing the machine to a safe location is unavoidable then...

Page 163: ...slowly not greater than 2 kph 1 24 mph smoothly and without shocks Tow the machine the minimum distance to a safe location for recovery by lifting not to exceed 20 m 65 ft Following this procedure the...

Page 164: ...hicles Note Before transporting the machine make sure you will be obeying the local rules and laws regarding machine transportation of all the areas that the machine will be carried through Make sure...

Page 165: ...tracks Make sure the machine will not foul on the ramp angle 8 2 9 33 1 Remove any dirt or debris from the trailer 2 Check the operation of the park brake 3 Check the trailer bodywork for signs of da...

Page 166: ...pper for stability With the machine in low speed mode track forward onto the ramp slowly and smoothly Ensure the bucket will not contact the transporter ramps when loading the machine 5 Slowly drive t...

Page 167: ...Operation Transporting the Machine 149 149 9811 9950 1 11 Raise any jacks to their transport position 800980 2 Fig 66 E S e r v i c e s...

Page 168: ...ly and lower the boom until the bucket rests on a wooden block on the trailer bed 3 Position a securing strap A of suitable breaking strain over the bucket and secure to the trailer shackles 4 Place s...

Page 169: ...Operation Transporting the Machine 151 151 9811 9950 1 800950 3 Fig 67 X B C B C A D C E S e r v i c e s...

Page 170: ...transporter Note Ramps should be level with each other in the lowered position 4 Remove the securing straps from the machine and stow them 5 Start the machine and raise the bucket MWARNING If the doze...

Page 171: ...Operation Transporting the Machine 153 153 9811 9950 1 800990 4 Fig 68 E S e r v i c e s...

Page 172: ...unladen weight of the machine Refer to Static Dimensions SPECIFICATIONS section MWARNING Lifting Equipment You can be injured if you use faulty lifting equipment Make sure that lifting equipment is in...

Page 173: ...red Make sure that the area is clear of other people before lowering the load If you do not follow these precautions you or others could be killed or seriously injured 2 3 5 3 MWARNING Communications...

Page 174: ...to 129 F When possible you must keep the machine in a dry building or shelter If only an outdoor storage area is available look for a storage area with good drainage If the machine is to be out of us...

Page 175: ...bers under the machine to eliminate direct contact with the ground 2 Retract all rams and lower the attachments to the ground 3 Vent the hydraulic system 4 Remove the starter key 5 Apply a thin layer...

Page 176: ...hydraulic functions operate correctly 6 Prepare the machine for storage Refer to Put the Machine into Storage Take the Machine Out of Storage T2 079 1 Examine the coolant condition Replace If necessar...

Page 177: ...he service requirements necessary to maintain your JCB machine at peak efficiency A Service Manual for your machine is available from your JCB Distributor The Service Manual contains information on ho...

Page 178: ...ied with your new JCB machine If you do encounter a problem however you should contact your Distributor s Service Department who are there to help you You will have been given the names of the relevan...

Page 179: ...annually in some countries to meet and comply with legislation and for insurance purposes Check with your local JCB distributor for further advice Obtaining Replacement Parts T3 096 If you use non gen...

Page 180: ...kin contact can remove the natural fats from your skin causing dryness and irritation Low viscosity oils are more likely to do this so take special care when handling used oils which might be diluted...

Page 181: ...uld be in accordance with any local regulations Never pour used engine oil into sewers drains or on the ground Handling MWARNING Oil Oil is toxic If you swallow any oil do not induce vomiting seek med...

Page 182: ...ine oil from skin a Wash your skin thoroughly with soap and water b Using a nail brush will help c Use special hand cleansers to help clean dirty hands d Never use petrol diesel fuel or paraffin for w...

Page 183: ...lly approved brand of absorbent granules Scrape up and remove to a chemical disposal area Fires MWARNING Do not use water to put out an oil fire This will only spread it because oil floats on water Ex...

Page 184: ...disconnecting and connecting the battery When disconnecting the battery take off the earth lead first Re charge the battery away from the machine in a well ventilated area Switch the charging circuit...

Page 185: ...rom fires or spillage should be put in a closed acid proof receptacle and must be disposed of in accordance with local environmental waste regulations INT 3 1 12 MWARNING Battery Gases Batteries give...

Page 186: ...llowing warning symbols may be found on the battery Symbol Meaning A289230 1 Keep away from children A289260 1 Shield eyes A289280 No smoking no naked flames no sparks A289250 Explosive Gas A289240 Ba...

Page 187: ...flush with water for 15 minutes always get medical help Is swallowed Do not induce vomiting Drink large quantities of water or milk Then drink milk of magnesia beaten egg or vegetable oil Get medical...

Page 188: ...ly maintained machine is a danger to the operator and the people working around him Make sure that the regular maintenance and lubrication jobs listed in the service schedules are done to keep the mac...

Page 189: ...s the requirements to be carried out every 500 hours Important Services should be carried out at either the hourly interval or calendar interval whichever occurs first Refer to Calendar Equivalents Im...

Page 190: ...ntenance Service Schedules 172 172 9811 9950 1 Calendar Equivalents T3 098 Every 10 Hours Daily Every 50 Hours Weekly Every 500 Hours Six Months Every 1000 Hours Yearly Every 2000 Hours 2 Years E S e...

Page 191: ...Oil level Check Oil and Filter Change Air Cleaner Element Dusty Conditions only Change Air Cleaner Outer Element Change Air Cleaner Inner Element Change Air Cleaner Hose Security Check and Adjust Air...

Page 192: ...Tension Condition Check and Adjust Valve Clearances 1 Check and Adjust Cylinder Head Bolts for Tightness Check and Adjust Engine Mounting Bolts for Tightness Check and Adjust Exhaust System Security C...

Page 193: ...Oil Change HYDRAULICS Oil Level Check Oil Change Rams Chrome Condition Check Hoses and Pipework Damage Leaks Check Return Filter Element Change Suction Strainer Clean Security of Mounting Bolts on Maj...

Page 194: ...Tightness Check UNDERCARRIAGE Track Rollers Bolts Check Track Rollers Oil and Seals Change Idler Wheels Oil and Seals Change Track Plate Condition and Bolt Torque Check Track Tension Check BODYWORK A...

Page 195: ...Check Slew Ring Pinion and Gear Teeth Grease Door Window Hinges Lubricate Windscreen Washer Fluid Level Check Machine Generally Check and Clean ATTACHMENTS Quick Hitch Grease OPTIONAL EQUIPMENT As Req...

Page 196: ...Smoke excessive Check Fuel System Leaks and Contamination Check HYDRAULICS Operation All Services Excavator Dozer etc Check Hoses and Pipework Damage Leaks Check Main Relief Valve Pressure 1 Check an...

Page 197: ...IAGE Track and Running Gear Operation Check BODYWORK AND CAB Excavator Lever and Swing Pedal Locks Check LIFTING EQUIPMENT Fit for Purpose Test 2 Complete 1 Jobs which should only be done by a special...

Page 198: ...ACEA E5 B3 A3 API CH4 SJ above 15 C above 5 F 5W 20 API CC SE recommended 15 C to 25 C 5 F to 13 F Engine Coolant 8 5 1 9 JCB High Performance Antifreeze and Inhibitor Water K Coolant Mixtures T 182...

Page 199: ...ank 40 8 8 JCB Special Hydraulic Fluid Up to 30 C 86 F JCB Hydraulic Fluid 46 Over 30 C 86 F Slew Ring Bearings JCB MPL Grease Lithium based no 2 consistency Slew Ring Gear Teeth JCB Slew Pinion Greas...

Page 200: ...more than a moderate hardness pH value 8 5 If this cannot be obtained use de ionized water For further information advice on water hardness contact your local water authority The correct concentratio...

Page 201: ...Specification ASTM D6210 Always read and understand the manufacturer s instructions Ensure that a corrosion inhibitor is included Serious damage to the cooling system can occur if corrosion inhibitors...

Page 202: ...d to the quality and grade of the fuel used MCAUTION Consult your fuel supplier or JCB distributor about the suitability of any fuel you are unsure of GEN 9 2 Table 2 Fuel Specification Applicable Eng...

Page 203: ...ortant Engines operated with these fuels may have a reduced service life Obey the usual routine maintenance schedules and procedures Fuel additives must be used 1 K Additives T 187 AVCAT FSII NATO F44...

Page 204: ...perated with these fuels AVTAG FSII obsolete NATO F40 JP4 DERD 2454 JET B ASTM D1655 BS MA100 JIS K2203 No 2 Unmodified vegetable oils 1 Use a fuel additive where instructed to make sure that the fuel...

Page 205: ...e products are given as examples only The information is derived from the manufacturers data The products are not recommended or endorsed by JCB Service Requirements for use of B5 Biodiesel The engine...

Page 206: ...formance related issues are to be reported to JCB Service and the engine has been run on biodiesel then the fuel system must be filled with standard diesel at least 2 x tank fills to EN590 specificati...

Page 207: ...appropriate fuel lubricity additives these lubricity improvers must not create residual deposits that block the fuel system e g injectors filters etc Contact your fuel Supplier MCAUTION A combination...

Page 208: ...or careless handling and will almost inevitably condense in fuel tanks The smallest amounts of water can result in effects that are just as disastrous to the fuel injection pump as dirt causing rapid...

Page 209: ...70 Carrying Tools onto the Machine When you carry tools onto the machine you must maintain three points of contact with the machine at all times Lift tools onto the machine in intervals if necessary P...

Page 210: ...hould be correctly parked on level ground To prevent anyone starting the engine remove the starter key Disconnect the battery when you are not using electrical power If you do not take these precautio...

Page 211: ...u differently you must lower the Excavator 1 Park the machine on level solid ground If necessary refer to Stopping and Parking the Machine in the Operator Manual 2 Lower the dozer 3 Lower the excavato...

Page 212: ...ine away from the wash area or alternatively clean away the material washed from the machine Important When removing components be aware of any dirt or debris that may be exposed Cover any open ports...

Page 213: ...s such as the engine electronic control unit ECU alternator or fuel injectors Use a low pressure water jet and brush to soak off caked mud or dirt Use a pressure washer to remove soft dirt and oil Not...

Page 214: ...ore often if required Before opening the engine cover ensure that the top is clear of debris 5 3 1 12_3 MCAUTION Never use water or steam to clean inside the cab The use of water or steam could damage...

Page 215: ...ent operator If the wrong control lever is moved or if the controls are moved violently the other person could be killed or injured If you will be working with another person make sure that you both u...

Page 216: ...ear Keep other people well clear 8 3 5 8 4 Operate the controls to rotate the track which is off the ground Rotate it one way and then the other to shake off the mud If necessary the person outside ma...

Page 217: ...damaged items Check all lamp lenses for damage Check all attachment teeth are undamaged and secure Check all safety and instructional labels are in place and undamaged Fit new labels where necessary C...

Page 218: ...ct the hoses regularly Do not use the machine if a hose or hose fitting is damaged INT 3 3 2_4 Inspect the hoses regularly for Damaged hose ends Chafed outer covers Ballooned outer covers Kinked or cr...

Page 219: ...electrical circuits regularly for Damaged connectors Loose connections Chafing on wiring harnesses Corrosion Missing insulation Incorrect routing of harness Do not use the machine if one or more of th...

Page 220: ...turer may be dangerous and will invalidate the ROPS FOPS certification INT 2 1 9_6 For assistance contact your JCB distributor Failure to take these precautions could result in death or injury to the...

Page 221: ...grease Do not mix different types of grease keep them separate In the following illustrations the grease points are numbered Count off the grease points as you grease each one Refit the dust caps aft...

Page 222: ...ttery This will prevent the engine being started 8 3 1 3 For the types of grease to use at each point K Fluids Lubricants and Capacities T 180 Do not mix different types of grease keep them separate A...

Page 223: ...Routine Maintenance Greasing 205 205 9811 9950 1 Fig 72 ZTS 8 0 4 0 B A A B C C C D D E E F F H H G E S e r v i c e s...

Page 224: ...kept full of grease With the cab in the straight ahead position as shown the grease point A is located near the front of the slew ring To ensure full distribution of the grease use the following proce...

Page 225: ...1 7 MWARNING Soft Ground A machine can sink into soft ground Never work under a machine on soft ground INT 3 2 4 MWARNING Jacking A machine can roll off jacks and crush you Do not work under a machine...

Page 226: ...Routine Maintenance Greasing 208 208 9811 9950 1 Fig 74 7 Repeat steps 4 to 6 as necessary 8 Refit the plate B using bolts A 9 Lower the machine to the ground C031400 E S e r v i c e s...

Page 227: ...g parts Switch OFF the engine before working in the engine compartment Do not use the machine with the engine cover open 5 2 6 5 MWARNING Touching hot surfaces can burn skin The engine and machine com...

Page 228: ...Maintenance Access Panels 210 210 9811 9950 1 Closing the Cover 1 Make sure that the hydraulic bay cover is closed 2 Push the engine cover down 3 Make sure it is locked in place Fig 75 A B E S e r v...

Page 229: ...t access to the engine Refer to Access Panels Engine Cover 3 Locate handle H which is positioned in the top right hand corner of the engine bay above the air filter K Fig 75 T 210 4 Pull the handle H...

Page 230: ...ery while the engine is running otherwise the electrical circuits may be damaged INT 3 1 14 Battery Access 1 Make the machine safe with the excavator lowered Refer to Prepare the Machine for Maintenan...

Page 231: ...e battery K Battery Access T 212 2 If the machine has a battery isolator move the switch to the OFF position then remove the key K Battery Isolator if fitted T 216 3 Remove the leads Disconnect the ea...

Page 232: ...s should not need topping up However in certain conditions such as prolonged operation at tropical temperatures or if the alternator overcharges the electrolyte level should be checked as described be...

Page 233: ...Routine Maintenance Electrical System 215 215 9811 9950 1 Fig 78 4 Refit battery 5 Close and lock the access panels E S e r v i c e s...

Page 234: ...rotect the circuits and components The battery must still be disconnected even if a battery isolator is fitted INT 3 1 13 To disconnect the machine electrics 1 Open the tool storage cover K Toolbox if...

Page 235: ...are not controlled by the starter switch Do not connect the booster slave supply directly across the starter motor Use only sound jump leads with securely attached connectors Connect one jump lead at...

Page 236: ...e not already there They will lower themselves under their own weight when you operate the control Operate the control carefully to control the rate of descent 2 Set all switches in the cab to OFF 3 G...

Page 237: ...he booster cables a Disconnect the negative booster cable from the machine frame earth Then disconnect if from the booster supply b Disconnect the positive booster cable from the positive terminal on...

Page 238: ...al circuits are protected by fuses If a fuse blows find out why before fitting a new one Two primary fuses A and B are located in the battery compartment below the cab door K Fig 80 T 220 The secondar...

Page 239: ...Engine Stop Solenoid 5 2 Instruments Two speed Circuit Servo Solenoid 5 3 Wash Wipe Circuit 15 4 Slew Swing Circuit SAE Control 15 5 Boom Light 7 5 6 Work Lights 15 7 Interior Light Horn Radio Access...

Page 240: ...the oil to drain back into the engine sump before taking a reading If insufficient time is given a false low reading may be recorded which will result in overfilling the engine 3 Withdraw dipstick an...

Page 241: ...slowly If the oil is added too rapidly it will enter the cylinders through the hose and intake manifold and cause serious engine damage 8 3 5 10 4 If necessary add oil slowly through the remote fille...

Page 242: ...lug 2 3 3 4 1 Remove the engine skid plate to gain access to the engine drain plug if necessary 2 Place a container beneath the engine to catch the oil Remove the drain plug A Let the oil drain out th...

Page 243: ...tainer neck Z completely into the filler hole K Fig 83 T 223 5 Allow oil to flow down from the filler to the crankcase Replace filler cap securely Use only the recommended oil Important Oil must be ad...

Page 244: ...e you work on the cooling system 9 3 3 1_2 1 Get access to the engine Refer to Access Panels Engine Cover Allow the engine to cool 2 Observe the coolant fluid in the expansion bottle the bottle A shou...

Page 245: ...ss Panels Engine Cover Allow the engine to cool 2 Carefully and slowly remove the radiator cap allowing any trapped pressure to escape 3 Undo the plug B on the cylinder block and let the coolant drain...

Page 246: ...er and anti freeze K Coolant Mixtures T 182 7 Refit the filler cap A making sure that it is tight 8 Run the engine for a while to raise the coolant to working temperature and pressure Stop the engine...

Page 247: ...the alternator pulley and the crankshaft pulley 3 If necessary adjust the fan belt as follows a Slacken lock nut B K Fig 87 T 229 b Turn screw C until there is 5mm 0 2in slack midway between the alte...

Page 248: ...Clean the inside of canister and dust valve with a vacuum cleaner 4 Prior to fitting new element smear the seal on the end of the element with grease Temporarily insert the filter element into the ca...

Page 249: ...o prevent dust getting into the engine remove the induction hose Y Cover the hose to prevent rain and dirt getting into the engine K Fig 89 T 231 3 Undo the two retaining clips holding the cover A and...

Page 250: ...grease inserting element correctly withdrawing and checking for continuous grease witness mark Refit element 8 Remove cover from induction hose Y and refit Check security and condition of all air hose...

Page 251: ...r working on the fuel system Do not refuel with the engine running Completely wipe off any spilt fuel which could cause a fire There could be a fire and injury if you do not follow these precautions I...

Page 252: ...always fit protective caps and plugs to prevent dirt ingress Failure to follow these instructions will lead to dirt entering the system Dirt in the system will seriously damage the systems components...

Page 253: ...e engine Refer to Access Panels Engine Cover 2 Locate the sedimenter under the engine compartment at the front in a central position 3 If there is any sediment in the bowl replace the fuel filter elem...

Page 254: ...ccess Panels Engine Cover 2 Drain the sediment bowl A K Draining the Fuel Filter Sedimenter T 235 3 Unscrew the filter and sediment bowl from the filter head B 4 Unscrew the sediment bowl A from the f...

Page 255: ...ine Refer to Access Panels Engine Cover 2 Clamp the fuel hoses A K Fig 92 T 237 3 Disconnect the fuel hose clips B 4 Remove the bolt C Collect the washer Remove the fuel pre filter D 5 Install new fil...

Page 256: ...ke sure that you have no loose clothing cuffs ties etc which could get caught in rotating parts When the engine is turning keep clear of rotating parts 2 3 3 8 1 Get access to the engine Refer to Acce...

Page 257: ...Routine Maintenance Fuel System 239 239 9811 9950 1 T015790 2 Fig 93 A E S e r v i c e s...

Page 258: ...en inspect the cardboard for signs of fluid If fluid penetrates your skin get medical help immediately INT 3 1 10_3 MWARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you Before...

Page 259: ...tem thoroughly clean around the connection When a component has been disconnected always fit protective caps and plugs to prevent dirt ingress Failure to follow these instructions will lead to dirt en...

Page 260: ...rvices turn the starter key to the ON position Operate the controls several times of the service s to be disconnected Set the starter switch to the OFF position then remove the starter key c Press the...

Page 261: ...nance 2 Check the Level Open the engine cover and hydraulic bay cover K Access Panels T 209 Check the level indicator A The fluid level should be visible in the level indicator K Fig 94 T 243 3 Top up...

Page 262: ...Access Panels T 209 2 Unscrew cap B and spring C K Fig 95 T 244 3 Withdraw bypass valve D cartridge filter E and seal F 4 Clean all metal parts Reassemble using new cartridge filter E and seal F 5 To...

Page 263: ...pare the Machine for Maintenance 2 Ensure that the gearbox plugs A and B are positioned as shown Stop the engine and remove starter key 3 Clean the area around the fill level plug A and remove the plu...

Page 264: ...drain plug is removed Keep to one side when you remove the plug 2 3 4 2 3 Remove level filler plug A Remove the drain plug B Allow the oil to drain out Wipe the drain plug clean Make sure that you rem...

Page 265: ...the posture shown with the track to be checked raised from the ground and supported K Fig 98 T 248 3 Check the Tension Check that the tension measurement at A is between 60mm 2 4in and 65mm 2 6in for...

Page 266: ...Routine Maintenance Tracks and Running Gear 248 248 9811 9950 1 Fig 98 E S e r v i c e s...

Page 267: ...slacken the track Slacken adjusting screw C until track tension is correct Rotate track and re check dimension A 5 Refit the cover plate Lower the track to the ground Note Track tension will increase...

Page 268: ...leaking Check that the gauge A indicates that the extinguisher is charged i e the needle is in the GREEN segment Note If the needle is in or very near the RED segment at either end of the gauge the ex...

Page 269: ...ate your warranty 2 4 5 2_1 MCAUTION If you have an attachment which is not covered in the Operator Manual do not install it use it or remove it until you have obtained read and understood the pertine...

Page 270: ...stance from power lines Practice using attachments off the job before working with them for the first time JCB attachments are designed and manufactured specifically to suit the machine s hydraulic sy...

Page 271: ...ttachments Introduction 253 253 9811 9950 1 MCAUTION Some attachments may contact parts of the machine when in the fully folded position Take extra care to avoid damage to the machine 3 4 1 4 E S e r...

Page 272: ...attachments until you have read and fully understand the attachment operating instructions Important Do not operate or work with attachments until the machine hydraulic oil has reached its normal work...

Page 273: ...ould cause injury 8 5 1 5 The decal A warns the operator against the risk of flying debris when using an attachment The attachment must not be used if a protective layer or screen guard has not been f...

Page 274: ...ard for signs of fluid If fluid penetrates your skin get medical help immediately INT 3 1 10_3 MWARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you Before connecting or removi...

Page 275: ...ne Maintenance Checking for Damage 5 Connect the hoses If the hoses have quick releases couplings refer to Quick Release Couplings a Make sure that the hose is not twisted Pressure applied to a twiste...

Page 276: ...1 T037420 Fig 102 To allow for length changes when the hose is pressurised do not clamp at the bend The curve absorbs the change T037410 Fig 103 6 Check for leaks a Start the engine b Operate the rel...

Page 277: ...hine safe Refer to Routine Maintenance Prepare the Machine for Maintenance 2 Vent the hydraulic system Refer to Routine Maintenance Releasing the Hydraulic Pressure 3 Disconnect the hoses If the hoses...

Page 278: ...lic Hoses 260 260 9811 9950 1 b Operate the related control to increase the pressure in the hydraulic system c Stop the engine then remove the starter key d Check for indications of leakage at the hos...

Page 279: ...hey are kept clean and used correctly The recommendations listed below should always apply when using flat face quick release couplings Finally please read the correct fitting and releasing procedures...

Page 280: ...couplings Periodically lubricate the internal locking balls on the female half of the coupling with silicone grease Essential Don ts Never attempt to reconnect using a damaged half coupling as this w...

Page 281: ...ses to unscrew screw together couplings Never use a coupling as a plug Do not connect and disconnect with pressure in the line unless the coupling type is specifically designed to do so Connecting Qui...

Page 282: ...Optional Attachments Connecting Disconnecting Hydraulic Hoses 264 264 9811 9950 1 3 Pull back sleeve E to release the coupling C007100 1 Fig 104 E S e r v i c e s...

Page 283: ...tachment are fitted 2 4 4 2 Note To prevent premature wear failure and breakage the Quickhitch assembly must be used with a rockbreaker for short periods only If the machine is to be used for rock bre...

Page 284: ...ickhitch on hard level ground Use the safe and correct lifting equipment to move the Quickhitch 3 Position the machine so that the dipper arm and Quickhitch are correctly aligned as shown 4 Engage the...

Page 285: ...ure Pay particular attention to safety notices Maintenance Examine the Quickhitch daily for broken or missing parts Remove any debris from the latch hook locking mechanism If the Quickhitch is cleaned...

Page 286: ...he machine especially if working on a slope If there is danger of the machine s stability being compromised then select a smaller bucket or reposition the machine 8 2 9 45 MCAUTION When buckets 750 mm...

Page 287: ...Rest the bucket on level ground with the dipper approximately vertical and the bucket flat to the ground Block the bucket to prevent its movement MWARNING Stand clear and to one side of the bucket whi...

Page 288: ...ure that the person working the controls is a competent operator If the wrong control lever is moved or if the controls are moved violently the other person could be killed or injured B 2 1 8 3 Withdr...

Page 289: ...vots 1 Position the Bucket Set the bucket flat on level ground using a suitable lifting device MWARNING Do not use your fingers through the holes to align the links 8 2 9 32 2 Engage the Dipper If nec...

Page 290: ...itting easy and safe 1 Park the machine on firm level ground Position the bucket so that it is approximately 150mm 6 in above the ground MWARNING The attachment will roll forward when released Stand c...

Page 291: ...272 at Z Remove the tommy bar from the Quickhitch 5 Rest the bucket on the ground 6 Slowly roll the Quickhitch back and simultaneously raise the dipper arm to release the buckets front pivot pin K Fi...

Page 292: ...on firm level ground Use safe and correct lifting equipment to move the bucket 2 Position the machine a Position the machine so that the Quickhitch and bucket are correctly aligned for connection as s...

Page 293: ...TION Make sure that the latch hook has fully engaged 2 4 4 3 d Fit the latch hook locking pin F and secure with lynch pin G MWARNING Always fit the Quickhitch latch hook locking pin Failure to fit the...

Page 294: ...001 1 Position the Bucket Make sure that the bucket is resting flat on the ground 2 Switch off the Engine Remove the starter key 3 Remove a Tooth Remove the nut and bolt B and the tooth A 4 Install a...

Page 295: ...ributor For details of the installation of the attachments refer to the Attachment Handbook for more information contact your JCB Distributor Removing a Quickhitch Rockbreaker MCAUTION When the Quick...

Page 296: ...Hoses Damaged hoses can cause fatal accidents Inspect the hoses regularly Do not use the machine if a hose or hose fitting is damaged INT 3 3 2_4 MWARNING Fluid Under Pressure Fine jets of fluid at hi...

Page 297: ...downward pressure on the bar to release the breakers rear pivot pin from the latch hook allowing the breaker to swing forward as shown at Z Remove the tommy bar from the Quickhitch 10 Refit the locki...

Page 298: ...Optional Attachments Quickhitch Rockbreaker 280 280 9811 9950 1 Fig 112 H F J K Z V Y E S e r v i c e s...

Page 299: ...equipment to move bucket e Position the machine f Use the excavator controls to engage the jaw of the Quickhitch with the pivot pin of the breaker g Use the excavator controls to roll the Quickhitch...

Page 300: ...injured 3 4 1 9 Operation MCAUTION When the Quick Hitch is installed and its attachment fitted there is a danger of the attachment hitting the underside of the boom Operate the boom and dipper carefu...

Page 301: ...ush the pedal at A to operate the single acting attachments K Fig 114 T 283 Push the pedal at B to operate the double acting attachments The Rockbreaker is a single acting attachment make sure the bal...

Page 302: ...Optional Attachments Quickhitch Rockbreaker 284 284 9811 9950 1 Page left intentionally blank E S e r v i c e s...

Page 303: ...all for the application of specific safety factors Consult your JCB distributor for information Safe Working Loads P11 5001_3 MWARNING The safe working load shown on lifting accessories for example ch...

Page 304: ...Specifications Lifting Regulations and Safe Working Loads 286 286 9811 9950 1 Load Charts 332 V2521 2 Fig 115 8025 ZTS 332 V2947 2 Fig 116 8025 ZTS France E S e r v i c e s...

Page 305: ...Specifications Lifting Regulations and Safe Working Loads 287 287 9811 9950 1 333 T3648 Fig 117 8026 CTS 332 V3004 2 Fig 118 8030 ZTS E S e r v i c e s...

Page 306: ...Specifications Lifting Regulations and Safe Working Loads 288 288 9811 9950 1 332 V3062 2 Fig 119 8035 ZTS E S e r v i c e s...

Page 307: ...Specifications Static Dimensions 289 289 9811 9950 1 Static Dimensions Fig 120 B E D F C A E S e r v i c e s...

Page 308: ...on 1 1 Does not include truck trailer height 2470 8 1 2470 8 1 2470 8 1 2475 8 2 B Overall Length transport position 4220 13 10 4280 14 0 4287 14 0 4462 14 8 C Tailswing 1225 4 0 750 2 5 800 2 7 850 2...

Page 309: ...kg 165 lb operator and full fuel tank 8030 ZTS 1 8035 ZTS 1 kg lb kg lb kg lb kg lb Cab Steel Tracks 2760 6085 2745 6052 3277 7225 3721 8186 Rubber Tracks 2700 5952 2685 5919 3217 7092 3651 8032 Canop...

Page 310: ...Specifications Performance Dimensions 292 292 9811 9950 1 Performance Dimensions Fig 121 E F B A C D G H E S e r v i c e s...

Page 311: ...0 6 3482 11 5 C Max vertical digging depth 1925 6 3 1542 5 1 1741 5 8 2165 7 1 D Max digging depth 1 1 Max dig depth when dozer blade fully lowered 2783 9 0 2832 9 3 3119 10 3 3512 11 6 E Max reach gr...

Page 312: ...ifications Auxiliary Pressures 294 294 9811 9950 1 Auxiliary Pressures Table 8 Auxiliary Flow L min Auxiliary Pressure Bar 8026 CTS 65 190 8025 ZTS 65 190 8030 ZTS 65 190 8035 ZTS 70 206 E S e r v i c...

Page 313: ...information relating to this machine when used with other JCB approved attachments please refer to the literature accompanying the attachments Definition of terms LpA A weighted sound pressure level m...

Page 314: ...6 296 9811 9950 1 All Machines Table 9 Engine rating 1 1 Nett installed power Machine LpA LwA 18 4kW 23 7Hp 8026 CTS 77 94 20 9kW 26 8Hp 8025 ZTS 77 95 20 9kW 26 8Hp 8030 ZTS 77 95 23 6kW 30 4Hp 8035...

Page 315: ...pecific operating condition vibration values are determined with the machine equipped with standard attachments i e bucket shovel fork etc for the respective operating condition Vibration values are d...

Page 316: ...g accelerating shifting gears moving the attachments and load smoothly Adjusting the machine speed and travel path to minimize the vibration level Keeping the terrain on worksites where the machine is...

Page 317: ...6 CTS 8025 ZTS 8030 ZTS Table 10 Whole Body Vibration Emission Under Representative Operating Conditions According to the Intended Use Dominant Axis X Y or Z Machine Operating Duties D1 D2 D3 m s A 8...

Page 318: ...811 9950 1 8035 ZTS Table 11 Whole Body Vibration Emission Under Representative Operating Conditions According to the Intended Use Dominant Axis X Y or Z Machine Operating Duties D1 D2 D3 Y Z Z m s A...

Page 319: ...eriod A 8 and based upon a test cycle defined in SAE J1166 Hand arm vibration determined in accordance with dynamic test conditions defined in ISO 5349 2 2001 does not exceed 2 5 m s Note Errors bars...

Page 320: ...Specifications Vibration 302 302 9811 9950 1 Page left intentionally blank E S e r v i c e s...

Page 321: ...heet 303 303 9811 9950 1 Warranty Information Machine Service Record Sheet Installation Checklist Date 1st 250 Hrs 3 Month Date Hour reading 500 Hrs 6 Month Date Hour reading 1000 Hrs 12 Month Annual...

Page 322: ...s 18 Month Date Hour reading 2000 Hrs 24 Month Annual insurance Date Hour reading 2500 Hrs 30 Month Date Hour reading 3000 Hrs 36 Month Annual insurance Date Hour reading 3500 Hrs 42 Month Date Hour r...

Page 323: ...s 54 Month Date Hour reading 5000 Hrs 60 Month Annual insurance Date Hour reading 5500 Hrs 66 Month Date Hour reading 6000 Hrs 72 Month Annual insurance Date Hour reading 6500 Hrs 78 Month Date Hour r...

Page 324: ...0 Month Date Hour reading 8000 Hrs 96 Month Annual insurance Date Hour reading 8500 Hrs 102 Month Date Hour reading 9000 Hrs 108 Month Annual insurance Date Hour reading 9500 Hrs 114 Month Date Hour r...

Page 325: ...ion Information T6 002 Customer Copy 1 2 Dealer Copy 1 2 Dealer Dealer JCB Model JCB Model P I N Machine Serial Number P I N Machine Serial Number V I N V I N Vehicle Registration Number Vehicle Regis...

Page 326: ...k to JCB Service A copy of the registration details to be sent direct to The Equipment Register Ltd T E R Bath and West Buildings Lower Bristol Road Bath BA2 3EG Tel 01225 464599 24 Hour Fax 01225 317...

Page 327: ...Declaration of Conformity is supplied with all machines manufactured according to EC type examination and or self certification requirements A sample copy of the EC Declaration of Conformity and a sum...

Page 328: ...Community Standards EC Declaration of Conformity 310 310 9811 9950 1 9814 0850 4 GB A5A Fig 123 Top Part of Declaration of Conformity JCB C D B E F A JCB XX XX XXXX C D B E G J H K L N M F A E S e r v...

Page 329: ...nity Standards EC Declaration of Conformity 311 311 9811 9950 1 9814 0850 4 GB A5B Fig 124 Bottom Part of Declaration of Conformity XX XX XXXX G J H K L M JCB XX XX XXXX C D B E G J H K L N M F A E S...

Page 330: ...Stoke On Trent United Kingdom ST14 5JP B Excavators Rope Or Hydraulic Hydraulic Tracked Compact C Refer to Machine Model and Serial Number Introduction Section D Refer to Typical Product Identificati...

Page 331: ...Lakeside Works Rocester Staffordshire United Kingdom ST14 5JP H ANNEX VI PROCEDURE 1 J A V Technology A V House Birdhall Lane Stockport Cheshire United Kingdom SK3 0XU K Refer to Noise Data Specifica...

Page 332: ...European Community Standards EC Declaration of Conformity 314 314 9811 9950 1 Page left intentionally blank E S e r v i c e s...