jcb 8026 CTS Operator's Manual
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jcb 8026 CTS Operator's Manual

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Dear JCB Customer
Even if you have operated this type of equipment before,
Your Local JCB Dealer is:
it is very important that your new machines operations and
functions are explained to you by a JCB Dealer
Representative following delivery of your new machine.
Following the installation you will know how to gain
maximum productivity and performance from your new
product.
Please contact your local JCB dealer if the Installation
Form has not yet been completed with you.
OPERATOR MANUAL
THIS MANUAL SHOULD ALWAYS STAY WITH THE MACHINE
8026 CTS, 8025 ZTS, 8030 ZTS, 8035 ZTS
ENGLISH - 9811/9950 - ISSUE 1 - JANUARY 2011
Copyright © 2004 JCB SERVICE.
All rights reserved. No part of this publication may be reproduced, stored in a retrieval
system, or transmitted in any form or by any other means, electronic, mechanical,
photocopying or otherwise, without prior permission from JCB SERVICE.
A5-3-MiniMidi - Printed In England

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  • Page 1 Your Local JCB Dealer is: it is very important that your new machines operations and functions are explained to you by a JCB Dealer Representative following delivery of your new machine. Following the installation you will know how to gain maximum productivity and performance from your new product.
  • Page 2 Notes: 9811/9950...

  • Page 3: Table Of Contents

    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 JCB Mini Excavator ................4 Intended Use .................... 4 Component Location ................4...
  • Page 4 Machine Identification Plate ..............37 Component Identification Plates ............. 39 Machine Security ..................42 Introduction ..................... 42 JCB Plantguard ..................42 Construction Equipment Security And Registration Scheme (CESAR) . 42 Operation Introduction ....................45 Before Entering the Cab ................46...
  • Page 5 Contents Contents Page No. Entering and Leaving the Cab ..............48 Emergency Exit ..................49 Doors and Windows ..................51 Opening and Closing the Door ............... 51 Securing the Door in the Open Position ..........52 Opening and Closing the Front Window ..........54 Removing and Refitting the Windscreen Lower Panel ......
  • Page 6 Contents Contents Page No. Drive Controls, Switches and Instruments ........... 66 Drive Controls ..................66 Switches ....................70 Instrument Panel ..................75 Heater and Air Conditioning (If fitted) ............. 79 Operating Levers/Pedals ................80 Introduction ..................... 80 Control Layouts ..................80 Excavator Controls .................
  • Page 7 Contents Contents Page No. Stopping and Parking the Machine ............111 Preparing the Machine for Travel .............. 113 Introduction ................... 113 Preparing for Site Travel ............... 113 Working with the Machine ................. 115 Operating Practices and Site Safety ............ 115 Clothing and Safety Equipment ............
  • Page 8 Contents Contents Page No. Operating Environment ................135 Operating in Low Temperatures ............135 Operating in a Cold Climate (Below 0°C) ..........136 Operating in High Temperatures ............136 Operating in Dusty or Sandy Areas ............137 Operating in Coastal Regions .............. 137 Operating on Wet or Soft Ground ............
  • Page 9 Contents Contents Page No. Transporting the Machine ................146 Preparing for Road Travel ..............146 Before Using the Trailer/Transporter ............ 147 Loading a Machine onto the Transporting Vehicle ....... 148 Securing the Machine ................150 Unloading a Machine from the Transporting Vehicle ......152 Lifting a Machine ..................
  • Page 10 Contents Contents Page No. Routine Maintenance Service Requirements ................159 Introduction ................... 159 Owner/Operator Support ..............160 Service/Maintenance Agreements ............161 Fit for Purpose Tests for Lifting Equipment ........... 161 Obtaining Replacement Parts ............... 161 Health and Safety ..................162 Lubricants .....................
  • Page 11 Contents Contents Page No. Tools ......................191 Toolbox (if fitted) ................... 191 Carrying Tools onto the Machine ............191 Prepare the Machine for Maintenance ............192 Introduction ................... 192 How to Make the Machine Safe (Excavator Lowered) ......193 Cleaning the Machine ................194 Introduction ...................
  • Page 12 Contents Contents Page No. Greasing ....................203 Introduction ................... 203 Pivot Pins ..................... 204 Slew Ring Bearings ................206 Slew Ring Gear Teeth ................207 Access Panels ................... 209 Introduction ................... 209 Engine Cover ..................209 Hydraulic Bay Cover ................211 Electrical System ..................
  • Page 13 Contents Contents Page No. Fuel System ....................233 Introduction ................... 233 Water Separator and Engine Fuel Filter ..........235 Bleeding the System ................238 Hydraulic System ..................240 Introduction ................... 240 Releasing the Hydraulic Pressure ............242 Oil and Filter ..................243 Tracks and Running Gear .................
  • Page 14 Contents Contents Page No. Connecting/Disconnecting Hydraulic Hoses ..........256 Introduction ................... 256 Connecting the Hydraulic Hoses ............257 Disconnecting the Hydraulic Hoses ............259 Quick Release Couplings ..............261 Quickhitch Assembly ................. 265 Introduction ................... 265 Installation .................... 266 Removal ....................267 Maintenance ..................
  • Page 15 Static Dimensions ..................289 Performance Dimensions ................292 Auxiliary Pressures ..................294 Noise Data ....................295 Introduction ................... 295 All Machines ..................296 Vibration ....................297 Introduction ................... 297 8026 CTS, 8025 ZTS, 8030 ZTS ............299 8035 ZTS ....................300 xiii xiii...
  • Page 16 Contents Contents Page No. 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 Conformity ......... 312...
  • Page 17 Operator Manual. You must understand 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,...

  • Page 18: Safety Notices Important Information

    Safety Notices Important Information Safety Warnings WARNING Denotes a hazard exists. If proper precautions are not This safety alert system identifies taken, the operator (or others) could be killed or important safety messages this seriously injured. manual. When you see this symbol, be INT-1-2-2 alert, your safety is involved, carefuly read the message that follows, and inform...

  • Page 19: Introduction

    This manual provides information for the following If there is anything you are not sure about, ask your JCB model(s) in the JCB machine range: distributor or employer. Do not guess, you or others could be killed or seriously injured.

  • Page 20: Left Side, Right Side

    Introduction About this Manual This manual contains original instructions, verified by the Left Side, Right Side manufacturer (or their authorised representative). In this manual, 'left' A and 'right' B mean your left and right manufacturer's policy continuous when you are seated correctly in the machine. improvement.

  • Page 21: Cab/Canopy

    Introduction About this Manual Cab/Canopy T1-003_2 This manual frequently makes references to the cab. For instance, 'do not operate the machine without a manual in the cab'. It should 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...

  • Page 22: Machine Description

    Machine Description The JCB Mini Excavator Component Location P11-1001_2 The JCB Mini machines are self-propelled tracked Note: The illustration(s) show a typical machine model; excavators with an upper structure capable of 360° your machine may look different from the model shown.
  • Page 23 Introduction Machine Description C031400-B1 Fig 2. 9811/9950-1...

  • Page 24: Safety Check List

    If you do not fully BE CAREFUL understand the warning messages, ask your employer or JCB distributor to explain them. BE ALERT BE SAFE But safety is not just a matter of responding to the warnings.

  • Page 25: General Safety

    Introduction Safety Check List General Safety WARNING T1-043 Clothing WARNING You can be injured if you do not wear the proper clothing. Loose clothing can get caught in the To operate the machine safely you must know the machinery. Wear protective clothing to suit the job. machine and have the skill to use it.
  • Page 26 Introduction Safety Check List WARNING WARNING Feeling Unwell Lifting Equipment Do not attempt to operate the machine if you are You can be injured if you use incorrect or faulty lifting feeling unwell. By doing so you could be a danger to equipment.
  • Page 27 It should not be supported. If the machine moves unexpectedly you altered in any way which could affect or invalidate any could become trapped and suffer serious injury or be of these requirements. For advice consult your JCB killed. Distributor. INT-3-3-7_1...

  • Page 28: Operating Safety

    Introduction Safety Check List Operating Safety WARNING Engine/Steering Failure WARNING If the engine or steering fails, stop the machine as quickly as possible. Do not operate the machine until Machine Condition the fault has been corrected. A defective machine can injure you or others. Do not operate a machine which is defective or has missing INT-2-1-5 parts.
  • Page 29 Introduction Safety Check List WARNING WARNING Work Sites Communications Work sites can be hazardous. Inspect the site before Bad communications can cause accidents. Keep working on it. You could be killed or injured if the people around you informed of what you will be doing. ground gives way under your machine or if piled If you will be working with other people, make sure any material collapses onto it.
  • Page 30 It should not be used in an people away. enclosed area without adequate ventilation. Do not machine potentially explosive INT-2-2-8 atmosphere, i.e. combustible vapours, gas or dust, without first consulting your JCB Distributor. INT-2-1-14 9811/9950-1...
  • Page 31 Introduction Safety Check List CAUTION WARNING Regulations Airborne particles of light combustible material such Obey all laws, work site and local regulations which as straw, grass, wood shavings, etc. must not be affect you and your machine. allowed to accumulate within the engine compartment or in the propshaft guards (when fitted).
  • Page 32 WARNING Before you start using the machine, check with your Use only the JCB approved attachments that are electricity supplier if there are any buried power specified for your machine. Operating with non- cables on the site.
  • Page 33 Introduction Safety Check List DANGER WARNING Working Platform Travelling at High Speeds Using the machine as a working platform is Travelling at high speeds can cause accidents. Do not hazardous; you can fall off and be killed or injured. reverse in a high gear with full throttle. Always travel Never use the machine as a working platform.
  • Page 34 Introduction Safety Check List WARNING WARNING You could be killed or seriously injured if you operate Hillsides a machine with a damaged or missing ROPS/FOPS. If Operating the machine on hillsides can be dangerous the Roll Over Protection Structure (ROPS)/Falling if proper precautions are not taken.
  • Page 35 Introduction Safety Check List WARNING CAUTION Keep Your Hands and Feet Inside the Vehicle Passengers When using the machine, keep your hands and feet Passengers in or on the machine can cause accidents. clear of moving parts. Keep your hands and feet within Do not carry passengers.
  • Page 36 Introduction Safety Check List WARNING WARNING Should the machine start to roll over, you can be Safe Working Loads crushed if you try to leave the cab. If the machine Overloading the machine can damage it and make it starts to roll over, do not try and jump from the cab. unstable.

  • Page 37: Maintenance Safety

    Introduction Safety Check List Maintenance Safety WARNING Machines with a TOPS structure are equipped with a WARNING seat belt. The TOPS structure is designed to give you protection in an accident. If you do not wear the seat Communications belt you could be thrown off the machine and crushed. Bad communications can cause accidents.
  • Page 38 Introduction Safety Check List WARNING WARNING Repairs Electrical Circuits If your machine does not function correctly in any way, Understand the electrical circuit before connecting or get it repaired straight away. Neglect of necessary disconnecting an electrical component. A wrong repairs could result in an accident or affect your connection can cause injury and/or damage.
  • Page 39 Introduction Safety Check List WARNING WARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Oil is toxic. If you swallow any oil, do not induce Before connecting or removing any hydraulic hose, vomiting, seek medical advice. Used engine oil residual hydraulic pressure trapped in the service contains harmful contaminants which can cause skin hose line must be vented.
  • Page 40 Introduction Safety Check List WARNING CAUTION Soft Ground Rams A machine can sink into soft ground. Never work The efficiency of the rams will be affected if they are under a machine on soft ground. not kept free of solidified dirt. Clean dirt from around the rams regularly.
  • Page 41 Introduction Safety Check List WARNING WARNING When using cleaning agents, solvents or other Hydraulic Hoses chemicals, you must adhere to the manufacturer's Damaged hoses can cause fatal accidents. Inspect the instructions and safety precautions. hoses regularly. Do not use the machine if a hose or hose fitting is damaged.
  • Page 42 Introduction Safety Check List WARNING 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 the battery. INT-3-3-8_2 9811/9950-1...
  • Page 43 WARNING Thoroughly wash contaminated area with 10% Certain seals and gaskets (e.g. crankshaft oil seal) on calcium hydroxide or other suitable alkali JCB machines contain fluoroelastomeric materials solution, if necessary use wire wool to remove such Viton, Fluorel Technoflon.
  • Page 44 Introduction Safety Check List WARNING Protect your eyes when grinding metal. Wear safety glasses goggles. Remove protect combustible materials from the area which could be ignited by sparks. GEN-1-12 WARNING To avoid burning, wear protective gloves when handling hot components. To protect your eyes, wear goggles when using a brush to clean components.
  • Page 45 Introduction Safety Check List bushes. Attach the welder earth (ground) cable no WARNING more than 0.6 metres (2 feet) from the part being welded. Arc Welding To prevent the possibility of damage to electronic INT-3-1-15_2 components, disconnect the battery and the alternator before arc-welding on the machine or attached WARNING implements.
  • Page 46 Prior to any work being carried out on damaged. systems incorporating accumulators, the system INT-3-1-14 pressure must be exhausted by a JCB distributor, as the sudden release of the hydraulic fluid or gas may WARNING cause injury. If you try to charge a frozen battery, or jump start and INT-3-1-17 run the engine, the battery could explode.
  • Page 47 Introduction Safety Check List WARNING WARNING Battery Gases Battery Terminals Batteries give off explosive gases. Keep flames and The machine is negatively earthed. Always connect sparks away from the battery. Do not smoke close to the negative pole of the battery to earth. the battery.
  • Page 48 Introduction Safety Check List WARNING Asbestos Asbestos dust can damage your lungs. Some engine gaskets contain asbestos. Do not dismantle the engine or exhaust system; get these jobs done by a qualified person who has a copy of the engine service manual.

  • Page 49: Safety Labels

    Safety labels on the machine warn you of particular has a part number printed on it, use this number to order a hazards. You can be injured if you do not obey the new safety label from your JCB distributor. safety instructions shown. INT-1-3-11 Safety labels are strategically placed around the machine to remind you of possible hazards.

  • Page 50: Safety Label Identification

    Introduction Safety Labels Safety Label Identification ISO-11A ISO-11E ISO-15E ISO-07B ISO-10A ISO-01A ISO-11D ISO-09C ISO-09A ISO-04A ISO-07D ISO-12A ISO-06D ISO-05C T038750-3 Fig 3. 9811/9950-1...
  • Page 51 Introduction Safety Labels Part Numbers and Descriptions ISO-04A Part Number: 817/70004 ISO-01A Description: Burns to fingers and Part Number: 817/70014 hands. Stay a safe distance away. Description: Warning. Read operator manual before you operate the machine. 817-70004-4 817-70014-3 ISO-05C Part Number: 817/70012 Description: Runover.
  • Page 52 Introduction Safety Labels ISO-06D ISO-07D Part Number: 817/70005 Part Number: 817/70112 Description: Hot fluid under pressure. Description: Crush hazard. Keep a Refer to Cooling System (Routine safe distance from the moving parts. Maintenance Section). 817-70005-3 817-70112-2 ISO-07B ISO-010A Part Number: 817/70018 Part Number: 817/70029 Description: Crush hazard.
  • Page 53 Introduction Safety Labels ISO-12A ISO-09C Part Number: 817/70106 Part Number: 817/70102 Description: Strike to whole body Description: Crushing of fingers or (machine swing). Keep a safe hands. Remove the starter key and distance from the machine. refer to the Service Manual before you start maintenance work.
  • Page 54 Introduction Safety Labels ISO-15E ISO-11A Part Number: 332/V3761 Part Number: 332/T9356 Description: Flying debris warning. Description: Falling hazard. Lift the Refer to Optional Attachments. lever lock. 332-V3761-1 332-T9356-2 ISO-09A Part Number: 332/P4581 Description: Severing of hands or fingers. Keep clear of/do not reach into the moving parts.

  • Page 55: Identifying Your Machine

    If the engine is replaced by a new one, the serial number on the identification plate will be wrong. Either get a replacement identification plate from your JCB Dealer or simply remove the old number. This will prevent the wrong unit number being quoted when replacement parts are ordered.
  • Page 56 Typical Product Identification Number (PIN) 08025 01226500 World Manufacturer Identification (3 Digits). JCB = UK Build. Machine Type and Model (5 Digits). 08025 = 8025. Random Check Letter (1 Digit). The Check Letter is used to verify the authenticity of a machine’s PIN.

  • Page 57: Component Identification Plates

    Year of Manufacture (1 Digit) A typical engine identification number is: 65692 500405 Engine Type (2 Digits) GJ = Naturally aspirated, 8026 CTS - 18.4kW GJ = Naturally aspirated, 8025 ZTS, 8030ZTS - 20.9kW GJ = Naturally aspirated, 8035ZTS - 23.6kW T017650-2 Fig 5.
  • Page 58 This must be done by a qualified person. For assistance, contact your JCB dealer. Failure to take precautions could result in death or injury to the operator. 5-3-1-7_2 Machines built to ROPS and TOPS standards have an Fig 6.
  • Page 59 Falling objects can cause serious injury. 8-2-8-17 If the machine is used in any application where there is a risk of falling objects then a falling-objects protective structure (FOPS) must be installed. For further information contact your JCB Dealer 9811/9950-1...

  • Page 60: Machine Security

    Registration Scheme (CESAR) T1-020 Your JCB Distributor or Dealer will be pleased to provide JCB are pleased to announce, the availability of CESAR a information on any of these sensible precautions. ACT simple, effective method of machine identification and...
  • Page 61 The Construction Equipment Association is managing the scheme, and Datatag are providing the security material and support. JCB is fully supportive of the CESAR initiative and will offer it as a factory fit option across the range. The CESAR kit includes 2 Tamper proof triangular ID...
  • Page 62 Introduction Machine Security Page left intentionally blank 9811/9950-1...

  • Page 63: Introduction

    Use your manual to identify each control lever, switch, gauge, button and pedal. Do not Remember guess. If there is anything you do not understand, ask your JCB distributor. BE CAREFUL BE ALERT The operator must always be aware of events happening BE SAFE in or around the machine.

  • Page 64: Before Entering The Cab

    Operation Before Entering the Cab Before Entering the Cab P11-2005_3 The following checks should be made each time you return Check for cleanliness. to the machine after leaving it for any period of time. We advise you also to stop the machine occasionally during a Clean the windows and light lenses.
  • Page 65 Operation Before Entering the Cab c Make sure that all pivot pins are secured correctly Make sure that all of the access panels are closed in place. and secure. d Inspect the windows for cracks and damage. Note: If the filler caps and access panels are fitted with Glass splinters can blind.

  • Page 66: Entering And Leaving The Cab

    Operation Entering and Leaving the Cab Entering and Leaving the Cab WARNING WARNING Entering/Leaving Do not enter or exit the cab unless the arm rest or lever Entering or leaving the cab or canopy must only be lock is fully engaged. made where steps and handrails are provided.

  • Page 67: Emergency Exit

    Operation Entering and Leaving the Cab When you get on or off the machine 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 near the corner, this will shatter the screen which can then be knocked out.
  • Page 68 Operation Entering and Leaving the Cab Fig 8. 9811/9950-1...

  • Page 69: Doors And Windows

    Operation Doors and Windows Doors and Windows Opening and Closing the Door To open the door from the outside, unlock it with the key 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.

  • Page 70: Securing The Door In The Open Position

    Operation Doors and Windows Securing the Door in the Open Position The door can be secured 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.
  • Page 71 Operation Doors and Windows C035100 Fig 11. 9811/9950-1...

  • Page 72: Opening And Closing The Front Window

    Operation Doors and Windows Opening and Closing the Front Window P11-2024 CAUTION Take care when raising and lowering the window; lower your head as you pull the window back. Isolate the hydraulic controls before opening and closing the window. 0120 To open the up and over window: Hold handles A, press and hold down securing levers Lift the screen into a position parallel with the roof...

  • Page 73: Removing And Refitting The Windscreen Lower Panel

    Operation Doors and Windows Removing and Refitting the Windscreen Lower Panel Make sure that the engine is stopped and the hydraulic controls are isolated. Open the front window and secure it in a position parallel K Opening and Closing the Front with the roof.
  • Page 74 Operation Doors and Windows Carefully lift out the windscreen 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.

  • Page 75: Opening And Closing The Side Window

    Operation Doors and Windows Opening and Closing the Side Window P11-2025 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 shut and check that the catch A has located on the frame.

  • Page 76: Seat Controls

    Operation Seat Controls Seat Controls Introduction T2-007_3 WARNING Seat Position the seat so that you can comfortably reach the machine controls. Do not adjust the seat while the machine is moving. You could have an accident if you operate the machine with the seat in the wrong position.

  • Page 77: Standard Seat

    Operation Seat Controls Standard Seat The forward and backwards adjustment is adjusted using lever B. T033180-1 Fig 16. 9811/9950-1...

  • Page 78: Suspension Seat (If Fitted)

    Operation Seat Controls Suspension 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 adjusted by lever D. T033180 Fig 17.

  • Page 79: Seat Belt

    Operation Seat Belt Seat Belt Static Seat Belt Fasten the Seat Belt T2-002 Sit correctly in the seat. WARNING Push the male fitting A into the buckle B until it If you do not wear your seat belt you could be thrown latches into position.
  • Page 80 Operation Seat Belt Release the Seat Belt WARNING 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 Fig 18. Adjusting the Seat Belt Make sure the belt is across your hips and not over your stomach.
  • Page 81 Operation Seat Belt To adjust the male fitting A: Pull toggle D down the strap by the required distance. a To make the strap longer, pull end E as far as it will b To make the strap shorter, pull end F as far as it will go.

  • Page 82: Cab Layout

    Operation Cab Layout Cab Layout C019600-1 Fig 20. 9811/9950-1...

  • Page 83: Component Key

    Operation Cab Layout Component Key K Track Controls ( T 66). K Hand Throttle Lever ( T 69). K Starter Switch ( T 72). K Horn ( T 74). K Auxiliary Power Socket ( T 73). K Console Switches ( T 70).

  • Page 84: Drive Controls, Switches And Instruments

    Operation Drive Controls, Switches and Instruments Drive Controls, Switches and Instruments Drive Controls Track Controls P11-2021 The two tracks are controlled by a pair of control levers A in front of the seat. Each lever controls one track and is spring loaded to a central position.
  • Page 85 Operation Drive Controls, Switches and Instruments Driving the Machine DANGER Drive Safely Drive the machine smoothly. Spin turn manoeuvres, zig-zag driving or turning too fast can cause the vehicle to overturn. 8-1-2-2_2 WARNING When the cab is swung around so that it is facing the track motor end of the undercarriage, the action of the 731911-5 tracking controls is reversed.
  • Page 86 Operation Drive Controls, Switches and Instruments 731911-7 731911-8 Fig 23. Turning the Machine Fig 24. Spinning the machine To turn the machine while you travel, move the lever back To spin the machine around through 360°, without moving towards the central position on the side towards which you it, operate one lever, in a forward position and the other in want to go e.g.
  • Page 87 Operation Drive Controls, Switches and Instruments Hand Throttle Lever A hand-operated throttle lever in the cab controls the K Fig 25. ( T speed of the engine. 69). Move the lever A to increase or B to decrease the engine speed.

  • Page 88: Switches

    Operation Drive Controls, Switches and Instruments Switches Console Switches Introduction The installed switches and their positions can change according 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.
  • Page 89 Operation Drive Controls, Switches and Instruments Console and Seat Switches Rear Window Wiper (if fitted) Three position rocker switch. The switch Beacon functions operate when the starter switch Two position rocker switch. The switch is in the ON position. functions operate when the starter switch Position 1: OFF is in the ON and OFF positions.
  • Page 90 Operation Drive Controls, Switches and Instruments Starter Switch does not fully start, allow the starter motor to cool for at least two minutes between starts. T2-071_2 This is operated by the starter key. It has four positions. Note: The starter switch has an inhibitor to stop the switch The key can be removed only with the switch set to 0.
  • Page 91 Operation Drive Controls, Switches and Instruments Cab Interior Light Auxiliary Power Socket T2-020 Press either end of the light unit A to switch on the cab The socket X supplies a 12 Volt DC power supply to interior light. Pressing the other end will switch the light off. electrical accessories (from the battery).
  • Page 92 Operation Drive Controls, Switches and Instruments Swing/Auxiliary Switch There is 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 Excavator Controls and Auxiliary Operation.

  • Page 93: Instrument Panel

    Operation Drive Controls, Switches and Instruments Instrument Panel Air Filter (Blocked) Indicator. Illuminates YELLOW when the air filter is blocked. Indicators for the engine and related systems are mounted Indicator not fitted to this machine. instrument cluster R.H. console. K Fig 30. ( T 76).
  • Page 94 Operation Drive Controls, Switches and Instruments 445991-B6 Fig 30. 9811/9950-1...
  • Page 95 Pump symbol remains flashing. 1 bar illuminated (nearly empty). 0 bars illuminated (tank empty). Note: The flashing of all fuel level bars and the filler pump Fig 31. symbol indicates a fault in the fuel sender circuit. Contact your JCB dealer. 9811/9950-1...
  • Page 96 Operation Drive Controls, Switches and Instruments Warning Indicators Charge (Fault) Indicator Audible/Visual. Indicates Alternator operation. CAUTION Illuminates RED when a fault occurs. If any of the audible/visual warnings operate while the engine is running, stop the engine as soon as it is safe Coolant Indicator (On) to do so and rectify the fault.

  • Page 97: Heater And Air Conditioning (If Fitted)

    Operation Drive Controls, Switches and Instruments Heater and Air Conditioning (If fitted) Cab Heater Controls Air can be directed into the cab by selecting the required On/Off fan speed using switch A. Temperature control is by Heat means of rotary dial B. Three speed fan Note: The air intake filter F should be washed in warm, soapy water if it becomes dirty.

  • Page 98: Operating Levers/Pedals

    Operation Operating Levers/Pedals Operating Levers/Pedals Introduction Control Layouts WARNING WARNING Controls Control lever/switch action may vary on machines, You or others can be killed or seriously injured if you instructional labels near the levers/switches show by operate the control levers from outside the machine. symbols, which levers/switches cause what actions.
  • Page 99 Operation Operating Levers/Pedals Page left intentionally blank 9811/9950-1...

  • Page 100: Excavator Controls

    Operation Operating Levers/Pedals Excavator Controls The speed and movement of the associated hydraulic function depends on how far you move the lever - the further you move the lever, the faster the action. WARNING Note: The boom ram incorporates damping at the limit of Controls - ISO/SAE boom raise, reducing the speed of the ram and eliminating Before operating the excavator controls always check...
  • Page 101 Operation Operating Levers/Pedals C035010-3 Fig 34. 9811/9950-1...
  • Page 102 Operation Operating Levers/Pedals Excavator Levers (ISO Control Pattern) Slew cab left Slew cab right Raise boom Lower boom Dipper in Dipper out Close bucket (to gather a load) Open bucket (to dump a load) Swing boom. Refer to Swing Pedal. 731911-11 Fig 35.
  • Page 103 Operation Operating Levers/Pedals 731911 Fig 36. 9811/9950-1...
  • Page 104 Operation Operating Levers/Pedals Excavator Levers (SAE Control Pattern) Slew cab left Slew cab right Raise boom Lower boom Dipper in Dipper out Close bucket (to gather a load) Open bucket (to dump a load) Swing boom. Refer to Swing Pedal. 731911-2 Fig 37.
  • Page 105 Operation Operating Levers/Pedals 731911 Fig 38. 9811/9950-1...
  • Page 106 Operation Operating Levers/Pedals Swing Pedal 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 the right side. Release the WARNING pedal when the excavator end has reached the desired position.
  • Page 107 Operation Operating Levers/Pedals 796300-B3 Fig 40. 9811/9950-1...

  • Page 108: Dozer Controls

    Operation Operating Levers/Pedals Dozer Controls Lower Dozer 'B' To lower the dozer push the lever forward until an CAUTION increased resistance is felt and the blade moves. At the required position release the lever. Before operating the dozer, make sure that large rocks or other objects are not between it and the tracks that can jam the mechanism.
  • Page 109 Operation Operating Levers/Pedals C019940-2 Fig 41. 9811/9950-1...

  • Page 110: Auxiliary Operation

    Operation Operating Levers/Pedals Auxiliary Operation Press the swing/auxiliary pedal D to the left A or right B depending on the attachment fitted and the function required. WARNING Note: Every time the swing/auxiliary switch C is operated Before operating the Auxiliary control system make the respective swing/auxiliary indicator will illuminate.
  • Page 111 Operation Operating Levers/Pedals 796300-B4 Fig 43. 9811/9950-1...

  • Page 112: Safety Equipment

    Operation Safety Equipment Safety Equipment Control Locks WARNING The boom/slew lock must be engaged when travelling on road or trailer, 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.

  • Page 113: Beacon

    Operation Safety Equipment Beacon In certain territories you will be breaking the law if you do not fit a rotating beacon before you travel on public highways - make sure you are complying with local laws. Note: Be careful when you operate the machine with a beacon.

  • Page 114: Overload Warning System (If Fitted)

    Operation Safety Equipment Overload Warning System (If fitted) The overload warning system senses the pressure in the boom raise pressure circuit, and gives an audible warning when the pressure exceeds the predetermined limits and there is a risk that the machine could become unstable. T034110 Fig 46.

  • Page 115: Fire Extinguisher (If Fitted)

    Operation Safety Equipment Fire 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 to use it. T059050-1 Fig 47.
  • Page 116 Operation Safety Equipment Operation Using the fire extinguisher: T2-041_3 If the circumstances permit and your safety is not WARNING endangered, move the machine to a safe place to prevent the fire from spreading. Do not use the fire extinguisher in a confined space. Make sure that the area is well ventilated during and Remove extinguisher from its stowage bracket.
  • Page 117 Operation Safety Equipment S170520-3 Fig 48. The fire extinguisher should be inspected daily. Refer to Routine Maintenance, Fire Extinguisher (if fitted). 9811/9950-1...

  • Page 118: Before Starting The Engine

    Operation Before Starting the Engine Before Starting the Engine P11-2002_2 Note: Read Operating in Low Temperatures or Lower the excavator bucket and dozer to the ground, Operating in High Temperatures in Operation section if if they are not already there. They will lower you will be using the machine in very cold or very hot themselves under their own weight when you operate climates.
  • Page 119 If that Inspect the ROPS/TOPS/FOGS structure for happens you could lose control of the machine. damage. Get your JCB Distributor to repair any 2-2-3-6 damage. Make sure all its securing bolts are fitted c Remove oil, grease and mud from the pedals and and correctly tightened.
  • Page 120 Operation Before Starting the Engine Inspect the seat belt and its mountings for Fasten the seat belt. See Seat Belt. damage and excessive wear. WARNING When a seat belt is fitted to your machine replace it with a new one if it is damaged, if the fabric is worn, or if the machine has been in an accident.

  • Page 121: Starting The Engine

    Operation Starting the Engine Starting the Engine Note: Outside temperatures below 0°C (32°F) will require WARNING extended times. Do not use ether or other starting fluids to assist cold c Turn the starter key further to position lll and hold starting.
  • Page 122 Operation Starting the Engine If the engine does not start, return to the 0 (OFF). Note: The engine noise and or tone may be louder than Allow the starter to cool for a few minutes before usual when cold. The engine will become quieter when the repeating step 3.

  • Page 123: Warming Up

    Operation Starting the Engine Warming Up Warm up hydraulic circuit: P11-2032 a Reduce engine speed by moving throttle lever to Before starting work in temperatures below -15°C (5°F), mid position. hydraulic fluid must be warmed. b Raise and lower boom from ground level to full Warm up the engine: height five times.

  • Page 124: Immobiliser

    Note: If your machine has an immobiliser system installed, PIN number. You must complete step 2 again. then your JCB dealer should enable the system as part of the standard machine installation. The LED A comes ON for three seconds after you enter a correct PIN number.
  • Page 125 Operation Starting the Engine Note: If you restart start the engine within 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. Turn the starter switch to position I.
  • Page 126 Operation Starting the Engine To Delete All PIN Codes 'Unique Key' Immobiliser System T2-029_4 Turn the starter switch to position I. Each machine is supplied with a master key (red) and two starter keys (black). The master key is used by the Push the MD button.
  • Page 127 Operation Starting the Engine Start the engine as shown in Starting the Engine. To Arm the Immobiliser When the engine starts, the red LED B comes ON for Stop the engine and remove the starter key. three seconds then goes OFF. The immobiliser arms automatically immediately.
  • Page 128 Operation Starting the Engine To Remove the Program from a Starter Key Put the master key in the starter switch then turn the starter switch to position I. The LED will flash 3 times. Keep the starter switch in position I for 60 seconds, the LED will flash 5 times.

  • Page 129: Stopping And Parking The Machine

    Operation Stopping and Parking the Machine Stopping and Parking the Machine WARNING CAUTION Low speed must always be selected when unloading Before stopping the engine, lower the dozer blade to the machine from a vehicle or tracking down steep the ground. slopes.
  • Page 130 Operation Stopping and Parking the Machine period, close and latch the window and lock the door. Make sure that the fuel filler cap is locked. Fig 53. 9811/9950-1...

  • Page 131: Preparing The Machine For Travel

    Operation Preparing the Machine for Travel Preparing the Machine for Travel Introduction Preparing for Site Travel P11-2029_2 When you travel on the road or on site there are usually Activate warning beacon if fitted. local rules and safety regulations for the machine travel position.
  • Page 132 Operation Preparing the Machine for Travel 732010-7 Fig 54. 9811/9950-1...

  • Page 133: Working With The Machine

    Operation Working with the Machine Working with the Machine Operating Practices and Site Safety Do not put your life, or the lives of others, at risk by using the machine irresponsibly. T2-057_2 This section explains some techniques and procedures for Before you start to work, tell your work mates what you will efficient and safe use of the machine and its attachments.

  • Page 134: Clothing And Safety Equipment

    The information in this section is given in good faith and in The danger zone is the circular area around the machine light of the best information available, JCB can accept no where the moving parts can reach. During operation of the...

  • Page 135: Log Moving/Handling

    If there are, obtain a map of their Contact your JCB dealer. locations and follow the advice given by the water supplier.
  • Page 136 Operation Working with the Machine Leaking gas is highly explosive. WARNING If a gas leak is suspected, contact the local gas Underground Gas Pipes company immediately and warn all personnel on the Before you start using the machine, check with your site.

  • Page 137: Working With The Excavator

    Operation Working with the Machine Working with the Excavator Make sure the correct bucket for the job is fitted. For instructions for removing and installing buckets, refer to Optional Attachments. Introduction P2-2020 Before you start using the excavator, you must convert the WARNING machine into a safe and stable working platform.
  • Page 138 Operation Working with the Machine Preparing to Use the Excavator WARNING P11-2031 Care must be taken with machines fitted with an extra When choosing a digging position, avoid digging downhill long dipper as it may affect the stability of the if possible.
  • Page 139 Operation Working with the Machine Digging CAUTION Introduction Do not excavate on hard or rocky ground with the boom positioned diagonally across the undercarriage. P11-2027 The resulting rocking motion could cause damage to WARNING the track gearbox sprockets and tracks. When you are excavating Do not rest your feet on the 8-2-2-6_2 foot pedals.
  • Page 140 Operation Working with the Machine When the bucket is full, close it fully and at the same Swing the bucket back to the excavation and start the time move the dipper out a little way. This will keep next dig. soil from building up under the machine.
  • Page 141 Operation Working with the Machine 731990-2 Fig 55. 9811/9950-1...
  • Page 142 Operation Working with the Machine Moving the Machine While Digging on the Level When this position is reached, move the machine a suitable distance away from the excavation. P11-2028 When digging a trench or hole which is longer than the excavator's reach, dig to the required depth and width A Lower the dozer blade until the machine is level, then until it is not possible to dig any closer without contacting...

  • Page 143: Lifting (Object Handling)

    Operation Working with the Machine Lifting (Object Handling) If your machine is not fitted with a lifting point such as hook or shackle, hose burst check valves, load charts and a overload warning system then it must not be used for Introduction object handling.
  • Page 144 Check that the load is not greater than the safe working load for the The correct JCB lifting shackle A must be fitted. The bucket. bucket ram must be fully extended as at B. If your...
  • Page 145 Operation Working with the Machine a decal C in the operators cab and you must use the machine for earth moving purposes only. Note: The lifting shackle must be removed when excavating to prevent the possibility of damage. Attach lifting chains to the shackle. Keep the chain length as short as possible, to prevent swinging.
  • Page 146 If the chart is missing or damaged a new decal must be fitted, contact your JCB dealer for advise if you are Important: If a load chart is not provided in the cab the K Load Charts ( T machine is not designed for lifting.
  • Page 147 Operation Working with the Machine Using the Load Chart Working Height at Bucket Pivot Distance of Bucket pivot from centre of machine (metres) Weight to be lifted (kgs) Safe Working Load 9811/9950-1...
  • Page 148 Operation Working with the Machine 8025 ZTS -0.5 -1.0 T052950-1 Fig 59. Example only 9811/9950-1...

  • Page 149: Use Of Machines On Gradients Or Slopes

    Operation Working with the Machine Use of Machines on Gradients or Slopes Travelling on Slopes P11-2011 The machine can operate without detriment to its systems WARNING on inclines of up to 25°. However, on slopes greater than 10° the operator must use his discretion and proceed with Ensure that you have been trained and are familiar extreme caution.
  • Page 150 Operation Working with the Machine Working on Slopes When working on inclines, position the dozer 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 prevent an instability problem, cut a level platform for the machine to stand on.

  • Page 151: Working With The Dozer

    Operation Working with the Machine Working with the Dozer Introduction P11-2026 Remember that you will be driving the machine while you are using the dozer. Keep alert for bystanders, animals and possible hazards. Ensure the slew lock is engaged when working with the dozer.
  • Page 152 Operation Working with the Machine Scraping and Cutting If a deep cut is to be made, do it in steps of about 50mm (2in). Do not forget to adjust the dozer height when the machines tracks enter the cut. Backfilling When backfilling on a slope, pile the material on the high side of the trench whenever possible.

  • Page 153: Operating Environment

    T3-069_2 starting aids may be needed. Examples are fuel, oil In low temperature situations, take the following and coolant heaters. Ask your JCB distributor for precautions. They will make for easier starting and prevent advice. possible damage to your machine.

  • Page 154: Operating In A Cold Climate (Below 0°C)

    Additional low temperature fuel and lubricants and covers. batteries may be required. Consult your local JCB dealer for advice. Until the machine is thoroughly warmed up never attempt to slew rapidly or operate the travel system, Operating in High Temperatures otherwise damage may result.

  • Page 155: Operating In Dusty Or Sandy Areas

    Operation Operating Environment Keep the radiator/oil cooler clean, regularly remove Operating in Coastal Regions dirt and debris from the radiator/oil cooler and the engine. Check that all the plugs, bolts and fasteners are all tightened properly. Check the fan belt regularly. After daily operations, wash the machine thoroughly Check the air vents.

  • Page 156: Getting The Machine Moving

    Operation Getting the Machine Moving Getting the Machine Moving Operating Practices WARNING Should the machine start to roll over, you can be The machine does not have gears. Do not overwork the crushed if you try to leave the cab. If the machine engine unnecessarily.

  • Page 157: Operating Procedure

    Operation Getting the Machine Moving Operating Procedure b Take hold of both track control levers in one hand. c Make sure that it is safe to move off. After you have warmed up the engine, move off as described below. d Move the levers forward or backward as required and pull the throttle lever slowly backward until the Note: Control and switch locations are provided within this...

  • Page 158: Refuelling The Machine

    CAUTION Note: If you Increase the engine speed or load while there Consult your fuel supplier or JCB distributor about the is air in the fuel system, then subsequent damage to the suitability of any fuel you are unsure of.
  • Page 159 Operation Refuelling the Machine WARNING WARNING Fuel Mobile Phones Fuel is flammable; keep naked flames away from the Switch off your mobile phone before entering an area fuel system. Stop the engine immediately if a fuel leak with a potentially explosive atmosphere. Sparks in is suspected.
  • Page 160 Operation Refuelling the Machine At the end of every working day, fill the tank with the correct type 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.

  • Page 161: Moving A Disabled Machine

    The machine can be lifted onto a trailer for transportation. In the event of a emergency: However, you must contact the nearest JCB Dealer before you try to tow, winch or push the machine. Towing, Turn the ignition to the 'ON' position.

  • Page 162: Retrieval

    Operation Moving A Disabled Machine Retrieval Important: It is not recommended to tow a disabled machine. Permanent damage to the track motors of the disabled machine may occur if the machine is towed. If the machine becomes disabled, the machine should be made safe, lifted onto a transporter and moved to a K Lifting a location where is can be repaired.
  • Page 163 Operation Moving A Disabled Machine Apply the minimum force to move the machine 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 machine should be inspected by a qualified person for damage to the track motors.

  • Page 164: Transporting The Machine

    Operation Transporting the Machine Transporting the Machine P11-2003_5 Preparing for Road Travel Make sure that the transporting vehicle is suitable. See Maintenance Section for the dimensions and weight of your machine. There is a travel height label fitted to the WARNING cab.

  • Page 165: Before Using The Trailer/Transporter

    Operation Transporting the Machine Before Using the Trailer/Transporter Check the breakaway cable is serviceable. WARNING Before moving the machine onto the trailer, make sure that the trailer and ramp are free from oil, grease and ice. Remove oil, grease and ice from the machine tracks.

  • Page 166: Loading A Machine Onto The Transporting Vehicle

    Operation Transporting the Machine Loading a Machine onto the contact the transporter ramps when loading the machine. Transporting Vehicle Slowly drive the machine to the top of the ramps. Position the transporting vehicle on firm level ground. Lower the boom until the bucket contacts the transporter deck.
  • Page 167 Operation Transporting the Machine Raise any jacks to their transport position. 800980-2 Fig 66. 9811/9950-1...

  • Page 168: Securing The Machine

    Operation Transporting the Machine Securing the Machine Place skids B under each track at front and rear to prevent movement of the machine in the fore and aft direction. WARNING Position a securing strap C of suitable breaking strain The machine must be securely tied down to the over the front and rear of the two track legs.
  • Page 169 Operation Transporting the Machine 800950-3 Fig 67. 9811/9950-1...

  • Page 170: Unloading A Machine From The Transporting Vehicle

    Operation Transporting the Machine Unloading a Machine from the Start the machine and raise the bucket. Transporting Vehicle WARNING Position the transporting vehicle on firm level ground. If the dozer is to the rear, the track controls will be reversed. Use extreme caution when tracking off the Apply the park brakes and lower any stability jacks.
  • Page 171 Operation Transporting the Machine 800990-4 Fig 68. 9811/9950-1...

  • Page 172: Lifting A Machine

    Operation Lifting a Machine Lifting a Machine P11-2009 CAUTION WARNING Do not lift the machine by the extended dozer (if fitted), Lifting Equipment remove the extensions before lifting. Ensure the lifting You can be injured if you use faulty lifting equipment. slings do not interfere with the top of the cab, Make sure that lifting equipment is in good condition.
  • Page 173 Operation Lifting a Machine DANGER Do not stand underneath the raised load during the lowering procedure. Stand clear and to one side until the load has been safely lowered. 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.

  • Page 174: Storage Of The Machine

    Prepare the Machine for Storage Note: JCB Dealers must check stock monthly. T2-076 Clean the machine to remove all unwanted material Storage Area and corrosive products.

  • Page 175: Put The Machine Into Storage

    Operation Storage of the Machine Fill the fuel tank to prevent a build up of condensation Remove the starter key. in the tank. Apply a thin layer of grease or petroleum jelly to all Examine the coolant condition. Replace if necessary. exposed ram piston rods.

  • Page 176: Take The Machine Out Of Storage

    Operation Storage of the Machine Clean the machine to remove all unwanted material Examine all fluid levels. Top up if necessary. and corrosives. Clean the machine to remove unwanted material and Remove the grease or petroleum jelly from the ram corrosives.

  • Page 177: Routine Maintenance Service Requirements

    Distributor to ensure that it reaches you in optimum carried out by a JCB trained specialist. Only JCB condition. To maintain this condition and ensure trouble Distributor Service Engineers have been trained by JCB to...

  • Page 178: Owner/Operator Support

    Remember, only your JCB Distributor has access to the JCB together with your Distributor wants you to be vast resources available at JCB to help support you. In completely satisfied with your new JCB machine. If you do addition, your Distributor is able to offer a variety of...

  • Page 179: Service/Maintenance Agreements

    Distributor can offer. These can be tailor made to meet your operating conditions, work schedule etc. A Parts Book for your machine is available from your JCB Distributor. The Parts Book will help you identify parts and Please consult your JCB Distributor for details.

  • Page 180: Health And Safety

    Hygiene Storage JCB lubricants are not a health risk when used properly for Always keep lubricants out of the reach of children. their intended purposes. Never store lubricants in open or unlabelled containers. However, excessive or prolonged skin contact can remove the natural fats from your skin, causing dryness and irritation.
  • Page 181 Routine Maintenance Health and Safety Waste Disposal Handling CAUTION WARNING It is illegal to pollute drains, sewers or the ground. Clean up all spilt fluids and/or lubricants. Oil is toxic. If you swallow any oil, do not induce vomiting, seek medical advice. Used engine oil Used fluids and/or lubricants, filters and contaminated contains harmful contaminants which can cause skin materials must be disposed of in accordance with...
  • Page 182 Routine Maintenance Health and Safety Used Oil d Never use petrol, diesel fuel, or paraffin for washing. Used engine crankcase lubricants contain harmful contaminants. Avoid skin contact with oil soaked clothing. Here are precautions to protect your health when handling Don't keep oily rags in pockets.
  • Page 183 Routine Maintenance Health and Safety Skin In the case of excessive skin contact, wash with soap and water. Spillage Absorb with sand or a locally approved brand of absorbent granules. Scrape up and remove to a chemical disposal area. Fires WARNING Do not use water to put out an oil fire.

  • Page 184: Battery

    Routine Maintenance Health and Safety Battery minutes before connecting it up. T3-061 When reconnecting, fit the positive (+) lead first. WARNING 5-3-4-12 Batteries give off an explosive gas. Do not smoke when handling or working on the battery. Keep the CAUTION battery away from sparks and flames.
  • Page 185 Routine Maintenance Health and Safety DANGER WARNING Electrolyte Battery Gases Battery electrolyte is toxic and corrosive. Do not Batteries give off explosive gases. Keep flames and breathe the gases given off by the battery. Keep the sparks away from the battery. Do not smoke close to electrolyte away from your clothes, skin, mouth and the battery.
  • Page 186 Routine Maintenance Health and Safety Warning Symbols Symbol Meaning Explosive Gas. The following warning symbols may be found on the battery. A289250 Symbol Meaning Battery acid. Keep away from children. A289240 Note operating instructions. A289230-1 Shield eyes. A289270 A289260-1 No smoking, no naked flames, no sparks. A289280 9811/9950-1...
  • Page 187 Routine Maintenance Health and Safety First Aid - Electrolyte Do the following if electrolyte: Gets into your eyes Immediately flush with water for 15 minutes, always get medical help. Is swallowed Do not induce vomiting. Drink large quantities of water or milk.

  • Page 188: Service Schedules

    Routine Maintenance Service Schedules Service Schedules Introduction service schedules are done to keep the machine in a safe and efficient working condition. T3-036_3 WARNING Apart from the daily jobs, the schedules are based on machine running hours. Keep a regular check on the Maintenance must be done only by suitably qualified hourmeter readings to correctly gauge service intervals.

  • Page 189: How To Use The Service Schedules

    Routine Maintenance Service Schedules How to Use the Service Schedules T3-012_4 In the example shown, A shows all service requirements to be carried out every 10 hours and B shows 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.

  • Page 190: Calendar Equivalents

    Routine Maintenance Service Schedules 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 9811/9950-1...

  • Page 191: Pre Start Cold Checks, Service Points And Fluid Levels

    Routine Maintenance Service Schedules Pre Start Cold Checks, Service Points and Fluid Levels Operation 1000 2000 ENGINE 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...
  • Page 192 Routine Maintenance Service Schedules Operation 1000 2000 Fuel Sedimenter - Drain and Clean Fuel Filter/Sedimenter Element - Change Primary Fuel Filter - Check Fuel Pre Filter - Check Fan Belt Tension/Condition - Check and Adjust Valve Clearances - Check and Adjust Cylinder Head Bolts for Tightness - Check and Adjust Engine Mounting Bolts for Tightness...
  • Page 193 Routine Maintenance Service Schedules Operation 1000 2000 - Drive Sprocket Bolts - Check - Slew Gearbox Bolts - Check Track Gearbox Oil - Change HYDRAULICS Oil Level - Check Change Rams - Chrome Condition - Check Hoses and Pipework - Damage/Leaks - Check Return Filter Element - Change...
  • Page 194 Routine Maintenance Service Schedules Operation 1000 2000 Starter Motor and Alternator Brush Gear - Check Wiring for Chaffing/Routing - Check Battery Terminals for Condition and 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...
  • Page 195 Routine Maintenance Service Schedules Operation 1000 2000 Slew Ring Bearing - Grease Slew Ring Mounting Bolts - 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...

  • Page 196: Functional Test And Final Inspection

    Routine Maintenance Service Schedules Functional Test and Final Inspection Operation 1000 2000 ENGINE Idle and Maximum Speed - Check and Adjust Exhaust Smoke (excessive) - Check Fuel System - Leaks and Contamination - Check HYDRAULICS Operation All Services - Excavator, Dozer etc. - Check Hoses and Pipework - Damage/Leaks - Check...
  • Page 197 Routine Maintenance Service Schedules Operation 1000 2000 ELECTRICS All Electrical Equipment Operation, (e.g. warning - Check lights, beacon, alarms, horn, wipers etc.) Hourmeter Operation - Check UNDERCARRIAGE Track and Running Gear Operation - Check BODYWORK AND CAB Excavator Lever and Swing Pedal Locks - Check LIFTING EQUIPMENT - Complete...

  • Page 198: Fluids, Lubricants And Capacities

    ASTM D6210 K Coolant Inhibitor/Water Mixtures ( T 182) Track Gearbox (each) 0.8 (0.2) JCB SAE 30 Engine Oil (Not Multigrade) API CD/SF, MIL-L-46152, MIL-L- 2104D Track Idler Wheels 0.08 (0.02) JCB HD90 Gear oil API-GL-5, MIL-L-2105D Track Roller (top) 0.03 (0.01)
  • Page 199 Item Capacity Fluid / Lubricant International Specification Litres (UK Gal) Track Rollers (bottom) 0.08 (0.02) JCB HD90 Gear Oil API-GL-5, MIL-L-2105D Hydraulic Tank 40 (8.8) JCB Special Hydraulic Fluid Up to 30°C (86°F) JCB Hydraulic Fluid 46 Over 30°C (86°F)

  • Page 200: Coolant Mixtures

    Check the strength of the coolant mixture at least once a year, preferably at the start of the cold period. The protection provided by JCB High Performance Antifreeze and Inhibitor is shown below. Replace the coolant mixture according to the intervals shown in the machine's Service Schedule.
  • Page 201 Routine Maintenance Fluids, Lubricants and Capacities – Ensure that the antifreeze complies with International 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 are not used.

  • Page 202: Fuels

    Routine Maintenance Fluids, Lubricants and Capacities Fuels CAUTION Consult your fuel supplier or JCB distributor about the Acceptable and Unacceptable Fuels suitability of any fuel you are unsure of. T3-048 Important: No warranty liability whatsoever will be GEN-9-2 accepted for failure of fuel injection equipment where the failure is attributed to the quality and grade of the fuel used.
  • Page 203 Routine Maintenance Fluids, Lubricants and Capacities Fuel Specification Applicable Engines Service Requirements ASTM D975-076 1-D Obey usual routine maintenance schedules MIL T38219 JP7 Important: Engines operated with procedures. Fuel additives are NATO F63 these fuels may have a reduced recommended for use with low service life.
  • Page 204 Routine Maintenance Fluids, Lubricants and Capacities Fuel Specification Applicable Engines Service Requirements AVTAG (obsolete) These fuels are not acceptable with or without additives. Engines must AVTAG FSII (obsolete), NATO F40, JP4, not be operated with these fuels. DERD 2454 JET B (ASTM D1655) BS MA100 JIS K2203 No.2 Unmodified vegetable oils...
  • Page 205 – Make sure the fuel is stored correctly, care must be Note: These products are given as examples only. The taken to make sure no water enters the machine fuel information is derived from the manufacturers data. The products are not recommended or endorsed by JCB. 9811/9950-1...
  • Page 206 Note: If performance related issues are to be reported to Warranty. 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 specification and relevant stall speeds recorded prior to making the report.
  • Page 207 Routine Maintenance Fluids, Lubricants and Capacities Sulphur Content Table 3. Sulphur Content Percentage of sulphur in Oil Change Interval T3-032 High sulphur content can cause engine wear. (High the fuel (%) sulphur fuel is not normally found in North America, Less than 0.5 Normal Europe or Australia.) If you have to use high sulphur fuel...
  • Page 208 Routine Maintenance Fluids, Lubricants and Capacities Effects of Fuel Contaminates in rough engine running. Special winter fuels may be available for engine operation at temperatures below T3-033 0°C (32°F). These fuels have a lower viscosity and The effect of dirt, water and other contaminants in diesel limit wax formation.

  • Page 209: Tools

    Routine Maintenance Tools Tools Toolbox (if fitted) Carrying Tools onto the Machine The machine has a lockable tool storage container A When you carry tools onto the machine you must maintain below the seat. three points of contact with the machine at all times. Lift tools onto the machine in intervals if necessary.

  • Page 210: Prepare The Machine For Maintenance

    Routine Maintenance Prepare the Machine for Maintenance Prepare the Machine for Maintenance Introduction Unless a maintenance procedure instructs you differently, you must lower the Excavator. Refer to How to Make the P11-3001 Machine Safe (Excavator Lowered). WARNING Maintenance must be done only by suitably qualified and competent persons.

  • Page 211: How To Make The Machine Safe (Excavator Lowered)

    Routine Maintenance Prepare the Machine for Maintenance How to Make the Machine Safe (Excavator Lowered) Important: Unless a maintenance procedure instructs you differently, you must lower the Excavator. Park the machine on level, solid ground. If necessary, refer to Stopping and Parking the Machine in the Operator Manual.

  • Page 212: Cleaning The Machine

    Routine Maintenance Cleaning the Machine Cleaning the Machine Introduction Detergents T3-062_2 Avoid using full strength detergent - always dilute Clean the machine using water and or steam. Do not allow detergents as per the manufacturer's recommendations, mud, debris etc. to build upon the machine. otherwise damage to the paint finish may occur.

  • Page 213: Preparing The Machine For Cleaning

    Routine Maintenance Cleaning the Machine Note: The machine must always be greased after CAUTION pressure washing or steam cleaning. The engine or certain components could be damaged Preparing the Machine for Cleaning high pressure washing systems; special precautions must be taken if the engine is to be P11-3004 washed using a high pressure system.

  • Page 214: Cleaning The Machine

    Routine Maintenance Cleaning the Machine Cleaning the Machine CAUTION Never use water or steam to clean inside the cab. The WARNING use of water or steam could damage the on-board computer and render the machine inoperable. Remove To avoid burning, wear protective gloves when dirt using a brush or damp cloth.

  • Page 215: Cleaning The Tracks

    Routine Maintenance Cleaning the Machine Do not allow debris to accumulate around the engine, Cleaning the Tracks pay particular attention to the exhaust area, remove P11-3003 all combustible material. WARNING Thoroughly dry piston rams and protect with clean If two people are doing this job make sure that the transmission or hydraulic oil if necessary.
  • Page 216 Replace any damaged parts. Operate the controls to slew the cab around across If in doubt consult your JCB Dealer. the tracks. Lower the bucket to the ground. Operate the controls slowly to lower the track to the Operate the controls to push the boom down so that ground.

  • Page 217: Checking For Damage

    Routine Maintenance Checking for Damage Checking for Damage Check the Machine Body and Structure Check all safety and instructional labels are in place and undamaged. Fit new labels where necessary. T3-063_4 Make sure that all guards and protective devices are in Check the Seat and Seat Belt place, attached by their locking devices and free from damage.

  • Page 218: Check The Hydraulic Hoses And Fittings

    Routine Maintenance Checking for Damage Check seats are undamaged and secure. Check seat Do not use the machine if a hose or hose fitting is adjustments for correct operation. damaged. Replace damaged hoses before you use the machine again. Check the Hydraulic Hoses and Fittings Replacement hoses must be of the same size and T3-072 standard.

  • Page 219: Check The Electrical Circuits

    Routine Maintenance Checking for Damage Check the Electrical Circuits T3-099 Inspect the 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 these faults are found.

  • Page 220: Checking The Rops/Fops Structure

    ROPS/FOPS. If for score marks, dents or similar defects. If a ram piston the Roll Over Protection Structure (ROPS)/Falling appears defective contact your service engineer or JCB Objects Protection Structure (FOPS) has been in an dealer.

  • Page 221: Greasing

    Routine Maintenance Greasing Greasing Introduction Note: Where applicable, refer to the manufacturers manual for instructions on the maintenance of optional T3-028_2 attachments. You must grease the machine regularly to keep it working efficiently. Regular greasing will also lengthen the machine's working life. Refer to the Service Schedule for CAUTION the correct intervals.

  • Page 222: Pivot Pins

    Routine Maintenance Greasing Pivot Pins Dozer ram pivot pins Dozer arm pivot pins WARNING You will be working close into the machine for these jobs. Lower the attachments if possible. Remove starter key and disconnect the battery. This will prevent the engine being started. 8-3-1-3 K Fluids, For the types of grease to use at each point,...
  • Page 223 Routine Maintenance Greasing Fig 72. 9811/9950-1...

  • Page 224: Slew Ring Bearings

    Routine Maintenance Greasing Slew Ring Bearings WARNING Do not overgrease the slew ring as this will result in the displacement of the grease seal. 8-2-9-35 Ensure the slew ring is 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.

  • Page 225: Slew Ring Gear Teeth

    A machine can roll off jacks and crush you. Do not work under a machine supported only by jacks. Slew Pinion Grease JCB Slew Pinion Grease is harmful as it contains 8-3-5-7 bitumen compounds 2811. Excessive contact may Raise the machine and support the undercarriage.
  • Page 226 Routine Maintenance Greasing C031400 Fig 74. Repeat steps 4 to 6 as necessary. Refit the plate B using bolts A. Lower the machine to the ground. 9811/9950-1...

  • Page 227: Access Panels

    Routine Maintenance Access Panels Access Panels Introduction WARNING T3-100 Touching hot surfaces can burn skin. The engine and When placed in their maintenance position, the access machine components will be hot after the unit has panels give you access to parts or areas of the machine been running.
  • Page 228 Routine Maintenance Access Panels Closing the Cover Make sure that the hydraulic bay cover is closed. Push the engine cover down. Make sure it is locked in place. Fig 75. 9811/9950-1...

  • Page 229: Hydraulic Bay Cover

    Routine Maintenance Access Panels Hydraulic Bay Cover Opening the Cover Make the machine safe with the excavator lowered, Refer to Prepare the Machine for Maintenance. Get access to the engine. Refer to Access Panels, Engine Cover. Locate handle H which is positioned in the top right hand corner of the engine bay, above the air filter.

  • Page 230: Electrical System

    Routine Maintenance Electrical System Electrical System Battery CAUTION Do not disconnect the battery while the engine is running, otherwise the electrical circuits may be damaged. INT-3-1-14 Battery Access Make the machine safe with the excavator lowered, Refer to Prepare the Machine for Maintenance. Remove the 4 bolts A.
  • Page 231 Routine Maintenance Electrical System Battery Disconnection/Connection Connection K Battery access battery. WARNING Access ( T 212), Check the battery. Keep metal watch straps and any metal fasteners on a If the terminal is dirty, clean the post. your clothes, clear of the positive (+) battery terminal. Such items can short between the terminal and nearby metal work.
  • Page 232 Routine Maintenance Electrical System c After cleaning, apply a thin coat of petroleum jelly Disconnect and remove battery. See Battery to the terminal. Disconnection/Connection. Re-connect the leads. Connect the earth (-) terminal WARNING last. Do not top the battery up with acid. The electrolyte If the machine has a battery isolator, move the switch could boil out and burn you.
  • Page 233 Routine Maintenance Electrical System Fig 78. Refit battery. Close and lock the access panels. 9811/9950-1...
  • Page 234 Routine Maintenance Electrical System Battery Isolator (if fitted) Turn the battery isolation switch A to the on position and remove the key. To disconnect the battery from the machine electrics a Close the tool storage cover. battery isolator switch has been installed. CAUTION Before carrying out arc welding on the machine, disconnect the battery and alternator to protect the...
  • Page 235 If you do not know the electrolyte levels. voltage of your booster (slave) supply, then contact your JCB dealer for advice. Do not attempt to jump- When jump-starting from another vehicle, make sure start the engine until you are sure of the voltage of the that the two vehicles do not touch each other.
  • Page 236 Routine Maintenance Electrical System K Battery Note: The machine has a 12 Volt electrical system. Using access battery. Access ( T a booster (slave) supply with a higher voltage will damage 212). the machine's electrical system. The negative (-) terminal on the battery is connected to frame earth.
  • Page 237 Routine Maintenance Electrical System Disconnect the 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 the battery. Then disconnect it from the booster supply.

  • Page 238: Fuses

    Routine Maintenance Electrical System Fuses Introduction CAUTION Fuses Always replace fuses with ones of correct ampere rating to avoid electrical system damage. 8-3-3-5 The electrical 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 K Fig 80.
  • Page 239 Routine Maintenance Electrical System All Machines Table 4. Fuse Circuit Rating (Amps) Engine Stop Solenoid Instruments, Two-speed Circuit, Servo Solenoid Wash/Wipe Circuit Slew/Swing Circuit, SAE Control Boom Light Work Lights Interior Light, Horn, Radio, Accessory Power Socket Beacon Heater Blower and Air Conditioning Primary fuse 862330-3 Fig 81.

  • Page 240: Engine

    Routine Maintenance Engine Engine Oil and Filter Checking the Oil Level Get access to the engine. Refer to Access Panels, Engine Cover. Open the engine cover. Allow time for 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.
  • Page 241 Routine Maintenance Engine CAUTION The engine has a closed ventilation system, (a hose connects the ventilation system and the inlet manifold). When oil is added through the oil filler it is important that the oil is added slowly. If the oil is added too rapidly it will enter the cylinders through the hose and intake manifold and cause serious engine damage.
  • Page 242 Routine Maintenance Engine Changing the Oil and Filter then clean refit drain plug. K Fig 84. ( T 225). WARNING CAUTION Hot oil and engine components can burn you. Make The oil filter canister will contain some oil which could sure the engine is cool before doing this job.
  • Page 243 Routine Maintenance Engine Fill the engine with new oil through the filler. DO NOT insert the container neck Z completely into the filler K Fig 83. ( T hole. 223). Allow oil to flow down from the filler to the crankcase. Replace filler securely.

  • Page 244: Cooling System

    Routine Maintenance Engine Cooling System Refit the filler cap B making sure that it is tight. Checking the Coolant Level WARNING The cooling system is pressurised when the coolant is hot. When you remove the cap, hot coolant can spray out and burn you.
  • Page 245 Routine Maintenance Engine Changing the Coolant CAUTION Keep your face away from the cylinder block tap and the radiator drain plug when you drain the system. MD-3-1-6 Get access to the engine. Refer to Access Panels, Engine Cover. Allow the engine to cool. Carefully and slowly remove the radiator cap allowing any trapped pressure to escape.
  • Page 246 Routine Maintenance Engine Refit the plug B. Refit bottom hose C and secure with hose clip D. Fill the system. Use the correct mix of clean, soft K Coolant Mixtures ( T water and anti-freeze. 182). Refit the filler cap A making sure that it is tight. Run the engine for a while, to raise the coolant to working temperature and pressure.

  • Page 247: Fan Belt

    Routine Maintenance Engine Fan Belt Close the engine cover. Adjusting the Fan Belt Get access to the engine. Refer to Access Panels, Engine Cover. Check that there is 5mm (0.2in) slack midway between the alternator pulley and the crankshaft pulley. If necessary, adjust the fan belt as follows: K Fig 87.

  • Page 248: Air Filter

    Routine Maintenance Engine Air Filter bypass the element. Refit the element and cover. Check all air hoses for condition and security. Changing the Outer Element Get access to the air filter. Refer to Access Panels, Engine Cover and Access Panels, Hydraulic Bay Cover.
  • Page 249 Routine Maintenance Engine Changing the Inner Element C035060 Fig 89. Get access to the air filter. Refer to Access Panels, Undo the two retaining clips holding the cover A and Engine Cover. remove the element B by twisting anti-clockwise. To prevent dust getting into the engine, remove the Remove inner element G.
  • Page 250 Routine Maintenance Engine Smear the seal J of new inner element and carefully insert into canister making sure that it seats correctly. Withdraw element and check for continuous grease witness mark on the canister base. Refit element. Follow the same practice when fitting outer element, this time smearing seal E with grease, inserting element correctly, withdrawing and checking for continuous grease witness mark.

  • Page 251: Fuel System

    Routine Maintenance Fuel System Fuel System Introduction WARNING Fine jets of fluid at high pressure can penetrate the WARNING skin. Keep face and hands well clear of pressurised fluid and wear protective glasses. If fluid penetrates Fuel your skin, get medical help immediately. Fuel is flammable;...
  • Page 252 Routine Maintenance Fuel System CAUTION Do not allow dirt to enter the system. Before disconnecting any part of the system, 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 entering the system.

  • Page 253: Water Separator And Engine Fuel Filter

    Routine Maintenance Fuel System Water Separator and Engine Fuel Filter Draining the Fuel Filter/Sedimenter Get access to the engine. Refer to Access Panels, Engine Cover. Locate sedimenter under engine compartment at the front in a central position. If there is any sediment in the bowl replace the fuel K Replacing filter element.
  • Page 254 Routine Maintenance Fuel System Replacing the Fuel Filter Element If the bowl A contains sediment carry out the following: Get access to the engine. Refer to Access Panels, Engine Cover. K Draining the Fuel Drain the sediment bowl A. Filter/Sedimenter ( T 235).
  • Page 255 Routine Maintenance Fuel System Replacing the Fuel Pre Filter Element Get access to the engine. Refer to Access Panels, Engine Cover. K Fig 92. ( T Clamp the fuel hoses A. 237). Disconnect the fuel hose clips B. Remove the bolt C, Collect the washer, Remove the fuel pre filter D.

  • Page 256: Bleeding The System

    Routine Maintenance Fuel System Bleeding the System Retighten bleed screw A when all air has been removed. WARNING To bleed the injectors you must turn the engine. When the engine is turning, there are parts rotating in the engine compartment. Before starting this job make sure that you have no loose clothing (cuffs, ties etc) which could get caught in rotating parts.
  • Page 257 Routine Maintenance Fuel System T015790-2 Fig 93. 9811/9950-1...

  • Page 258: Hydraulic System

    Routine Maintenance Hydraulic System Hydraulic System Introduction WARNING Hydraulic Pressure WARNING Hydraulic fluid at system pressure can injure you. Before connecting or removing any hydraulic hose, The temperature of the hydraulic oil will be high soon residual hydraulic pressure trapped in the service after stopping the engine.
  • Page 259 Routine Maintenance Hydraulic System CAUTION Do not allow dirt to enter the system. Before disconnecting any part of the system, 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 entering the system.

  • Page 260: Releasing The Hydraulic Pressure

    Routine Maintenance Hydraulic System Releasing the Hydraulic Pressure Important: To release the hydraulic pressure from the electrical and servo operated services the battery must be connected while you operate the controls. Make the machine safe with the boom lowered. Refer to Prepare the Machine for Maintenance.

  • Page 261: Oil And Filter

    Routine Maintenance Hydraulic System Oil and Filter Checking and Adjusting the Fluid Level Make the machine safe with the boom lowered. Refer to Prepare the Machine for Maintenance. Check the Level Open the engine cover and hydraulic bay cover. K Access Panels ( T 209).
  • Page 262 Routine Maintenance Hydraulic System Replacing the Hydraulic Filter Open the engine cover and hydraulic bay cover. K Access Panels ( T 209). K Fig 95. ( T Unscrew cap B and spring C. 244). Withdraw bypass valve D, cartridge filter E and seal Clean all metal parts.

  • Page 263: Tracks And Running Gear

    Routine Maintenance Tracks and Running Gear Tracks and Running Gear Tracks Checking the Track Gearbox Oil Level Make the machine safe with the excavator lowered, Refer to Prepare the Machine for Maintenance. Ensure that the gearbox plugs A and B are positioned as shown.
  • Page 264 Routine Maintenance Tracks and Running Gear Changing the Track Gearbox Oil Run the machine, operate the track controls and then make sure there are no leaks. Make the machine safe with the excavator lowered, Refer to Prepare the Machine for Maintenance. Place a suitable container beneath the drain plug B to collect the oil.
  • Page 265 60mm (2.4in) and 65mm (2.6in) for rubber tracks and K Fig 98. ( T 248) 120mm (4.8in.) for steel tracks. Recoil unit servicing must only be carried out by JCB distributors. You could be killed or injured if you tamper with it.
  • Page 266 Routine Maintenance Tracks and Running Gear Fig 98. 9811/9950-1...
  • Page 267 Routine Maintenance Tracks and Running Gear Rotate track and re-check dimension A. b To slacken the track: Slacken adjusting screw C until track tension is correct. Rotate track and re-check dimension A. Refit the cover plate. Lower the track to the ground. Note: Track tension will increase during rotation.

  • Page 268: Fire Extinguisher (If Fitted)

    Routine Maintenance Fire Extinguisher (if fitted) Fire Extinguisher (if fitted) T3-022 Checking the Fire Extinguisher Check the fire extinguisher for damage, security and signs of 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 extinguisher must be serviced or replaced.

  • Page 269: Optional Attachments

    A wide range of optional attachments is available to increase the versatility of your machine. Only JCB 2-4-5-2_1 approved attachments are recommended for use with your machine. Consult your JCB Distributor for the full list of approved attachments available. 9811/9950-1...
  • Page 270 Read and fully understand the information machine's warranty and any other legislative compliance before fitting, using and servicing the attachment. If there may be affected by the use of non JCB approved is anything you do not understand, ask your JCB attachments.
  • Page 271 Optional Attachments Introduction CAUTION 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 9811/9950-1...

  • Page 272: Attachments For Your Machine

    Optional Attachments Attachments For Your Machine Attachments For Your Machine Attachments will help increase the productivity of your machine, for more information contact your JCB Distributor. Remember, do not operate attachments until you have read and fully understand the attachment operating instructions.

  • Page 273: Impact Protection

    Make sure that the attachment for example a hydraulic breaker B is positioned in front of the cab, before it is 732000-4 operated. Do not swing the boom to the side during Fig 100. operation of the attachment. Consult your JCB dealer for further information. 9811/9950-1...

  • Page 274: Connecting/Disconnecting Hydraulic Hoses

    Optional Attachments Connecting/Disconnecting Hydraulic Hoses Connecting/Disconnecting Hydraulic Hoses T4-004_2 Introduction WARNING Hydraulic Pressure WARNING Hydraulic fluid at system pressure can injure you. Before connecting or removing any hydraulic hose, Fluid Under Pressure residual hydraulic pressure trapped in the service Fine jets of fluid at high pressure can penetrate the hose line must be vented.

  • Page 275: Connecting The Hydraulic Hoses

    Optional Attachments Connecting/Disconnecting Hydraulic Hoses Connecting the Hydraulic Hoses Make machine safe. Refer Routine Maintenance, Prepare Machine Maintenance. Vent the hydraulic system. Refer to Routine Maintenance, Releasing the Hydraulic Pressure. If necessary, remove the blanking caps. T037400 Check the hoses and adaptors for damage. Refer to Fig 101.
  • Page 276 Optional Attachments Connecting/Disconnecting Hydraulic Hoses 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. Check for leaks. a Start the engine. b Operate the related control to increase the pressure in the hydraulic system.

  • Page 277: Disconnecting The Hydraulic Hoses

    Optional Attachments Connecting/Disconnecting Hydraulic Hoses c Stop the engine then remove the starter key. Disconnecting the Hydraulic Hoses d Check for indications of leakage at the hose Make machine safe. Refer Routine connections. Correct, as necessary. Maintenance, Prepare Machine Maintenance. Vent the hydraulic system.
  • Page 278 Optional Attachments Connecting/Disconnecting Hydraulic Hoses 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 hose connections. Correct, as necessary. 9811/9950-1...

  • Page 279: Quick Release Couplings

    Optional Attachments Connecting/Disconnecting Hydraulic Hoses Quick Release Couplings Finally, please read the correct fitting and releasing procedures before you install or remove any optional attachment fitted with quick release couplings. WARNING Essential Do's The external surfaces of the couplings must be clean before connecting or disconnecting.
  • Page 280 Optional Attachments Connecting/Disconnecting Hydraulic Hoses by dirt in the coupling or physical damage due to Essential Don'ts abuse. – Never attempt to reconnect using a damaged half – Connect and disconnect new couplings two or three coupling as this will destroy the seals in the mating times to work the PTFE seals.
  • Page 281 Optional Attachments Connecting/Disconnecting Hydraulic Hoses be replaced with a new one. See coupling guides for Connecting Quick Release Couplings a reference. Remove any residual hydraulic pressure trapped in – Never hit the centre poppet of the coupling to try and the service line hose.
  • Page 282 Optional Attachments Connecting/Disconnecting Hydraulic Hoses Pull back sleeve E to release the coupling. C007100-1 Fig 104. 9811/9950-1...

  • Page 283: Quickhitch Assembly

    Optional Attachments Quickhitch Assembly Quickhitch Assembly Introduction for short periods only. If the machine is to be used for rock breaking for a long period of time, it is recommended that the rockbreaker is installed directly on the machine. When The Excavator Quickhitch, which is attached to the dipper using a rockbreaker, it must be curled towards the machine permits fast removal and installation of the bucket (and...

  • Page 284: Installation

    Optional Attachments Quickhitch Assembly Installation Engage the tipping link: Operate the controls to line up hole E in the tipping Note: This operation is easier done by two people - one link with hole F in the Quickhitch. person to operate the controls and one to line up the pivots.

  • Page 285: Removal

    Optional Attachments Quickhitch Assembly Removal The removal of the Quickhitch is a reversal of the installation procedure. 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.

  • Page 286: Buckets

    Optional Attachments Buckets Buckets Bucket Selection Use the 300 mm (12 in.) wide bucket for narrow excavations or for maximum penetration when digging in hard, rocky or clay soils. WARNING Larger buckets are ideally suited to bulk shifting light or The bucket selected should be the correct width to suit loose materials.

  • Page 287: Removing A Bucket - Non Quickhitch Models

    Optional Attachments Buckets Removing a Bucket - Non Quickhitch Models P11-4002 Position the Boom Slew the boom so that it is straight in front of the machine. Rest the bucket on level ground, with the dipper approximately vertical and the bucket flat to the ground.
  • Page 288 Optional Attachments Buckets WARNING If two people are doing this job make sure 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.

  • Page 289: Installing A Bucket - Non Quickhitch Models

    Optional Attachments Buckets Installing a Bucket - Non Quickhitch bucket link with the bucket. Fit the pivot pins B and K Fig 106. ( T 269) lynch pin A. Models See Bucket Selection. Note: This job is easier done by two people - one to operate the controls and one to line up the pivots.

  • Page 290: Removing A Bucket From A Quickhitch

    Optional Attachments Buckets Removing a Bucket from a Quickhitch P11-4003 Note: Deposit Quickhitch attachments on firm level ground whenever possible. This will make later refitting easy and safe. Park the machine on firm level ground. Position the bucket so that it is approximately 150mm (6 in) above the ground.
  • Page 291 Optional Attachments Buckets Apply a downward pressure on the bar to release the buckets' rear pivot pin from the latch hook, K Fig 108. ( T 272) at Z. Remove the tommy bar from the Quickhitch. Rest the bucket on the ground. Slowly roll the Quickhitch back and simultaneously raise the dipper arm to release the buckets' front pivot K Fig 109.

  • Page 292: Installing A Bucket On A Quickhitch

    Optional Attachments Buckets Installing a Bucket on a Quickhitch See Bucket Selection. Position the Bucket Set the bucket on firm level ground. Use safe and correct lifting equipment to move the bucket. Position the machine a Position the machine so that the Quickhitch and bucket are correctly aligned for connection as shown.
  • Page 293 Optional Attachments Buckets c Use the excavator controls to roll the Quickhitch in WARNING the direction of arrow C until the latch hook D has fully engaged the pivot pin E on the bucket. Due Always fit the Quickhitch latch hook locking pin. to the light weight of some bucket it may be Failure to fit the pin will result in possible failure of the necessary to apply a load on the bucket teeth to...

  • Page 294: Replacing Bucket Teeth

    Optional Attachments Buckets Replacing Bucket Teeth P11-4001 Position the Bucket Make sure that the bucket is resting flat on the ground Switch off the Engine Remove the starter key. Remove a Tooth Remove the nut and bolt B and the tooth A. Install a Tooth Position the tooth A and fit the bolts B.

  • Page 295: Quickhitch Rockbreaker

    The attachments that need double-acting When the Quick-Hitch is installed and its attachment hydraulics for example the JCB Augers must have fitted, there is a danger of the attachment hitting the additional...
  • Page 296 Optional Attachments Quickhitch Rockbreaker CAUTION WARNING The rockbreaker must be positioned correctly before Fluid Under Pressure attempting to release it from the Quickhitch. if Fine jets of fluid at high pressure can penetrate the incorrectly positioned, the rockbreaker could swing or skin.
  • Page 297 Optional Attachments Quickhitch Rockbreaker WARNING The attachment will roll forward when released. Stand clear and to one side when releasing the attachment. 2-4-4-1 Remove lynch pin H, and locking pin F. Insert the tommy bar J into the hole K of the latch hook.
  • Page 298 Optional Attachments Quickhitch Rockbreaker Fig 112. 9811/9950-1...

  • Page 299: Installing A Quickhitch Rockbreaker

    Optional Attachments Quickhitch Rockbreaker Installing a Quickhitch Rockbreaker on the breaker. It may be necessary to apply a load on the bucket teeth to achieve Quickhitch connection. CAUTION Alternatively, use the tommy bar to lever the latch When the Quick-Hitch is installed and its attachment off, allowing the breaker pivot pin to locate in jaw fitted, there is a danger of the attachment hitting the of the Quickhitch.

  • Page 300: Operation

    Optional Attachments Quickhitch Rockbreaker Make sure that the swing/auxiliary switch is set to WARNING `auxiliary'. Always fit the Quickhitch latch hook locking pin. The double acting ball valve should be open for single Failure to fit the pin will result in possible failure of the acting attachments and closed for double acting latching mechanism.
  • Page 301 Optional Attachments Quickhitch Rockbreaker Push the pedal at A to operate the single acting K Fig 114. ( T attachments. 283). Push the pedal at B to operate the double acting attachments. The Rockbreaker is a single acting attachment, make sure the ball valve is in the correct position.
  • Page 302 Optional Attachments Quickhitch Rockbreaker Page left intentionally blank 9811/9950-1...

  • Page 303: Specifications

    (for example chains, etc.) is not the safe working load understands the laws and regulations concerning the use of the machine. of the JCB Excavator as an earthmover and for lifting. Consult your JCB Distributor for further information. M0002 The maximum load which may be lifted depends on the...
  • Page 304 Specifications Lifting Regulations and Safe Working Loads Load Charts 332/V2947-2 Fig 116. 8025 ZTS (France) 332/V2521-2 Fig 115. 8025 ZTS 9811/9950-1...
  • Page 305 Specifications Lifting Regulations and Safe Working Loads 332/V3004-2 Fig 118. 8030 ZTS 333/T3648 Fig 117. 8026 CTS 9811/9950-1...
  • Page 306 Specifications Lifting Regulations and Safe Working Loads 332/V3062-2 Fig 119. 8035 ZTS 9811/9950-1...

  • Page 307: Static Dimensions

    Specifications Static Dimensions Static Dimensions Fig 120. 9811/9950-1...
  • Page 308 Specifications Static Dimensions Table 5. Machine Dimensions 8026 CTS 8025 ZTS 8030 ZTS 8035 ZTS mm (ft-in) mm (ft-in) mm (ft-in) mm (ft-in) 2470 (8-1) 2470 (8-1) 2470 (8-1) 2475 (8-2) Overall Height (transport position) Overall Length (transport position) 4220 (13 -10)
  • Page 309 Specifications Static Dimensions Table 6. Machine Weights 8026 CTS 8025 ZTS 8030 ZTS 8035 ZTS kg (lb) kg (lb) kg (lb) kg (lb) Steel Tracks 2760 (6085) 2745 (6052) 3277 (7225) 3721 (8186) Rubber Tracks 2700 (5952) 2685 (5919) 3217 (7092)

  • Page 310: Performance Dimensions

    Specifications Performance Dimensions Performance Dimensions Fig 121. 9811/9950-1...
  • Page 311 Specifications Performance Dimensions Table 7. 8026 CTS 8025 ZTS 8030 ZTS 8035 ZTS mm (ft-in) mm (ft-in) mm (ft-in) mm (ft-in) Max. digging height 4435 (14-6) 4333 (14 -2) 4453 (14-7) 4601 (15 -2) Max. dumping height 3088 (10 -1)

  • Page 312: Auxiliary Pressures

    Specifications Auxiliary Pressures Auxiliary Pressures Table 8. Auxiliary Flow Auxiliary Pressure (L/min.) (Bar) 8026 CTS 8025 ZTS 8030 ZTS 8035 ZTS 9811/9950-1...

  • Page 313: Noise Data

    (2) Guaranteed equivalent sound power (external noise) For information relating to this machine when used with determined in accordance with the dynamic test other JCB approved attachments, please refer to the conditions defined in 2000/14/EC. literature accompanying the attachments. 9811/9950-1...

  • Page 314: All Machines

    Specifications Noise Data All Machines Table 9. Machine Engine rating 18.4kW (23.7Hp) 8026 CTS 20.9kW (26.8Hp) 8025 ZTS 20.9kW (26.8Hp) 8030 ZTS 23.6kW (30.4Hp) 8035 ZTS (1) Nett installed power. 9811/9950-1...

  • Page 315: Vibration

    Specifications Vibration Vibration Introduction Machine Operating Duties, see Dominant Axis (X, Y or T5-001 To assist in compliance with European Directive 2002/44/ EC, duty specific vibration emission values for this machine type have been provided on the following page(s) and may be used for the assessment of risks to exposure from vibration.
  • Page 316 Specifications Vibration Minimising Exposure to Vibration any large rocks or obstacles and filling in any ditches and holes. Exposure to vibration can be minimised through: – Choosing routes that avoid rough surfaces and, if this is not possible, drive more slowly to avoid bumping –...

  • Page 317: 8026 Cts, 8025 Zts, 8030 Zts

    Specifications Vibration 8026 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) 0.48 0.44 0.08 0.07 Machine Operating Duties 9811/9950-1...

  • Page 318: 8035 Zts

    Specifications Vibration 8035 ZTS Table 11. Whole-Body Vibration Emission Under Representative Operating Conditions (According to the Intended Use) Dominant Axis (X, Y or Z) 0.39 0.31 0.07 Machine Operating Duties 9811/9950-1...
  • Page 319 Whole-body vibration emission determined in accordance Machine Operating Duties with ISO 2631-1:1997 for this machine type is 0.08 m/s (8026 CTS, 8025 ZTS and 8030 ZTS) 0.31 m/s (8035Z) Low Idle normalised to an 8-hour reference period [A(8)] and based Excavating upon a test cycle defined in SAE J1166.
  • Page 320 Specifications Vibration Page left intentionally blank 9811/9950-1...

  • Page 321: Warranty Information

    Warranty Information Machine Service Record Sheet Warranty Information Machine Service Record Sheet Installation Checklist 500 Hrs./6 Month Date: Date: Hour reading: 1st 250 Hrs./3 Month 1000 Hrs./12 Month Annual insurance Date: Date: Hour reading: Hour reading: 9811/9950-1...
  • Page 322 Warranty Information Machine Service Record Sheet 1500 Hrs./18 Month 3000 Hrs./36 Month Annual insurance Date: Date: Hour reading: Hour reading: 2000 Hrs./24 Month 3500 Hrs./42 Month Annual insurance Date: Date: Hour reading: Hour reading: 2500 Hrs./30 Month 4000 Hrs./48 Month Annual insurance Date: Date:...
  • Page 323 Warranty Information Machine Service Record Sheet 4500 Hrs./54 Month 6000 Hrs./72 Month Annual insurance Date: Date: Hour reading: Hour reading: 5000 Hrs./60 Month 6500 Hrs./78 Month Annual insurance Date: Date: Hour reading: Hour reading: 5500 Hrs./66 Month 7000 Hrs./84 Month Annual insurance Date: Date:...
  • Page 324 Warranty Information Machine Service Record Sheet 7500 Hrs./90 Month 9000 Hrs./108 Month Annual insurance Date: Date: Hour reading: Hour reading: 8000 Hrs./96 Month 9500 Hrs./114 Month Annual insurance Date: Date: Hour reading: Hour reading: 8500 Hrs./102 Month 10000 Hrs./120 Month Annual insurance Date: Date:...

  • Page 325: Registration Information

    Warranty Information Registration Information Registration 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 Registration Number Engine Serial Number Engine Serial Number 9811/9950-1...
  • Page 326 Installing Engineer Installing Engineer Customer's Name Dealer Copy (U.K. and Eire only) - Do not send back to JCB Service. A copy of the registration details to be Address sent direct to: The Equipment Register Ltd. (T.E.R.) Bath and West Buildings P.D.I.

  • Page 327: European Community Standards

    European Community Standards EC Declaration of Conformity Introduction TS-007_3 A completed copy of the EC 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 summary of the information that can appear is provided.
  • Page 328 European Community Standards EC Declaration of Conformity XX/XX/XXXX 9814-0850-4-GB-A5A Fig 123. Top Part of Declaration of Conformity 9811/9950-1...
  • Page 329 European Community Standards EC Declaration of Conformity XX/XX/XXXX XX/XX/XXXX 9814-0850-4-GB-A5B Fig 124. Bottom Part of Declaration of Conformity 9811/9950-1...

  • Page 330: Explanation Of The Ec Declaration Of Conformity

    (PIN) (Introduction Section). K Fig 123. ( T K Fig 124. ( T 310), 311). EN 474-1:2006+A1:2009 EN 474-4:2006 +A1:2009 JCB Compact Products Limited Harewood Estate Engineering Manager Leek Road JCB Compact Products Limited Cheadle Harewood Estate Stoke On Trent...
  • Page 331 European Community Standards EC Declaration of Conformity Mr C J Knowles Refer to Noise Data (Specification Section). J. C. Bamford Excavators Limited Refer to Noise Data (Specification Section). Lakeside Works Rocester Rocester Staffordshire United Kingdom Managing Director ST14 5JP Compact excavator ANNEX VI PROCEDURE 1 A.
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