JCB JS81 Tracked Excavator Operator Manual 9821-4050

Description

• Model List:
  • JS81 Tracked Excavator

• 1. Important Information ………………………………………………………………………..vii
• 2. The Operator Manual ……………………………………………………………………vii
• 3. Safety Warnings …………………………………………………………………………..vii
• 4. Introduction
• 5. About this Manual ………………………………………………………………………………1
• 6. Machine Model and Serial Number ………………………………………………….1
• 7. Using this Manual ………………………………………………………………………….1
• 8. Left Side, Right Side ………………………………………………………………………1
• 9. Cross References ………………………………………………………………………….1
• 10. Machine Description …………………………………………………………………………..2
• 11. The JCB Tracked Excavator ……………………………………………………………2
• 12. Intended Use ………………………………………………………………………………..2
• 13. Component Location ……………………………………………………………………..4
• 14. Safety Check List ……………………………………………………………………………….6
• 15. Safety – Yours and Others ………………………………………………………………6
• 16. General Safety ……………………………………………………………………………..6
• 17. Operating Safety …………………………………………………………………………..8
• 18. Maintenance Safety …………………………………………………………………….. 11
• 19. Safety Labels …………………………………………………………………………………..16
• 20. Introduction …………………………………………………………………………………16
• 21. Safety Label Identification …………………………………………………………….17
• 22. Identifying Your Machine …………………………………………………………………..19
• 23. Machine Identification Plate ………………………………………………………….19
• 24. Component Identification Plates …………………………………………………….20
• 25. Operation
• 26. Introduction ……………………………………………………………………………………..21
• 27. Before Entering the Cab ……………………………………………………………………22
• 28. Entering and Leaving the Cab ……………………………………………………………23
• 29. Standard Cab Machines ……………………………………………………………….23
• 30. Doors and Windows …………………………………………………………………………24
• 31. Opening and Closing the Door ………………………………………………………24
• 32. Opening and Closing the Front Upper Window ………………………………..24
• 33. Door Sliding Window ……………………………………………………………………25
• 34. Access to the Upper Structure ……………………………………………………………26
• 35. Standard Machines ………………………………………………………………………26
• 36. Seat Controls …………………………………………………………………………………..27
• 37. Introduction …………………………………………………………………………………27
• 38. Operators Seat-Console ……………………………………………………………….27
• 39. Operators Seat – Standard-Heated …………………………………………………27
• 40. Air Suspension Seat …………………………………………………………………….28
• 41. Seat Belts(If fItted) ……………………………………………………………………………29
• 42. Static Seat Belt ……………………………………………………………………………29
• 43. Visibility Aids (if fitted) ……………………………………………………………………….30
• 44. Mirrors ……………………………………………………………………………………….30
• 45. Cab Layout ……………………………………………………………………………………..34
• 46. Components Key …………………………………………………………………………34
• 47. Drive Controls, Switches and Instruments ……………………………………………35
• 48. Drive Controls ……………………………………………………………………………..35
• 49. Switches …………………………………………………………………………………….36
• 50. Instruments …………………………………………………………………………………39
• 51. Operating Levers-Pedals …………………………………………………………………..40
• 52. Excavating Controls …………………………………………………………………….40
• 53. Operation Levers …………………………………………………………………………43
• 54. Optional Circuit Pedal (if fitted) ………………………………………………………44
• 55. ISO Operating Method …………………………………………………………………44
• 56. Safety Equipment …………………………………………………………………………….45
• 57. Control Locks ……………………………………………………………………………..45
• 58. Before Starting the Engine …………………………………………………………………46
• 59. Starting the Engine …………………………………………………………………………..47
• 60. Warming-Up ……………………………………………………………………………….47
• 61. Getting the Machine Moving ………………………………………………………………48
• 62. Stopping and Parking the Machine ……………………………………………………..49
• 63. Stopping and Parking …………………………………………………………………..49
• 64. Working with your Machine ……………………………………………………………….50
• 65. Operating Practices and Site Safety ………………………………………………50
• 66. Clothing and Safety Equipment ……………………………………………………..50
• 67. Danger Zone ………………………………………………………………………………50
• 68. Log Moving-Handling ……………………………………………………………………50
• 69. Safety Practices ………………………………………………………………………….50
• 70. Working With the Excavator ………………………………………………………….52
• 71. Use of Machines on Gradients and Slopes ……………………………………..60
• 72. Pulling out of Soft Ground …………………………………………………………….63
• 73. Water …………………………………………………………………………………………64
• 74. Towing Other Equipment ………………………………………………………………65
• 75. Machine Stability …………………………………………………………………………65
• 76. Reducing Wear ……………………………………………………………………………66
• 77. Operating Environment ……………………………………………………………………..70
• 78. Operating in Cold Climates …………………………………………………………..70
• 79. Operating in a Cold Climate (Below 0°C) ………………………………………..70
• 80. Operating in a Hot Climate (Above 35°C) ……………………………………….70
• 81. Operating in Dusty or Sandy Areas ………………………………………………..71
• 82. Operating in Coastal Regions ……………………………………………………….71
• 83. Operating on Wet or Soft Ground …………………………………………………..71
• 84. Refuelling the Machine ……………………………………………………………………..72
• 85. Low Fuel Levels ………………………………………………………………………….72
• 86. Filling the Tank ……………………………………………………………………………72
• 87. Fuel Level …………………………………………………………………………………..73
• 88. Moving a Disabled Machine ………………………………………………………………74
• 89. Lowering the Boom in an Emergency …………………………………………….74
• 90. Retrieval …………………………………………………………………………………….74
• 91. Transporting the Machine ………………………………………………………………….75
• 92. Lifting The Machine ………………………………………………………………………….77
• 93. JS81 Machines ……………………………………………………………………………77
• 94. Storage of the Machine …………………………………………………………………….79
• 95. Introduction …………………………………………………………………………………79
• 96. Storage Area ………………………………………………………………………………79
• 97. Prepare the Machine for Storage …………………………………………………..79
• 98. Put the Machine into Storage ………………………………………………………..79
• 99. During Storage ……………………………………………………………………………79
• 100. Take the Machine Out of Storage …………………………………………………..80
• 101. Routine Maintenance
• 102. Service Requirements ………………………………………………………………………81
• 103. Introduction …………………………………………………………………………………81
• 104. Owner-Operator Support ………………………………………………………………81
• 105. Service-Maintenance Agreements …………………………………………………81
• 106. Fit for Purpose Tests for Lifting Equipment ………………………………………81
• 107. Obtaining Replacement Parts ………………………………………………………..82
• 108. Health and Safety …………………………………………………………………………….83
• 109. Lubricants …………………………………………………………………………………..83
• 110. Battery ……………………………………………………………………………………….85
• 111. Warning Symbols ………………………………………………………………………..86
• 112. Battery Maintenance Check ………………………………………………………….86
• 113. First Aid-Electrolyte ……………………………………………………………………..86
• 114. Service Schedules ……………………………………………………………………………87
• 115. Introduction …………………………………………………………………………………87
• 116. How to Use the Service Schedules ………………………………………………..87
• 117. Calendar Equivalents …………………………………………………………………..87
• 118. Pre Start Cold Checks, Service Points and Fluid Levels ……………………88
• 119. Functional Test and Final Inspection ………………………………………………91
• 120. Service Intervals for Attachments …………………………………………………..92
• 121. Periodic Replacement of Safety Related Components ……………………..93
• 122. Fluids, Lubricants and Capacities ……………………………………………………….94
• 123. JS81 ………………………………………………………………………………………….94
• 124. Engine Lubrication Chart ………………………………………………………………95
• 125. Hydraulic Oil Chart ………………………………………………………………………95
• 126. Typical Lubrication Chart ………………………………………………………………96
• 127. Coolant Mixtures …………………………………………………………………………97
• 128. Fuel …………………………………………………………………………………………..98
• 129. Tools …………………………………………………………………………………………….100
• 130. Carrying Tools onto the Machine ………………………………………………….100
• 131. Locations ………………………………………………………………………………….100
• 132. Prepare the Machine for Maintenance ………………………………………………101
• 133. Introduction ……………………………………………………………………………….101
• 134. How to Make the Machine Safe (Excavator Lowered) …………………….101
• 135. Cleaning the Machine ……………………………………………………………………..102
• 136. Introduction ……………………………………………………………………………….102
• 137. Preparing the Machine for Cleaning ……………………………………………..102
• 138. Cleaning the Machine …………………………………………………………………103
• 139. Cleaning the Tracks ……………………………………………………………………103
• 140. Cleaning the Radiator and Oil Cooler ……………………………………………103
• 141. Checking for Damage ……………………………………………………………………..104
• 142. Check the Machine Body and Structure ………………………………………..104
• 143. Check the Seat and Seat Belt ……………………………………………………..104
• 144. Daily Checking ……………………………………………………………………………….105
• 145. Greasing ……………………………………………………………………………………….108
• 146. General Notes …………………………………………………………………………..108
• 147. Slew Ring Bearing ……………………………………………………………………..108
• 148. Slew Ring Teeth and Slew Pinion …………………………………………………108
• 149. Greasing Points …………………………………………………………………………109
• 150. Electrical System …………………………………………………………………………… 110
• 151. Battery …………………………………………………………………………………….. 110
• 152. Jump-Starting the Engine …………………………………………………………… 112
• 153. Fuses ………………………………………………………………………………………. 113
• 154. Bolt and Nut Torque Specifications …………………………………………………… 115
• 155. JS81 ……………………………………………………………………………………….. 115
• 156. Engine …………………………………………………………………………………………. 118
• 157. Checking the Oil Level ………………………………………………………………. 118
• 158. Changing the Oil and Filter …………………………………………………………. 119
• 159. Changing the Outer Air Filter Element ………………………………………….120
• 160. Changing the Inner Air Filter Element …………………………………………..121
• 161. Fan Belt ……………………………………………………………………………………122
• 162. Checking the Coolant Level ………………………………………………………..123
• 163. Cleaning the Radiator and Oil Cooler ……………………………………………123
• 164. Changing The Coolant ……………………………………………………………….124
• 165. Fuel System …………………………………………………………………………………..125
• 166. Introduction ……………………………………………………………………………….125
• 167. Fuel Supply ………………………………………………………………………………125
• 168. Sedimentor and Coarse filter ……………………………………………………….125
• 169. Draining the Water Separator and Engine Fuel Filter ………………………126
• 170. Mud Filter …………………………………………………………………………………126
• 171. Bleeding the System ………………………………………………………………….126
• 172. Hydraulic System ……………………………………………………………………………127
• 173. Checking the Fluid Level …………………………………………………………….127
• 174. Releasing Tank Pressure ……………………………………………………………128
• 175. Topping-up Fluid Level ……………………………………………………………….128
• 176. Changing the Fluid …………………………………………………………………….129
• 177. Draining Water and Sediment from the Hydraulic Tank ……………………129
• 178. Cleaning-Changing the Suction Strainer ……………………………………….130
• 179. Changing the Return Filter ………………………………………………………….130
• 180. Changing the Plexus Filter ………………………………………………………….131
• 181. Changing the Air Breather Element ………………………………………………132
• 182. Changing the Pilot Oil Filter …………………………………………………………133
• 183. Changing the Breaker In-line Filter (If fitted) ………………………………….134
• 184. Changing the Drain Line Filter ……………………………………………………..134
• 185. Air Bleeding Procedures ……………………………………………………………..135
• 186. Slew Gearbox ………………………………………………………………………………..137
• 187. Checking the Slew Gearbox Oil Level …………………………………………..137
• 188. Changing the Slew Gearbox Oil Level ………………………………………….137
• 189. Tracks and Running Gear ……………………………………………………………….138
• 190. Tracks ………………………………………………………………………………………138
• 191. Running Gear ……………………………………………………………………………141
• 192. Bucket ………………………………………………………………………………………….142
• 193. Checking-Adjusting For Side Play ………………………………………………..142
• 194. Fire Extinguisher (If fitted) ……………………………………………………………….143
• 195. Troubleshooting ……………………………………………………………………………..144
• 196. Engine and Related Area ……………………………………………………………144
• 197. Monitor Display – Fault Messages ………………………………………………..147
• 198. Operations ………………………………………………………………………………..149
• 199. Hydraulic pump …………………………………………………………………………149
• 200. Working Attachments …………………………………………………………………150
• 201. Travel ……………………………………………………………………………………….151
• 202. Slew …………………………………………………………………………………………152
• 203. Hydraulic ram ……………………………………………………………………………152
• 204. Optional Attachments
• 205. Introduction ……………………………………………………………………………………153
• 206. Attachments For Your Machine ………………………………………………………..154
• 207. Connecting-Disconnecting Hydraulic Hoses ……………………………………….155
• 208. Introduction ……………………………………………………………………………….155
• 209. Connecting the Hydraulic Hoses ………………………………………………….155
• 210. Disconnecting the Hydraulic Hoses ………………………………………………156
• 211. Hydraulic Rockbreaker ……………………………………………………………………157
• 212. Preparation ……………………………………………………………………………….157
• 213. Operation and Maintenance ………………………………………………………..157
• 214. Crusher …………………………………………………………………………………………158
• 215. General …………………………………………………………………………………….158
• 216. Preparation ……………………………………………………………………………….158
• 217. Specifications
• 218. Static Dimensions …………………………………………………………………………..159
• 219. JS81 ………………………………………………………………………………………..159
• 220. Dig Depth Chart ……………………………………………………………………………..160
• 221. JS81 ………………………………………………………………………………………..160
• 222. Shipping Weight …………………………………………………………………………….161
• 223. Travel Speeds ………………………………………………………………………………..162