jcb 2069289 Page 163 Operator'S Manual Download

Page: 163 / 208

Maintenance

Electrical System

151

9821/6100-4

151

Battery

Clean

WARNING

Keep metal watch straps and any metal fasteners on your clothes, clear of the positive (+)

battery terminal. Such items can short between the terminal and nearby metal work. If it happens you can

get burned.

1. Make the machine safe.

Refer to: Maintenance Positions (Page 122).

2. Get access to the battery.

Refer to: Access Apertures (Page 125).

3. If the terminal posts are corroded and covered with white powder wash them with hot water. If there is

considerable corrosion, clean the terminal posts with a wire brush or abrasive paper. Refer to Figure 110.

Figure 110.

4. Apply a thin layer of petroleum jelly to the terminal posts.

Connect

CAUTION

The machine is negatively earthed. Always connect the negative pole of the battery to earth.

When connecting the battery, connect the earth (-) lead last.
When disconnecting the battery, disconnect the earth (-) lead first.

1. Get access to the batteries.

Refer to: Disconnect (Page 151).

2. Connect the battery leads. Connect the earth (-) terminal last.
3. If the machine has a battery isolator, move the switch to the on position.

Refer to: Battery Isolator (Page 34).

Disconnect

CAUTION

The machine is negatively earthed. Always connect the negative pole of the battery to earth.

When connecting the battery, connect the earth (-) lead last.
When disconnecting the battery, disconnect the earth (-) lead first.

Notice:

Do not disconnect the battery while the engine is running, otherwise the electrical circuits may

be damaged.

1. Make the machine safe.

Summary of Contents for 2069289

Page 1: ...OPERATOR S MANUAL COMPACT EXCAVATOR 8014 CTS 8016 CTS 8018 CTS 8020 CTS EN 9821 6100 ISSUE 4 03 2017 THIS MANUAL SHOULD ALWAYS STAY WITH THE MACHINE...

Page 2: ......

Page 3: ...the Operator s Manual If you do not understand anything ask your employer or JCB dealer to explain it Do not operate the machine without an Operator s Manual or if there is anything on the machine you...

Page 4: ...9821 6100 4 Notes...

Page 5: ...ral 7 Name and Address of the Manufacturer 7 Product Compliance 7 Description General 8 Intended Use 8 Log Moving Object Handling 8 Optional Equipment and Attachments 8 Danger Zone 8 Main Component Lo...

Page 6: ...eral 35 Operator Seat General 36 Basic Seat 36 Suspension Seat 37 Seat Belt General 38 Inertia Reel Seat Belt 38 Static Seat Belt 39 Starting the Engine General 41 Immobiliser 42 Warming Up 45 Stoppin...

Page 7: ...lade General 71 Dozing and Grading 71 Scraping and Cutting 71 Backfilling 72 Heating Ventilating and Air Conditioning HVAC General 73 Cab Heater Controls 73 Power Sockets Auxiliary Power Socket 74 Fir...

Page 8: ...ation 105 Checking For Damage General 107 Storage General 108 Put into Storage 108 During Storage 108 Take out of Storage 109 Security General 110 JCB Plantguard 110 Construction Equipment Security an...

Page 9: ...al 129 Slew Ring Bearings 129 Pivot Pins 130 Operator Station General 132 Operator Protective Structure 132 Seat 132 Seat Belt 132 Controls 133 Engine General 134 Oil 134 Drive Belt 136 Air Filter Gen...

Page 10: ...xcavator Arm Dimensions and Performance 162 Noise Emissions General 170 Noise Data 170 Vibration Emissions General 171 Vibration Data 172 Fluids Lubricants and Capacities General 173 Fuel 173 Coolant...

Page 11: ...Engine Shut Off Solenoid FOGS Falling Object Guard System FOPS Falling Object Protective Structure HVAC Heating Ventilation Air Conditioning ISO International Organization for Standardization LCD Liqu...

Page 12: ...Notes viii 9821 6100 4 viii...

Page 13: ...g and maintaining the machine If there is anything you are not sure about ask your JCB dealer or employer Do not guess you or others could be killed or seriously injured The general and specific warni...

Page 14: ...is manual cross references are made by presenting the subject title in blue electronic copy only The number of the page upon which the subject begins is indicated within the brackets For example Refer...

Page 15: ...se around you will be safe If you are not sure of anything about the machine or the work ask someone who knows Do not assume anything Remember Be careful Be alert Be safe Safety Warnings In this manua...

Page 16: ...ich can cause drowsiness Feeling Unwell Do not attempt to operate the machine if you are feeling unwell By doing so you could be a danger to yourself and those you work with Mobile Phones Switch off y...

Page 17: ...otective Equipment PPE Do not wear loose clothing or jewellery that can get caught on controls or moving parts Wear protective clothing and personal safety equipment issued or called for by the job co...

Page 18: ...Notes 6 9821 6100 4 6...

Page 19: ...ct your JCB and some of its components may bear approval numbers and marking s and may have been supplied with a Declaration Certificate of Conformity These marking s and documents are relevant only f...

Page 20: ...e machine should not be operated by any person who does not have an appropriate level of qualification training or experience of use of this type of machine Prior to use of the machine its suitability...

Page 21: ...t safe Main Component Locations Figure 3 F J K M L D B N A C E H G A Bucket ram B Dipper part of the excavator arm C Dipper ram D Boom part of the excavator arm E Boom ram F Cab contains the operator...

Page 22: ...ts and must be read from left to right For example JCB08025L01226500 Table 1 Explanation of the PIN Digit Description 1 to 3 World manufacturer identification For example JCB UK Build 4 to 8 Machine t...

Page 23: ...pped with a seat belt The ROPS FOPS FOGS or TOPS is designed to give you protection in an accident If you do not wear the seat belt you could be thrown off the machine and crushed You must wear a seat...

Page 24: ...rt number printed on it use this number to order a new safety label from your JCB dealer Safety Label Identification Figure 7 817 7006 2 332 V3761 1 F 817 70102 G 817 7004 J 817 70106 2 A B C D E 817...

Page 25: ...ety Labels 13 9821 6100 4 13 Item Part Number Description Qty H 817 70005 Hot fluid under pressure Refer to Cooling System Page 141 1 J 817 70106 Strike to whole body machine swing Keep a safe distanc...

Page 26: ...r to Excavator Arm Controls Page 58 E Two speed tracking switch F Dozer blade control Refer to Dozer Blade Controls Page 61 G Hand throttle control Refer to Hand Throttle Control Page 52 H Instrument...

Page 27: ...re the controls are in neutral and the excavator and dozer are lowered before you stop the engine I On Turn the ignition key to this position to connect the battery to all of the elec trical circuits...

Page 28: ...bar illuminates to show that the switch function is active Figure 11 1 3 2 A B A Graphic symbol B Light bar Work Lights Two or three position rocker switch The switch functions operate when the igniti...

Page 29: ...821 6100 4 17 Window Wipers Three position rocker switch The switch functions operate when the ignition switch is in the on position The wiper will self park when switched off Position 1 Off Position...

Page 30: ...Notes 18 9821 6100 4 18...

Page 31: ...e aware of events happening in or around the machine Safety must always be the most important factor when you operate the machine When you understand the operating controls gauges and switches practic...

Page 32: ...rmance with unapproved modifications or additional equipment Engine Steering Failure If the engine or steering fails stop the machine as quickly as possible Do not operate the machine until the fault...

Page 33: ...n crate if applicable Machine Safety Stop work at once if a fault develops Abnormal sounds and smells can be signs of trouble Examine and repair before resuming work Hot Components Touching hot surfac...

Page 34: ...hine If the machine is struck by lightning do not use the machine until it has been checked for damage and malfunction by trained personnel Worksite Safety WARNING You or others can be killed or serio...

Page 35: ...e into account the specific application and conditions of use at the time It is essential that a risk assessment of the work to be done is completed and that the operator obeys any safety precautions...

Page 36: ...sufficient for safe manoeuvring Are any other machines or persons likely to be in or to enter the area while operations are in progress The Route to be Travelled How solid is the ground will it provi...

Page 37: ...pivot points and radiator 1 3 Make sure the cab step and handrails are clean and dry 1 4 Clean all of the safety and instructional labels Replace any label that is missing or cannot be read 2 Check fo...

Page 38: ...e steps and handrails are provided Always face the machine when entering and leaving Make sure the step s handrails and your boot soles are clean and dry Do not jump from the machine Do not use the ma...

Page 39: ...ate the hydraulic controls several times to release any residual hydraulic pressure in the system 5 Turn the ignition key to position 0 6 Raise the left controls console 7 Open the cab door and latch...

Page 40: ...per structure parallel to the undercarriage 2 Stop the engine 3 Turn the ignition switch to position 1 4 Operate the hydraulic controls several times to release any residual hydraulic pressure in the...

Page 41: ...Operation Entering and Leaving the Operator Station 29 9821 6100 4 29 Figure 15 A A Glazing breaker...

Page 42: ...ards you Figure 16 A A Lever Close the door from the inside by pulling it towards you it will latch itself Latch the Door in the Open Position To latch the door in the open position open the door unti...

Page 43: ...andles Release the levers to hold it in position Figure 18 B A B A A Handles B Levers Care must be taken when lowering the window not to bump the top edge of the lower front window Removing and Instal...

Page 44: ...n bolts To install the front window lower panel reverse the removal procedure Make sure the right hand edge of the panel is located correctly in the groove on the front window pillar before installing...

Page 45: ...Operation Windows 33 9821 6100 4 33 Figure 21 A B A Latch B Frame...

Page 46: ...U Electronic Control Unit to shutdown correctly you must wait 30s before you isolate the battery The 30s period starts when you turn the ignition off If a radio is fitted you may loose any settings Di...

Page 47: ...hers and for the maximum service life of your machine do a pre start inspection before you start the engine 4 1 If you have not done it do a walk around inspection of the outside of the machine Refer...

Page 48: ...operator s seat can be adjusted for your comfort A correctly adjusted seat will decrease the operator fatigue Adjust the seat so that you can comfortably reach the machine controls For driving the ma...

Page 49: ...Operation Operator Seat 37 9821 6100 4 37 Suspension Seat Figure 23 B A A Lever fowards backwards adjustment B Lever weight adjustment...

Page 50: ...ne 1 Sit correctly in the seat 2 Pull the seat belt and the tongue from the inertia reel holder in one continuous movement 3 Push the tongue into the latch Make sure the seat belt worn is snug and pro...

Page 51: ...inertia reel holder Static Seat Belt Fasten the Seat Belt WARNING If you do not wear your seat belt you could be thrown about inside the machine or thrown out of the machine and crushed You must wear...

Page 52: ...ter pull the end as far as it will go Figure 27 D A B C A Tongue B Toggle C Strap pull here to lengthen D Strap pull here to shorten Release the Seat Belt WARNING Release the seat belt only after safe...

Page 53: ...49 4 Move the throttle lever to the half speed position 5 To warm the engine combustion chambers turn the ignition key to position 2 for Duration 6s 6 Extend the time if the outside temperature is bel...

Page 54: ...operate buttons with sharp objects they may damage and disable the keypad If you make an error entering your PIN code and you realise this before pressing the ENT button then pressing the MD button c...

Page 55: ...e the acceptance of the master code 4 Within 59 seconds of the three flashes push the MD button 5 Enter your new four digit PIN code using the keypad Push the ENT button The LED will flash four times...

Page 56: ...the ignition key 2 The immobiliser immediately arms automatically To Add a New or Additional Ignition Key The ignition keys can be programmed to start more than one machine 1 Put the master key in th...

Page 57: ...run for Duration 10min 1 3 Do not operate any services 2 After the warm up period make sure that everyone is clear of the machine 3 Warm up the hydraulic oil 3 1 Increase the engine speed to maximum 3...

Page 58: ...ver to the idle position 3 Lower the bucket and dozer to the ground 4 Stop the engine 5 Discharge the hydraulic pressure Refer to Discharge Page 147 6 Switch off all unnecessary switches If you are le...

Page 59: ...g beacon if installed Refer to Beacon Page 47 2 Position the excavator 2 1 Position the cab facing forward over the dozer 2 2 Raise the dozer blade 2 3 Level Site Conditions Position boom fully up ope...

Page 60: ...t the beacon on the cab roof A magnetic base keeps the beacon in position 2 Put the plug into the socket on the cab roof 3 Use the beacon switch in the cab on the console to operate the amber beacon T...

Page 61: ...controls and causing a dangerous movement of the machine Before adjusting the cab environment e g opening the windows or adjusting the seat you must always isolate the controls WARNING When the machi...

Page 62: ...Operation Safety Equipment 50 9821 6100 4 50 Figure 36 A B A Handle B Left hand console Figure 37 A A Controls isolation switch in operator station...

Page 63: ...1 Figure 38 A A Controls isolation switch in toolbox compartment Make a note that the control isolation switch in the toolbox compartment mainly used to enable hydraulics for operating the hand held t...

Page 64: ...ers can be operated individually or together as necessary to move the machine as required The control levers are spring loaded to a central position In this position the tracks do not operate The cont...

Page 65: ...nates green when high speed is engaged C Indicator is not installed on this machine D SAE Controls Selected Indicator Illuminates green when the SAE control pattern is selected E Air Filter Blocked In...

Page 66: ...lluminated and re ducing as level drops ie 11 bars 10 bars 9 bars etc 4 bars to 3 bars Buzzer gives 3 short beeps Pump symbol starts to flash 3 bars to 1 bar Pump symbol remains flashing 1 bar illumin...

Page 67: ...ter you have warmed up the engine move off as described below Control and switch locations are provided within this manual 1 Make sure that your seat belt is correctly fastened 2 Make sure that the se...

Page 68: ...eted and that the operator complies with any safety precautions that the assessment identifies Driving on Slopes 0 10 Machine can be operated normally on stable ground conditions without any detriment...

Page 69: ...chine forward push both levers forward Release the levers to stop Track motor braking occurs automatically when the levers are released To move the machine backward pull both levers backward Release t...

Page 70: ...es may vary on machines Excavator Arm Controls ISO SAE Switch Figure 47 A D B B SAE h 1 C A Swing pedal B Excavator levers C SAE indicator lamp D ISO SAE switch The ISO SAE switch allows the operator...

Page 71: ...Locations Page 14 Press and hold the button to activate the horn It functions only when the ignition switch is on Travel Speed Selector Switch The travel speed selector switch is located on the dozer...

Page 72: ...0 4 60 Excavator Levers ISO Control Pattern Figure 49 C D E G F B A H A G B F D E C H J A Slew cab left B Slew cab right C Raise boom D Lower boom E Dipper in F Dipper out G Crowd bucket to gather a l...

Page 73: ...edal forward into its operating position Push the swing pedal to the right side Release the pedal when the excavator end has reached the required position Dozer Blade Controls Notice Before operating...

Page 74: ...s to slew the machine 90 degrees across the tracks Refer to Excavator Arm Controls Page 58 5 Operate the excavator controls to select boom down and lift one track just off the ground 6 Push the switch...

Page 75: ...ARNING Before operating the auxiliary control system make sure that you are aware of all safety notices that apply to the attachment you are using Also make sure you have installed the attachment corr...

Page 76: ...trols if installed Figure 54 A B A Left hand pedal disabled B Right hand aux roller switch The attachment is operated by the right hand joystick roller switch Move the switch left or right depending o...

Page 77: ...ecific safety factors Consult your JCB dealer for more information All figures and lift capacities if applicable in this publication are based on the machine being on level solid ground Safe Working L...

Page 78: ...there is a risk that the machine could become unstable When the machine is used for lifting the system must be switched on The system defaults to on every time the hydraulic isolation switch is presse...

Page 79: ...gnalling procedures Do not rely on shouting he or she will not hear you Make sure the correct bucket for the job is installed Refer to Buckets Page 98 Preparing to Use the Excavator Arm When choosing...

Page 80: ...ity of the load or the machine When you are using the dipper movement to lift always lift by moving the dipper away from you as shown not towards you This is because hose burst protection valves if in...

Page 81: ...reach out with the boom and dipper and position the bucket 2 Slowly crowd the bucket at the same time bring the dipper in Make sure the bucket stays at the same angle to the ground while it travels I...

Page 82: ...he side of the bucket Moving the Machine While Digging When digging a trench or hole which is longer than the excavator s reach dig to the required depth and width until it is not possible to dig any...

Page 83: ...a dozer blade task it will create large side loads on the dig end and this will cause twisting and bending Figure 62 Dozing and Grading Keep the bottom of the dozer parallel to the ground When gradin...

Page 84: ...the high side of the trench when possible Move the dozer blade level to the ground Work at right angles to the trench fill a dozer blades width at a time Leave any spillage until the trench is filled...

Page 85: ...dusty conditions Poor ventilated air can cause tiredness Do not operate the machine for long periods without ventilation or with the operator station fully closed and the fan turned off Cab Heater Con...

Page 86: ...which can be used for mobile phone chargers or other 12V powered devices Only connect items which are compatible with the power rating of the socket and have the correct plug Always operate the engine...

Page 87: ...re that you understand how to use the fire extinguisher If necessary refer to the instructions found on the fire extinguisher Only try to extinguish a fire if the circumstances permit and your safety...

Page 88: ...he starter motor Use only sound jump leads with securely attached connectors Connect one jump lead at a time The machine has a negative earth electrical system Check which battery terminal is positive...

Page 89: ...use the tow eye or tie down points if installed to tow the machine as this will cause damage to the machine Apply the minimum force to move the machine slowly not greater than 2km h 1 2mph smoothly an...

Page 90: ...ing a Disabled Machine 78 9821 6100 4 78 3 Use the right and left control levers to move the dipper and lower the boom 4 Vent the hydraulics Refer to Discharge Page 147 5 Turn the ignition key to the...

Page 91: ...t interfere with the top of the cab damaging the top glazing It may be necessary to remove the FOGS if installed Carry out the following procedure when lifting a machine 1 Remove all attachments 2 Rem...

Page 92: ...for the dimensions and weight of your machine Measure the clearance height Make sure that the truck driver knows the clearance height before he drives away Figure 69 A A Clearance height 2 Remove all...

Page 93: ...the transporter bed 13 Crowd the bucket Position the dipper vertically and lower the boom until the bucket rests on a wooden block on the trailer bed 14 Stop the engine 15 Position a strap of suitable...

Page 94: ...transporting vehicle on solid level ground 2 Apply the park brakes and lower any stability jacks 3 Attach the loading ramps on to the transporter Ramps must be level with each other in the lowered po...

Page 95: ...artment or snow could get into the air filter Operating in Extremely Low Temperatures In extremely low temperatures below 0 C 32 0 F special care must be taken Extend the warm up time and cover the fr...

Page 96: ...gularly remove dirt and debris from the cooling pack and the engine 5 Check the fan belt regularly 6 Check the air vents Make sure that the air vents to and from the engine compartment are not blocked...

Page 97: ...operates on steep slopes If you increase the engine speed or load when there is air in the fuel system then damage to the engine can occur If the fuel supply contains air you must stop the engine fill...

Page 98: ...Notes 86 9821 6100 4 86...

Page 99: ...o operate or the safe distance from power lines Practice with an attachment off the job before you work with it for the first time A JCB attachment is designed and manufactured specifically to suit th...

Page 100: ...service line has been vented before connecting or removing hoses Make sure the engine cannot be started while the hoses are open Some attachments are hydraulically powered The following procedures sho...

Page 101: ...e 107 5 If necessary install the blanking caps 6 Check for leaks 6 1 Start the engine 6 2 Operate the related controls to increase the pressure in the hydraulic system 6 3 Stop the engine then remove...

Page 102: ...damage to the seals and cause leaks They can also impede connection and disconnection of the couplings Periodically lubricate the internal locking balls on the female half of the coupling with silicon...

Page 103: ...lic breaker where the risk of flying debris is present a protective layer or screen guard must be attached to the front of the canopy or close the cab front window s to protect the operator from flyin...

Page 104: ...ot use your fingers through the holes to align the links 2 Carefully align the holes in the dipper and bucket link with the bucket If necessary move the machine to align the pivot pin holes 3 Install...

Page 105: ...the rockbreaker is installed directly on the machine When using a rockbreaker it must be curled towards the machine as a typical digging operation Do not use the rockbreaker as a lever as this causes...

Page 106: ...t pin dipper J Hole Quickhitch K Bolt dipper pivot pin L Hole dipper arm Removal The removal of the Quickhitch is a reversal of the installation procedure Pay particular attention to safety notices Ma...

Page 107: ...le force is required to engage them Make sure that the couplings have fully engaged To allow the use of hand held tools the machine is installed with a EHTMA European Hydraulic Tool Manufacturers Asso...

Page 108: ...r Station Page 26 5 Lower the left hand console and press the control isolation switch in toolbox compartment to enable the hydraulics Figure 82 A A Control isolation switch in toolbox compartment 6 L...

Page 109: ...osition 9 Hand held tool is live now and ready to use Operate the hand held tool in accordance with the relevant tool operator manual Disconnecting the Hand Held Tool 1 Make the machine safe Refer to...

Page 110: ...or reposition the machine Use the 300mm wide bucket for narrow excavations or for maximum penetration when digging in hard rocky or clay soils Larger buckets are ideally suited to bulk shifting light...

Page 111: ...m consists of an adaptor tooth and locking pin Refer to Figure 85 The adaptor remains attached to the bucket and the teeth can be easily and quickly changed by one person The method of removal install...

Page 112: ...Figure 87 Figure 87 Installation 1 Install the tooth over the adaptor The reverse movement of step 5 in the Removal procedure Refer to Figure 87 2 Install a new locking pin Make sure that the locking...

Page 113: ...Attachments Buckets 101 9821 6100 4 101 Figure 88 3 Carefully hit the locking pin with a hammer until it is flush with its guide and locks in position Refer to Figure 89 Figure 89...

Page 114: ...digging operation Do not use the rockbreaker as a lever as this causes excessive loads on the locking mechanism Installation 1 Set the rockbreaker on solid level ground Use safe and correct lifting eq...

Page 115: ...k Figure 92 C D C Latch hook D Tommy bar 10 Apply a downward pressure on the bar to release the breakers rear pivot pin from the latch hook allowing the breaker to swing forward as shown Figure 93 11...

Page 116: ...achments Rockbreaker 104 9821 6100 4 104 Figure 94 Operation The Rockbreaker is a single acting attachment make sure the ball valve is in the correct position Refer to Auxiliary Circuit Controls Page...

Page 117: ...d When cleaning is complete move the machine away from the wash area or alternatively remove the material washed from the machine When you remove components be aware of exposure to dirt and debris Cov...

Page 118: ...e engine and let it cool for at least one hour Do not try to clean any part of the engine while it is running 3 Make sure that all of the electrical connectors are correctly coupled If the connectors...

Page 119: ...ervation and Storage Checking For Damage 107 9821 6100 4 107 Checking For Damage General Refer to the individual condition checks throughout the Maintenance section Refer to Maintenance Schedules Page...

Page 120: ...ondensation in the tank if applicable 7 Examine the coolant condition Replace if necessary 8 Examine all fluid levels Top up if necessary Put into Storage 1 Park the machine on solid level ground 1 1...

Page 121: ...amine the coolant condition Replace if necessary 2 Examine all fluid levels If necessary replace the fluid or add more fluid 3 Clean the machine to remove all unwanted material and corrosive products...

Page 122: ...ion and registration that operates throughout the United Kingdom and Ireland and across the whole spectrum of JCB products CESAR is a scheme to help decrease plant theft and was developed by the Metro...

Page 123: ...aintenance or repairs you must complete the functional checks according to the maintenance schedule JCB regularly updates its dealers to advise them of any machine developments changes in specificatio...

Page 124: ...parts or consumables then you can compromise the health and safety of the operator and cause machine failure A parts book for your machine is available from your JCB dealer The parts book will help y...

Page 125: ...y way get it repaired straight away Neglect of necessary repairs could result in an accident or affect your health Do not try to do repairs or any other type of maintenance work you do not understand...

Page 126: ...ponent or surrounding area Used fluoroelastomeric components subjected to temperatures greater than 300 C 571 6 F e g engine fire must be treated using the following safety procedure Make sure that he...

Page 127: ...It is illegal to pollute drains sewers or the ground Clean up all spilt fluids and or lubricants Used fluids and or lubricants filters and contaminated materials must be disposed of in accordance wit...

Page 128: ...ing instructions First Aid Oil Eyes In the case of eye contact flush with water for 15min If irritation persists get medical attention Swallowing If oil is swallowed do not induce vomiting Get medical...

Page 129: ...led immediately Do not induce vomiting unless directed to do so by medical personnel Never give anything by mouth to an unconscious person Avoid prolonged or repeated skin contact After contact with s...

Page 130: ...nce with the requirements in this manual Apart from the daily tasks the schedules are based on the machine running hours Keep a regular check on the hourmeter readings to correctly gauge the service i...

Page 131: ...n Retaining Plate Bolts Torque Check condition Operator Station Operator Protective Structure Check condition Seat Belt Check condition Engine Oil Check leaks Oil Check level Oil Replace Drive Belt Ch...

Page 132: ...Replace Rams Check condition Return Filter Replace Suction Strainer Clean Security of Mounting Bolts on Ma jor Components Check condition Electrics Wiring Check condition Battery Clean Battery Electro...

Page 133: ...ondition Fuel System Fuel System Check leaks Hydraulics Hoses and Pipework Check operation Relief Valves 1 Check condition Services Check operation Electrics General Check operation Miscellaneous Fit...

Page 134: ...excavator arm Refer to Maintenance Positions Page 122 The machine has a cab tilt feature This feature must only be used out by trained personnel Refer to the service manual for the cab tilt procedure...

Page 135: ...maintenance tasks Engine Compartment Figure 97 J B C E F D G H L P N A M K A Engine oil dipstick B Engine oil filler cap C Radiator filler cap D Fuel filter E Fuses F Battery isolator switch G Air in...

Page 136: ...Maintenance Service Points 124 9821 6100 4 124 Cab and Exterior Figure 98 R S R Track gearbox S Track tensioner...

Page 137: ...particles of light combustible material such as straw grass wood shavings etc must not be allowed to accumulate within the engine compartment or in the propshaft guards when installed Examine these ar...

Page 138: ...00 4 126 Tools General All tools must be kept in the toolbox if installed when not in use Toolbox The machine has a lockable toolbox on the side of the cab Use the ignition key to open and close the t...

Page 139: ...orking efficiently Regular greasing will also lengthen the machine s working life Refer to the individual condition checks throughout the Maintenance section The machine must always be greased after p...

Page 140: ...ubricate Where applicable refer to the specific manufacturers manual for instructions on the lubrication of optional attachments Check Condition Where applicable refer to the specific manufacturers ma...

Page 141: ...ot pins are correctly in position and secured by their locking devices 3 Check the steps and handrails are undamaged and correctly attached 4 Check for broken cracked or crazed window glass and mirror...

Page 142: ...upper structure Angle 180 3 2 Grease in use four strokes of the grease gun then turn the upper structure Angle 180 3 3 Grease in use four strokes of the grease gun Pivot Pins Lubricate WARNING You wil...

Page 143: ...1 9821 6100 4 131 Figure 102 G H C A D E H F F B A Dipper ram pivot pins B Bucket ram pivot pins C Bucket pivot pins D Boom ram pivot pins E Kingpost ram pivot pins F Swing ram pivot pins G Dozer ram...

Page 144: ...ake the machine safe Refer to Maintenance Positions Page 122 2 Check the structure for damage 3 Make sure that all of the ROPS FOPS mounting bolts are undamaged and in position 4 Make sure that the RO...

Page 145: ...k that the belt mounting bolts are undamaged correctly installed and tight 5 Check that the buckle assembly is undamaged and operates correctly Controls Check Operation Check the operation of the non...

Page 146: ...2 3 ESOS Engine Shut Off Solenoid if applicable 2 4 Electrical connections 2 5 ECU Electronic Control Unit if applicable 3 Ensure that the alternator starter motor and any other electrical components...

Page 147: ...dipstick 8 4 Remove the dipstick 8 5 Check the oil level if necessary add more oil 8 6 Replace the dipstick 8 7 Replace the filler cap 9 Close and secure the engine cover if applicable Replace Notice...

Page 148: ...d above idle speed 15 Check for leaks 16 Check the oil level when the oil has cooled 16 1 Fill with clean engine oil if necessary Drive Belt Check Condition Notice A drive belt that is loose can cause...

Page 149: ...Maintenance Engine 137 9821 6100 4 137 Figure 103 B C A A Top mounting bolt B Bottom mounting bolt C Mid point deflection 5 Close the engine cover...

Page 150: ...r to Service Points Page 123 3 Check the system hoses for 3 1 Condition 3 2 Damage 3 3 Security 4 Replace the system hoses if necessary 5 Close the engine cover Dust Valve Check Condition Check the du...

Page 151: ...ion this will start the electric fuel pump 5 When all of the air has been released tighten the bleed screw 6 Close the engine cover 7 Turn the ignition key to the off position Check Leaks 1 Make the m...

Page 152: ...ss to the engine compartment Refer to Access Apertures Page 125 3 If there is water but no sediment open the tap to drain the water If there is any sediment in the bowl replace the fuel filter element...

Page 153: ...ing system is pressurised when the coolant is hot When you remove the cap hot coolant can spray out and burn you Make sure that the engine is cool before you work on the cooling system 4 Check the lev...

Page 154: ...o Maintenance Positions Page 122 2 Let the engine cool 3 Get access to the radiator Refer to Service Points Page 123 4 Check the condition of the coolant hoses 5 Check the radiator and intercooler sur...

Page 155: ...tamper with it Notice Always make sure that the track tension measurement is not less than specified or severe strain to the track will result Check the Tension WARNING A raised and badly supported m...

Page 156: ...ugh the nipple in the adjusting screw until track tension is correct 3 Rotate the track Track tension will increase during rotation 4 Check the track tension at its tightest point to avoid over tensio...

Page 157: ...d B Nipple C Adjusting screw Check Condition Check the condition of the track plates Check the track plate bolt torques Refer to Torque Values Page 181 Rubber Check Operation Refer to Check Operation...

Page 158: ...tion Excavator Arm Lowered Page 122 3 Clean the area around the fill level plug 4 Remove the fill level plug 5 Make sure that the oil inside the gearbox is level with the fill level plug 6 Top up the...

Page 159: ...Remove the ignition key 5 Carefully remove the hydraulic tank filler cap to vent residual tank hydraulic pressure 6 Install the hydraulic tank filler cap Check Condition Hydraulic Hoses WARNING Damage...

Page 160: ...ing Abnormal noises Do not use the machine if one or more of these faults are found You must make sure that the hydraulic service is repaired immediately Oil Check Level 1 Make the machine safe with t...

Page 161: ...Maintenance Hydraulic System 149 9821 6100 4 149 If a ram piston appears defective contact your service engineer or JCB dealer...

Page 162: ...rging circuit off before connecting or disconnecting the battery When you have installed the battery in the machine wait 5min before connecting it up When reconnecting attach the positive lead first D...

Page 163: ...m jelly to the terminal posts Connect CAUTION The machine is negatively earthed Always connect the negative pole of the battery to earth When connecting the battery connect the earth lead last When di...

Page 164: ...e machine electrics are isolated A defective isolator must be repaired before the machine is used For more information contact your JCB dealer Fuses Replace The electrical circuits are protected by fu...

Page 165: ...he front window washer bottle Refer to General Page 123 3 Remove the filler cap 4 Fill the washer bottle with clean water The liquid should contain a de icing fluid to prevent it freezing Refer to Flu...

Page 166: ...the fire extinguisher for damage and leaks 2 Make sure the fire extinguisher is correctly attached 3 Make sure that the gauge indicates that the extinguisher is charged i e the needle is in the green...

Page 167: ...8014 CTS Dimension Description mm A Sprocket idler centres 1 027 B Undercarriage overall length 1 382 C Kingpost clearance 373 D Tailswing radius 1 059 E Overall width 996 F Height over the cab withou...

Page 168: ...1 127 B Undercarriage overall length 1 484 C Kingpost clearance 394 D Tailswing radius 1 080 E Overall width 996 F Height over the cab 2 318 G Ground clearance 158 H Track gauge 750 to 1 110 I Width o...

Page 169: ...1 127 B Undercarriage overall length 1 484 C Kingpost clearance 394 D Tailswing radius 1 080 E Overall width 996 F Height over the cab 2 318 G Ground clearance 158 H Track gauge 750 to 1 110 I Width o...

Page 170: ...ll width 996 F Height over the cab 2 318 G Ground clearance 148 H Track gauge 752 to 1 112 I Width over the tracks retracted 1 002 F Width over the tracks extended 1 362 J Transport length standard di...

Page 171: ...nd steel tracks 1 647 Machine with canopy and rubber tracks 1 577 For 8018 CTS Approximate figures with a 75kg operator a standard dipper a 300mm bucket and a full fuel tank Table 16 Machine Weights 8...

Page 172: ...ed to improve visibility or as part of a risk assessment for work site safe operation introduction of additional visual aids or site management Refer to Risk Assessment Page 23 The visibility map show...

Page 173: ...6 2006 This represents the approximately visible area to operator from the seat wearing a seat belt The visibility map does not represent the visibility requirements as specified in EN 474 part 1 2006...

Page 174: ...F C E G D B A H I J Table 18 Machine Dimensions 8014 CTS Dimension Description Length mm Boom length 1 715 Dipper length 1 161 A Max digging reach 4 021 B Max dumping reach on ground 3 973 C Max digg...

Page 175: ...ng 1 16 Metre Dipper Figure 119 0 1 5 2 0 23 0M Pa 197 152 1 2 0 5 _ 1 5 27 5M Pa 157 0 1 266 315 1 0 360 2 5 1 0 0 266 401 0 5 257 227 3 0 1 365 _ C 218 222 169 3 362 289 B m D 0 98m _ 139 kg 333 W81...

Page 176: ...715 Dipper length 1 161 1 261 A Max digging reach 4 021 X B Max dumping reach on ground 3 973 4 060 C Max digging depth dozer up 2 271 2 366 C Max digging depth dozer down 1 X X D Max digging height 3...

Page 177: ...5M Pa A m E 1 161m 405 352 176 221 338 430 2 5 1 5 1 0 0 345 _ 173 203 289 350 306 3 0 1 506 380 B m D 0 98m 161 _ 200 0 259 265 294 232 3 _ 508 381 158 199 264 333 W8181 270 234 B m 0 5 _ _ 150 199...

Page 178: ...00 A Max digging reach 4 121 4 222 4 449 B Max dumping reach on ground 4 073 4 170 4 401 C Max digging depth dozer up 2 343 2 442 2 682 C Max digging depth dozer down 1 2 736 2 836 3 075 D Max digging...

Page 179: ...Technical Data Performance Dimensions 167 9821 6100 4 167 Lifting 1 16 Metre Dipper Figure 123 1 26 Metre Dipper Figure 124...

Page 180: ...cription mm Boom length 1 899 Dipper length 1 261 A Max digging reach 4 308 B Max dumping reach on ground 4 252 C Max digging depth dozer up 2 504 C Max digging depth dozer down 1 X D Max digging heig...

Page 181: ...Pa 320 _ 475 583 333 W8186 275 152 B m 461 360 758 B m D 0 98m 308 461 407 565 259 211 2 A m A m E 1 261m 707 C kg 323 396 527 2 0 251 E B D 1 89m 186 kg 190 1 2 0 _ 1 5 307 2 0 433 C 551 186 182 0 1...

Page 182: ...approved attachments please refer to the literature accompanying the attachments Table 22 Definition of terms Term Definition Notes LpA A weighted sound pressure level mea sured at the operator s sta...

Page 183: ...e operating duties see dominant axis X Y or Z Figure 127 Z X Y Exposure to Vibration Exposure to vibration can be minimised through Selection of the correct size and capacity of machine equipment and...

Page 184: ...tative operating conditions according to the intended use are shown Refer to Figure 128 Whole body vibration emission determined in accordance with ISO 2631 1 1997 for this machine type is 0 31 m s no...

Page 185: ...4000 0305 20L Up to 30 C 86 F JCB Hydraulic Fluid HP32 4002 1025 20L Hydraulic Tank 25 4 Over 30 C 86 F JCB Hydraulic Fluid HP46 4002 0805 20L Slew Ring Bearings As required JCB HP Grease 4003 2017 0...

Page 186: ...O 20844 Kinematic viscosity 5 mm The viscosity of the fuel that is deliv ered to the fuel in jection pump 1 4 minimum 4 5 maxi mum D445 ISO 3405 Water and sedimant Weight 0 1 maximum D1796 ISO 3734 Wa...

Page 187: ...ation Cetane Number Fuel that has a high cetane number will give a shorter ignition delay This will produce a better ignition quality Cetane numbers are derived for fuels against proportions of cetane...

Page 188: ...the content of sulfur in ULSD fuel must be below 15 PPM 0 0015 The lubricity of these fuels must not exceed wear scar diameter of 0 46mm The fuel lubricity test must be performed on a HFRR operated a...

Page 189: ...ents that are stated in Refer to Table 25 BS2869 class A2 off highway gas oil red diesel BS2869 can only be used if the sulfur level meets the specifications that are listed in Refer to Table 26 Refer...

Page 190: ...ency and european certification fuels Perkins does not certify engines on any other fuel The user of the engine has the responsibility of using the correct fuel that is recommended by the manufacturer...

Page 191: ...led discretion of the physical properties of the fuel The diesel fuel ASTM 0975 grade 1 D S15 or SSOO that is used in the united states of america may be used in very cold temperatures that are below...

Page 192: ...be obtained use de ionized water For further information advice on water hardness contact your local water authority The correct concentration of antifreeze protects the engine against frost damage in...

Page 193: ...Technical Data Torque Values 181 9821 6100 4 181 Torque Values General Table 31 Torque Values Torque Item N m ROPS cab mounts Bolts 70 Track Plate Bolts 74 FOGS Bolts 74...

Page 194: ...ystem voltage 12 Fuses Table 33 All Machines Rating Fuse Circuit A 1 Engine stop 60 2 Servo control instruments two speed range selector 60 3 Windscreen wiper 5 4 Blower 5 5 Boom light 15 6 Work light...

Page 195: ...Technical Data Engine 183 9821 6100 4 183 Engine General Table 34 Drive Belt Tension Measurement Dimension Deflection at mid point between alternator and crank shaft pulley 5mm...

Page 196: ...Table 35 Auxiliary Flow Auxiliary Pressure Model L min bar psi 8014 CTS 26 230 3 333 3 For 8016 CTS Table 36 Auxiliary Flow Auxiliary Pressure Model L min bar psi 8016 CTS 26 230 3 333 3 For 8018 CTS...

Page 197: ...TS Page 185 For 8020 CTS Table 39 Track Tension Minimum Track Tension Maximum Track Tension Track Type mm mm Rubber Track 55 55 Steel Track 80 80 For 8014 CTS Table 40 Track Tension Track Type mm Rubb...

Page 198: ...S 8016 CTS 8018 CTS 8020 CTS General A completed copy of the EC Declaration of Conformity is supplied with all machines manufactured according to EC type examination and or self certification requirem...

Page 199: ...aration of Conformity For 8014 CTS 8016 CTS 8018 CTS 8020 CTS 187 9821 6100 4 187 Data Figure 130 Table 42 A Refer to Name and Address of the Manufacturer Page 7 B Excavators Rope Or Hydraulic Hydraul...

Page 200: ...B Compact Products Limited Harewood Estate Leek Road Chea dle Stoke On Trent United Kingdom ST14 5JP G Mr C J Knowles J C Bamford Excavators Limited Lakeside Works Rocester Staffordshire United Kingdo...

Page 201: ...Information 189 9821 6100 4 189 Warranty Information Service Record Sheet Table 43 Signature and stamp Date Annual Insurance Yes Hours Figure 131 Installation Checklist h Figure 132 250h 3 Month h Fi...

Page 202: ...Technical Data Warranty Information 190 9821 6100 4 190 Figure 134 1000h 12 Month h Figure 135 1500h 18 Month h Figure 136 2000h 24 Month h Figure 137 2500h 30 Month h...

Page 203: ...Technical Data Warranty Information 191 9821 6100 4 191 Figure 138 3000h 36 Month h Figure 139 3500h 42 Month h Figure 140 4000h 48 Month h Figure 141 4500h 54 Month h...

Page 204: ...Technical Data Warranty Information 192 9821 6100 4 192 Figure 142 5000h 60Month h Figure 143 5500h 66 Month h Figure 144 6000h 72 Month h Figure 145 6500h 78 Month h...

Page 205: ...Technical Data Warranty Information 193 9821 6100 4 193 Figure 146 7000h 84 Month h Figure 147 7500h 90 Month h Figure 148 8000h 96 Month h Figure 149 8500h 102 Month h...

Page 206: ...Technical Data Warranty Information 194 9821 6100 4 194 Figure 150 9000h 108 Month h Figure 151 9500h 114 Month h Figure 152 10000h 120 Month h Figure 153 10500h 126 Month h...

Page 207: ...Technical Data Warranty Information 195 9821 6100 4 195 Figure 154 11000h 132 Month h...

Page 208: ...Notes 196 9821 6100 4 196...

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