jcb 8025 ZTS User manual

OPERATOR'S MANUAL
8025 ZTS, 8026 CTS, 8030 ZTS, 8035 ZTS
EN - 9811/9950
ISSUE 4 - 11/2016
THIS MANUAL SHOULD ALWAYS STAY WITH THE MACHINE

OPERATOR'S
MANUAL
8025 ZTS, 8026 CTS,
8030 ZTS, 8035 ZTS
EN - 9811/9950 - ISSUE 4 - 11/2016
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
Copyright 6-11-11 © 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.
www.jcb.com
Foreword
The Operator's Manual
You and others can be killed or seriously injured
if you operate or maintain the machine without
first studying the Operator's Manual. You must
understand and follow the instructions in 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
do not understand.
Treat the Operator's Manual as part of the machine.
Keep it clean and in good condition. Replace the
Operator's Manual immediately if it is lost, damaged
or becomes unreadable.
Machine Delivery and Installation
Even if you have operated this type of equipment
before, it is very important that your new machines
operations and functions are explained to you by
a JCB Dealer 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 (included in this manual) has not
yet been completed with you.
Your local JCB Dealer is
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9811/9950-4
Notes:
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Table of Contents
i 9811/9950-4 i
Contents Page No.
Acronyms Glossary ........................................................................................................................................ vii
Introduction
About this Manual
Model and Serial Number ..................................................................................................................... 1
Using the Manual .................................................................................................................................. 1
Left-Hand Side, Right-Hand Side ......................................................................................................... 1
Cab/Canopy .......................................................................................................................................... 1
Cross References ................................................................................................................................. 2
Location of Manual ............................................................................................................................... 2
Safety
Safety - Yours and Others .................................................................................................................... 3
Safety Warnings .................................................................................................................................... 3
General Safety ...................................................................................................................................... 4
Clothing and Personal Protective Equipment (PPE) ............................................................................ 5
About the Product
Introduction
General .................................................................................................................................................. 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 Locations .................................................................................................................. 9
Product and Component Identification
Machine ............................................................................................................................................... 10
Engine ................................................................................................................................................. 10
Operator Protective Structure ............................................................................................................. 11
Safety Labels
General ................................................................................................................................................ 12
Safety Label Identification ................................................................................................................... 12
Operator Station
Component Locations ......................................................................................................................... 14
Console Switches
General ................................................................................................................................................ 15
Work Lights ......................................................................................................................................... 15
Beacon ................................................................................................................................................ 15
Overload Warning System .................................................................................................................. 15
Window Wipers ................................................................................................................................... 16
Interior Switches
Ignition Switch ..................................................................................................................................... 17
Cab Interior Light ................................................................................................................................ 17
Operation
Introduction
General ................................................................................................................................................ 19
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Table of Contents
ii 9811/9950-4 ii
Operating Safety
General ................................................................................................................................................ 20
Worksite Safety ................................................................................................................................... 22
Risk Assessment ................................................................................................................................ 23
Walk-Around Inspection
General ................................................................................................................................................ 25
Entering and Leaving the Operator Station
General ................................................................................................................................................ 26
Emergency Exit ................................................................................................................................... 28
Doors
Operator Door ..................................................................................................................................... 30
Windows
Front Window ...................................................................................................................................... 32
Side Window ....................................................................................................................................... 33
Before Starting the Engine
General ................................................................................................................................................ 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 ................................................................................................................................................ 42
Immobiliser .......................................................................................................................................... 43
Warming Up ........................................................................................................................................ 46
Stopping and Parking
General ................................................................................................................................................ 47
Preparing for Travel
General ................................................................................................................................................ 48
Preparing for Worksite Travel ............................................................................................................. 48
Beacon ................................................................................................................................................ 48
Safety Equipment
General ................................................................................................................................................ 50
Slew Lock ........................................................................................................................................... 50
Control Lock ........................................................................................................................................ 50
Drive Controls
Track Controls ..................................................................................................................................... 52
Hand Throttle Control ......................................................................................................................... 52
Instruments
General ................................................................................................................................................ 54
Instrument Panel ................................................................................................................................. 54
Fuel Gauge ......................................................................................................................................... 54
Getting the Machine Moving
General ................................................................................................................................................ 56
Driving the Machine
General ................................................................................................................................................ 57
Operating Levers/Pedals
General ................................................................................................................................................ 58
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Table of Contents
iii 9811/9950-4 iii
Control Layouts ................................................................................................................................... 58
Excavator Arm Controls ...................................................................................................................... 58
Dozer Blade Controls ......................................................................................................................... 63
Auxiliary Circuit Controls ..................................................................................................................... 63
Lifting and Loading
General ................................................................................................................................................ 66
Load Charts ........................................................................................................................................ 66
Overload Warning System .................................................................................................................. 67
Working with the Excavator Arm
General ................................................................................................................................................ 68
Preparing to Use the Excavator Arm ................................................................................................. 68
Lifting With the Excavator Arm ........................................................................................................... 68
Digging ................................................................................................................................................ 69
Working with the Dozer Blade
General ................................................................................................................................................ 72
Dozing and Grading ............................................................................................................................ 72
Scraping and Cutting .......................................................................................................................... 72
Backfilling ............................................................................................................................................ 73
Slopes
General ................................................................................................................................................ 74
Driving on Slopes ............................................................................................................................... 74
Working on Slopes ............................................................................................................................. 74
Heating, Ventilating and Air-Conditioning (HVAC)
General ................................................................................................................................................ 76
Air-Conditioning Controls .................................................................................................................... 76
Cab Heater Controls ........................................................................................................................... 76
Power Sockets
Auxiliary Power Socket ....................................................................................................................... 78
Battery Isolator
General ................................................................................................................................................ 79
Fire Extinguisher
General ................................................................................................................................................ 80
Moving a Disabled Machine
General ................................................................................................................................................ 82
Getting the Machine Unstuck ............................................................................................................. 82
Jump-Starting the Engine ................................................................................................................... 82
Retrieval .............................................................................................................................................. 83
Excavator Arm (Emergency Operation) .............................................................................................. 83
Lifting the Machine
General ................................................................................................................................................ 85
Transporting the Machine
General ................................................................................................................................................ 86
Loading the Machine onto the Transporting Vehicle/Trailer ............................................................... 86
Unloading the Machine from the Transporting Vehicle/Trailer ............................................................ 88
Operating Environment
General ................................................................................................................................................ 90
Operating in Low Temperatures ......................................................................................................... 90
Operating in High Temperatures ......................................................................................................... 90
Refuelling
General ................................................................................................................................................ 92
Low Fuel Levels .................................................................................................................................. 92
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Table of Contents
iv 9811/9950-4 iv
Filling the Tank .................................................................................................................................... 92
Attachments
Working with Attachments
Introduction .......................................................................................................................................... 93
Attachments for your Machine ............................................................................................................ 93
Connecting/Disconnecting Hydraulic Hoses ....................................................................................... 94
Impact Protection ................................................................................................................................ 97
Direct-Mounted Attachments
General ................................................................................................................................................ 98
Quickhitch
Excavator Arm Quickhitch .................................................................................................................. 99
Buckets
General .............................................................................................................................................. 101
Bucket Teeth ..................................................................................................................................... 101
Rockbreaker
General .............................................................................................................................................. 105
Preservation and Storage
Cleaning
General .............................................................................................................................................. 109
Preparation ........................................................................................................................................ 109
Checking For Damage
General .............................................................................................................................................. 111
Storage
General .............................................................................................................................................. 112
Put into Storage ................................................................................................................................ 112
During Storage .................................................................................................................................. 112
Take out of Storage .......................................................................................................................... 113
Security
General .............................................................................................................................................. 114
JCB Plantguard ................................................................................................................................. 114
Construction Equipment Security and Registration Scheme (CESAR) ............................................ 114
Maintenance
Introduction
General .............................................................................................................................................. 115
Owner/Operator Support ................................................................................................................... 115
Service/Maintenance Agreements .................................................................................................... 115
Obtaining Spare Parts ...................................................................................................................... 116
Maintenance Safety
General .............................................................................................................................................. 117
Fluids and Lubricants ....................................................................................................................... 118
Maintenance Schedules
General .............................................................................................................................................. 122
How to Use the Maintenance Schedules ......................................................................................... 122
Maintenance Intervals ....................................................................................................................... 122
Pre-start Cold Checks, Service Points and Fluid Levels .................................................................. 123
Functional Tests and Final Inspection .............................................................................................. 124
Maintenance Positions
General .............................................................................................................................................. 126
Maintenance Position (Excavator Arm Lowered) ............................................................................. 126
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Table of Contents
v 9811/9950-4 v
Service Points
General .............................................................................................................................................. 127
Access Apertures
General .............................................................................................................................................. 130
Battery Cover .................................................................................................................................... 130
Engine Compartment Cover ............................................................................................................. 130
Hydraulic Compartment Cover ......................................................................................................... 131
Tools
General .............................................................................................................................................. 133
Toolbox .............................................................................................................................................. 133
Lubrication
General .............................................................................................................................................. 134
Preparation ........................................................................................................................................ 134
Attachments
General ............................................................................................................................................. 135
Body and Framework
General ............................................................................................................................................. 136
Slew Ring Bearings .......................................................................................................................... 136
Pivot Pins .......................................................................................................................................... 137
Operator Station
General ............................................................................................................................................. 139
Operator Protective Structure ........................................................................................................... 139
Seat ................................................................................................................................................... 139
Seat Belt ........................................................................................................................................... 139
Controls ............................................................................................................................................. 140
Engine
General ............................................................................................................................................. 141
Oil ...................................................................................................................................................... 141
Drive Belt .......................................................................................................................................... 144
Air Filter
General ............................................................................................................................................. 145
Dust Valve ........................................................................................................................................ 145
Fuel System
General ............................................................................................................................................. 146
Water Separator ............................................................................................................................... 146
Cooling System
General ............................................................................................................................................. 148
Coolant .............................................................................................................................................. 148
Cooling Pack .................................................................................................................................... 148
Tracks
General ............................................................................................................................................. 150
Steel .................................................................................................................................................. 150
Rubber .............................................................................................................................................. 152
Track Gearbox
Oil ...................................................................................................................................................... 153
Hydraulic System
General ............................................................................................................................................. 154
Services ............................................................................................................................................ 155
Oil ...................................................................................................................................................... 155
Cylinder Rams .................................................................................................................................. 155
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Table of Contents
vi 9811/9950-4 vi
Electrical System
General ............................................................................................................................................. 157
Battery ............................................................................................................................................... 157
Battery Isolator ................................................................................................................................. 158
Fuses ................................................................................................................................................ 159
Window Washer ................................................................................................................................ 160
Miscellaneous
Fire Extinguisher ............................................................................................................................... 161
Technical Data
Static Dimensions
Dimensions ........................................................................................................................................ 163
Weights ............................................................................................................................................. 166
Visibility Diagrams ............................................................................................................................. 168
Performance Dimensions
Excavator Arm Dimensions and Performance .................................................................................. 170
Noise Emissions
General .............................................................................................................................................. 178
Noise Data ........................................................................................................................................ 178
Vibration Emissions
General .............................................................................................................................................. 179
Vibration Data ................................................................................................................................... 180
Fluids, Lubricants and Capacities
General .............................................................................................................................................. 182
Fuel ................................................................................................................................................... 182
Coolant .............................................................................................................................................. 189
Torque Values
General .............................................................................................................................................. 190
Electrical System
General .............................................................................................................................................. 191
Fuses ................................................................................................................................................. 191
Engine
General .............................................................................................................................................. 192
Hydraulic System
Auxiliary Circuits ............................................................................................................................... 193
Tracks
General .............................................................................................................................................. 194
Declaration of Conformity
General .............................................................................................................................................. 195
Data ................................................................................................................................................... 196
Warranty Information
Service Record Sheet ....................................................................................................................... 198
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Table of Contents
vii 9811/9950-4 vii
Acronyms Glossary
CESAR Construction Equipment Security and Registration
DEF Diesel Exhaust Fluid
ECU Electronic Control Unit
ESOS 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 Liquid Crystal Display
LED Light Emitting Diode
PIN Product Identification Number
PPE Personal Protective Equipment
RMS Root Mean Square
ROPS Roll-Over Protective Structure
SWL Safe Working Load
TOPS Tip-Over Protective Structure
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