JCB JS81 Tracked Excavator Service Manual
654 pages · Publication 9813-2000-2
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- Models
- JS81
- Serial coverage
- from SN 1480500 to 1481999, from SN 1798936 to 1799936, from SN 2426501 to 2427000
- Manual type
- Service Manual
- Pages
- 654
- Publication
- 9813-2000-2
- Condition
- Brand new
What's inside
From the manual's own table of contents: 4 sections, 349 entries. See sample pages (PDF, 430 KB)
General133 topics
- About this Manual
- Machine Description
- Identifying Your Machine
- Zinc Plated Fasteners and Dacromet Fasteners
- Hydraulic Connections
- Numerical List
- Tool Detail Reference
- Sealing and Retaining Compounds
- Colour Coding
- Acronyms Glossary
- Model and Serial Number
- Using the Manual
- Left-Hand Side, Right-Hand Side
- Cross References
- Safety - Yours and Others
- Safety Warnings
- General Safety
- Clothing and Personal Protective Equipment (PPE)
- General
- Name and Address of the Manufacturer
- Product Compliance
- Intended Use
- Log Moving/Object Handling
- Optional Equipment and Attachments
- Danger Zone
- Main Component Locations
- Machine
- Engine
- Safety Label Identification
- Component Locations
- Work Lights
- Control Locks
- Slew Lock
- Window Wipers
- Two Speed Range
- Power Mode
- Ignition Switch
- Cab Interior Light
- Worksite Safety
- Risk Assessment
- Emergency Exit
- Operator Door
- Front Window
- Side Window
- Sunblind
- Suspension Seat
- Seat Ventilation Controls
- Inertia Reel Seat Belt
- Static Seat Belt
- Warming Up
- Preparing for Worksite Travel
- Control Lock
- Track Controls
- Travel Speed Selector
- Instrument Panel
- Towing Other Equipment
- Control Layouts
- Excavator Arm Controls
- Dozer Blade Controls
- Auxiliary Circuit Controls
- Preparing to Use the Excavator Arm
- Lifting With the Excavator Arm
- Digging
- Changing the Bucket Linkage
- Dozing and Grading
- Scraping and Cutting
- Backfilling
- Driving on Slopes
- Working on Slopes
- Air-Conditioning Controls
- Face Level Fan
- Auxiliary Power Socket
- Getting the Machine Unstuck
- Jump-Starting the Engine
- Retrieval
- Excavator Arm (Emergency Operation)
- Loading the Product onto the Transporting Vehicle/Trailer
- Unloading the Product from the Transporting Vehicle/Trailer
- Operating in Low Temperatures
- Operating in High Temperatures
- Cab Filters
- Low Fuel Levels
- Filling the Tank
- Introduction
- Attachments for your Product
- Connecting/Disconnecting Hydraulic Hoses
- Impact Protection
- Bucket Teeth
- Preparation
- Put into Storage
- During Storage
- Take out of Storage
- LiveLink
- Owner/Operator Support
- Service/Maintenance Agreements
- Obtaining Spare Parts
- Fluids and Lubricants
- How to Use the Maintenance Schedules
- Maintenance Intervals
- Pre-start Cold Checks, Service Points and Fluid Levels
- Functional Tests and Final Inspection
- Maintenance Position (Excavator Arm Lowered)
- Battery Cover
- Engine Compartment Cover
- Hydraulic Compartment Cover
- Toolbox
- Slew Ring Bearings
- Pivot Pins
- Seat
- Seat Belt
- Controls
- Drive Belt
- Pre-Cleaner
- Dust Valve
- Tank
- Fuel Filter
- Water Separator
- Coolant
- Cooling Pack
- Steel
- Idler Wheels
- Rollers
- Services
- Cylinder Rams
- Battery
- Battery Isolator
- Fuses
- Relays
- Window Washer
- Dimensions
- Weights
- Excavator Arm Dimensions and Performance
- Driving Performance
Section B - Body & Framework23 topics
- Static Dimensions
- Dig Depth Chart
- Shipping Weight
- Cab Structure
- Direct Glazing
- Checks
- System Charging
- Refrigerant Leaks Detections
- Lubrications
- System Flushing
- Air Conditioning
- System Initial Check Points
- Temperature Pressure Data
- System Diagnosis based on Pressures
- Gauges Reading Interpretation
- Noise from A/C System
- Unpleasant Odour from A/C System
- Cab Panel Removal
- Right Hand Cab Panels
- Left Hand Cab Panels
- Wiper/Wash (Optional)
- Removal and Replacement
- Replacement
Section C - Electrics67 topics
- Circuit Symbols
- Inputs and Outputs
- Schematic Diagram
- Ignition Circuit
- Face Fan Circuit
- Horn Circuit
- Wiper Circuit
- Main Harness
- Roof and Boom Lamp Harness
- Cab Harness
- Using a Multimeter
- Measuring DC Voltage
- Measuring Resistance
- Measuring Continuity
- Measuring Frequency
- Testing a Diode or a Diode Wire
- Alternator
- General Description
- Service Precautions
- Charging Circuit Test
- Alternator Charging Test
- Maintenance
- Testing
- Specific Gravity Testing
- Wiring Harness Repair
- Repair Procedure
- Monitor Panel
- Mode Status
- Warning Lights
- General Data
- Main Hydraulic Pump
- Servo Pump
- Slew Motor/Gearbox
- Main Control Valve
- Dozer Control Valve
- Boom Ram
- Dipper Ram
- Bucket Ram
- Dozer Ram
- Specifications
- Introduction to Hydraulic Schematic Symbols
- General (Basic and Functional Symbols)
- Control Valves
- Example of Schematic Circuit
- Hydraulic Schematic
- Hydraulic Schematic (Serial Number - 24266501 to 2427000)
- Servo Line
- Pilot Pressure and Return Line
- Neutral Circuit
- Travel - Single Speed
- Boom Up
- Boom Down
- Dipper Out
- Dipper In
- Bucket Opening
- Bucket Closing
- Swing
- Operation
- Function
- Removal
- Dismantling and Assembly
- Dismantling
- Inspection
- Assembly
- Fault Finding
- Description
- Reduction Gear Structure and Working Principles
Section E - Hydraulics107 topics
- Motor Operating Principles
- Slew Brake Operation
- Motor Does Not Rotate
- Motor Rotates in the Reverse Direction
- Motor Speed is Low
- Motor Brake Working Poorly
- Motor is Driven by Exterior Torque
- Oil Leakage
- Slew Motor Configuration
- Hydraulic Pump Operation
- Pump Hydraulic Circuit Diagram
- Hydraulic Pump Exploded View
- Disassembly
- Pump Maintenance Criteria
- Precautions During Use
- Installation
- Caution During Use
- Maintenance, Inspection Points
- Typical Bucket Ram
- Typical Boom Ram
- Typical Dipper Ram
- Assembling and disassembling procedures
- Cylinder Disassembly
- Cylinder Assembly
- Do’s in a Hydraulic Cylinder
- Dont’s in a Hydraulic Cylinder
- Make the Machine Safe
- Pressure Testing - General
- Confirmation of the Oil Temperature
- Warming-up Procedure
- Pressure Testing Points
- Pressure Relief Valve Location
- Main Relief Valve (MRV) Pressure
- Servo Relief Pressure
- Slew Motor Pressure Relief
- Auxiliary Relief Valves
- Option ARV (Monoboom)
- Travel Motor Relief Pressure
- Scheduled Tasks
- Service Points
- Upper Structure
- Hydraulic Compartment
- Dozer Assembly
- Fuel Tank
- Hydraulic Oil
- Replace
- Hydraulic Tank Breather
- Return Filter
- Drain Filter
- Suction Strainer
- Clean / Replace
- Major Component Mounting Bolts
- Check
- Breaker In-Line Filter Element
- Relief Valves
- Check (Condition)
- Slew Gearbox
- Check (Oil Level)
- Replace (Oil)
- Hydraulic Contamination
- Hydraulic Fluid Quality
- Effects of Contamination
- Cleaning Operation
- Contaminant Standards
- Filters
- Relief Valve
- Hydraulic System
- Slew Motor
- Hydraulic Pump
- Hydraulic Rams
- Hydraulic Ram Faults and Remedies
- Fault Finding Tests
- Slow or Underpowered
- Harsh Operation When Selecting
- Tracking Off Line
- Poor Tractive Effort
- Loss of Creep Speed
- Loss of High Speed
- Machine Selects High Speed Travel
- Slew Bearing Faults
- Test 001: Testing Negative Control Signal
- Test 002: Test Max Flow Signal
- Test 003: Testing Main Pump Pressure
- Test 004: Testing Horsepower Control
- Test 005: Checking the Operation of the Main Hydraulic Spool
- Test 006: Test the Pressure Switches
- Symptoms of Pressure Switch Failures
- Test 007: Testing Engine Speed Settings
- Pressure Switches vs Engine Speed
- Test 008: Testing Machine Cycle Times
- Bucket Ram Speed
- Dipper Ram Speed
- Boom Ram Speed
- Slew Speed
- Travel Speed
- Travel Linearity
- Test 011: Testing Swing Brake Pressure
- Test 012: Testing Track Motor Relief Valve Settings
- Test 013: Testing Track Motor Drain Line Flow Rate
- Test 014: Loss of High Speed Tracking
- Additional information
- Test 016 - Flow Testing Hydraulic Pumps - Record Sheet
- Test 017: Testing Slew Bearing
- Checking Slew Bearing Backlash
- Checking Slew Bearing Vertical Lift
- Ram Creep Tests - All Services
- Test for Ram Creep
Section F - Transmission15 topics
- Middle Speed
- Slow Speed Travel (Creep)
- High Speed
- Brake Valve
- Parking Brake
- Rotation Direction
- Precautions During Installation
- Start Up and Running In
- Start Up
- Running In
- Transmission
- Traction Motor
- Counterbalance Valve
- Speed Range Changing
- Torque Specifications
Inside this manual
Real pages from this service manual (654 pages). Open the sample pages (PDF, 429 KB)
- Specifications, page 219: Technical Data
- Diagram, page 309: Section C - Electrics
- Troubleshooting, page 529: Fault Finding
- Color page, page 414: Section E - Hydraulics
- Color page, page 471: Section E - Hydraulics
This is a service manual
Here's how it compares to the other manual types.
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 654 pages
Quantity one is the manual described above.
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Ships in 1 business day.
60-day returns
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Binder not included
Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.
Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).