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Page 1: ...chine 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 co...

Page 2: ...9813 5350 2 Notes Find manuals at https best manuals com ...

Page 3: ...AL Volume 1 10TFT 9TFT 9TST EN 9813 5350 SERVICE MANUAL Volume 2 10TFT 9TFT 9TST EN 9813 5350 SERVICE MANUAL Volume 3 10TFT 9TFT 9TST EN 9813 5350 SERVICE MANUAL Volume 4 10TFT 9TFT 9TST EN 9813 5350 Find manuals at https best manuals com ...

Page 4: ...Notes 9813 5350 2 Find manuals at https best manuals com ...

Page 5: ...ce Safety 01 6 01 03 18 Operating Safety 01 8 01 03 21 Worksite Safety 01 10 01 03 24 Risk Assessment 01 11 01 03 27 Maintenance Positions 01 12 01 06 About this Manual 01 06 00 General 01 15 01 06 03 Model and Serial Number 01 16 01 09 Description 01 09 12 Main Component Locations 01 19 01 09 15 Service Point Locations 01 20 01 33 Cleaning 01 33 00 General 01 25 Find manuals at https best manuals...

Page 6: ...9813 5350 2 2017 11 16 Acronyms Glossary PIL Parts Identification List ROPS Roll Over Protective Structure Find manuals at https best manuals com ...

Page 7: ...ty Yours and Others 01 3 01 03 06 Safety Warnings 01 4 01 03 09 General Safety 01 5 01 03 12 Maintenance Safety 01 6 01 03 18 Operating Safety 01 8 01 03 21 Worksite Safety 01 10 01 03 24 Risk Assessment 01 11 01 03 27 Maintenance Positions 01 12 Find manuals at https best manuals com ...

Page 8: ...Notes 01 2 9813 5350 2 01 2 Find manuals at https best manuals com ...

Page 9: ...tial hazards and how to avoid them If you do not fully understand the warning messages ask your employer or JCB dealer to explain them Safety is not just a matter of responding to the warnings All the time you are working on or with the machine you must be thinking of what hazards there might be and how to avoid them Do not work with the machine until you are sure that you can control it Do not st...

Page 10: ...rdous situation which if not avoided could result in death or serious injury The signal word CAUTION indicates a hazardous situation which if not avoided could result in minor or moderate injury The signal word Notice indicates a hazardous situation which if not avoided could result in machine damage The safety alert system symbol shown also helps to identify important safety messages in this manu...

Page 11: ...aware of medicines which 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 your mobile phone before entering an area with a potentially explosive atmosphere Sparks in such an area could cause an explosion or fire resulting in death or serious injury Switc...

Page 12: ...aulic Pressure Hydraulic fluid at system pressure can injure you Before connecting or removing any hydraulic hose residual hydraulic pressure trapped in the service hose line must be vented Make sure the hose service line has been vented before connecting or removing hoses Make sure the engine cannot be started while the hoses are open O rings Seals and Gaskets Badly installed damaged or rotted O ...

Page 13: ...ecomposition e g charring is found refer to the next paragraph for safety instructions Do not touch component 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 heavy duty gloves and special safety glasses are worn Thoroughly wash contaminated area with 10 cal...

Page 14: ...ly kill you or bystanders if they are inhaled Do not operate the machine in closed spaces without making sure there is good ventilation If possible install an exhaust extractor If you begin to feel drowsy stop the machine at once and get into fresh air Worksites Worksites can be hazardous Examine the site before working on it You could be killed or injured if the ground gives way under your machin...

Page 15: ...see clearly Modification of the machine s configuration by the user e g the fitting of large and non approved attachments may result in a restriction of the machine visibility Hands and Feet Keep your hands and feet inside the machine When using the machine keep your hands and feet clear of moving parts Keep your hands and feet within the operator compartment while the vehicle is in motion Control...

Page 16: ... leak is suspected contact the local gas company immediately and warn all personnel on the site Ban smoking make sure that all naked lights are extinguished and switch off any engines which may be running You are strongly advised to make sure that the safety arrangements on site comply with the local laws and regulations concerning work near buried gas pipes CAUTION Before you start using the mach...

Page 17: ...and is there sufficient fuel to complete the job if applicable The Load How heavy is it Is it within the capabilities of the machine How bulky is it The greater the surface area the more affected it will be by wind speeds Is it an awkward shape How is the weight distributed Uneven loads are more difficult to handle Is there a possibility of the load shifting while being moved Loading Unloading Are...

Page 18: ...Make the machine safe before you start a maintenance procedure Figure 2 A B A Dumper body lowered B Dumper body raised Dumper Body Lowered 1 Park the machine on level solid ground 2 Lower the dumper body 3 Stop the engine and remove the ignition key 4 Disconnect the battery to prevent accidental operation of the engine Refer to PIL 33 03 00 5 If necessary put blocks against the two sides of the wh...

Page 19: ...01 Machine 06 About this Manual 01 13 9813 5350 2 01 13 06 About this Manual Contents Page No 01 06 00 General 01 15 01 06 03 Model and Serial Number 01 16 ...

Page 20: ...Notes 01 14 9813 5350 2 01 14 ...

Page 21: ...ics Information in this manual can help you diagnose machine faults Before attempting to diagnose possible faults check the following Ensure that the operator understands the machine controls functions and use Refer to the applicable Operator Manual Check that the maintenance record complies with the applicable schedule for the operating environment Refer to PIL 78 24 Check that the fluids in use ...

Page 22: ...roduction This manual provides information for the following model s in the JCB machine range Model From To GRN1313 GRN1313 10TFT HRN3737 HRN3737 FRM7139 FRM8868 GRM0011 GRM9989 9TFT HRM1382 HRM4003 GRM0011 GRM9989 GRP0854 GRP1363 GRS1346 GRS9572 HPS2406 HPS3751 HPT2080 HPT2080 HRP3406 HRP3917 9TST HRS1645 HRS3767 ...

Page 23: ...01 Machine 09 Description 01 17 9813 5350 2 01 17 09 Description Contents Page No 01 09 12 Main Component Locations 01 19 01 09 15 Service Point Locations 01 20 ...

Page 24: ...Notes 01 18 9813 5350 2 01 18 ...

Page 25: ...in Component Locations 01 19 9813 5350 2 01 19 12 Main Component Locations Introduction For 10TFT 9TFT Figure 3 E F A B D G C A ROPS Roll Over Protective Structure B Seat C Engine compartment cover D Tyres E Steps F Skip G Hand rails ...

Page 26: ...9813 5350 2 01 20 15 Service Point Locations Introduction Engine Compartment Figure 4 A B A Engine oil dipstick B Engine oil filler cap Figure 5 A A Coolant expansion tank Hydraulic System Figure 6 B A A Hydraulic filler dipstick B Hydraulic return line filter ...

Page 27: ...Locations 01 21 9813 5350 2 01 21 Fuel System Figure 7 A A Fuel filter cap Battery Isolator Figure 8 A B A Battery isolator on position B Battery isolator off position Brake System Figure 9 A B A Brake fluid reservoir cap B Brake fluid reservoir ...

Page 28: ...01 Machine 09 Description 15 Service Point Locations 01 22 9813 5350 2 01 22 Gearbox Figure 10 A A Gearbox dipstick powershift shown ...

Page 29: ...01 Machine 09 Description 15 Service Point Locations 01 23 9813 5350 2 01 23 Batteries Figure 11 A A Batteries ...

Page 30: ...01 Machine 33 Cleaning 01 24 9813 5350 2 01 24 33 Cleaning Contents Page No 01 33 00 General 01 25 ...

Page 31: ...render the machine inoperable Remove dirt using a brush or damp cloth Clean the product with water and or steam Do not let mud debris etc to collect on the product Before you do any service procedures that require components to be removed The cleaning must be done either in the area of components to be removed or in the case of major work or work on the fuel system the whole engine and the surroun...

Page 32: ...t aim the water jet directly at bearings oil seals or the engine air induction system Use a low pressure water jet and brush to remove dried mud or dirt Use a pressure washer to remove soft dirt and oil The product must always be greased if appropriate after pressure washing or steam cleaning Preparation 1 Make the machine safe Stop the machine and let it cool for at least one hour Do not try to c...

Page 33: ... 19 06 12 Lift Arm 06 12 00 General 06 21 06 24 Slew Ring 06 24 00 General 06 25 06 24 24 Shim 06 28 06 27 Transportation Lock 06 27 15 Articulated Joint 06 33 06 33 Articulated Joint 06 33 00 General 06 37 06 33 21 Bearing 06 42 06 39 Carriage 06 39 00 General 06 45 06 63 Identification Label 06 63 00 General 06 49 06 63 03 Machine 06 50 06 63 06 Engine 06 51 06 66 Tools 06 66 00 General 06 55 06...

Page 34: ...9813 5350 2 2017 09 21 Acronyms Glossary ECM Engine Control Module FOPS Falling Object Protective Structure ROPS Roll Over Protective Structure VIN Vehicle Identification Number ...

Page 35: ...06 Body and Framework 00 Body and Framework 06 1 9813 5350 2 06 1 00 Body and Framework Contents Page No 06 00 00 General 06 3 ...

Page 36: ...Notes 06 2 9813 5350 2 06 2 ...

Page 37: ...813 5350 2 06 3 00 General Technical Data 06 3 Check Condition 06 4 Technical Data For 10TFT 9TFT Table 3 Description Torque value Rear upper crossmem ber retaining bolts 105N m Rear lower crossmem ber retaining bolts 105N m Centre pivot pin retain ing nut 800N m ...

Page 38: ...e properly secured 7 Check all the safety and instructional labels are in place and are free from damage 8 Install new labels where necessary Make a note of the damaged paintwork for future repair Check the ROPS FOPS Structure WARNING You could be killed or seriously injured if you operate a machine with a damaged or missing ROPS FOPS FOGS If the ROPS FOPS FOGS has been in an accident do not use t...

Page 39: ...06 Body and Framework 03 Chassis 06 5 9813 5350 2 06 5 03 Chassis Contents Page No 06 03 00 General 06 7 06 03 36 Upper Crossmember 06 10 06 03 37 Lower Crossmember 06 12 ...

Page 40: ...Notes 06 6 9813 5350 2 06 6 ...

Page 41: ...eneral 06 7 9813 5350 2 06 7 00 General Introduction 06 7 Health and Safety 06 8 Component Identification 06 9 Introduction The chassis is the underpart of the vehicle or machine consisting of the frame on which the body or cab is mounted ...

Page 42: ...06 Body and Framework 03 Chassis 00 General 06 8 9813 5350 2 06 8 Health and Safety CAUTION This component is heavy It must only be removed or handled using a suitable lifting method and device ...

Page 43: ...06 Body and Framework 03 Chassis 00 General 06 9 9813 5350 2 06 9 Component Identification Figure 12 A B A Front chassis B Rear chassis ...

Page 44: ... Figure 13 H A Side access panel 4 Remove the top bolts 1 from the engine compartment cover Figure 14 C B B Bolts 1 5 Remove the bolts 2 from the upper crossmember Figure 15 C C Bolts 2 6 Remove the bolts 3 from the reverse alarm cover Figure 16 D D Bolts 3 7 Disconnect the reverse alarm electrical connector Figure 17 E E Electrical connector 8 Support the upper crossmember with suitable lifting e...

Page 45: ... 11 Figure 18 G F F Lifting equipment G Upper crossmember Install 1 The installation procedure is the opposite of the removal procedure Additionally do the following step 2 Tighten the bolts 2 to the correct torque value Table 4 Torque Values Item Description Nm C Bolts 2 105 ...

Page 46: ...g method and device Remove 1 Make the machine safe Refer to PIL 01 03 27 2 Isolate the battery Refer to PIL 33 03 3 Remove the pin from the tow hitch 4 Remove the screws 5 Support the lower crossmember with suitable lifting equipment 6 Remove the lower crossmember from the machine Figure 19 C B D A A Lower crossmember B Screws C Pin D Tow hitch Install 1 The installation procedure is the opposite ...

Page 47: ... and Framework 06 Moveable Panel and Cover 06 13 9813 5350 2 06 13 06 Moveable Panel and Cover Contents Page No 06 06 00 General 06 15 06 06 06 Engine Compartment 06 16 06 06 10 Transmission Compartment 06 19 ...

Page 48: ...Notes 06 14 9813 5350 2 06 14 ...

Page 49: ...roduction Access panels provide easy access to the machine major components test and service points and other parts which require routine testing servicing adjusting replacement or repair Before you operate the machine make sure that all of the access panels are in their operation position and secure ...

Page 50: ...has exposed rotating parts Switch off the engine before working in the engine compartment Do not use the machine with the engine cover open Open 1 Make the machine safe 2 Stop the engine and remove the ignition key 3 Apply the park brake 4 Open the engine covers on each side of the machine Close 1 Make sure the battery isolator is installed in the on position 2 Close the engine covers on each side...

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