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 01 - Machine

 03 - Safety

 09 - General Safety

01 - 5

9813/8950-2

01 - 5

09 - General Safety
Introduction

Training

To operate the machine safely you must know the

machine and have the skill to use it. You must abide

by  all  relevant  laws,  health  and  safety  regulations

that apply to the country you are operating in. The

operator's manual instructs you on the machine, its

controls  and  its  safe  operation;  it  is  not  a  training

manual. Ensure that you receive the correct training

before operating any machinery. Failing to do so will

result in incorrect operation of the machine and you

will be putting yourself and others at risk. In some

markets, and for work on certain jobsites, you may

be required to have been trained and assessed in

accordance with an operator competence scheme.

Make sure that you and your machine comply with

relevant local laws and jobsite requirements – it is

your responsibility.

Care and Alertness

All the time you are working with or on the machine,

take care and stay alert. Always be careful. Always

be alert for hazards.

Clothing

You  can  be  injured  if  you  do  not  wear  the  correct

clothing.  Loose  clothing  can  get  caught  in  the

machinery.  Keep  cuffs  fastened.  Do  not  wear  a

necktie or scarf. Keep long hair restrained. Remove

rings, watches and personal jewellery.

Alcohol and Drugs

It is extremely dangerous to operate machinery when

under  the  influence  of  alcohol  or  drugs.  Do  not

consume  alcoholic  drinks  or  take  drugs  before  or

while  operating  the  machine  or  attachments.  Be

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.
Switch off and do not use your mobile phone when

refuelling the machine.

Lifting Equipment

You can be injured if you use incorrect or faulty lifting

equipment. You must identify the weight of the item to

be lifted then choose lifting equipment that is strong

enough and suitable for the job. Make sure that lifting

equipment is in good condition and complies with all

local regulations.

Raised Equipment

Never walk or work under raised equipment unless

it is supported by a mechanical device. Equipment

which is supported only by a hydraulic device can

drop  and  injure  you  if  the  hydraulic  system  fails

or  if  the  control  is  operated  (even  with  the  engine

stopped).
Make sure that no-one goes near the machine while

you install or remove the mechanical device.

Raised Machine

Never  position  yourself  or  any  part  of  your  body

under  a  raised  machine  which  is  not  correctly

supported. If the machine moves unexpectedly you

could become trapped and suffer serious injury or be

killed.

Lightning

Lightning can kill you. Do not use the machine if there

is lightning in your area.

Machine Modifications

This  machine  is  manufactured  in  compliance  with

prevailing  legislative  requirements.  It  must  not  be

altered in any way which could affect or invalidate its

compliance. For advice consult your JCB dealer.

Summary of Contents for 6T-1 Front Tip

Page 1: ...achine 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 explai...

Page 2: ...9813 8950 2 Notes Find manuals at https best manuals com...

Page 3: ...AL Volume 2 6T 1 Front Tip 6T 1 Swivel Tip 7T 1 Front Tip Hi Viz 9T 1 Front Tip EN 9813 8950 SERVICE MANUAL Volume 3 6T 1 Front Tip 6T 1 Swivel Tip 7T 1 Front Tip Hi Viz 9T 1 Front Tip EN 9813 8950 SE...

Page 4: ...Notes 9813 8950 2 Find manuals at https best manuals com...

Page 5: ...ety 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 03 Model and Serial Number 01 1...

Page 6: ...9813 8950 2 2018 03 12 Acronyms Glossary FOPS Falling Object Protective Structure PIL Parts Identification List ROPS Roll Over Protective Structure Find manuals at https best manuals com...

Page 7: ...y 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 Assessme...

Page 8: ...Notes 01 2 9813 8950 2 01 2 Find manuals at https best manuals com...

Page 9: ...ial 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...

Page 10: ...dous 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 si...

Page 11: ...e 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 Ph...

Page 12: ...lic 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 th...

Page 13: ...composition 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 tha...

Page 14: ...y 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 dro...

Page 15: ...ee 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...

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 runn...

Page 17: ...nd 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 wi...

Page 18: ...intenance strut or other method of supporting the skip in the raised position must be installed and locked in position before working under a raised skip Do not reach or work under a raised skip unles...

Page 19: ...ition key 5 Disconnect the battery to prevent accidental operation of the engine 6 If necessary put blocks against the two sides of the wheels before you get below the machine Dumper Body Raised DANGE...

Page 20: ...4 Figure 4 B C A A Maintenance strut installed position B Pin C Maintenance strut stowage position Remove 1 Raise the dumper to take the weight off the strut 2 Remove the pin and grip clip 3 Remove th...

Page 21: ...on solid level ground To prevent anyone starting the engine remove the ignition key Disconnect the battery by means of the battery isolator if installed when you are not using electrical power If you...

Page 22: ...01 Machine 06 About this Manual 01 16 9813 8950 2 01 16 06 About this Manual Contents Page No 01 06 03 Model and Serial Number 01 17 01 06 06 Using the Manual 01 18...

Page 23: ...1 17 9813 8950 2 01 17 03 Model and Serial Number Introduction This manual provides information for the following model s in the JCB machine range Model From To 6T 1 Front Tip 2561001 6T 1 Swivel Tip...

Page 24: ...information is for which variant Make sure you use the correct information Diagnostics Information in this manual can help you diagnose machine faults Before attempting to diagnose possible faults ch...

Page 25: ...01 Machine 09 Description 01 19 9813 8950 2 01 19 09 Description Contents Page No 01 09 12 Main Component Locations 01 21 01 09 15 Service Point Locations 01 24...

Page 26: ...Notes 01 20 9813 8950 2 01 20...

Page 27: ...uction For 6T 1 Swivel Tip Without Cab Page 01 21 For 6T 1 Front Tip 9T 1 Front Tip Without Cab Page 01 22 For 6T 1 Front Tip 7T 1 Front Tip Hi Viz 9T 1 Front Tip Cab Page 01 23 For 6T 1 Swivel Tip Wi...

Page 28: ...s 01 22 9813 8950 2 01 22 G Skip H Mirrors J Hand rails K FOPS Falling Object Protective Structure For 6T 1 Front Tip 9T 1 Front Tip Without Cab Figure 6 A ROPS B Beacon C Engine D Tyres Wheels E Step...

Page 29: ...Component Locations 01 23 9813 8950 2 01 23 For 6T 1 Front Tip 7T 1 Front Tip Hi Viz 9T 1 Front Tip Cab Figure 7 G A F E J C B A D H A ROPS FOPS Cab B Beacons C Engine D Tyres Wheels E Steps F Head li...

Page 30: ...Locations 01 24 9813 8950 2 01 24 15 Service Point Locations Introduction Engine Compartment Figure 8 A Fuel filter Separator B Engine oil filter C Engine oil dipstick D Engine oil filler cap E Fuel f...

Page 31: ...01 Machine 09 Description 15 Service Point Locations 01 25 9813 8950 2 01 25 Figure 9 B A C A Coolant expansion tank B Hydraulic oil filler neck C Washer fluid tank...

Page 32: ...01 Machine 09 Description 15 Service Point Locations 01 26 9813 8950 2 01 26 Battery Isolator Figure 10 A Battery isolator B Relays C Fuses...

Page 33: ...01 Machine 09 Description 15 Service Point Locations 01 27 9813 8950 2 01 27 Brake System Figure 11 A A Brake fluid tank cap...

Page 34: ...01 Machine 09 Description 15 Service Point Locations 01 28 9813 8950 2 01 28 Gearbox Figure 12 A Gearbox dipstick...

Page 35: ...achine 09 Description 15 Service Point Locations 01 29 9813 8950 2 01 29 Batteries Remove the floor plate battery access cover to access the battery Figure 13 A Floor plate battery access cover B Batt...

Page 36: ...01 Machine 33 Cleaning 01 30 9813 8950 2 01 30 33 Cleaning Contents Page No 01 33 00 General 01 31...

Page 37: ...ender 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...

Page 38: ...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 oi...

Page 39: ...12 00 General 06 21 06 24 Slew Ring 06 24 00 General 06 29 06 24 24 Shim 06 32 06 27 Transportation Lock 06 27 15 Articulated Joint 06 37 06 30 Pivot Pins 06 30 00 General 06 41 06 33 Articulated Joi...

Page 40: ...9813 8950 2 2018 02 26 Acronyms Glossary FOPS Falling Object Protective Structure PIN Product Identification Number ROPS Roll Over Protective Structure...

Page 41: ...06 Body and Framework 00 Body and Framework 06 1 9813 8950 2 06 1 00 Body and Framework Contents Page No 06 00 00 General 06 3...

Page 42: ...Notes 06 2 9813 8950 2 06 2...

Page 43: ...at all attachment teeth are properly secured 8 Check all the safety and instructional labels are in place and are free from damage 9 Install new labels where necessary Make a note of the damaged paint...

Page 44: ...06 Body and Framework 03 Chassis 06 4 9813 8950 2 06 4 03 Chassis Contents Page No 06 03 00 General 06 5 06 03 36 Upper Crossmember 06 8 06 03 37 Lower Crossmember 06 11...

Page 45: ...neral 06 5 9813 8950 2 06 5 00 General Introduction 06 5 Health and Safety 06 6 Component Identification 06 7 Introduction The chassis is the underpart of the vehicle or machine consisting of the fram...

Page 46: ...06 Body and Framework 03 Chassis 00 General 06 6 9813 8950 2 06 6 Health and Safety CAUTION This component is heavy It must only be removed or handled using a suitable lifting method and device...

Page 47: ...06 Body and Framework 03 Chassis 00 General 06 7 9813 8950 2 06 7 Component Identification Figure 14 A B A Front chassis B Rear chassis...

Page 48: ...light electrical harness 5 Disconnect the reverse alarm electrical connector Figure 15 A A Electrical connector 6 Remove the bolts 7 Support the upper crossmember with suitable lifting equipment Figu...

Page 49: ...Figure 18 C B B Bolts 1 5 Remove the bolts 2 from the upper crossmember Figure 19 C C Bolts 2 6 Remove the bolts 3 from the reverse alarm cover Figure 20 D D Bolts 3 7 Disconnect the reverse alarm el...

Page 50: ...10 Figure 22 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 c...

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