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 01 - Machine

 03 - Safety

 12 - Maintenance Safety

01 - 6

9813/8950-2

01 - 6

12 - Maintenance Safety
Introduction

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.

Air Conditioning Maintenance

The air conditioning system is a closed loop system

and contains pressurised refrigerant. No part of the

system  should  be  disconnected  until  the  system

has  been  discharged  by  a  refrigeration  engineer

or  a  suitably  trained  person.  You  can  be  severely

frostbitten or injured by escaping refrigerant.

Compressed Air

Compressed  air  is  dangerous.  Wear  personal

protective equipment. Never point a compressed air

jet at yourself or others.

Springs

Always  wear  personal  protective  equipment  when

dismantling  assemblies  containing  components

under pressure from springs. This will protect against

eye injury from components accidentally flying out.

Metal Splinters

You  can  be  injured  by  flying  metal  splinters  when

driving metal pins in or out. Use a soft faced hammer

or  copper  drift  to  remove  and  install  metal  pins.

Always wear personal protective equipment.

Communications

Bad  communications  can  cause  accidents.  If  two

or more people are working on the machine, make

sure  each  is  aware  of  what  the  others  are  doing.

Before starting the engine make sure the others are

clear of the danger areas. Examples of danger areas

are: the rotating blades and belt on the engine, the

attachments and linkages, and anywhere beneath or

behind the machine. People can be killed or injured

if these precautions are not taken.

Repairs

If  your  machine  does  not  function  correctly  in

any  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. To

avoid injury and/or damage get the work done by a

specialist engineer.

Hydraulic 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'  rings,  seals

and  gaskets  can  cause  leakages  and  possible

accidents.  Renew  whenever  disturbed  unless

otherwise instructed. Do not use Triochloroethane or

paint thinners near 'O' rings and seals.

Arc Welding

To  prevent  the  possibility  of  damage  to  electronic

components,  disconnect  the  battery  and  the

alternator  before  arc-welding  on  the  machine  or

attached implements.
If the machine is equipped with sensitive electrical

equipment,  i.e.  amplifier  drivers,  electronic  control

units (ECUs), monitor displays, etc., then disconnect

them  before  welding.  Failure  to  disconnect  the

sensitive  electrical  equipment  could  result  in

irreparable damage to these components.
Parts of the machine are made from cast iron, welds

on cast iron can weaken the structure and break. Do

not weld cast iron. Do not connect the welder cable

or apply any weld to any part of the engine.
Always connect the welder earth (ground) cable to

the same component that is being welded to avoid

damage to pivot pins, bearings and bushes. Attach

the welder earth (ground) cable a distance from the

part being welded no more than  0.6 m.

Counterweights

Your machine may be installed with counterweights.

They are extremely heavy. Do not attempt to remove

them.

Accumulators

The accumulators contain hydraulic fluid and gas at

high  pressure.  Prior  to  any  work  being  carried  out

on systems incorporating accumulators, the system

pressure  must  be  discharged  by  a  JCB  dealer,  as

the sudden release of the hydraulic fluid or gas may

cause serious injury or death.

Hot Components

Touching hot surfaces can burn skin. The engine and

machine components will be hot after the unit has

been running. Allow the engine and components to

cool before servicing the unit.

Soft Ground

A  machine  can  sink  into  soft  ground.  Never  work

under a machine on soft ground.

Содержание 6T-1 Front Tip

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 51: ...This as a preview PDF file from best manuals com Download full PDF manual at best manuals com...

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