jcb 6TFT Operator's Manual
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SERVICE MANUAL
6TFT, 6TST
EN - 9813/5300 - ISSUE 1 - 09/2015
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
Copyright 2015 © 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.
Contents
01 - Machine
06 - Body and Framework
09 - Operator Station
15 - Engine
18 - Fuel and Exhaust System
21 - Cooling System
24 - Brakes
25 - Steering System
27 - Driveline
30 - Hydraulic System
33 - Electrical System
72 - Fasteners and Fixings
75 - Consumable Products
78 - After Sales

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Table of Contents
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Summary of Contents for jcb 6TFT

  • Page 1 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. SERVICE MANUAL Do not operate the machine without an Operator's Manual, or if there is anything on the machine you do not understand.
  • Page 2 Notes: 9813/5300-1 Find manuals at https://best-manuals.com...
  • Page 3 Spine Cards SERVICE MANUAL SERVICE MANUAL Volume 1 Volume 2 6TFT, 6TST 6TFT, 6TST EN 9813/5300 EN 9813/5300 SERVICE MANUAL SERVICE MANUAL Volume 3 Volume 4 6TFT, 6TST 6TFT, 6TST EN 9813/5300 EN 9813/5300 9813/5300-1 Find manuals at https://best-manuals.com...
  • Page 4 Notes: 9813/5300-1 Find manuals at https://best-manuals.com...
  • Page 5: Table Of Contents

    01 - Machine Contents Page No. Acronyms Glossary ............................ 01-2 01-03 Safety 01-03-03 Safety - 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 ......................
  • Page 6: Acronyms Glossary

    Acronyms Glossary ROPS Roll-Over Protective Structure 9813/5300-1 2015-08-28 Find manuals at https://best-manuals.com...
  • Page 7: Safety

    01 - Machine 03 - Safety 03 - Safety Contents Page No. 01-03-03 Safety - 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 ......................
  • Page 8 Notes: 01 - 2 9813/5300-1 01 - 2 Find manuals at https://best-manuals.com...
  • Page 9: Safety - Yours And Others

    They inform you of potential 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.
  • Page 10: Safety Warnings

    01 - Machine 03 - Safety 06 - Safety Warnings 06 - Safety Warnings Introduction In this manual and on the product, there are safety notices. Each notice starts with a signal word. The signal word meanings are given below. The signal word 'DANGER' indicates a hazardous situation which, if not avoided, will result in death or serious injury.
  • Page 11: General Safety

    Keep long hair restrained. Remove altered in any way which could affect or invalidate its rings, watches and personal jewellery. compliance. For advice consult your JCB dealer. Alcohol and Drugs It is extremely dangerous to operate machinery when under the influence of alcohol or drugs.
  • Page 12: Maintenance Safety

    People can be killed or injured on systems incorporating accumulators, the system if these precautions are not taken. pressure must be discharged by a JCB dealer, as the sudden release of the hydraulic fluid or gas may Repairs cause injury.
  • Page 13 01 - Machine 03 - Safety 12 - Maintenance Safety Chemicals Certain seals and gaskets (e.g. crankshaft oil seal) on JCB machines contain fluoroelastomeric materials such Viton®, FluorelTM Technoflon®. Fluoroelastomeric materials subjected high temperatures produce highly corrosive hydrofluoric acid. This acid can severely burn.
  • Page 14: Operating Safety

    Before doing any job not covered in this manual, find Parking out the correct procedure. Your local JCB distributor will be glad to advise you. An incorrectly parked machine can move without an operator. Follow the instructions in the Operator's Fuel Manual to park the machine correctly.
  • Page 15 01 - Machine 03 - Safety 18 - Operating Safety Electrical Power Cables Hands and Feet You could be electrocuted or badly burned if you get Keep your hands and feet inside the machine. the machine or its attachments too close to electrical When using the machine, keep your hands and feet power cables.
  • Page 16: Worksite Safety

    01 - Machine 03 - Safety 21 - Worksite Safety 21 - Worksite Safety An applicable worksite organisation is required in order to minimise hazards that are caused by restricted visibility. The worksite organisation is a Introduction collection of rules and procedures that coordinates the machines and people that work together in WARNING You or others can be killed or seriously the same area.
  • Page 17: Risk Assessment

    If you are unsure of the suitability of the machine for • Are any other machines or persons likely to be a specific task, contact your JCB dealer who will be in or to enter the area while operations are in pleased to advise you.
  • Page 18: Maintenance Positions

    27 - Maintenance Positions 27 - Maintenance Positions Introduction WARNING Make the machine safe before getting For: 6TFT ........Page 01-12 beneath it. Make sure that any attachments on For: 6TST ........Page 01-12 the machine are correctly attached. Engage the...
  • Page 19 01 - Machine 03 - Safety 27 - Maintenance Positions Figure 3. Dumper body lowered 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.
  • Page 20: Description

    01 - Machine 09 - Description 09 - Description Contents Page No. 01-09-12 Main Component Locations ................... 01-15 01 - 14 9813/5300-1 01 - 14...
  • Page 21: Main Component Locations

    01 - Machine 09 - Description 12 - Main Component Locations 12 - Main Component Locations Introduction Figure 4. ROPS (Roll-Over Protective Structure) Steps Hand rail Head lights Engine Skip Tyres 01 - 15 9813/5300-1 01 - 15...
  • Page 22 Notes: 01 - 16 9813/5300-1 01 - 16...
  • Page 23 06 - Body and Framework Contents Page No. Acronyms Glossary ............................ 06-2 06-00 General 06-00-00 General ..........................06-3 06-03 Chassis 06-03-00 General ..........................06-7 06-03-36 Upper Crossmember ...................... 06-10 06-03-37 Lower Crossmember ...................... 06-11 06-06 Access Cover 06-06-00 General ........................... 06-13 06-06-06 Engine Compartment .....................
  • Page 24 Acronyms Glossary Engine Control Module FOPS Falling Object Protective Structure ROPS Roll-Over Protective Structure Vehicle Identification Number 9813/5300-1 2015-09-21...
  • Page 25 06 - Body and Framework 00 - General 00 - General Contents Page No. 06-00-00 General ..........................06-3 06 - 1 9813/5300-1 06 - 1...
  • Page 26 Notes: 06 - 2 9813/5300-1 06 - 2...
  • Page 27 06 - Body and Framework 00 - General 00 - General 00 - General Technical Data Technical Data ..........06-3 Table 1. Check (Condition) ..........06-4 Description Torque value Rear upper crossmem- 120N·m ber retaining bolts Rear lower crossmem- 120N·m ber retaining bolts Slew ring retaining bolts 175N·m Slew ram pin mounting...
  • Page 28 06 - Body and Framework 00 - General 00 - General Check (Condition) Protective Structure) mounting bolts undamaged and in position. 5. Make sure that the ROPS/FOPS mounting bolts Check the Machine Body and Structure are tightened to the correct torque setting. 1.
  • Page 29 06 - Body and Framework 03 - Chassis 03 - Chassis Contents Page No. 06-03-00 General ..........................06-7 06-03-36 Upper Crossmember ...................... 06-10 06-03-37 Lower Crossmember ...................... 06-11 06 - 5 9813/5300-1 06 - 5...
  • Page 30 Notes: 06 - 6 9813/5300-1 06 - 6...
  • Page 31: General

    06 - Body and Framework 03 - Chassis 00 - General 00 - General Introduction Introduction ............06-7 The chassis is the underpart of the vehicle or Health and Safety ........... 06-8 machine, consisting of the frame on which the body or cab is mounted.
  • Page 32 06 - Body and Framework 03 - Chassis 00 - General Health and Safety CAUTION This component is heavy. It must only be removed or handled using a suitable lifting method and device. 06 - 8 9813/5300-1 06 - 8...
  • Page 33 06 - Body and Framework 03 - Chassis 00 - General Component Identification Figure 5. Front chassis Rear chassis 06 - 9 9813/5300-1 06 - 9...
  • Page 34: Upper Crossmember

    06 - Body and Framework 03 - Chassis 36 - Upper Crossmember 36 - Upper Crossmember Install 1. The installation procedure is the opposite of the Remove and Install removal procedure. Additionally do the following step. Remove 2. Tighten the bolts to the correct torque value. 1.
  • Page 35: Lower Crossmember

    06 - Body and Framework 03 - Chassis 37 - Lower Crossmember 37 - Lower Crossmember Remove and Install CAUTION This component is heavy. It must only be removed or handled using a suitable lifting method and device. Remove 1. Make the machine safe. Refer to (PIL 01-03). 2.
  • Page 36 06 - Body and Framework 06 - Access Cover 06 - Access Cover Contents Page No. 06-06-00 General ........................... 06-13 06-06-06 Engine Compartment ..................... 06-14 06-06-10 Transmission Compartment ................... 06-17 06 - 12 9813/5300-1 06 - 12...
  • Page 37 06 - Body and Framework 06 - Access Cover 00 - General 00 - General Introduction 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 38 06 - Body and Framework 06 - Access Cover 06 - Engine Compartment 06 - Engine Compartment Open and Close WARNING The engine has exposed rotating Open and Close ..........06-14 parts. Switch off the engine before working in the Remove and Install ........
  • Page 39 06 - Body and Framework 06 - Access Cover 06 - Engine Compartment Remove and Install 11. Remove the bolts 1. 12. Remove the air filter assembly. Remove Figure 11. 1. Make the machine safe. Refer to (PIL 01-03). 2. Isolate the battery. Refer to (PIL 33-03). 3.
  • Page 40 06 - Body and Framework 06 - Access Cover 06 - Engine Compartment Install 1. The installation procedure is the opposite of the removal procedure. 06 - 16 9813/5300-1 06 - 16...
  • Page 41 06 - Body and Framework 06 - Access Cover 10 - Transmission Compartment 10 - Transmission Compartment Open and Close Open 1. Make the machine safe. 2. Stop the engine and remove the ignition key. 3. Apply the park brake. 4.
  • Page 42 06 - Body and Framework 12 - Lift Arm 12 - Lift Arm Contents Page No. 06-12-00 General ........................... 06-19 06 - 18 9813/5300-1 06 - 18...
  • Page 43 06 - Body and Framework 12 - Lift Arm 00 - General 00 - General Introduction Introduction ............ 06-19 The lift arm on this machine is a one piece assembly. Health and Safety .......... 06-20 The assembly is a heavy item, you must not attempt to lift this component without suitable lifting Check (Condition) ..........
  • Page 44 06 - Body and Framework 12 - Lift Arm 00 - General Health and Safety Check (Condition) Lifting Equipment 1. Make sure that the bushes and the pivot pins are within the permitted tolerances. Replace the You can be injured if you use incorrect or faulty lifting pivot pin or bushes as necessary.
  • Page 45 06 - Body and Framework 24 - Slew Ring 24 - Slew Ring Contents Page No. 06-24-00 General ........................... 06-23 06-24-24 Shim ..........................06-26 06 - 21 9813/5300-1 06 - 21...
  • Page 46 Notes: 06 - 22 9813/5300-1 06 - 22...
  • Page 47 06 - Body and Framework 24 - Slew Ring 00 - General 00 - General Introduction Introduction ............ 06-23 The slew ring bearing is a rotational rolling-element Remove and Install ........06-24 bearing that supports the heavy but slow-turning upper structure. They often use three race elements, such as an inner ring and two outer ring halves that clamp together axially.
  • Page 48 06 - Body and Framework 24 - Slew Ring 00 - General Remove and Install 7. Manually turn the slew base to the specified angle whilst an assistant operates the hydraulic control valve to prevent hydraulic lock-up. (For: 6TST) Angle: 45° If the slew ring is to be removed it is important that Figure 17.
  • Page 49 06 - Body and Framework 24 - Slew Ring 00 - General Hoses 3. Tighten the bolts to the correct torque value. 14. Remove the bolts 1. 4. Bleed the hydraulic system. Refer to (PIL 30-00). 15. Remove the slew base from the chassis with Table 3.
  • Page 50 06 - Body and Framework 24 - Slew Ring 24 - Shim 24 - Shim Introduction Introduction ............ 06-26 Shims can be used as spacers to fill gaps between Remove and Install ........06-27 parts subject to wear. Shims are also used to adjust for a better fit, or to provide a level surface.
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