jcb 1THT Service Manual

jcb 1THT Service Manual

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SERVICE MANUAL
DUMPER
1THT
EN - 9813/5200 - ISSUE 2 - 07/2018
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
Copyright 2017 © 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 - Brake System
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 1THT

  • 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: 9813/5200-2 Find manuals at https://best-manuals.com...
  • Page 3 Spine Cards SERVICE MANUAL SERVICE MANUAL Volume 1 Volume 2 1THT 1THT EN 9813/5200 EN 9813/5200 SERVICE MANUAL SERVICE MANUAL Volume 3 Volume 4 1THT 1THT EN 9813/5200 EN 9813/5200 9813/5200-2 Find manuals at https://best-manuals.com...
  • Page 4 Notes: 9813/5200-2 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 Parts Identification List ROPS Roll-Over Protective Structure 9813/5200-2 2018-06-18 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 9813/5200-2 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 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

    Repairs pressure must be discharged by a JCB dealer, as the sudden release of the hydraulic fluid or gas may If your machine does not function correctly in cause serious injury or death.
  • Page 13 Chemicals Certain seals and gaskets (e.g. crankshaft oil seal) on JCB machines contain fluoroelastomeric materials such Viton®, FluorelTM Technoflon®.
  • Page 14: Operating Safety

    Your doing. If you will be working with other people, local JCB distributor will be glad to advise you. make sure any hand signals that may be used are understood by everybody. Worksites can be noisy, do Fuel not rely on spoken commands.
  • Page 15 01 - Machine 03 - Safety 18 - Operating Safety Regulations 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 Obey all laws, worksite and local regulations which the machine visibility.
  • Page 16 01 - Machine 03 - Safety 18 - Operating Safety has passed. Do not attempt to mount or enter the machine. If the machine is struck by lightning do not use the machine until it has been checked for damage and malfunction by trained personnel. 01 - 10 9813/5200-2 01 - 10...
  • Page 17: 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 18: 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 19: Maintenance Positions

    01 - Machine 03 - Safety 27 - Maintenance Positions 27 - Maintenance Positions Introduction WARNING A machine can sink into soft ground. park brake, remove the ignition key, disconnect Never work under a machine on soft ground. the battery. WARNING Make the machine safe before getting Make the machine safe before you start a beneath it.
  • Page 20: About This Manual

    01 - Machine 06 - About this Manual 06 - About this Manual Contents Page No. 01-06-00 General ........................... 01-15 01 - 14 9813/5200-2 01 - 14...
  • Page 21: General

    00 - General 00 - General Introduction Information in this manual conforms to a standard List). These headings are assigned numerical JCB service manual format. The format uses section identification references. headings taken from a PIL (Parts Identification Table 1. Example...
  • Page 22: Description

    01 - Machine 09 - Description 09 - Description Contents Page No. 01-09-12 Main Component Locations ................... 01-17 01 - 16 9813/5200-2 01 - 16...
  • Page 23: Main Component Locations

    01 - Machine 09 - Description 12 - Main Component Locations 12 - Main Component Locations Introduction Figure 3. A ROPS (Roll-Over Protective Structure) B Hand rails C Tyres D Steps E Head lights F Dumper body G Beacon H Engine 01 - 17 9813/5200-2 01 - 17...
  • Page 24 01 - Machine 33 - Cleaning 33 - Cleaning Contents Page No. 01-33-00 General ........................... 01-19 01 - 18 9813/5200-2 01 - 18...
  • Page 25 01 - Machine 33 - Cleaning 00 - General 00 - General Introduction WARNING When using cleaning agents, solvents Introduction ............ 01-19 or other chemicals, you must adhere to Preparation ............ 01-20 the manufacturer's instructions and safety precautions. CAUTION To avoid burning, wear personal protective equipment when...
  • Page 26 01 - Machine 33 - Cleaning 00 - General Preparation Notice: The engine and other components could be damaged by high pressure washing systems. Special precautions must be taken if the machine 1. Make the machine safe. Stop the machine and is to be washed using a high pressure system.
  • Page 27 06 - Body and Framework Contents Page No. Acronyms Glossary ............................ 06-2 06-00 Body and Framework 06-00-00 General ..........................06-3 06-03 Chassis 06-03-00 General ..........................06-7 06-06 Moveable Panel and Cover 06-06-00 General ........................... 06-11 06-06-06 Engine Compartment ..................... 06-12 06-06-12 Front Cover ........................
  • Page 28 Acronyms Glossary FOPS Falling Object Protective Structure ROPS Roll-Over Protective Structure Vehicle Identification Number 9813/5200-2 2018-07-02...
  • Page 29 06 - Body and Framework 00 - Body and Framework 00 - Body and Framework Contents Page No. 06-00-00 General ..........................06-3 06 - 1 9813/5200-2 06 - 1...
  • Page 30 Notes: 06 - 2 9813/5200-2 06 - 2...
  • Page 31 06 - Body and Framework 00 - Body and Framework 00 - General 00 - General Technical Data Technical Data ..........06-3 Table 3. Check (Condition) ..........06-4 Description Torque value Pivot cap retaining bolts 190 N·m Thrust cap retaining 60 N·m bolts Engine cover retaining...
  • Page 32 06 - Body and Framework 00 - Body and Framework 00 - General Check (Condition) 3. Any damage must be repaired before the machine is used again. 4. Make sure that all of the ROPS (Roll- Check the Machine Body and Structure Over Protective Structure)/FOPS (Falling Object Protective Structure)
  • Page 33 06 - Body and Framework 03 - Chassis 03 - Chassis Contents Page No. 06-03-00 General ..........................06-7 06 - 5 9813/5200-2 06 - 5...
  • Page 34 Notes: 06 - 6 9813/5200-2 06 - 6...
  • Page 35 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 36 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 9813/5200-2 06 - 8...
  • Page 37 06 - Body and Framework 03 - Chassis 00 - General Component Identification Figure 4. A Front chassis B Rear chassis 06 - 9 9813/5200-2 06 - 9...
  • Page 38 06 - Body and Framework 06 - Moveable Panel and Cover 06 - Moveable Panel and Cover Contents Page No. 06-06-00 General ........................... 06-11 06-06-06 Engine Compartment ..................... 06-12 06-06-12 Front Cover ........................06-15 06-06-14 Rear Cover ........................06-16 06-06-30 Undershield ........................
  • Page 39 06 - Body and Framework 06 - Moveable Panel and 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.
  • Page 40 06 - Body and Framework 06 - Moveable Panel and Cover 06 - Engine Compartment 06 - Engine Compartment Open and Close WARNING The engine has exposed rotating Open and Close ..........06-12 parts. Switch off the engine before working in the Remove and Install ........
  • Page 41 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...

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