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SERVICE MANUAL
DUMPER
6T-1 Front Tip, 6T-1 Swivel Tip,
7T-1 Front Tip Hi-Viz, 9T-1 Front Tip
EN - 9813/8950 - ISSUE 2 - 03/2018
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
Copyright 2018 © 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
12
-
Heating,
Conditioning (HVAC)
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
Ventilating
and
Air-

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Summary of Contents for jcb 6T-1 Front Tip

  • 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: 9813/8950-2 Find manuals at https://best-manuals.com...
  • Page 3 Spine Cards SERVICE MANUAL SERVICE MANUAL Volume 1 Volume 2 6T-1 Front Tip, 6T-1 Swivel Tip, 6T-1 Front Tip, 6T-1 Swivel Tip, 7T-1 Front Tip Hi-Viz, 9T-1 Front Tip 7T-1 Front Tip Hi-Viz, 9T-1 Front Tip EN 9813/8950 EN 9813/8950...
  • Page 4 Notes: 9813/8950-2 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 FOPS Falling Object Protective Structure Parts Identification List ROPS Roll-Over Protective Structure 9813/8950-2 2018-03-12 Find manuals at https://best-manuals.com...
  • Page 7 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 9813/8950-2 01 - 2 Find manuals at https://best-manuals.com...
  • Page 9: Safety

    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

    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

    01 - Machine 03 - Safety 27 - Maintenance Positions 27 - Maintenance Positions Introduction For: 6T-1 Front Tip, 7T-1 Front Tip [Hi-Viz], Introduction ............ 01-12 9T-1 Front Tip ......Page 01-12 Health and Safety .......... 01-15 For: 6T-1 Swivel Tip ....Page 01-13...
  • Page 19 01 - Machine 03 - Safety 27 - Maintenance Positions movement immediately when the weight of the dumper is supported by the safety strut. (For: 6T-1 Swivel Tip) Figure 2. Dumper Body Lowered 1. Park the machine on level solid ground. 2.
  • Page 20 01 - Machine 03 - Safety 27 - Maintenance Positions Figure 4. 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.
  • Page 21 01 - Machine 03 - Safety 27 - Maintenance Positions Health and Safety WARNING Maintenance must be done only by suitably qualified and competent persons. Before doing any maintenance make sure the machine is safe, it must be correctly parked on solid, level ground.
  • Page 22: About This Manual

    01 - Machine 06 - About this Manual 06 - About this Manual Contents Page No. 01-06-03 Model and Serial Number ....................01-17 01-06-06 Using the Manual ......................01-18 01 - 16 9813/8950-2 01 - 16...
  • Page 23: Model And Serial Number

    06 - About this Manual 03 - Model and Serial Number 03 - Model and Serial Number Introduction This manual provides information for the following model(s) in the JCB machine range: Model From: 6T-1 Front Tip 2561001 6T-1 Swivel Tip...
  • Page 24: Using The Manual

    06 - Using the Manual 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 25: Description

    01 - Machine 09 - Description 09 - Description Contents Page No. 01-09-12 Main Component Locations ................... 01-21 01-09-15 Service Point Locations ....................01-24 01 - 19 9813/8950-2 01 - 19...
  • Page 26 Notes: 01 - 20 9813/8950-2 01 - 20...
  • Page 27: Main Component Locations

    12 - Main Component Locations Introduction 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, Without Cab) Figure 5.
  • Page 28 09 - Description 12 - Main Component Locations 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...
  • Page 29 01 - Machine 09 - Description 12 - Main Component Locations (For: 6T-1 Front Tip, 7T-1 Front Tip [Hi-Viz], 9T-1 Front Tip, Cab) Figure 7. A ROPS/FOPS/Cab B Beacons C Engine D Tyres/ Wheels E Steps F Head lights G Skip...
  • Page 30: Service Point Locations

    01 - Machine 09 - Description 15 - Service Point Locations 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 filler cap F Air filter G Engine fuel filter 01 - 24...
  • Page 31 01 - Machine 09 - Description 15 - Service Point Locations Figure 9. A Coolant expansion tank B Hydraulic oil filler neck C Washer fluid tank 01 - 25 9813/8950-2 01 - 25...
  • Page 32 01 - Machine 09 - Description 15 - Service Point Locations Battery Isolator Figure 10. A Battery isolator B Relays C Fuses 01 - 26 9813/8950-2 01 - 26...
  • Page 33 01 - Machine 09 - Description 15 - Service Point Locations Brake System Figure 11. A Brake fluid tank cap 01 - 27 9813/8950-2 01 - 27...
  • Page 34 01 - Machine 09 - Description 15 - Service Point Locations Gearbox Figure 12. A Gearbox dipstick 01 - 28 9813/8950-2 01 - 28...
  • Page 35 01 - Machine 09 - Description 15 - Service Point Locations Batteries Remove the floor plate battery access cover to access the battery. Figure 13. A Floor plate battery access cover B Battery 01 - 29 9813/8950-2 01 - 29...
  • Page 36 01 - Machine 33 - Cleaning 33 - Cleaning Contents Page No. 01-33-00 General ........................... 01-31 01 - 30 9813/8950-2 01 - 30...
  • Page 37 01 - Machine 33 - Cleaning 00 - General 00 - General Introduction WARNING When using cleaning agents, solvents Introduction ............ 01-31 or other chemicals, you must adhere to Preparation ............ 01-32 the manufacturer's instructions and safety precautions. CAUTION To avoid burning, wear personal protective equipment when...
  • Page 38 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 39 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 ..........................06-5 06-03-36 Upper Crossmember ......................06-8 06-03-37 Lower Crossmember ...................... 06-11 06-06 Moveable Panel and Cover 06-06-00 General ...........................
  • Page 40 Acronyms Glossary FOPS Falling Object Protective Structure Product Identification Number ROPS Roll-Over Protective Structure 9813/8950-2 2018-02-26...
  • Page 41 06 - Body and Framework 00 - Body and Framework 00 - Body and Framework Contents Page No. 06-00-00 General ..........................06-3 06 - 1 9813/8950-2 06 - 1...
  • Page 42 Notes: 06 - 2 9813/8950-2 06 - 2...
  • Page 43 06 - Body and Framework 00 - Body and Framework 00 - General 00 - General 2. Carry out a thorough inspection of the operator's station. Check (Condition) 3. Any damage must be repaired before the machine is used again. 4.
  • Page 44 06 - Body and Framework 03 - Chassis 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 06 - 4 9813/8950-2 06 - 4...
  • Page 45 06 - Body and Framework 03 - Chassis 00 - General 00 - General Introduction Introduction ............06-5 The chassis is the underpart of the vehicle or Health and Safety ........... 06-6 machine, consisting of the frame on which the body or cab is mounted.
  • Page 46 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 - 6 9813/8950-2 06 - 6...
  • Page 47 06 - Body and Framework 03 - Chassis 00 - General Component Identification Figure 14. A Front chassis B Rear chassis 06 - 7 9813/8950-2 06 - 7...
  • Page 48 36 - Upper Crossmember 36 - Upper Crossmember Figure 16. Remove and Install For: 6T-1 Front Tip, 6T-1 Swivel Tip, 7T-1 Front Tip [Hi-Viz] ......Page 06-8 For: 9T-1 Front Tip ...... Page 06-8 (For: 6T-1 Front Tip, 6T-1 Swivel Tip, 7T-1...
  • Page 49 06 - Body and Framework 03 - Chassis 36 - Upper Crossmember Figure 17. Figure 20. A Side access panel D Bolts 3 4. Remove the top bolts 1 from the engine 7. Disconnect reverse alarm electrical compartment cover. connector. Figure 18.
  • Page 50 06 - Body and Framework 03 - Chassis 36 - Upper Crossmember Figure 22. 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.
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This manual is also suitable for:

6t-1 swivel tip7t-1 front tip hi-viz9t-1 front tip

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