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SERVICE MANUAL
2TFT, 2THS, 2TST,
3.5TST, 3TFT, 3TST
EN - 9813/5250 - ISSUE 1 - 08/2015
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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Summary of Contents for jcb TFT

  • 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: 9813/5250-1 Find manuals at https://best-manuals.com...
  • Page 3 Spine Cards SERVICE MANUAL SERVICE MANUAL Volume 1 Volume 2 2TFT, 2THS, 2TST, 2TFT, 2THS, 2TST, 3.5TST, 3TFT, 3TST 3.5TST, 3TFT, 3TST EN 9813/5250 EN 9813/5250 SERVICE MANUAL SERVICE MANUAL Volume 3 Volume 4 2TFT, 2THS, 2TST, 2TFT, 2THS, 2TST, 3.5TST, 3TFT, 3TST 3.5TST, 3TFT, 3TST EN 9813/5250...
  • Page 4 Notes: 9813/5250-1 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 9813/5250-1 2015-06-22 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 9813/5250-1 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

    01 - Machine 03 - Safety 27 - Maintenance Positions 27 - Maintenance Positions Introduction WARNING Make the machine safe before getting For: 2TFT, 3TFT ......Page 01-12 beneath it. Make sure that any attachments on For: 2TFT, 2THS, 2TST, 3.5TST, 3TST the machine are correctly attached.
  • 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 9813/5250-1 01 - 14...
  • Page 21: Main Component Locations

    01 - Machine 09 - Description 12 - Main Component Locations 12 - Main Component Locations Introduction For: 2TFT, 2THS, 2TST ..... Page 01-15 For: 3.5TST, 3TFT, 3TST ... Page 01-16 (For: 2TFT, 2THS, 2TST) Figure 4. ROPS (Roll-Over Protective Structure) Steps Hand rail Head lights...
  • Page 22 01 - Machine 09 - Description 12 - Main Component Locations (For: 3.5TST, 3TFT, 3TST) Figure 5. ROPS Steps Hand rail Head lights Engine Skip Tyres Beacon 01 - 16 9813/5250-1 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 ..........................06-5 06-06 Access Cover 06-06-00 General ..........................06-9 06-06-06 Engine Compartment ..................... 06-10 06-06-10 Transmission Compartment ................... 06-14 06-06-14 Rear Cover ........................
  • Page 24 Acronyms Glossary FOPS Falling Object Protective Structure Left Hand Right Hand ROPS Roll-Over Protective Structure Vehicle Identification Number 9813/5250-1 2015-08-06...
  • Page 25 06 - Body and Framework 00 - General 00 - General Contents Page No. 06-00-00 General ..........................06-3 06 - 1 9813/5250-1 06 - 1...
  • Page 26 Notes: 06 - 2 9813/5250-1 06 - 2...
  • Page 27 06 - Body and Framework 00 - General 00 - General 00 - General 4. Make sure that all of the ROPS (Roll- Over Protective Structure)/FOPS (Falling Object Protective Structure) mounting bolts Check (Condition) 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.
  • Page 28 06 - Body and Framework 03 - Chassis 03 - Chassis Contents Page No. 06-03-00 General ..........................06-5 06 - 4 9813/5250-1 06 - 4...
  • Page 29 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 30 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 9813/5250-1 06 - 6...
  • Page 31 06 - Body and Framework 03 - Chassis 00 - General Component Identification Figure 6. Front chassis Rear chassis 06 - 7 9813/5250-1 06 - 7...
  • Page 32 06 - Body and Framework 06 - Access Cover 06 - Access Cover Contents Page No. 06-06-00 General ..........................06-9 06-06-06 Engine Compartment ..................... 06-10 06-06-10 Transmission Compartment ................... 06-14 06-06-14 Rear Cover ........................06-16 06 - 8 9813/5250-1 06 - 8...
  • Page 33 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 34 06 - Body and Framework 06 - Access Cover 06 - Engine Compartment 06 - Engine Compartment Open and Close For: 2TFT, 2THS, 2TST ..... Page 06-10 Open and Close ..........06-10 For: 3.5TST, 3TFT, 3TST ... Page 06-11 Remove and Install ........
  • Page 35 06 - Body and Framework 06 - Access Cover 06 - Engine Compartment Remove and Install A lock with removable key is installed to prevent the unauthorised access to the engine compartment. For: 2TFT, 2THS, 2TST ..... Page 06-11 Close For: 3.5TST, 3TFT, 3TST ...
  • Page 36 06 - Body and Framework 06 - Access Cover 06 - Engine Compartment Figure 10. 3.1. Use the ignition key to unlock the engine compartment cover. 3.2. Press the button on the handle to release the catch 3.3. Lift the engine cover. Figure 12.
  • Page 37 06 - Body and Framework 06 - Access Cover 06 - Engine Compartment Figure 14. Engine compartment cover Nuts 2 Washers Bolts Hinges 4.5. Remove the engine compartment cover from the machine. Install 1. The installation procedure is the opposite of the removal procedure.
  • Page 38 06 - Body and Framework 06 - Access Cover 10 - Transmission Compartment 10 - Transmission Compartment 7. Lift the floor plate and clear of the machine to gain access to the engine compartment. Open and Close 8. Do not open the floor plate when the engine is running.
  • Page 39 06 - Body and Framework 06 - Access Cover 10 - Transmission Compartment Figure 17. Lock Engine cover 6. Remove the bolts and washers from the floor plate. Refer to Figure 18. 7. Lift the floor plate and clear of the machine to gain access to the engine compartment.
  • Page 40 06 - Body and Framework 06 - Access Cover 14 - Rear Cover 14 - Rear Cover Figure 21. Remove and Install For: 2TFT, 2THS, 2TST ..... Page 06-16 For: 3.5TST, 3TFT, 3TST ... Page 06-17 (For: 2TFT, 2THS, 2TST) Remove Bolts 1 1.
  • Page 41 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...

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