JCB 1THT Dumper Service Repair Manual Instant Download

1
Foreword
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 Â 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
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
2
15 - Engine 24 - Air Filter 03 - Outer Element
03 - Outer Element
Clean
Clean ............................................
................. 15-58 Remove and Install
....................................... 15-59

1. Make the machine safe.
2. Get access to the air filter.
3. Clean the area around the air cleaner.
4. The dust ejector should be squeezed to release
   any build up of dust in the air cleaner case
   before removing the elements Refer to Figure 94.

Figure 94.
A
B C
D
F
E
A Sediment cup C Inner element E Dust ejector
B Outer element D Body F Clamp

• Loosen the clamps holding the sediment cup to
  the air cleaner body and pull cup clear. Refer
  to Figure 94.
• Pull out the outer element from the body.
• Clean the outer element by tapping gently on a
  firm object or by blowing gently with compressed
  air from inside the element. Refer to Figure 94.
• Replace the outer element, if it is damaged or
  severely contaminated.
• Do not clean the inner element.
• Replace the inner element, if it is
  contaminated.
• Clean the outer body and sediment cup.
• Assemble the cleaner.

15 - 58
3
15 - Engine 24 - Air Filter 03 - Outer Element
Remove and Install
Install
1. The installation procedure is the opposite of
the removal procedure.
Remove

• Make the machine safe. Refer to (PIL 01-03).
• Isolate the battery. Refer to (PIL 33-03).
• Open the air cleaner end cap clips (x2).
• Remove the air filter assembly end cap.
• Figure 95.
• B
• A
• A

• End cap clips (x2)
• Air filter assembly end cap
• 5. Remove the outer air filter element.
• Figure 96.
• C

C Outer air filter element 6. Remove the inner
air filter element. Figure 97. D
D Inner air filter element
15 - 59
4
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5
15 - Engine 54 - Flywheel
54 - Flywheel
Contents Page No. 15-54-00 General
..................................................
..................................................
....................... 15-85 15-54-12 Drive
Plate ............................................
..................................................
....................... 15-86
15 - 84
6
15 - Engine 54 - Flywheel 00 - General
00 - General Introduction Flywheels are used to
provide continuous energy in systems, where the
energy source is not continuous. In such cases,
the flywheel stores energy when torque is applied
by the energy source, and it releases stored
energy when the energy source is not applying
torque to it. In a reciprocating engine, a
flywheel is used to maintain constant angular
velocity of the crankshaft. The flywheel, which
is mounted on the crankshaft, stores energy when
torque is exerted on it by a firing piston, and
it releases energy to its mechanical loads when
no piston is exerting torque on it.
15 - 85
7
15 - Engine 54 - Flywheel 12 - Drive Plate
12 - Drive Plate Remove and Install
Install

1. The installation procedure is the opposite of the
   removal procedure. Additionally do the following
   step.
2. Tighten the bolts to the correct torque value.

Remove

• Make the machine safe. Refer to PIL 01-03-27.
• Isolate the battery. Refer to PIL 33-03.
• Remove the wheel drive pump. Refer to PIL
  27-31-00.
• Remove the bolts 1 (x8).
• Remove the adaptor plate.
• Figure 99.

Table 29. Torque Values
Item Description Nm
B Bolts 1 30
C Bolts 2 30
B A

• Adaptor plate
• Bolts 1 (x8)
• Remove the bolts 2 (x6).
• Remove the drive plate.
• Figure 100.

D
C

1. Bolts 2 (x6)
2. Drive plate

15 - 86
8
15 - Engine 75 - Starter Motor 00 - General
00 - General
Introduction
Introduction .....................................
............. 15-101 Health and Safety
........................................
15-102 Component Identification
............................. 15-103 Check
(Condition) ......................................
.. 15-104 Remove and Install .....................
................ 15-106
The electric starter motor is either a permanent-
magnet or a series-parallel wound direct current
electric motor with a starter solenoid mounted on
to it. When the current from the battery is
applied to the solenoid, through the key-operated
ignition switch, the solenoid engages a lever
that pushes out the drive pinion on the starter
driveshaft and meshes the pinion with the starter
ring gear on the flywheel of the engine.
The solenoid also closes high current contacts
for the starter motor, which begins to turn. Once
the engine starts, the key-operated ignition
switch is opened, a spring in the solenoid
assembly pulls the pinion gear away from the ring
gear, and the starter motor stops. The starter
motor pinion is clutched to the drive shaft
through an overrunning clutch which permits the
pinion to transmit drive in only one direction.
Drive is then transmitted through the pinion to
the flywheel ring gear, but if the pinion remains
engaged (as for example because the operator
fails to release the key as soon as the engine
starts, or if there is a short and the solenoid
remains engaged), the pinion will spin
independently of the drive shaft, this prevents
the engine driving the starter. The starter motor
is only designed for intermittent use, the
electrical components are designed only to
operate for a time period of 20 s before
overheating.
15 - 101
9
15 - Engine 75 - Starter Motor 00 - General
Health and Safety WARNING Make the machine
safe before working on it. Park the machine on
level ground and lower the loader arm. Stop the
engine and remove the ignition key. Make sure the
park brake is engaged. Disconnect the battery to
prevent the engine being started. Block all four
wheels. Notice Before carrying out arc welding
on the machine, disconnect the battery and
alternator to protect the circuits and
components. The battery must still be
disconnected even if a battery isolator is
installed. Notice Do not isolate the machine
electrics when the engine is running, this may
cause damage to the machine electrics.
15 - 102
10
15 - Engine 75 - Starter Motor 00 - General
Component Identification Figure 107. 1
2

• 3
• Solenoid
• Brush gear
• Tie bolts

Figure 108.
A
B
D
C
A Solenoid positive terminal (From battery) C
Negative terminal (To ground)
B Solenoid terminal (From ignition switch) D
Solenoid positive after contact terminal (To
motor)
15 - 103
11
15 - Engine 75 - Starter Motor 00 - General
Check (Condition)
Figure 110.
Before carrying out the multimeter tests, check
the battery condition and make sure that all the
applicable electrical connections are clean and
tight. Make sure that the starter motor fixing
bolts are tightened to the correct torque. To
prevent the engine starting during the tests make
sure that the applicable engine stop fuse is
removed.
Check the readings in the following sequence
using a multimeter. Unless otherwise stated, the
readings must be taken with the ignition switch
held in the start position (HS) and the controls
set to enable the starter motor. The readings are
shown for both 12 V and 24 V systems. The
highest values are for machines with 24 V
systems. Identify the applicable system before
carrying out the tests.

• Starter main terminal
• Commutator end bracket (Starter earth
  connection)
• Minimum permissible reading in start
  position
• Voltage 9 V
• Voltage 17 V
• If the reading is within this limit, continue to
• 3. If the reading is outside the limit, proceed
  to 4.
• 3. Connect the multimeter between the solenoid
  terminal and a good earth. Minimum permissible
  reading in start position
• Voltage 8 V
• Voltage 16 V
• Figure 111.

Do not operate the starter motor for more than 20
s at one time. Let the starter motor cool for at
least 2 min between starts.
1. Connect the multimeter across the
battery terminals. Figure 109.

• Reading in start position approximately Voltage
  10 V
• Voltage 20 V
• Minimum permissible reading in start
  position
• Voltage 9.5 V
• Voltage 18 V
• A low reading probably indicates a fault in the
  starter motor.
• 2. Connect the multimeter between the starter
  main terminal and the commutator end bracket. In
  the start position, the reading should not be
  below the reading obtained in 1 by any more than
• Voltage 0.5 V
• Voltage 1 V

C Solenoid terminal 4. If the reading is less
than specified, connect the multimeter between
the start relay switched output and earth. A
fault is indicated with the wiring from the start
relay to the solenoid if the reading increases
to Voltage 8 V Voltage 16 V
15 - 104
12
15 - Engine 75 - Starter Motor 00 - General
Figure 112.
5.1. If the reading is above the maximum
permissible voltage, a high resistance in the
earth lead or connections is indicated. 6.
Connect the voltmeter between battery positive
and the starter main terminal. With the starter
switch off, the voltmeter should indicate battery
voltage, but it should fall to practically zero
when the switch is turned to the on position,
maximum permissible reading Voltage 0.25
V Figure 114.

• Starter main terminal
• Starter earth connection
• Solenoid terminal
• Start relay feed
• Start relay switched output
• H Battery positive and solenoid connection
• If the reading is less than specified, connect
  the multimeter between the start relay feed and
  earth.
• A faulty start relay or a fault in the feed to
  the relay solenoid is indicated if the voltage
  increases to
• Voltage 8 V
• Voltage 16 V
• Check also the solenoid earth connection. The
  fault must be in either the starter switch or in
  the wiring between the solenoid, starter switch,
  and the start relay, if the reading between
  terminal and earth is less than
• Voltage 8 V
• Voltage 16 V
• 5. Connect the multimeter between battery
  negative and starter earth connection. The
  reading in the start position should be
  practically zero, maximum permissible reading
• Voltage 0.25 V
• Figure 113.

A Starter main terminal 7. If the reading is
above the maximum permissible voltage, a high
resistance is present in the insulated lead or in
the solenoid. Connect the multimeter between the
battery positive and solenoid connection. If the
multimeter now reads zero with the switch closed,
the fault is in the solenoid. Figure 115.
H Battery positive and solenoid connection 8.
Finally install the engine stop fuse.
B Starter earth connection
15 - 105
13
15 - Engine 75 - Starter Motor 00 - General
Remove and Install
Figure 118.
Remove 1. Make the machine safe.

• Refer to PIL 01-03-27.
• Isolate the battery. Refer to PIL 33-03.
• Remove the floor plate. Refer to PIL 09-78-00.
• Remove the cable ties.

AA
Z

1. Battery positive cable
2. Starter solenoid connector

Figure 116.
8. Remove the lower retaining bolt. Figure 119.
W
A

• W Cable ties (x2)
• Put a label on the electrical connectors to help
  installation.
• Remove the battery positive cable cover.
• Figure 117.

A Lower retaining bolt 9. Remove the upper
retaining bolt. Figure 120.
B
Y
B Upper retaining bolt 10. Disconnect the
electrical connector.
Y Cable cover 7. Disconnect the battery positive
cable and the starter solenoid connector.
15 - 106
14
15 - Engine 75 - Starter Motor 00 - General
Figure 121.
C
C Electrical connector 11. Remove the starter
motor. Figure 122.
D

• D Starter motor
• Install
• The installation procedure is the opposite of the
  removal procedure. Additionally do the following
  step.
• Tighten the nuts to the correct torque value.
• Table 31. Torque Values

Item Description Nm
A Lower retaining bolt 44
B Upper retaining bolt 44
15 - 107
15
15 - Engine 75 - Starter Motor 06 - Brush Gear
06 - Brush Gear Remove and Install The starter
motor brushes are an integral part of the starter
motor. This part is a non-serviceable part if it
fails, replace the complete starter motor.
15 - 108
16
18 - Fuel and Exhaust System 03 - Tank 00 -
General
00 - General
Introduction
Introduction .....................................
............... 18-11 Remove and Install
....................................... 18-12
The fuel tank is a safe container for storing
flammable fluids, from here the fuel is pumped
into the engine.
There can be condensation in a partially filled
fuel tank. Therefore, you must fill the fuel tank
after you operate the engine. Drain the water and
sediment from any fuel storage tank at the
recommended service intervals.
18 - 11
18 - 11
17
18 - Fuel and Exhaust System 03 - Tank 00 -
General
Remove and Install CAUTION This component is
heavy. It must only be removed or handled using a
suitable lifting method and device.
Figure 129.
Obey all fuel system health and safety
information when working on the fuel system.
Refer to PIL 18-00-00.
Remove 1. Make the machine safe.
B
Refer to PIL 01-03-27.

• B Electrical connectors 1
• Disconnect the electrical connectors 2.
• Remove the screws and remove the clamps.
• Reposition the harness.
• Figure 130.

• Isolate the battery. Refer to PIL 33-03-00.
• Remove the drive control cable from the reaction
  bracket.
• Figure 127.

T
V
F
G
E
H

• Electrical connectors 2
• Screws
• Clamp
• Harness
• 9. Disconnect the fuel spill hose and the fuel
  supply hose.
• Figure 131.

T Drive control cable V Reaction bracket 4.
Remove the cable ties. Figure 128.
A
J
A
K
A Cable ties 5. Disconnect the electrical
connectors 1.

• Fuel spill hose
• Fuel supply hose
• 10. Remove the bolt 1 from the retaining bar.

18 - 12
18
18 - Fuel and Exhaust System 03 - Tank 00 -
General
11. Remove the retaining bar. Figure 132.
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 36. Torque Values
Item Description Nm
Q Bolts 2 105
L M

• Bolt 1
• Retaining bar
• 12. Support the fuel tank with suitable
  equipment.
• Figure 133.

lifting
P
N N Fuel tank P Lifting equipment 13. Remove
the bolts 2 from the fuel tank. Figure 134. Q
N
N Fuel tank Q Bolts 2 14. Carefully remove the
fuel tank from the machine.
18 - 13
19
18 - Fuel and Exhaust System 09 - Filter
09 - Filter
Contents Page No. 18-09-00 General
..................................................
..................................................
....................... 18-15
18 - 14
20
18 - Fuel and Exhaust System 09 - Filter 00 -
General
00 - General
Component Identification
Component Identification .........................
...... 18-15 Clean ...............................
.............................. 18-16
Figure 135.
A
A Fuel filter
18 - 15
21
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18 - Fuel and Exhaust System 09 - Filter 00 -
General

• Clean
• Make the machine safe. Refer to (PIL 01-03).
• Isolate the battery. Refer to (PIL 33-03).
• Remove the cap off the filter housing.
• Rinse the inside of the fuel filter housing with
  fuel.
• Remove the filter element from the filter
  assembly.
• Clean the fuel filter with fuel.
• Install the fuel filter assembly.
• Bleed the fuel system. Refer to (PIL 18-00).
• Figure 136.

A
A Fuel filter
18 - 16
9813/5200-2
18 - 16
23
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