jcb HTD5 Service Manual
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jcb HTD5 Service Manual

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Service Manual
Dumpster HTD5
Section 1 - General Information
Section 2 - Care & Safety
Section 3 - Maintenance
Section B - Body and Framework
Section C - Electrics
Section E - Hydraulics
Section J - Tracks
Section K - Engine
Publication No.
9803/9570-4
World Class
Customer Support
Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400

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  • Page 1 Section E - Hydraulics Section J - Tracks Section K - Engine Publication No. 9803/9570-4 World Class Customer Support Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400...
  • Page 2 Section E - Hydraulics Section J - Tracks Section K - Engine Publication No. 9803/9570-4 World Class Customer Support Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400...
  • Page 3 Section 1 - General Information Notes: 9803/9570-4...

  • Page 4: Table Of Contents

    Section 1 - General Information Contents Page No. Introduction About this Publication ................1 - 1 Machine Identification Identifying Your Machine ................1 - 3 Torque Settings Zinc Plated Fasteners and Dacromet Fasteners ........1 - 5 Hydraulic Connections ................1 - 9 Service Tools Numerical List ..................1 - 13 Consumables Sealing and Retaining Compounds ............1 - 15...

  • Page 5: Introduction

    About this Publication Introduction About this Publication This publication is designed for the benefit of JCB Where a torque setting is given as a single figure it may be Distributor Service Engineers who are receiving, or have varied by plus or minus 3%. Torque figures indicated are received, training by JCB Technical Training Department.

  • Page 6: Machine Identification

    The serial (VIN) number of the machine is stamped on the plate together with the machine weight, engine power and year of manufacture. JCB COMPACT PRODUCTS LIMITED HAREWOOD ESTATE, LEEK ROAD, CHEADLE, STOKE ON TRENT, UNITED KINGDOM, ST10 2JU.

  • Page 7: Torque Settings

    For the same reason, a Dacromet nut should not be used with a Zinc or Yellow plated bolt. Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification.
  • Page 8 Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 2. Torque Settings - UNF Grade 'S' Fasteners Bolt Size Hexagon (A/F) Condition 1 Condition 2 kgf m lbf ft kgf m lbf ft 7/16 11.2 10.0 5/16 22.3...
  • Page 9 Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 4. Metric Grade 10.9 Fasteners Bolt Size Hexagon (A/F) Condition 1 Condition 2 ISO Metric Thread kgf m lbf ft kgf m lbf ft 13.9 10.2 12.5 34.0 25.0...
  • Page 10 Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 6. Torque Settings - Rivet Nut Bolts/Screws Bolt Size ISO Metric Thread kgf m lbf ft 10.0 24.0 18.0 48.0 35.5 82.0 60.5 Table 7. Torque Settings - Internal Hexagon Headed Cap Screws (Zinc) Bolt Size ISO Metric Thread...

  • Page 11: Hydraulic Connections

    Section 1 - General Information Torque Settings Hydraulic Connections Hydraulic Connections T11-003 'O' Ring Face Seal System Adaptors Screwed into Valve Blocks Adaptor screwed into valve blocks, seal onto an 'O' ring which is compressed into a 45° seat machined into the face of the tapped port.
  • Page 12 Section 1 - General Information Torque Settings Hydraulic Connections Hoses Screwed into Adaptors Fig 2. Hoses 2-B screwed into adaptors 2-A seal onto an `O' ring Note: Dimension 2-D will vary depending upon the torque 2-C which is compressed into a 45° seat machined into the applied.
  • Page 13 Section 1 - General Information Torque Settings Hydraulic Connections Adaptors into Component Connections with Bonded Washers Table 11. BSP Adaptors with Bonded Washers - Torque Settings BSP Size kgf m lbf ft 20.0 15.0 34.0 25.0 75.0 55.0 102.0 10.3 75.0 122.0 12.4...
  • Page 14 Section 1 - General Information Torque Settings Hydraulic Connections 'Torque Stop' Hose System Fig 3. `Torque Stop' Hoses 3-B screwed into adaptors 3-A seal Stop' Hoses have an additional shoulder 3-D, which acts onto an 'O' ring 3-C which is compressed into a 45° seat as a physical stop.

  • Page 15: Service Tools Numerical List

    These tools are available from JCB Service. Note: Tools other than those listed will be required. It is Some tools are available as kits or sets, the part numbers expected that such general tools will be available in any for parts within such kits or sets are not listed here.

  • Page 16: Consumables

    A medium strength sealant suitable for all sizes of 4102/1212 50 ml gasket flanges, and for hydraulic fittings of 25-65 mm diameter. JCB High Strength Threadlocker A high strength locking fluid for use with threaded 4102/0551 50 ml components. Gasketing for all sizes of flange where the strength of the joint is important.
  • Page 17 Section E - Hydraulics Section J - Tracks Section K - Engine Publication No. 9803/9570-4 World Class Customer Support Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400...
  • Page 18 Section 2 - Care and Safety Notes: 9803/9570-4...
  • Page 19 Section 2 - Care and Safety Contents Page No. Safety Notices Important Information ................2-1 Safety Checklist ..................2-2 Safety Decals .................... 2-9...
  • Page 20 If you are other operators. unsure about anything, ask your JCB dealer or employer. Do not guess, you or others could be killed In this publication and on the machine, there are safety or seriously injured.
  • Page 21 If you do not understand messages. Read and understand them. They tell you of anything, ask your employer or JCB dealer to explain potential hazards and how to avoid them. If you do not fully it. Keep the Operator Manual clean and in good understand the warning messages, ask your employer or condition.
  • Page 22 Sparks in altered in any way which could affect or invalidate any such an area could cause an explosion or fire of these requirements. For advice consult your JCB resulting in death or serious injury. Distributor.
  • Page 23 Work sites can be noisy, do not rely on atmosphere, i.e. combustible vapours, gas or dust, spoken commands. without first consulting your JCB Distributor. INT-2-2-3 INT-2-1-14 WARNING CAUTION Banks and Trenches Regulations Banked material and trenches can collapse.
  • Page 24 Section 2 - Care and Safety Safety Notices Safety Checklist Maintenance Safety WARNING Use only the JCB approved attachments that are WARNING specified for your machine. Operating with non- specified attachments can overload the machine, Communications causing possible damage and machine instability Bad communications can cause accidents.
  • Page 25 Section 2 - Care and Safety Safety Notices Safety Checklist WARNING WARNING If you try to charge a frozen battery, or jump start and Hydraulic Pressure run the engine, the battery could explode. Do not use Hydraulic fluid at system pressure can injure you. a battery if its electrolyte is frozen.
  • Page 26 5-3-1-9 Cleaning metal parts with incorrect solvents can cause corrosion. Use only recommended cleaning WARNING agents and solvents. INT-3-2-11 Certain seals and gaskets (e.g. crankshaft oil seal) on JCB machines contain fluoroelastomeric materials WARNING such Viton, Fluorel Technoflon. Fluoroelastomeric materials...
  • Page 27 Section 2 - Care and Safety Safety Notices Safety Checklist Thoroughly wash contaminated area with WARNING detergent and water. Arc Welding Contain all removed material, gloves etc. used in To prevent the possibility of damage to electronic this operation in sealed plastic bags and dispose components, disconnect the battery and the alternator accordance with...
  • Page 28 Keep all decals clean and readable. Replace lost or damaged decals. Each decal has a part number printed on it, use this number to order a new decal from your JCB distributor. INT-3-3-3_1 WARNING If you need eye-glasses for reading, make sure you wear them when reading the safety decals.
  • Page 29 Section E - Hydraulics Section J - Tracks Section K - Engine Publication No. 9803/9570-4 World Class Customer Support Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400...
  • Page 30 Section 3 - Maintenance Notes: 9803/9570-4...
  • Page 31 Section 3 - Maintenance Contents Page No. Routine Maintenance Health and Safety ..................3-1 Service Schedules ..................3-5 Lubricants and Capacities ................. 3-8 Check for Damage and Cleaning .............. 3-9 Safety Strut ....................3-10 Greasing ....................3-11 Engine Air Filter ..................3-13 Engine Oil ....................
  • Page 32 New Oil Hygiene There are no special precautions needed for the handling JCB lubricants are not a health risk when used properly for or use of new oil, beside the normal care and hygiene their intended purposes. practices. However, excessive or prolonged skin contact can remove...
  • Page 33 Section 3 - Maintenance Routine Maintenance Health and Safety Throw away oil-soaked shoes. First Aid - Oil Eyes In the case of eye contact, flush with water for 15 minutes. If irritation persists, get medical attention. Swallowing If oil is swallowed do not induce vomiting. Get medical advice.
  • Page 34 Section 3 - Maintenance Routine Maintenance Health and Safety Battery Warning Symbols The following warning symbols may be found on the WARNING battery. Batteries give off an explosive gas. Do not smoke when handling or working on the battery. Keep the Symbol Meaning battery away from sparks and flames.
  • Page 35 Section 3 - Maintenance Routine Maintenance Health and Safety WARNING Electrical Circuits Understand the electrical circuit before connecting or disconnecting an electrical component. A wrong connection can cause injury and/or damage. INT-3-1-4 DANGER Electrolyte Battery electrolyte is toxic and corrosive. Do not breathe the gases given off by the battery.
  • Page 36 Section 3 - Maintenance Routine Maintenance Service Schedules Service Schedules A badly maintained machine is a danger to the operator Apart from the daily jobs, the schedules are based on and the people working around him. Make sure that the machine running hours.
  • Page 37 Download the full PDF manual instantly. Our customer service e-mail: aservicemanualpdf@yahoo.com...

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