Dumpster HTD5
Copyright © 2004 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. World Class Customer Support 9803/9570-4 Publication No. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400 Service Manual
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
Identification
Torque Settings
Tools
Consumables
Page No.Contents Section 1 - General Information 1 - i 1 - i Introduction About this Publication ...............................................................................1 - 1 Machine
Identifying Your Machine ..........................................................................1 - 3
Zinc Plated Fasteners and Dacromet Fasteners ......................................1 - 5 Hydraulic Connections ..............................................................................1 - 9 Service
Numerical List .........................................................................................1 - 13
Sealing and Retaining Compounds ........................................................1 - 15
Introduction
About this Publication
Introduction
About this Publication
This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training by JCB Technical Training Department.
These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated with the maintenance and repair of hydraulic earth moving equipment.
Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt. Finally, please remember above all else SAFETY MUST COME FIRST!
The manual is compiled in sections, the first three are numbered and contain information as follows:
1 General Information - includes torque settings and service tools.
2 Care & Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc.
3 Routine Maintenance - includes service schedules and recommended lubricants for all the machine.
The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for example:
A Attachments
B Body and Framework...etc.
Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each alphabetically coded section.
All sections are listed on the front cover; tabbed divider cards align directly with individual sections on the front cover for rapid reference.
Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry threads, hence for lubricated threads may be reduced by one third.
'Left Hand' and 'Right Hand' are as viewed from the rear of the machine facing forwards.
Section 1 - General Information
1-1 1-19803/9570-4
Identifying Your Machine
Machine Identification
Identifying Your Machine
The machine has a data plate A attached to the chassis as shown.
The serial (VIN) number of the machine is stamped on the plate together with the machine weight, engine power and year of manufacture.
1.
The machine serial number is also stamped on the chassis in two places - on the top face of the tower arm B and on the top face of the main chassis under the hydraulic tank (not shown).
2.
3.
Section 1 - General Information Machine Identification
1-3 1-39803/9570-4
Fig
Fig
Fig
S YEAR OF MANUF. T PIN Prod.Ident. No. 817/18435 ENGINE POWER kW @ RPM E I F VIN Vehicle Ident. No. ER IR MR WEIGHT Kg EG D JCB COMPACT PRODUCTS LIMITED HAREWOOD ESTATE, LEEK ROAD, CHEADLE, STOKE ON TRENT, UNITED KINGDOM, ST10 2JU. xx xx xxxx xxx xxxxx xx xx xx xxxxxx xx x xx xx x xxx xx x xx xx x xx xxxx A B
Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
Introduction
Some external fasteners on JCB machines are manufactured using an improved type of corrosion resistant finish. This type of finish is called Dacromet and replaces the original Zinc and Yellow Plating used on earlier machines.
The two types of fasteners can be readily identified by colour and part number suffix. K Table 1. Fastener Types ( T 1-5)
Table 1. Fastener Types
Fastener Type ColourPart No. Suffix
Zinc and Yellow Golden finish'Z' (e.g. 1315/3712Z)
DacrometMottled silver finish'D' (e.g. 1315/3712D)
Note: As the Dacromet fasteners have a lower torque setting than the Zinc and Yellow fasteners, the torque figures used must be relevant to the type of fastener.
Note: A Dacromet bolt should not be used in conjunction with a Zinc or Yellow plated nut, as this could change the torque characteristics of the torque setting further. 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.
Note: Dacromet bolts, due to their high corrosion resistance are used in areas where rust could occur. Dacromet bolts are only used for external applications. They are not used in applications such as gearbox or engine joint seams or internal applications.
Bolts and Screws
Use the following torque setting tables only where no torque setting is specified in the text.
Note: Dacromet fasteners are lubricated as part of the plating process, do not lubricate.
Torque settings are given for the following conditions:
Condition 1
–Un-lubricated fasteners
–Zinc fasteners
–Yellow plated fasteners
Condition 2
–Zinc flake (Dacromet) fasteners
–Lubricated zinc and yellow plated fasteners
–Where there is a natural lubrication. For example, cast iron components
Verbus Ripp Bolts
Fig 1.
Torque settings for these bolts are determined by the application. Refer to the relevant procedure for the required settings.
Section 1 - General Information
1-5 1-59803/9570-4
T11-002
1 - General Information Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
Table 2. Torque Settings - UNF Grade 'S' Fasteners
Bolt SizeHexagon (A/F)Condition 1Condition 2 in.mmin.Nmkgf mlbf ftNmkgf mlbf ft 1/46.37/1611.21.18.310.01.07.4 5/167.91/222.32.316.420.02.014.7 3/89.59/1640.04.129.536.03.726.5 7/1611.15/864.06.547.257.05.842.0 1/212.73/498.0010.072.388.09.064.9 9/1614.313/16140.014.3103.2126.012.892.9 5/815.915/16196.020.0144.6177.018.0130.5 3/419.01 1/8343.035.0253.0309.031.5227.9 7/822.21 15/16547.055.8403.4492.050.2362.9 125.41 1/2814.083.0600.4732.074.6539.9 1 1/831.71 7/81181.0120.4871.11063.0108.4784.0 1 1/438.12 1/41646.0167.81214.01481.0151.01092.3
Table 3. Torque Settings - Metric Grade 8.8 Fasteners
Bolt SizeHexagon (A/F)Condition 1Condition 2 ISO Metric
ThreadmmmmNmkgf mlbf ftNmkgf mlbf ft M5585.80.64.35.20.53.8 M66109.91.07.39.00.96.6 M881324.02.417.722.02.216.2 M10101747.04.834.743.04.431.7 M12121983.08.561.274.07.554.6 M161624205.020.9151.2184.018.8135.7 M202030400.040.8295.0360.036.7265.5 M242436690.070.4508.9621.063.3458.0 M3030461372.0139.91011.91235.0125.9910.9 M3636552399.0244.61769.42159.0220.01592.4
Section
1-6 1-69803/9570-4
Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
Table 4. Metric Grade 10.9 Fasteners
Bolt SizeHexagon (A/F)Condition 1Condition 2
ISO Metric
ThreadmmmmNmkgf mlbf ftNmkgf mlbf ft M5588.10.86.07.30.75.4 M661013.91.410.212.51.39.2 M881334.03.525.030.03.022.1 M10101767.06.849.460.06.144.2 M121219116.011.885.5104.010.676.7 M161624288.029.4212.4259.026.4191.0 M202030562.057.3414.5506.051.6373.2 M242436971.099.0716.9874.089.1644.6 M3030461930.0196.81423.51737.0177.11281.1 M3636553374.0344.02488.53036.0309.62239.2
Table 5. Metric Grade 12.9 Fasteners
Bolt SizeHexagon (A/F)Condition 1Condition 2
ISO Metric
ThreadmmmmNmkgf mlbf ftNmkgf mlbf ft M5589.81.07.28.80.96.5 M661016.61.712.215.01.511.1 M881340.04.129.536.03.726.5 M10101780.08.159.072.07.353.1 M121219139.014.2102.5125.012.792.2 M161624345.035.2254.4311.031.7229.4 M202030674.068.7497.1607.061.9447.7 M2424361165.0118.8859.21048.0106.9773.0 M3030462316.0236.21708.22084.0212.51537.1 M3636554049.0412.92986.43644.0371.62687.7
Section 1 - General Information
1-7 1-79803/9570-4
Section 1 - General Information Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
Table 6. Torque Settings - Rivet Nut Bolts/Screws
Bolt Size
ISO Metric Threadmm
Nmkgf mlbf ft
M331.20.10.9
M443.00.32.0 M556.00.64.5 M6610.01.07.5
M8824.02.518.0 M101048.04.935.5
M121282.08.460.5
Table 7. Torque Settings - Internal Hexagon Headed Cap Screws (Zinc)
Bolt Size
ISO Metric Thread
Nmkgf mlbf ft
M32.00.21.5
M46.00.64.5
M511.01.18.0
M619.01.914.0
M846.04.734.0
M1091.09.367.0
M12159.016.2117.0 M16395.040.0292.0
M18550.056.0406.0
M20770.079.0568.0 M241332.0136.0983.0
1-8 1-89803/9570-4
Settings
Hydraulic Connections
Hydraulic Connections
'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.
Table 8. Torque Settings - BSP Adaptors
BSP Adaptor Size Hexagon (A/F)
Nmkgf mlbf ftin.mm
1/419.018.01.813.0
3/822.031.03.223.0
1/227.049.05.036.0 5/830.060.06.144.0 3/432.081.08.260.0 138.0129.013.195.0 1 1/450.0206.021.0152.0
Table 9. Torque Settings - SAE Connections
SAE Tube Size SAE Port Thread Size Hexagon (A/F)
Nmkgf mlbf ftmm 47/16 - 2015.920.0 - 28.02.0 - 2.816.5 - 18.5 69/16 - 1819.146.0 - 54.04.7 - 5.534.0 - 40.0 83/4 - 1622.295.0 - 105.09.7 - 10.769.0 - 77.0 107/8 - 1427.0130.0 - 140.013.2 - 14.396.0 - 104.0 121 1/16 - 1231.8190.0 - 210.019.4 - 21.4141.0 - 155.0 161 5/16 - 1238.1290.0 - 310.029.6 - 31.6216.0 - 230.0 201 5/847.6280.0 - 380.028.5 - 38.7210.0 - 280.0
Section 1 - General Information Torque
1-9 1-99803/9570-4
T11-003
Information Torque Settings
Hydraulic Connections
Hoses Screwed into Adaptors
Fig 2.
Hoses 2-B screwed into adaptors 2-A seal onto an `O' ring 2-C which is compressed into a 45° seat machined into the face of the adaptor port.
Note: Dimension 2-D will vary depending upon the torque applied.
Table 10. BSP Hose - Torque Settings
BSP Hose SizeHexagon (A/F)
Nmkgf mlbf ftin.mm
1/814.014.0 - 16.001.4 - 1.610.3 - 11.8
1/419.024.0 - 27.02.4 - 2.717.7 - 19.9
3/822.033.0 - 40.03.4 - 4.124.3 - 29.5
1/227.044.0 - 50.04.5 - 5.132.4 - 36.9
5/830.058.0 - 65.05.9 - 6.642.8 - 47.9
3/432.084.0 - 92.08.6 - 9.461.9 - 67.8 138.0115.0 - 126.011.7 - 12.884.8 - 92.9
1 1/450.0189.0 - 200.019.3 - 20.4139.4 - 147.5
1 1/255.0244.0 - 260.024.9 - 26.5180.0 - 191.8
Section 1 - General
1-10 1-109803/9570-4
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
Nmkgf mlbf ftin.
1/820.02.115.0
1/434.03.425.0
3/875.07.655.0
1/2102.010.375.0
5/8122.012.490.0
3/4183.018.7135.0 1203.020.7150.0
1 1/4305.031.0225.0
1 1/2305.031.0225.0
Section
1-11 1-119803/9570-4
Torque Settings
Hydraulic Connections
'Torque Stop' Hose System
Fig 3.
`Torque Stop' Hoses 3-B screwed into adaptors 3-A seal onto an 'O' ring 3-C which is compressed into a 45° seat machined in the face of the adaptor port. To prevent the 'O' ring being damages as a result of over tightening, 'Torque
Stop' Hoses have an additional shoulder 3-D, which acts as a physical stop.
Note: Minimum dimension 3-E fixed by shoulder 3-D
Table 12. BSP `Torque Stop' Hose - Torque Settings
BSP Hose SizeHexagon (A/F)
Nmkgf mlbf ftin.mm
1/814.014.01.410.0 1/419.027.02.720.0 3/822.040.04.130.0 1/227.055.05.640.0 5/830.065.06.648.0 3/432.095.09.770.0 138.0120.012.289.0
1 1/450.0189.019.3140.0
1 1/255.0244.024.9180.0
Section 1 - General Information
1-12 1-129803/9570-4
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Service Tools
Numerical List
The tools listed in the table are special tools required for carrying out the procedures described in this manual. These tools are available from JCB Service.
Some tools are available as kits or sets, the part numbers for parts within such kits or sets are not listed here. For full
details of all tools, including the content of kits and sets, see the relevant section in this manual.
Note: Tools other than those listed will be required. It is expected that such general tools will be available in any well equipped workshop or be available locally from any good tool supplier.
Part Number DescriptionTool Detail Reference - see Section:
-AVO Test Kit - see tool detail reference for content C
-Electrical Repair Kit - see tool detail reference for content C 993/85700Battery Tester C
Section 1 - General Information Service Tools
Numerical
List 1-13 1-139803/9570-4
Sealing and Retaining Compounds
Consumables
Sealing and Retaining Compounds
T11-001_4 Table 1.
TypeDescriptionPart No.Quantity
JCB Multi-GasketA medium strength sealant suitable for all sizes of gasket flanges, and for hydraulic fittings of 25-65 mm diameter.
JCB High Strength ThreadlockerA high strength locking fluid for use with threaded components. Gasketing for all sizes of flange where the strength of the joint is important.
4102/121250 ml
4102/055150 ml
JCB Retainer (High Strength) For all retaining parts which are unlikely to be dismantled. 4101/060110 ml 4101/065150 ml
JCB Threadlocker and SealerA medium strength locking fluid for sealing and retaining nuts, bolts, and screws up to 50 mm diameter, and for hydraulic fittings up to 25 mm diameter.
JCB Threadlocker and Sealer (High Strength)
A high strength locking fluid for sealing and retaining nuts, bolts, and screws up to 50 mm diameter, and for hydraulic fittings up to 25 mm diameter.
4101/025010 ml 4101/025150 ml
4101/055010 ml 4101/0552200 ml
JCB ThreadsealA medium strength thread sealing compound.4102/195150 ml
JCB ActivatorA cleaning primer which speeds the curing rate of anaerobic products. 4104/0251200 ml (Aerosol) 4104/02531 ltr (Bottle)
JCB Cleaner/DegreaserFor degreasing components prior to use of anaerobic adhesives and sealants. 4104/1557400 ml (Aerosol)
Direct Glazing KitFor one pane of glass; comprises of:
–1 x Ultra Fast Adhesive (310 ml)
–1 x Active Wipe 205 (30 ml) –1 x Black Primer 206J (30 ml) –plus applicator nozzle etc.
993/55700
Ultra Fast AdhesiveFor direct glazing.4103/2109310 ml Active Wipe 205For direct glazing.4104/1203250 ml Black Primer 206JFor direct glazing.4201/490630 ml
Clear Silicone SealantTo seal butt jointed glass. 4102/0901 Plastic to Metal BonderTo seal plastic to metal joints.4103/095650 g Black Polyurethane SealantTo finish exposed edges of laminated glass.4102/2309310 ml
Section 1 - General Information Consumables
1-15 1-159803/9570-4
Care & Safety
Copyright © 2004 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. World Class Customer Support 9803/9570-4 Publication No. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400 Section 2
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
