JCB HTD5 Tracked Dumpster Repair Service Manual

(S/N: 1360000 Onwards)
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This service manual PDF download for the HTD5 JCB Tracked Dumpster has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.


APPLICABLE MODELS :

JCB Tracked Dumpster HTD5
S/N: 1360000 Onwards


TABLE OF CONTENTS :

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


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Publication No. : 9803/9570-4
Total Pages : 182


This service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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9803-9570
Dumpster HTD5

Section 1
General Information
Introduction
About this Publication
Machine Identification
Identifying Your Machine
Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
Introduction
Bolts and Screws
Condition 1
Condition 2
Verbus Ripp Bolts
Hydraulic Connections
'O' Ring Face Seal System
Adaptors Screwed into Valve Blocks
Hoses Screwed into Adaptors
Adaptors into Component Connections with Bonded Washers
'Torque Stop' Hose System
Service Tools
Numerical List
Consumables
Sealing and Retaining Compounds

Section 2
Care & Safety
Safety Notices
Important Information
The Operator Manual
Safety Warnings
Safety Checklist
Safety - Yours and Others
General Safety
Operation Safety
Maintenance Safety
Safety Decals

Section 3
Maintenance
Routine Maintenance
Health and Safety
Lubricants
Introduction
Hygiene
Storage
Waste Disposal
Handling
New Oil
Used Oil
First Aid - Oil
Eyes
Swallowing
Skin
Spillage
Fires
Battery
First Aid - Electrolyte
GETS INTO YOUR EYES
IS SWALLOWED
GETS ONTO YOUR SKIN
Warning Symbols
Service Schedules
Lubricants and Capacities
Check for Damage and Cleaning
Safety Strut
Fitting the Safety Strut
Removing the Safety Strut
Greasing
Skip Greasing Points
Lift Arm Greasing Points
Engine Air Filter
Changing the Element - Honda Petrol Engine
Changing the Element - Yanmar Engine
Cleaning/changing the Element - Lombardini Engine
Engine Oil
Checking the Oil Level - Honda Petrol Engine
Changing the Oil - Honda Petrol Engine
Checking the Oil Level - Yanmar Engine
Changing the Oil - Yanmar Engine
Checking the Oil Level - Lombardini Engine
Changing the Oil - Lombardini Engine
Spark Plug
Honda Petrol Engine
Fuel System
Honda Petrol Engine
Idle Speed Adjustment
Cleaning the Sedimenter
Draining the Fuel System
Changing the Fuel Filter - Lombardini Engine
Hydraulic System
Checking the Oil Level
Replacing the Hydraulic Filter

Section B
Body and Framework
Engine Cover
Removal and Replacement
Removal
Replacement
Skip
Removal and Replacement
Removal
Replacement
Skip Mechanism
Removal and Replacement
General Notes
Link Removal
Link Replacement
Outer Arms Removal
Outer Arms Replacement
Inner Arms Removal
Inner Arms Replacement
Bump Stop Removal
Bump Stop Replacement
Hydraulic Tank
Removal and Replacement - up to machine no. 1360211
Removal
Replacement
Removal and Replacement - from machine no. 1360212
Removal
Replacement

Section C
Electrics
Circuit Diagrams
Engine Electrical Circuits
Yanmar Engine
Lombardini Engine
Switches
Ignition Switch
Yanmar Engine
Removal
Replacement
Lombardini Engine
Removal
Replacement
Battery
Battery Checks
Checking the Battery Terminals - up to machine no. 1360211
Checking the Battery Terminals - from machine no. 1360212
Checking the Electrolyte Level - up to machine no. 1360211
Checking the Electrolyte Level - from machine no. 1360212
Battery Removal and Replacement
Removal - up to machine no. 1360211
Replacement - up to machine no. 1360211
Removal - from machine no. 1360212
Replacement - from machine no. 1360212

Section E
Hydraulics
Technical Data
General Data
Loader Pump up to machine no. 1360178
Loader Pump from machine no. 1360179
Track Motors
Valve Block
Relief Valve Operating Pressures
Filter
Rams
Dimensions
Torque Settings
Operation Description
Introduction to Hydraulic Schematic Symbols
General (Basic and Functional Symbols)
Control Valves
Example of Schematic Circuit
Example Circuit Key
Machine Schematic Circuit
Component Key
Service Procedures
Hydraulic Contamination
Hydraulic Fluid Quality
Effects of Contamination
Cleaning Operation
Procedure
Contaminant Standards
Filters
Cleaning Operation
Procedure
Pressure Testing
Main Relief Valve (M.R.V.)
Track Motor Relief Valve
Loader Pump
Pump
Removal
Replacement
Dismantling, Inspection and Assembly
Dismantling
Inspection
Assembly
Drive Motors
Track Drive Motor
Removal
Replacement
Dismantling
Cleaning and checking
Assembly
Valves
Control Valve
Removal
Replacement
Hose Connections
Control Valve Block
Inlet Section
Tip Section
2nd Speed Section
Track Section
Lift Section
Rams
Lift Ram
Removal
Replacement
Tilt Ram
Removal
Replacement
Lift and Tilt Ram
Dismantling and Assembly
When Dismantling
When Assembling
Oil Cooler
Cooler Removal and Replacement
Removal
Replacement

Section J
Tracks
Technical Data
General Data
Tracks
Bottom Rollers
Idler Wheels
Wear Tolerances
Track Maintenance
Track Cleaning
Raising the Machine
Cleaning the Tracks
Track Adjustment
Checking the Track Tension
Adjusting the Track Tension - Manual Tensioner
Adjusting the Track Tension - Hydraulic Tensioner
Track Removal and Replacement
Removing a Track
Installing a Track
Track Rollers
Roller - Removal and Replacement
Removing
Replacing
Roller - Dismantling and Assembly
Dismantling
Assembly
Idler Wheel and Recoil Unit
Recoil Unit - Removal and Replacement
Removal
Replacement
Idler Wheel - Removal and Replacement
Removal
Replacement
Idler Wheel - Dismantling and Assembly
Dismantling
Assembly
Drive Sprocket
Removal and Replacement
Removal
Replacement
Track Damage
Types of Rubber Track Damage
Core Bars - Separation
Additional Notes:
Core Bars - Breaking
Breaking in the middle
Breaking on the wings
Additional Notes:
Core Bars - Fast Abrasion
Additional Notes:
Core Bars - Oxidation (Rusting)
Additional Notes:
Steel Cord - Breaking
Additional Notes:
Steel Cord - Separation
Additional Notes:
Steel Cord - Exposure
Additional Notes:
Steel Cord - Sticking Out
Additional Notes:
Outer Track Rubber - Tearing/Cuts
Additional Notes:
Outer Track Rubber - Fast Abrasion
Additional Notes:
Outer Track Rubber - Cracks
Additional Notes:
Outer Track Rubber - Longitudinal Cracks
Inner Track Rubber - Tearing/Cuts
Additional Notes:
Inner Track Rubber - Cracks
Additional Notes:
Miscellaneous - Not Engaging Correctly
Miscellaneous - Detracking
Track Repair
Recommended Repair Procedures
Additional Notes:

Section K
Engine
Technical Data
All Engines
Specifications
Engine Mounting
Moving the Engine
Sliding the Engine Backwards
Sliding the Engine Forwards

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