jcb 530-70 User manual
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
9813/3850-2
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
530-70, 530-110
Section 1 - General Information
Section 2 - Operator’s Manual
Section B - Body and Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section H - Steering
Section K - Engine
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
9813/3850-2
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 1
General Information
Service Manual - 530-70, 530-110
Section 1 - General Information
Section 2 - Operator’s Manual
Section B - Body and Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section H - Steering
Section K - Engine
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Section 1 - General Information
Contents
1-i 1-i
Page No.Contents
Introduction
Identifying Your Machine ........................................................................... 1-1
Safety
Introduction ................................................................................................ 1-3
Use
Introduction ................................................................................................ 1-5
Scope ........................................................................................................ 1-6
Personnel ..............................................................................................1-6
Newest Data ..........................................................................................1-6
Format ....................................................................................................... 1-7
Left Side, Right Side ..............................................................................1-7
Hydraulic Schematic Codes ...................................................................... 1-8
Colour Codes ........................................................................................1-8
Routine Maintenance
Maintenance Schedules ............................................................................ 1-9
Service Tools
Numerical List .......................................................................................... 1-11
Section B ................................................................................................. 1-14
Section C ................................................................................................. 1-18
Section E ................................................................................................. 1-19
Section F ................................................................................................. 1-27
Section H ................................................................................................. 1-35
Section K ................................................................................................. 1-36
Service Aids
Sealing and Retaining Compounds ......................................................... 1-37
Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners ..................................... 1-39
Introduction ..........................................................................................1-39
Bolts and Screws .................................................................................1-39
Hydraulic Connections ............................................................................. 1-43
'O' Ring Face Seal System ..................................................................1-43
'Torque Stop' Hose System .................................................................1-46
`Quick-Connect' Pilot Hoses .................................................................... 1-47
Disconnecting ......................................................................................1-47
Connecting ..........................................................................................1-47
General Procedures
Introduction .............................................................................................. 1-49
Parking the Machine and Making it Safe ................................................. 1-50
Venting the Hydraulic Pressure ............................................................... 1-51
Connecting/Disconnecting Hydraulic Hoses ............................................ 1-52
Battery Disconnection/Connection .......................................................... 1-53
Removing and Replacing Components ................................................... 1-54
Preparation ..........................................................................................1-54
Original Components ...........................................................................1-54
New Components ................................................................................1-54
Torques and Fixings ............................................................................1-54
Battery Charging System Precautions ..................................................... 1-55
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Section 1 - General Information
Contents
1-ii 1-ii
Page No.Contents
Gas Hydraulic Bladder Accumulators ...................................................... 1-56
Replacement .......................................................................................1-56
Charging ..............................................................................................1-56
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Section 1 - General Information
1-3 1-3
9813/3850-2
Safety
Introduction
In this manualand onthe machine there aresafety notices.
The safety notices have different signal words as follows:
– DANGER
–WARNING
–CAUTION
–Notice
For an explanation of the safety notice signal words, refer
to Section 2, Introduction, Safety.
For general safety notices, refer to Section 2,
Introduction, Safety Check List.
For maintenance safety notices, refer to Section 2,
Routine Maintenance, Health and Safety.
For safety notices specific to maintenance procedures,
refer to the relevant procedure.
If you do not fully understand a safety notice ask your
employer to explain it.
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Section 1 - General Information
1-5 1-5
9813/3850-2
Use
Introduction
This topic contains information about the structure of the manual and how to use the manual.
KScope ( T1-6)
KPersonnel ( T1-6)
KNewest Data ( T1-6)
KFormat ( T1-7)
KLeft Side, Right Side ( T1-7)
KHydraulic Schematic Codes ( T1-8)
KColour Codes ( T1-8)
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Section 1 - General Information
Use
Scope
1-6 1-6
9813/3850-2
Scope
Personnel
This manual 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 earthmoving equipment. Finally, please
remember above all else SAFETY MUST COME FIRST!
Newest Data
From time to time new machines, systems or devices
require the manual to be re-issued. Make sure you have
the newest issue.
Always check the on-line JCB data system for relevant
technical information.
Section 1 - General Information
Use
Format
1-7 1-7
9813/3850-2
Format
The manual is compiled in sections, the first two are
numbered and contain information as follows:
1 General Information - The section includes general
information such as torque settings and service tools.
2 Operator Manual - The section contains a copy of
the applicable machine Operator Manual. Refer to
this sectionwhen necessaryfor informationabout the
main machine components and controls. Refer also
to the safety and daily / weekly maintenance
information.
The remaining sections are alphabetically coded and deal
with dismantling, overhaul etc. of specific components, for
example:
Each section contains data such as technical data,
descriptions, fault finding and test procedures.
Some sections contain procedures and specifications for
different variants. This happens because of market
requirements, or when the machine specification changes
after a period of time. Where applicable, a table contains
information to help you identify the correct data and
procedures.
Left Side, Right Side
In this manual, 'left' A and 'right' B mean your left and right
when you are seated correctly in the machine.
D071040-52
Fig 1.
A Attachments
B Body and Framework...etc.
Section 1 - General Information
Use
Hydraulic Schematic Codes
1-8 1-8
9813/3850-2
Hydraulic Schematic Codes
Colour Codes
The following colour coding, usedon illustrationsto denote
various conditions of oil pressure and flow, is standardised
throughout JCB Service Publications.
Red Full Pressure: Pressure generated from operation of a service. Depending on application this
may be anything between neutral circuit pressure and LSRV operating pressure.
Pink Pressure: Pressure that is above neutral circuit pressure but lower than that denoted by Red.
Orange Pilot: Oil pressure used in controlling a device (Pilot).
Blue Neural: Neutral circuit pressure.
Green Exhaust:
Light Green Cavitation: Oil subjected to a partial vacuum due to a drop in pressure (cavitation).
Yellow Lock Up: Oil trapped within a chamber or line, preventing movement of components (lock up).
Section 1 - General Information
1-9 1-9
9813/3850-2
Routine Maintenance
Maintenance Schedules
This publication contains procedures for carrying out the
routine maintenance tasks listed on the maintenance
schedules. Refer to Operator’s Manual, Maintenance
Schedules.
The procedures for the daily and weekly (10 and 50 hour)
tasks are given in Operator’s Manual, Maintenance.
The procedures for the 100 hour and above tasks are
given in the related sections of this publication. For
example the procedures for engine related tasks are given
in Section K.
Section 1 - General Information
Routine Maintenance
Maintenance Schedules
1-10 1-10
9813/3850-2
Page left intentionally blank
Section 1 - General Information
1-11 1-11
9813/3850-1
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 Description Tool Detail Reference
- see Section:
- AVO Test Kit - see tool detail reference for content C
- Bonded Washers - see tool detail reference for content E
- Female Cone Blanking Plugs - see tool detail reference for content E
- Female Connectors - see tool detail reference for content E
- Hydraulic Flow Test Equipment - see tool detail reference for content E
- Hydraulic Hand Pump Equipment - see tool detail reference for content E
- Male Adaptors - BSP x BSP - see tool detail reference for content E
- Male Adaptors - BSP x NPT (USA only) - see tool detail reference for content E
- Male Cone Blanking Caps - see tool detail reference for content E
- Pressure Test Points - `T' Adaptors - see tool detail reference for content E
- Pressure Test Points - Adaptors - see tool detail reference for content E
- Rivet Nut Tool - see tool detail reference for content B
825/10053 Pilot hose release tool - for quick-connect hose fittings E
892/01160 Engine lifting bracket (2-off) K
4104/1310 Hand Cleaner B
460/15708 Flow test adaptor - Powershift - Other components required, see tool detail F
716/30313 Test relay - with LED indicator L
721/10885 Interconnecting cable - use with 892/01033 F
825/10035 Adaptor plate spanner - viscous cooling fan K
825/10036 Fan coupling spanner - viscous cooling fan K
892/00011 Spool Clamp E
892/00167 Ram Protection Sleeve for 90 mm Rod Diameter E
892/00180 Seal Fitting Tool - Hydraulic Steer Unit H
892/00181 Replacement Plastic Boss for 892/00180 H
892/00252 Test Block for Loader Valve A.R.V. (214e & 3C Machines Only) E
892/00253 Hydraulic Pressure Test Kit - see tool detail reference for content E, F
Section 1 - General Information
Service Tools
Numerical List
1-12 1-12
9813/3850-1
892/00268 Flow monitoring unit - Other components required, see tool detail F
892/00301 Flow test adaptor - Synchro Shuttle - Other components required, see tool detail F
892/00309 A.R.V. Pressure Test Kit - see tool detail reference for content E
892/00334 Ram Seal Fitting Tool E
892/00812 Drive coupling spanner F
892/00822 Splined bolt socket F
892/00842 Glass Lifter B
892/00843 Folding Stand for Holding Glass B
892/00844 Long Knife B
892/00845 Cartridge Gun B
892/00846 Glass Extractor (Handles) B
892/00847 Nylon Spatula B
892/00848 Wire Starter B
892/00849 Braided Cutting Wire B
892/00881 Valve Spool Seal Fitting Tool E
892/00913 Grease gun attachment - Use where access to the grease nipple is restricted E.g.
Axle driveshaft universal joints F
892/00964 Test point 1/8 BSP Powershift F
892/00965 Test point 3/8 BSP Powershift F
892/00966 Test point 1/4 BSP Synchro Shuttle F
892/01016 Ram Protection Sleeve for 25 mm Rod Diameter E
892/01017 Ram Protection Sleeve for 30 mm Rod Diameter E
892/01018 Ram Protection Sleeve for 40 mm Rod Diameter E
892/01019 Ram Protection Sleeve for 50 mm Rod Diameter E
892/01020 Ram Protection Sleeve for 50 mm Rod Diameter (slew ram) E
892/01021 Ram Protection Sleeve for 60 mm Rod Diameter E
892/01022 Ram Protection Sleeve for 60 mm Rod Diameter (slew ram) E
892/01023 Ram Protection Sleeve for 65 mm Rod Diameter E
892/01024 Ram Protection Sleeve for 70 mm Rod Diameter E
892/01025 Ram Protection Sleeve for 75 mm Rod Diameter E
892/01026 Ram Protection Sleeve for 80 mm Rod Diameter E
892/01027 Piston Seal Assembly Tool E
892/01033 Electronic service tool kit - also requires 721/10885 F
892/01042 Nitrogen Charging Tool Kit E
892/01094 Transmission jack - support plates also required, see tool detail F
892/01096 Speed sensor test harness - Powershift F
892/01110 Torque converter alignment tool F
Part
Number Description Tool Detail Reference
- see Section:
Section 1 - General Information
Service Tools
Numerical List
1-13 1-13
9813/3850-1
926/15500 Rubber Spacer Blocks B
992/04000 Torque Multiplier F
992/09100 Excavator Spool Clamp E
992/09300 Hexagon Spanner 55mm A/F E, H
992/09400 Hexagon Spanner 65mm A/F E, H
992/09500 Hexagon Spanner 75mm A/F E, H
992/09600 Hexagon Spanner 85mm A/F E, H
992/09700 Hexagon Spanner 95mm A/F E, H
992/09900 Hexagon Spanner 115mm A/F E, H
992/10000 Hexagon Spanner 125mm A/F E, H
992/12300 12V Mobile Oven B
992/12400 24V Static Oven (2 Cartridge) B
992/12600 24V Static Oven (6 Cartridge) B
992/12800 Cut-Out Knife B
992/12801 `L' Blades B
993/68100 Slide Hammer Kit - see tool detail reference for content B
993/85700 Battery Tester C
998/11051 Digital Pressure Test Set
(1)
C
332/F1311 Gear shift cable tool F
332/H1950 LMI transducer tester B
(1) Only required for Joystick Control (Servo) machines.
Part
Number Description Tool Detail Reference
- see Section:
Section 1 - General Information
Service Tools
Section B
1-14 1-14
9813/3850-1
Section B
Note: Not all service tools are illustrated.
Fig 2. 993/68100 Slide Hammer Kit
1993/68101 Slide Hammer 7993/68107 Bar - M20 x M20 X 800 mm
2993/68102 End Stops 8993/68108 Adaptor - M20 x 7/8" UNF
3993/68103 Adaptor - M20 x 5/8" UNF 9993/68109 Adaptor - M20 x M12
4993/68104 Adaptor - M20 x 1" UNF 10 993/68110 Adaptor - M20 x 5/8" UNF (Shoulder)
5993/68105 Adaptor - M20 x M20 11 993/68111 Adaptor - M20 x 1/2" UNF
6993/68106 Adaptor - M20 x M24
Fig 3. 892/00842 Glass Lifter
Minimum2 off - Essential for glass installation, 2 required
to handle large panes of glass. Ensure suction cups are
protected from damage during storage. Fig 4. 892/00843 Folding Stand
Essential for preparing new glass prior to installation.
Section 1 - General Information
Service Tools
Section B
1-15 1-15
9813/3850-1
Fig 5. 892/00845 Cartridge Gun
Hand operated. Essential for the application of sealants,
polyurethane materials etc.
Fig 6. 892/00846 Glass Extractor (Handles)
Used with braided cutting wire to cut out broken glass.
KFig 9. ( T1-16).
Fig 7. 892/00847 Nylon Spatula
General tool used for smoothing sealants - also used to
re-install glass in rubber glazing because metal tools will
chip the glass edge.
Fig 8. 892/00848 Wire Starter
Used to access braided cutting wire through original
polyurethane seal. KFig 9. ( T1-16).
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