jcb 530-70, Service Manual

Page 1: ...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 Se...

Page 2: ...upport 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 Sectio...

Page 3: ...Section 1 General Information 1 0 1 0 9813 3850 2 Notes Find manuals at https best manuals com ...

Page 4: ... 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...

Page 5: ...Section 1 General Information Contents 1 ii 1 ii Page No Contents Gas Hydraulic Bladder Accumulators 1 56 Replacement 1 56 Charging 1 56 Find manuals at https best manuals com ...

Page 6: ...1 1 1 1 9813 3850 2 Introduction Identifying Your Machine For information about identifying your machine and its main components refer to Operator s Manual Introduction Identifying Your Machine Find manuals at https best manuals com ...

Page 7: ...Section 1 General Information Introduction Identifying Your Machine 1 2 1 2 9813 3850 2 Page left intentionally blank Find manuals at https best manuals com ...

Page 8: ... 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...

Page 9: ...Section 1 General Information Safety Introduction 1 4 1 4 9813 3850 2 Page left intentionally blank Find manuals at https best manuals com ...

Page 10: ...opic contains information about the structure of the manual and how to use the manual K Scope T 1 6 K Personnel T 1 6 K Newest Data T 1 6 K Format T 1 7 K Left Side Right Side T 1 7 K Hydraulic Schematic Codes T 1 8 K Colour Codes T 1 8 Find manuals at https best manuals com ...

Page 11: ...onnel 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 ...

Page 12: ...intenance 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 change...

Page 13: ...ation 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...

Page 14: ...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 ...

Page 15: ...Section 1 General Information Routine Maintenance Maintenance Schedules 1 10 1 10 9813 3850 2 Page left intentionally blank ...

Page 16: ...draulic 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...

Page 17: ...int 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 fo...

Page 18: ... 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 sh...

Page 19: ...3 Adaptor M20 x 5 8 UNF 9 993 68109 Adaptor M20 x M12 4 993 68104 Adaptor M20 x 1 UNF 10 993 68110 Adaptor M20 x 5 8 UNF Shoulder 5 993 68105 Adaptor M20 x M20 11 993 68111 Adaptor M20 x 1 2 UNF 6 993 68106 Adaptor M20 x M24 Fig 3 892 00842 Glass Lifter Minimum 2 off Essential for glass installation 2 required to handle large panes of glass Ensure suction cups are protected from damage during stor...

Page 20: ... Fig 6 892 00846 Glass Extractor Handles Used with braided cutting wire to cut out broken glass K Fig 9 T 1 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 K Fig 9 T 1 16 ...

Page 21: ...it quantity 500 off Fig 11 992 12300 Mobile Oven 12V 1 cartridge capacity Required to pre heat adhesive prior to use It is fitted with a male plug 703 23201 which fits into a female socket 715 04300 Fig 12 992 12400 Static Oven 240V Required to pre heat adhesive prior to use No plug supplied Note 110V models available upon request contact JCB Technical Service Fig 13 992 12800 Cut Out Knife Used t...

Page 22: ...ction 1 General Information Service Tools Section B 1 17 1 17 9813 3850 1 Fig 15 4104 1310 Hand Cleaner Special blend for the removal of polyurethane adhesives 454g 1 lb tub Fig 16 332 H1950 LMI Test Box ...

Page 23: ... Section C 1 18 1 18 9813 3850 1 Section C Fig 17 892 00298 Fluke Meter Fig 18 892 00285 Hydraulic Temperature Probe Fig 19 892 00284 Venture Microtach Digital Tachometer Fig 20 993 85700 Battery Tester Fig 21 998 11051 Digital Pressure Test Set ...

Page 24: ... x 3 8 in 1606 0015 1 in x 1 1 4 in Fig 23 Pressure Test Adapters 892 00255 1 4 in BSP x Test Point 892 00256 3 8 in BSP x Test Point 892 00257 1 2 in BSP x Test Point 892 00258 5 8 in BSP x Test Point 816 15118 3 4 in BSP x Test Point 892 00259 1 in BSP x Test Point 892 00260 1 1 4 in BSP x Test Point 892 00261 5 8 in UNF x Test Point Fig 24 Pressure Test T Adapters 816 55045 1 4 in M BSP x 1 4 i...

Page 25: ...26 Female Blanking Caps 892 00055A 1 4 in BSP 892 00056A 3 8 in BSP 892 00057 1 2 in BSP 892 00058A 5 8 in BSP 892 00059A 3 4 in BSP 892 00060 1 in BSP Fig 27 Male Cone Blanking Caps 816 90045 1 4 in BSP 816 00189A 3 8 in BSP 816 00190A 1 2 in BSP 816 90022 5 8 in BSP 816 90274 3 4 in BSP 816 90205 1 in BSP Fig 28 Female Connectors 892 00074 3 8 in BSP x 3 8 in BSP 892 00075 1 2 in BSP x 1 2 in BS...

Page 26: ...022 For 60 mm Rod Diameter slew ram 892 01023 For 65 mm Rod Diameter 892 01024 For 70 mm Rod Diameter 892 01025 For 75 mm Rod Diameter 892 01026 For 80 mm Rod Diameter 892 00167 For 90 mm Rod Diameter Fig 31 892 00334 Ram Seal Fitting Tool Fig 32 Hexagon Spanners for Ram Pistons and End Caps 992 09300 55mm A F 992 09400 65mm A F 992 09500 75mm A F 992 09600 85mm A F 992 09700 95mm A F 992 09900 11...

Page 27: ...2 00271 Adapter 3 4 in F x 5 8 in M BSP 892 00272 Adapter 5 8 in F x 3 4 in M BSP 816 20008 Adapter 3 4 in F x 1 2 in M BSP 892 00275 Adapter 1 2 in F x 3 4 in M BSP 892 00276 Adapter 3 4 in F x 3 8 in M BSP 892 00277 Adapter 3 8 in F x 3 4 in M BSP 1606 0015 Adapter 1 1 4 in M BSP x 1 in M BSP 892 00078 Connector 1 in F x 1 in F BSP 1604 0008 Adapter 1 in M x 1 in M BSP 1606 0012 Adapter 1 in M x...

Page 28: ...0 Seal Kit for 892 00254 can also be used with probe 892 00706 892 00706 Test Probe 892 00347 Connector Hose to gauge Fig 37 998 11051 JCB ServiceMaster Digital Hydraulic Datalogger Pressure Test Kit 998 11052 Hand Held 4 Channel ServiceMaster Unit 998 11053 SensoWin Software Kit and PC Cable 998 11054 Equiment Case SCC 750 998 11055 0 600 Bar Pressure Transduce x2 998 11056 0 100 Bar pressureTran...

Page 29: ...st Point 892 00706 Test Probe 892 00278 Gauge 0 40 bar 0 600 lbf in2 892 00279 Gauge 0 400 bar 0 6000 lbf in2 Fig 39 Hydraulic Circuit Test Gauges and Connections 892 00280 Pressure Gauge 0 600 bar 0 9000 lbf in2 892 00279 Pressure Gauge 0 400 bar 0 6000 lbf in2 892 00346 Pressure Gauge 0 70 bar 0 1000 lbf in2 892 00347 Connector 892 00254 Hose Fig 40 892 00881 Valve Spool Seal Fitting Tool Fig 41...

Page 30: ... Fig 43 892 01042 Nitrogen Charging Tool Kit 892 01043 Connector Fig 44 892 00309 A R V Pressure Test Kit For 4CX Variable Flow machines use 25 201103 1 892 00340 Test Block Body 2 892 00341 Setting Body 3 993 68300 Adjusting Pin 4 892 00343 Spanner 5 892 00345 Anti cavitation Lock Out Bung 6 892 00335 A R V Cartridge Removal Tool ...

Page 31: ...Section 1 General Information Service Tools Section E 1 26 1 26 9813 3850 1 Fig 45 825 10053 Pilot Hose Release Tool 892 01043 Connector ...

Page 32: ...3 4 in F x 3 4 in M BSP 892 00271 Adapter 3 4 in F x 5 8 in M BSP 892 00272 Adapter 5 8 in F x 3 4 in M BSP 816 20008 Adapter 3 4 in F x 1 2 in M BSP 892 00275 Adapter 1 2 in F x 3 4 in M BSP 892 00276 Adapter 3 4 in F x 3 8 in M BSP 892 00277 Adapter 3 8 in F x 3 4 in M BSP 1606 0015 Adapter 1 1 4 in M BSP x 1 in M BSP 892 00078 Connector 1 in F x 1 in F BSP 1604 0008 Adapter 1 in M x 1 in M BSP ...

Page 33: ...0 Seal Kit for 892 00254 can also be used with probe 892 00706 892 00706 Test Probe 892 00347 Connector Hose to gauge Fig 49 998 11051 JCB ServiceMaster Digital Hydraulic Datalogger Pressure Test Kit 998 11052 Hand Held 4 Channel ServiceMaster Unit 998 11053 SensoWin Software Kit and PC Cable 998 11054 Equiment Case SCC 750 998 11055 0 600 Bar Pressure Transduce x2 998 11056 0 100 Bar pressureTran...

Page 34: ...Item Description 1 460 15707 Banjo bolt 2 2401 0222 O ring 3 2403 0110 O ring 4 2403 0108 O ring 5 1604 0004 Adaptor 2 off 6 1406 0018 Sealing washer 2 off A313250 C1 1 3 4 2 6 5 Fig 51 892 00301 Flow Test Adaptor Note Components listed as follows also required Item Description 1 892 00920 Adaptor 2 892 00302 Adaptor Fig 52 332 F1311 Neutral Locking Tool ...

Page 35: ...13 3850 1 Fig 53 892 00812 Drive Coupling Spanner Fig 54 892 00822 Splined Bolt Socket Fig 55 992 04000 Torque Multiplier Fig 56 892 00913 Grease Gun Attachment Fig 57 892 00964 Test Point 1 8 BSP Fig 58 892 00965 Test Point 3 8 BSP Fig 59 892 00966 Test Point 1 4 BSP ...

Page 36: ...change between the machine ECU Electronic Control Unit and laptop PC loaded with the applicable ShiftMaster diagnostics software 2 Interconnecting cable DLA to laptop PC Several cables are included to enable compatibility with different PC port types 3 Kit carrying case Fig 61 892 01096 Speed Sensor Test Harness A406130 C1 711300 C1 Fig 62 721 10885 Interconnecting Cable Use with 892 01033 A406130...

Page 37: ...of a special transmission jack is strongly recommended This jack can also be used when removing Synchro Shuttle gearboxes Note The jack must be used with special support plates Manufacture the plates locally refer to Figs 64 65 and 66 Rear Jack Plate 4 and 6 speed Powershift Manufacture locally from 5 mm thick mild steel plate Fig 64 A402680 A706940 C1 ...

Page 38: ...Section F 1 33 1 33 9813 3850 1 Front Jack Plate 6 speed Powershift Manufacture locally from 5 mm thick mild steel plate Fig 65 Front Jack Plate 4 speed Powershift Manufacture locally from 5 mm thick mild steel plate Fig 66 A706940 C2 A706940 C3 ...

Page 39: ...67 892 01110 Torque Converter Alignment Tool Note Use with 12 and W300 torque converters A A SECTION A A 30 2 30 1 43 4 43 3 57 0 REF 2 DOWELS 8 0 12 0 10 0 TYP 10 0 TYP 10 0 x 45 TYP 1 0 65 0 171 0 185 0 342 0 370 0 0 3 X 2 DOWELS 8 x 32 LONG PRESS FIT 0 3 X 5 3 x 35 25 X A436700 ...

Page 40: ...tting Tool Seal Fitting Tool for fitting O ring and back up ring to Danfoss Orbitrol Unit 892 00181 Replacement Plastic Boss Fig 69 Hexagon Spanners For ram pistons and end caps 992 09300 55mm A F 992 09400 65mm A F 992 09500 75mm A F 992 09600 85mm A F 992 09700 95mm A F 992 09900 115mm A F 992 10000 125mm A F ...

Page 41: ...This as a preview PDF file from best manuals com Download full PDF manual at best manuals com ...