jcb JZ 70, Service Manual

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Page 22: ...al TRACK ROLLERS AND IDLER WHEEL Engine Oil see separate chart HYDRAULIC SYSTEM JCB Special Hydraulic Vickers 35VQ25 V104C 92 litres Fluid HP46 Sundstrand Denison and 20 26 UK gal FZG Approval Tests 2...

Page 23: ...rbon dioxide dry chemical or foam Fire fighters should use self contained breathing apparatus Hygiene Storage Handling New Oil Used Oil 1 2 3 a b c d e f g h Waste Disposal Spillage Routine Maintenanc...

Page 24: ...ters when using a Breaker The hydraulic oil must be sampled and checked for contamination and degradation at the intervals shown Use Frequency Use Frequency Use Frequency Use Frequency 100 40 20 10 It...

Page 25: ...obs plus 2 Clean a b 3 Grease a Every 100 Operating Hours or 2 Weekly Whichever occurs first 1 Do a 50 hour service plus 2 Clean a b 3 Change a b c d e f g h 4 Check Engine Stopped a b c d e f g h i j...

Page 26: ...ine Stopped a b c d e f 6 Check Engine Running a b c Every 1000 Operating Hours or 6 Monthly Whichever occurs first 1 Do a 500 hour service plus 2 Clean a b 3 Change Engine Stopped a b c d e f g 4 Che...

Page 27: ...Every 5000 Operating Hours or 2 Years 6 Months Whichever occurs first 1 Do a 1000 hour service plus 2 Change a b c Routine Maintenance...

Page 28: ...ocations 1 Make the Machine Safe 2 Grease the Slew Ring a A B b C 3 Slew the Machine 4 Refit the Cover B A Slew Ring Bearing D WARNING You will be working close into the machine for these jobs Lower t...

Page 29: ...r End Standard Boom 19 Grease points WARNING You will be working close into the machine for these jobs Lower the attachments if possible Remove the starter key and disconnect the battery This will pre...

Page 30: ...rking close into the machine for these jobs Lower the attachments if possible Remove starter key and disconnect the battery This will prevent the engine being started Excavator End Offset Boom 27 Grea...

Page 31: ...before connecting or disconnecting the battery When you have installed the battery in the machine wait five minutes before connecting it up CAUTION Do not disconnect the alternator the battery or any...

Page 32: ...y Keep the electrolyte away from your clothes skin mouth and eyes Wear safety glasses INT 3 2 1 3 CAUTION Damaged or spent batteries and any residue from fires or spillage should be put in a closed ac...

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Page 42: ...r Side Changing the Track Gearbox Oil 1 Prepare the Machine Checking the Track Gearbox Oil Level 2 Drain the Oil on One Side a B Fluids and Lubricants Capacities and Specifications CAUTION Oil will gu...

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Page 83: ...oystick Control 3 Monitor Panel 4 Dozer Blade Lever 5 Foot Rest 6 Right Hand Track Control 7 Left Hand Track Control 8 Travel Speed Range Change Switch 9 Left Excavator Joystick Control 10 Control Loc...

Page 84: ...Right Console 1 Starter Switch 2 Throttle Dial...

Page 85: ...9 One Touch Idle Switch 10 Auxiliary Circuit Switch...

Page 86: ...Left Console 1 Hammer Auxiliary Switch 2 Horn Switch Control Lock Lever Left Console Servo Isolator Switch...

Page 87: ...S S STANDARD MODE L LIGHT MODE 3 Set Switch 4 ACK Switch 5 Scroll Up Switch 6 Scroll Down Switch 7 Warning lamps Monitor Panel CAUTION All the warning lights should go out when the engine is started R...

Page 88: ...Coolant Level Not used Engine Oil Filter Blocked Not used Slew Lock ON Servo Isolator ON Engine Air Filter Blocked Not used Low Hydraulic Oil Level Not Used Direction Indicator Not used Hazard Warnin...

Page 89: ...el cont d Set Switch This allows the operator to change the settings of some of the machine s functions Set clock Use to adjust the displayed time Language Used to change the language of the display m...

Page 90: ...e in ohms OIL PRESS Low oil pressure OVER RIDE Solenoid over ride system for test PERC Percent PILOT SWITCH Pilot pressure switch PREHEAT Engine preheat on Glow plugs RES FUEL Reserve level in fuel ta...

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Page 92: ...Electrics...

Page 93: ...Throttle dial input Potentiometer type input Throttle dial input Potentiometer type input Throttle dial Throttle position sensor Water temp sensor Hyd oil temp sensor Fuel level sensor Engine temp in...

Page 94: ...Electrics Output Output EMS Actuator solenoid motor bulb horn relay Proportional solenoid EMS 24v...

Page 95: ...Electrics Current Time Time Voltage 4 5 5 4 ON 1cycle Current Current 75 Duty cycle 5 4 A B...

Page 96: ...cs EMS EMS Input Output Red lead Red lead Switch lights engine preheat etc Actuator solenoid motor bulb horn relay Black lead Black lead V V A EMS IN OUT Vbb Driver ST A Output supply 24v Pull up Resi...

Page 97: ...Functional Description The following notations are used in the functional description circuit drawings Circuit Symbols Electrics...

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Page 104: ...Electrics 0 5000 10000 15000 20000 25000 30000 35000 40000 10 0 10 20 30 40 50 60 70 80 90 100 110 120 Temperature deg C...

Page 105: ...Electrics 0 5000 10000 15000 20000 25000 30000 35000 40000 10 10 30 50 70 90 110 Temperature deg C...

Page 106: ...Electrics...

Page 107: ...Electrics A358380...

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Page 118: ...Electrics 35 34 33 32 31 30 29 28 27 26 25 24 36 23 22 21 20 19 MONITOR EMS C203 17 16 15 14 13 12 11 10 9 8 7 6 18 5 4 3 2 1 A358470...

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Page 162: ...A354050...

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Page 164: ...A354060 P pN piN pZ pi2 R 280 300 bar...

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Page 166: ...B1 b1 B2 b2 pi1 A1 a1 A2 a2 A356840...

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Page 168: ...A4 C2 A5 A6 B1 S1 S2 B2 B3 B4 B5 B6 pZ pi2 R p pN pi1 280 300 bar A2 a2 B2 b2 P2 B3 b3 a3 A3 bar 305 bar 305 i 54 0 284 bar 284 bar 284 bar 29 9 44 1 cc rev 29 9 44 1 cc rev 284 bar Ps Ps P1 P2 T1 P2...

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Page 174: ...A356830 M A1 C1 A2 A3 A4 C2 A5 A6 B1 S1 S2 B2 B3 B4 B5 B6 B1 Z 11 Z 84 pZ pi2 R P P D Au Mu B A pN pi1 A1 a1 b1 A2 A B T P A PV D C PI2 EC A1 B2 B1 P1 T P2 40...

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Page 178: ...M A356850 B8 b8 A8 P pN piN a8 305 bar 305 bar pZ pi2 R 280 300 bar...

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Page 242: ...H2070...

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Page 244: ...C C D A357430...

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Page 276: ...achine See Track Motor Removal and Replacement Dismantling 1 Unscrew and remove the two plugs 1 A 1 B from the end of the cover Fig 1 2 Remove the elastic ring 2 A using pliers Fig 2 3 Remove the end...

Page 277: ...its seat in the gearbox housing Fig 5 6 Remove the first stage sun gear 6 A Fig 6 7 Remove the first stage reduction assembly 7 A Fig 7 8 Using pliers remove the circlips 8 A from their seats in the...

Page 278: ...3 9803 6030 Fig 9 10 Using the torque multiplier 10 A see Service Tools loosen the nut Fig 10 11 Remove the nut 11 A Fig 11 12 Using the puller and stopper see Service Tools Remove the hydraulic motor...

Page 279: ...Dismantling and Assembly F 4 F 4 9803 6030 Fig 13 14 Remove the bearing inner ring 14 A Fig 14 15 Using the torque multiplier 15 A see Service Tools loosen the nut Fig 15 16 Remove the nut 16 A Fig 1...

Page 280: ...ervice Tools Remove the bearing from the gearbox housing 18 A Fig 18 19 Remove the first half seal 19 A from the hydraulic motor Note In case of oil leakages it may be necessary to check and eventuall...

Page 281: ...Track Gearbox Key 1 Plug 11 Nut Ring 2 Cover Assembly 12 Bearing 3 Pad 13 Spacer 4 Circlip 14 Spacer 5 O Ring 15 O Ring 6 Gearbox Housing 16 Nut Ring 7 Sun Gear 17 Seal 8 First Stage Reduction Assemb...

Page 282: ...asy to trace It is also possible that a failed component may have caused damage to other areas of the valve 1 Carefully clean all components using a suitable degreasing agent 2 Carefully insect all co...

Page 283: ...mpressed air Note Apply a thin film of hydraulic fluid to all sliding parts bearings and other contact surfaces before assembly Note Replace all O rings and seals and thoroughly clean the grooves that...

Page 284: ...0 Fig 26 4 Insert the spacer 27 A Fig 27 5 Fit the bearing outer ring 28 A into the gearbox housing ensuring that it sits correctly Fig 28 Fig 29 6 Using a puller 30 A and pad 30 B see Service Tools P...

Page 285: ...Fig 31 8 Fit the o ring 32 A into its seat in the gearbox housing Fig 32 9 Locate the nut ring 33 A onto the gearbox Fig 33 10 Using the torque multiplier 34 A see Service Tools tighten the nut ring...

Page 286: ...solvent if necessary The surfaces in contact with the O ring 38 C must be perfectly clean and dry b Make sure that the sealing surfaces 38 D of the metal rings are free from scratches and abrasions a...

Page 287: ...0 A by using service tool 40 B Fig 40 16 Assemble the 2nd half seal on the hydraulic motor 41 A by using service tool 41 B Carefully clean the metal faces of the half seals Fig 41 17 Lubricate the sur...

Page 288: ...r until assembly of the unit is complete Fig 44 20 Place the nut ring 45 A into position Fig 45 21 Using the torque multiplier 46 A see Service Tools tighten the nut ring by using a torque wrench to 9...

Page 289: ...to the pins of the hydraulic motor ensuring they sit in the correct position Fig 48 Fig 49 24 By using a puller push the 2nd reduction planet 50 A againt the shoulder of the pins Fig 50 25 Using plier...

Page 290: ...803 6030 Fig 52 27 Fit the 1st stage sun gear 53 A Fig 53 28 Fit the o ring seal 54 A into its seat on the gearbox housing 54 B Fig 54 29 By using a puller push the pad 55 A into its seat on the end c...

Page 291: ...d Assembly F 16 F 16 9803 6030 Fig 56 31 By using pliers fit the elastic ring 57 A into its seat on the gearbox housing Fig 57 32 Fill the gearbox with oil see Section 3 changing Gear Box Oil fit the...

Page 292: ...ng is required the Track Gearbox does not need to be removed Before starting the dismantling drain the oil clean all the surfaces with a suitable solvent and dry with compressed air Discard all O ring...

Page 293: ...he shims 5 A from the plug 5 B being careful not to change their order Remove the o ring 5 C from the plug Fig 5 f Remove the spring 6 A from each relief valve Fig 6 g Take out the spring seat 7 A fro...

Page 294: ...he Base plate a loosen the plugs in the base plate 9 A without removing them Fig 9 b Unscrew the eight socket head screw 10 A in the base plate Fig 10 c Carefully remove the base plate 11 A ensuring p...

Page 295: ...y F 20 F 20 9803 6030 Fig 12 e Remove the valve plate 13 A Fig 13 f By using a puller remove the bearing 14 A from the base plate Fig 14 g Unscrew and remove the plugs 15 A from the base plate Fig 15...

Page 296: ...s 17 A from the base plate and remove the o ring seals Fig 17 j Unscrew the plug 18 A from the base plate and remove the o ring seal from its seat on the plug Fig 18 k Unscrew the plug 19 A from the b...

Page 297: ...g 21 A from the two speed spool 21 B Fig 21 3 Dismantle the Counter Balance Valve a Unscrew the plugs 22 A previously loosened and remove the o ring seals 22 B from their seats on the plugs Fig 22 b R...

Page 298: ...A from the plunger assembly 25 B Fig 25 e Take out the plunger assembly 26 A from the opposite side Fig 26 f Remove the 2nd spring seat 27 A from the plunger Fig 27 Note The restrictor orifice may be...

Page 299: ...ig 28 g Unscrew the orifices 29 A from the base plate Fig 29 4 Dismantle the motor shaft and clyinder block a Remove the springs 30 A from the brake pistion 30 B Fig 30 b Remove the o ring seal 31 A f...

Page 300: ...F 25 9803 6030 Fig 32 d Remove the spherical retainer plate holder 33 A Fig 33 e Remove the pins 34 A from their seats in the cylinder block 34 B Fig 34 f Remove the pistons and the retainer plate 35...

Page 301: ...6 F 26 9803 6030 Fig 36 h by using a puller remove the brake piston 37 A Fig 37 i Remove the o ring seals 38 A and the backup rings from their seats in the brake piston Fig 38 j Remove the brake disc...

Page 302: ...speed control pistons 41 A from the flanged hub Fig 41 m Remove the two speed control springs 42 A from the seats in the flanged hub Fig 42 n Remove the steel balls 43 A from their seats in the flang...

Page 303: ...8 9803 6030 Fig 44 p By using a puller remove the beraring 45 A from the motor shaft 45 B Fig 45 q By using a screwdriver remove the seal 46 A from it s seat in the flanged hub Note Only remove the se...

Page 304: ...Section F Transmission Track Motor Dismantling and Assembly F 29 F 29 9803 6030 Fig 47 Track Motor...

Page 305: ...Swash Plate T5 Counterbalance Spool M11 Piston T6 Orifice M12 Retainer Plate T7 Plug M13 Spherical Retainer Plate Holder T8 O Ring M14 Brake Disc T9 Spring M15 Pin T10 Two Speed Spool M16 Cylinder Bl...

Page 306: ...to trace It is also possible that a failed component may have caused damage to other areas of the motor 1 Carefully clean all components using a suitable degreasing agent 2 Carefully insect all compon...

Page 307: ...re inserting the bearing and shaft make sure that the seal is greased b Using the tool 49 A and rubber hammer push the seal ring against its seat shoulder Fig 49 c Assemble the two steel balls 50 A in...

Page 308: ...haft 53 B Fig 53 g Using a rubber hammer and drift push the bearing 54 A against the motor shaft 54 B shoulder Fig 54 h Place the bearing motor shaft assembly 55 A in the seat inside the flanged hub N...

Page 309: ...ub being careful that the spherical housings matches with the steel balls Fig 57 k Assemble the three pins 58 A in their seats in the cylinder block Fig 58 l Assemble the spherical retainer holder 59...

Page 310: ...be open and free of dust or dirt Fig 61 n Assemble the pistons retainer plate unit 62 A in the cylinder block 62 B Fig 62 o Insert the brake disc 63 A into the cylinder block Fig 63 p Position the fla...

Page 311: ...llowed by the O rings 65 B 65 C and backup ring 65 D into their seats on the brake pistion Fig 65 b Insert the brake piston66 A inside the flanged hub 66 B being careful not to damage the seals alread...

Page 312: ...ase Plate Plugs and Restrictor Orifices a By using a torque wrench tighten the restrictor orifice 70 A in the base plate at 2 5 0 5 Nm Fig 70 b By using a torque wrench tighten plugs 71 A in the base...

Page 313: ...bearing 73 A into its seat in the base plate Fig 73 e Place the valve plate 74 A on to the base plate Fig 74 Note The bronze layer surface must be upwards i e Facing away from the base plate f Fit th...

Page 314: ...77 Note The base plate is centered by the two pins and the second speed oil passages must match h Fix the base plate to the flanged hub by the eight socket head screws 78 A Tighten to 128 7 Nm Fig 78...

Page 315: ...A into the two speed spool 81 B Fig 81 d Insert the two speed spool 82 A in the base plate Fig 82 Note Make sure the two speed spool can move smoothly within the base plate e By using a stopper fit o...

Page 316: ...rque wrench tighten orifices 85 A into base plate at 2 5 0 5 Nm Fig 85 b By using a punch deform the threaded hole c Insert the first spring seat 86 A on the counterbalance valve spool 86 B Fig 86 d I...

Page 317: ...mble the o ring seal 89 A in its seat in the 1st plug 89 B Fig 89 g By using a torque wrench tighten the plug 90 A at 325 10 Nm Fig 90 h Insert the 2nd spring seat 91 A in the opposite side of the cou...

Page 318: ...ring seal onto the 2nd plug By using a torque wrench tighten the plug 93 A at 325 10 Nm Fig 93 6 Relief Valve Assembly a Assemble the relief valve 94 A into the valve housing 94 B Fig 94 b Insert the...

Page 319: ...its seat on the plug 97 B Insert the shims 97 C into the plug in the same order that they were removed Fig 97 e Screw the plugs 98 A into the relief valve housing Fig 98 f By using a torque wrench tig...

Page 320: ...ion F Transmission Track Motor Dismantling and Assembly F 45 F 45 9803 6030 Fig 100 h Place the valve housing on the base plate a secure using four socket head screws 101 A tighten to 27 5 31 5 Nm Fig...

Page 321: ...red 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 Nut Adaptor...

Page 322: ...il Reference Section F Transmission F 47 F 47 9803 6030 Tool Detail Reference Section F Transmission Note Not all service tools are illustrated Illustrations are shown in tool number order Fig 1 Note...

Page 323: ...Section F Transmission Service Tools Tool Detail Reference Section F Transmission F 48 F 48 9803 6030 Fig 2 Note For use with torque multiplier...

Page 324: ...Section F Transmission Service Tools Tool Detail Reference Section F Transmission F 49 F 49 9803 6030 Fig 3 Note For disassembly and assembly of track gearbox...

Page 325: ...Section F Transmission Service Tools Tool Detail Reference Section F Transmission F 50 F 50 9803 6030 Fig 4 Note For disassembly and assembly of track gearbox...

Page 326: ...Section F Transmission Service Tools Tool Detail Reference Section F Transmission F 51 F 51 9803 6030 Fig 5 Note For assembly of lifetime seal...

Page 327: ...Detail Reference Section F Transmission F 52 F 52 9803 6030 Fig 6 Plug Size A B C D E 3 8 13 6 10 5 7 5 16 9 18 3 3 4 23 5 14 5 11 5 27 2 28 6 Note For assembly of slew O Ring seals to plugs Fig 7 Not...

Page 328: ...Section F Transmission Service Tools Tool Detail Reference Section F Transmission F 53 F 53 9803 6030 Fig 8 Note For disassembly and assembly of slew motor gearbox...

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