JCB 530-120 Telehandler Service & Repair Manual

PUBLISHED BY THE TECHNICAL PUBLICATIONS DEPARTMENT OF JCB SERVICE; © ROCESTER,STAFFORDSHIRE, ST14 5LS, ENGLAND Tel. ROCESTER (01889) 590312 PRINTED IN ENGLAND Publication No. 9803/3600 Service Manual 500 Series From m/c No. 561001

Contents 9803/3600 Issue 8* This Service Manual covers the following Machines:- 525-58 and 525-58 Farm Special - from machine Serial Number 561001 525-67 and 525-67 Farm Special - from machine Serial Number 561001 525-58 and 525-67 Farm Special Plus 525-58 and 525-67 Basic Servo Options 527-58 and 527-67 - from machine Serial Number 572775 530-95 - from machine Serial Number 564980 530-110 - from machine Serial Number 563359 530-110 and 530-120 - PlaceAce 530-110 and 530-120 Servo Options 530-120 - from machine Serial Number 562601 530-67 and 530-67 Farm Special - from machine Serial Number 571001 535-67 - from machine Serial Number 572775 537-120 and 537-130 from machine Serial Number 572900 Information covers two stage and three stage boom machines. General 1 Hydraulics 2 Body and Framework 3 PlaceAce Control System 4 Servo Control System 4A Engine 5 Transmission 6 Axles 7 Brakes 8 Hydraulic Steering 9 Electrics 10 Service Tools 11 Index *

Contents 9803/3600 Issue 2* Introduction This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training by JCB Technical Training Department. It is assumed that these personnel have a sound knowledge of workshop practice, safety procedures, and general techniques associated with the maintenance and repair of hydraulic earthmoving equipment. Therefore these basic subjects generally are omitted from this manual, the intention being to convey only more specialised information concerning particular aspects of a machine or component. For example, renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of course, and therefore information of this nature is included only in the context of specialised procedures or where a range of wear tolerances is required. Similarly, it is expected that components will be cleaned and lubricated where appropriate, also that any opened hose or pipe connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt. For convenience this manual is compiled in sections, e.g. "Hydraulics", "Electrics", etc. but, to find details of a specific component, reference should be made to the alphabetical index at the back of the book. Illustrations which show a dismantled component are numbered as a guide to the dismantling sequence, which generally can be reversed for assembly. Torque settings are given as a 'mean' figure which 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. Where no figure is quoted in the text, refer to page 1/1 - 3. 'Left Hand' and 'Right Hand' are as viewed from the rear of the machine looking forward. ! WARNING Asbestos Asbestos dust can damage your lungs. Some engine joints and gaskets may contain asbestos. Take the following precautions when working on them. 1 Wear a face mask and gloves. 2 Work in a well ventilated area and do not smoke. 3 Do not use a rotary wire brush, use a hand scraper. 4 Make sure the material to be removed is wet with oil or water to contain loose particles. 5 Place all material into plastic bags and dispose in accordance with local regulations. GEN-1-8 ! WARNING Fluoroelastomeric Materials Certain seals and gaskets (e.g. crankshaft oil seal) on JCB machines contain fluoroelastomeric materials such as Viton, Fluorel and Technoflon. Fluoroelastomeric materials subjected to high temperatures can produce highly corrosive hydrofluoric acid. THIS ACID CAN SEVERELY BURN. New fluoroelastomeric components at ambient temperature require no special safety precautions. Used fluoroelastomeric components whose temperatures have not exceeded 300°C require no special safety precautions. If evidence of decomposition (e.g. charring) is found, refer to the next paragraph for safety instructions DO NOT TOUCH COMPONENT OR SURROUNDING AREA. Used fluoroelastomeric components subjected to temperatures greater than 300°C (e.g. engine fire) must be treated using the following safety procedure. Make sure that heavy duty gloves and special safety glasses are worn: 1 Ensure that components have cooled then remove and place material into plastic bags. 2 Thoroughly wash contaminated area with 10% calcium hydroxide or other suitable alkali solution, if necessary use wire wool to remove burnt remains. 3 Thoroughly wash contaminated area with detergent and water. 4 Contain all removed material, gloves etc. used in this operation in sealed plastic bags and dispose of in accordance with Local Authority Regulations. DO NOT BURN FLUOROELASTOMERIC MATERIALS. If contamination of skin or eyes occurs, wash the affected area with a continuous supply of clean water or with calcium hydroxide solution for 15-60 minutes. Get medical attention immediately. INT-3-3-5/1

Colour Coding The following colour coding, used on illustrations to denote various conditions of oil pressure and flow, is standardised throughout JCB Service publications. 9803/3600 Issue 1 A390940 Full Pressure Pressure generated from operation of a service. Depending on application this may be anything between neutral circuit pressure and M.R.V. operating pressure. Pressure Pressure that is above neutral circuit pressure but lower than that denoted by red. Servo Oil pressure used in controlling a device (servo). Neutral Neutral circuit pressure. Exhaust Cavitation Oil subjected to a partial vacuum due to a drop in pressure (cavitation). Lock Up Oil trapped within a chamber or line, preventing movement of components (lock up). Red Pink Orange Blue Green Light Green Yellow

General Issue 3* i 1 9803/3600E 1 i Contents Page No. Fluids, Lubricants, Capacities & Specifications - 525-58/67, 527-58/67 & 530-95 1 - 1 - 530-110 1 - 2 - 530-120, 537-120 & 537-130 1 - 2A - 525-58 Farm Special Plus 530-67 & 535-67 1 - 2B - Torque Settings 1 - 3 - Identifing Your Machine 1 - 4 Service Schedules 2 - 1 Greasing Pivot Pins - 525-58/67, 527-58/67, 530-67 & 535-67 3 - 1 - 530-120 3 - 2 - 530-110 3 - 3 - 530-95 3 - 4 Front Axle 3 - 5 Rear Axle 3 - 6 Carriage Lock Pins 3 - 7 Boom Wear Pad Runways 3 - 8 Extension Ram Pivots - 525-58/67, 527-58/67, 530-67/95 & 535-67 3 - 9 - 530-120 3 - 10 - 530-110 3 - 11 Oiling 3 - 12 Boom Safety Strut 4 - 1 *

1 - 1 1 General 9803/3600 1 1 - 1 Issue 7* FLUIDS, LUBRICANTS, CAPACITIES AND SPECIFICATIONS (525-58, 67, 527-58, 67, 530-95) Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run- in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below. ITEM CAPACITY FLUID/LUBRICANT INTERNATIONAL Litres (Gal) SPECIFICATION Fuel Tank 90 (20) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D Engine (Oil) 10 (2.2) JCB 15W/40 Multigrade SAE15W/40, MIL-L-46152B, -10 °C to 50 °C (14 °F to 122 °F) API CD/SE, MIL-L-2104 JCB Super Universal Agricultural SAE10W/30, MIL-L-2105, MIL-L-46152 -15 °C to 30 °C (5 °F to 86 °F) API CD/SE, MIL-L-2104C JCB Torque Converter Fluid SAE10W, MIL-L-46152, MIL-L-2104D -18 °C to 0 °C (0 °F to 32 °F) API CD/SE Engine (Coolant) 17 (3.7) JCB Universal Antifreeze/water ASTM D3306-74 ( See Coolant Mixtures) Gearbox Syncro Shuttle 18.25 (4.0) JCB Special Transmission Fluid ESP-M2C 33G Powershift †15.0 (3.3) JCB Special Transmission Fluid ESP-M2C 33G Front Axle Housing 18 (3.9) JCB Special Gear Oil ESEN-M2C 86A/B Hubs (x2) 2.0 (0.4) JCB Special Gear Oil ESEN-M2C 86A/B Rear Axle Housing 13 (2.8) JCB Special Gear Oil ESEN-M2C 86A/B Hubs (x2) 2.0 (0.4) JCB Special Gear Oil ESEN-M2C 86A/B Brake System JCB Light Hydraulic Fluid ISO VG15 DO NOT USE ORDINARY BRAKE FLUID Hydraulic Tank *152 (33.5) JCB High Performance Hydraulic Oil ISO VG46 (Above 38 °C, 100 °F) JCB Special Hydraulic Fluid ISO VG32 (Below 38 °C, 100 °F) Grease Points JCB Special MPL Grease Lithium based, No. 2 consistency Wear Pad Runways JCB Waxoyl Boom Hoses JCB Special Slide Lubricant * Note: This is nominal machine capacity. The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level sight glass when filling. † Note: This is a system capacity. Use the 'MIN' and 'MAX' marks on the dipstick when refilling the system. Coolant Mixtures % Antifreeze Starts to Freeze 55 9.35 litres (2.04 gal) -36° C (-33 °F) * *

1 - 2 1 General 9803/3600 1 1 - 2 Issue 8* Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run- in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below. ITEM CAPACITY FLUID/LUBRICANT INTERNATIONAL Litres (Gal) SPECIFICATION Fuel Tank 90 (20) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D Engine (Oil) Engine Type: 10 (2.2) JCB Super Multigrade 15W/40 SAE15W/40 AA, AB, AR & AK -10°C to 50°C (14°F to 122°F) API CF4/SG Builds JCB Super Multigrade 10W/30 SAE 10W/30 -15°C to 40°C (5°F to 104°F) API CF4/SG Engine Type: JCB Super Universal Agricultural SAE10W/30 AA & AB Builds -15°C to 30°C (5°F to 86°F) API CD/SE Only JCB Torque Converter Fluid SAE10W -18°C to 0°C (0°F to 32°F) API CD/SE Engine (Coolant) JCB Four Seasons Antifreeze ASTM D3306-74 System 18 (3.9) And Summer Coolant Antifreeze 10 (2.2) ( See Coolant Mixtures) Syncro Shuttle 18.25 (4.0) JCB Special Transmission Fluid ESP-M2C 33G Axles Housing (Front) 18 (3.9) JCB High Performance Gear Oil API GL4 Housing (Rear) 13 (2.8) Hubs (x2) 2.0 (0.4) Brake System JCB Light Hydraulic Fluid ISO VG15 DO NOT USE ORDINARY BRAKE FLUID Hydraulic Tank (*) 190 (41.8) JCB High Performance Hydraulic Oil ISO VG46 (Above 38°C, 100°F) JCB Special Hydraulic Fluid ISO VG32 (Below 38 °C, 100 °F) JCB Light Hydraulic Fluid ISO VG15 (For Iceland, Norway, Sweden and Finland ONLY) Grease Points (**) JCB HP Grease Lithium complex NLGI No. 2 consistency including extreme pressure additives JCB Special MPL-EP Grease Lithium based NLGI No. 2 consistency including extreme pressure additives Wear Pad Runways JCB Waxoyl Boom Hoses JCB Special Slide Lubricant (*) Note: This is nominal machine capacity. The total hydraulic system capacity depends on the equipment being used. Fill and check with all rams closed. Watch level sight glass when filling. (**) Note: If JCB MPL Grease is used, all 50 hour greasing operations must be carried out at TEN (10) HOUR intervals; all 500 hour greasing operations must be carried out at 50 HOUR intervals. FLUIDS, LUBRICANTS, CAPACITIES AND SPECIFICATIONS (530-110)

1 - 2A 1 General 9803/3600 1 1 - 2A Issue 2* Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run- in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below. ITEM CAPACITY FLUID/LUBRICANT INTERNATIONAL Litres (Gal) SPECIFICATION Fuel Tank 90 (20) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D Engine (Oil) 10 (2.2) JCB 15W/40 Multigrade SAE15W/40, MIL-L-46152B, -10 °C to 50 °C (14 °F to 122 °F) API CD/SE, MIL-L-2104 JCB Super Universal Agricultural SAE10W/30, MIL-L-2105, MIL-L-46152 -15 °C to 30 °C (5 °F to 86 °F) API CD/SE, MIL-L-2104C JCB Torque Converter Fluid SAE10W, MIL-L-46152, MIL-L-2104D -18 °C to 0 °C (0 °F to 32 °F) API CD/SE Engine (Coolant) 23.5 (5.2) JCB Universal Antifreeze/water ASTM D3306-74 ( See Coolant Mixtures) Syncro Shuttle 18.25 (4.0) JCB Special Transmission Fluid ESP-M2C 33G Front Axle Housing 17 (3.7) JCB Special Gear Oil ESEN-M2C 86A/B Hubs (x2) 2.0 (0.4) JCB Special Gear Oil ESEN-M2C 86A/B Rear Axle Housing 18 (3.9) JCB Special Gear Oil ESEN-M2C 86A/B Hubs (x2) 0.75 (0.16) JCB Special Gear Oil ESEN-M2C 86A/B Brake System JCB Light Hydraulic Fluid ISO VG15 DO NOT USE ORDINARY BRAKE FLUID Hydraulic Tank †292 (64.3) JCB High Performance Hydraulic Oil ISO VG46 (Above 38 °C, 100 °F) JCB HP32 ISO 32 (Below 38 °C, 100 °F) Grease Points JCB Special MPL Grease Lithium based, No. 2 consistency Wear Pad Runways JCB Waxoyl Boom Hoses JCB Special Slide Lubricant † Note: This is nominal machine capacity. The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level sight glass when filling. Coolant Mixtures % Antifreeze Starts to Freeze 55 12.92 litres (2.84 gal) -36° C (-33 °F) FLUIDS, LUBRICANTS, CAPACITIES AND SPECIFICATIONS (530-120, 537-120 & 537-130) * * *

JCB 530-120 Telehandler Service & Repair Manual

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