Jcb 525 67 telescopic handler service repair manual all561001 onwards

Service Manual

500 Series From m/c No. 561001

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

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Contents 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

9803/3600

Issue 8*

Contents 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

9803/3600

Issue 2*

Colour Coding The following colour coding, used on illustrations to 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 M.R.V. operating pressure.

Pink

Pressure Pressure that is above neutral circuit pressure but lower than that denoted by red.

Orange

Servo Oil pressure used in controlling a device (servo).

Blue

Neutral 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).

A390940

9803/3600

Issue 1

1

General

1

i

i

Contents Fluids, Lubricants, Capacities & Specifications - 525-58/67, 527-58/67 & 530-95 - 530-110 - 530-120, 537-120 & 537-130 * - 525-58 Farm Special Plus 530-67 & 535-67 - Torque Settings - Identifing Your Machine Service Schedules Greasing Pivot Pins - 525-58/67, 527-58/67, 530-67 & 535-67 - 530-120 - 530-110 - 530-95 Front Axle Rear Axle Carriage Lock Pins Boom Wear Pad Runways Extension Ram Pivots - 525-58/67, 527-58/67, 530-67/95 & 535-67 - 530-120 - 530-110 Oiling Boom Safety Strut

9803/3600E

Page No.

1-1 1-2 1 - 2A 1 - 2B 1-3 1-4 2-1

3-1 3-2 3-3 3-4 3-5 3-6 3-7 3-8 3-9 3 - 10 3 - 11 3 - 12 4-1

Issue 3*

1

General

1

1-1

1-1

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 runin. 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 Litres (Gal)

FLUID/LUBRICANT

INTERNATIONAL 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 -10 °C to 50 °C (14 °F to 122 °F)

SAE15W/40, MIL-L-46152B, API CD/SE, MIL-L-2104

JCB Super Universal Agricultural -15 °C to 30 °C (5 °F to 86 °F)

SAE10W/30, MIL-L-2105, MIL-L-46152 API CD/SE, MIL-L-2104C

JCB Torque Converter Fluid -18 °C to 0 °C (0 °F to 32 °F)

SAE10W, MIL-L-46152, MIL-L-2104D API CD/SE

JCB Universal Antifreeze/water ( See Coolant Mixtures)

ASTM D3306-74

JCB Special Transmission Fluid JCB Special Transmission Fluid

ESP-M2C 33G ESP-M2C 33G

Engine (Coolant)

Gearbox Syncro Shuttle Powershift

17 (3.7)

18.25 (4.0) †15.0 (3.3)

Front Axle Housing Hubs (x2)

18 (3.9) 2.0 (0.4)

JCB Special Gear Oil JCB Special Gear Oil

ESEN-M2C 86A/B ESEN-M2C 86A/B

Rear Axle * Housing * Hubs (x2)

13 (2.8) 2.0 (0.4)

JCB Special Gear Oil JCB Special Gear Oil

ESEN-M2C 86A/B ESEN-M2C 86A/B

JCB Light Hydraulic Fluid

ISO VG15

Brake System

DO NOT USE ORDINARY BRAKE FLUID Hydraulic Tank

*152 (33.5)

JCB High Performance Hydraulic Oil (Above 38 °C, 100 °F) JCB Special Hydraulic Fluid (Below 38 °C, 100 °F)

ISO VG46

Grease Points

JCB Special MPL Grease

Lithium based, No. 2 consistency

Wear Pad Runways

JCB Waxoyl

Boom Hoses

JCB Special Slide Lubricant

ISO VG32

* 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

9803/3600

%

Antifreeze

Starts to Freeze

55

9.35 litres (2.04 gal)

-36° C (-33 °F)

Issue 7*

1

General

1

1-2

1-2

FLUIDS, LUBRICANTS, CAPACITIES AND SPECIFICATIONS (530-110) 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 runin. 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 Litres (Gal)

FLUID/LUBRICANT

INTERNATIONAL SPECIFICATION

Fuel Tank

90 (20)

Diesel Oil (See Types of Fuel)

ASTM D975-66T Nos. 1D, 2D

10 (2.2)

JCB Super Multigrade 15W/40 -10°C to 50°C (14°F to 122°F) JCB Super Multigrade 10W/30 -15°C to 40°C (5°F to 104°F)

SAE15W/40 API CF4/SG SAE 10W/30 API CF4/SG

JCB Super Universal Agricultural -15°C to 30°C (5°F to 86°F) JCB Torque Converter Fluid -18°C to 0°C (0°F to 32°F)

SAE10W/30 API CD/SE SAE10W API CD/SE

Engine (Oil) Engine Type: AA, AB, AR & AK Builds

Engine Type: AA & AB Builds Only

Engine (Coolant) System Antifreeze

JCB Four Seasons Antifreeze And Summer Coolant ( See Coolant Mixtures)

ASTM D3306-74

18 (3.9) 10 (2.2)

Syncro Shuttle

18.25 (4.0)

JCB Special Transmission Fluid

ESP-M2C 33G

Axles Housing (Front) Housing (Rear) Hubs (x2)

18 (3.9) 13 (2.8) 2.0 (0.4)

JCB High Performance Gear Oil

API GL4

JCB Light Hydraulic Fluid DO NOT USE ORDINARY BRAKE FLUID

ISO VG15

JCB High Performance Hydraulic Oil (Above 38°C, 100°F) JCB Special Hydraulic Fluid (Below 38 °C, 100 °F) JCB Light Hydraulic Fluid (For Iceland, Norway, Sweden and Finland ONLY)

ISO VG46

JCB HP Grease

Lithium complex NLGI No. 2 consistency including extreme pressure additives Lithium based NLGI No. 2 consistency including extreme pressure additives

Brake System

Hydraulic Tank (*)

Grease Points (**)

190 (41.8)

JCB Special MPL-EP Grease

Wear Pad Runways

JCB Waxoyl

Boom Hoses

JCB Special Slide Lubricant

ISO VG32 ISO VG15

(*) 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.

9803/3600

Issue 8*

1

General

1

1 - 2A *

1 - 2A

FLUIDS, LUBRICANTS, CAPACITIES AND SPECIFICATIONS (530-120, 537-120 & 537-130) 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 runin. 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 Litres (Gal)

FLUID/LUBRICANT

INTERNATIONAL 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 -10 °C to 50 °C (14 °F to 122 °F)

SAE15W/40, MIL-L-46152B, API CD/SE, MIL-L-2104

JCB Super Universal Agricultural -15 °C to 30 °C (5 °F to 86 °F)

SAE10W/30, MIL-L-2105, MIL-L-46152 API CD/SE, MIL-L-2104C

JCB Torque Converter Fluid -18 °C to 0 °C (0 °F to 32 °F)

SAE10W, MIL-L-46152, MIL-L-2104D API CD/SE

Engine (Coolant)

23.5 (5.2)

JCB Universal Antifreeze/water ( See Coolant Mixtures)

ASTM D3306-74

Syncro Shuttle

18.25 (4.0)

JCB Special Transmission Fluid

ESP-M2C 33G

Front Axle * Housing Hubs (x2)

17 (3.7) 2.0 (0.4)

JCB Special Gear Oil JCB Special Gear Oil

ESEN-M2C 86A/B ESEN-M2C 86A/B

Rear Axle * Housing Hubs (x2)

18 (3.9) 0.75 (0.16)

JCB Special Gear Oil JCB Special Gear Oil

ESEN-M2C 86A/B ESEN-M2C 86A/B

JCB Light Hydraulic Fluid

ISO VG15

Brake System

DO NOT USE ORDINARY BRAKE FLUID Hydraulic Tank

†292 (64.3)

JCB High Performance Hydraulic Oil (Above 38 °C, 100 °F) JCB HP32 (Below 38 °C, 100 °F)

ISO VG46

Grease Points

JCB Special MPL Grease

Lithium based, No. 2 consistency

Wear Pad Runways

JCB Waxoyl

Boom Hoses

JCB Special Slide Lubricant

ISO 32

† 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

9803/3600

%

Antifreeze

Starts to Freeze

55

12.92 litres (2.84 gal)

-36° C (-33 °F)

Issue 2*

1

General

1

1 - 2B

1 - 2B

FLUIDS, LUBRICANTS, CAPACITIES AND SPECIFICATIONS (525-58 Farm Special Plus, 530-67, 535-67) 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 runin. 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 Litres (Gal)

FLUID/LUBRICANT

INTERNATIONAL 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 -10 °C to 50 °C (14 °F to 122 °F)

SAE15W/40, MIL-L-46152B, API CD/SE, MIL-L-2104

JCB Super Universal Agricultural -15 °C to 30 °C (5 °F to 86 °F)

SAE10W/30, MIL-L-2105, MIL-L-46152 API CD/SE, MIL-L-2104C

JCB Torque Converter Fluid -18 °C to 0 °C (0 °F to 32 °F)

SAE10W, MIL-L-46152, MIL-L-2104D API CD/SE

JCB Universal Antifreeze/water ( See Coolant Mixtures)

ASTM D3306-74

JCB Special Transmission Fluid JCB Special Transmission Fluid

ESP-M2C 33G ESP-M2C 33G

Engine (Coolant)

Gearbox Syncro Shuttle Powershift

17 (3.7)

18.25 (4.0) †15.0 (3.3)

Front Axle Housing Hubs (x2)

18 (3.9) 2.0 (0.4)

JCB Special Gear Oil JCB Special Gear Oil

ESEN-M2C 86A/B ESEN-M2C 86A/B

Rear Axle * Housing * Hubs (x2)

13 (2.8) 2.0 (0.4)

JCB Special Gear Oil JCB Special Gear Oil

ESEN-M2C 86A/B ESEN-M2C 86A/B

JCB Light Hydraulic Fluid

ISO VG15

Brake System

DO NOT USE ORDINARY BRAKE FLUID Hydraulic Tank

††152 (34.5)

JCB High Performance Hydraulic Oil (Above 38 °C, 100 °F) JCB Special Hydraulic Fluid (Below 38 °C, 100 °F)

ISO VG46

Grease Points

JCB Special MPL Grease

Lithium based, No. 2 consistency

Wear Pad Runways

JCB Waxoyl

Boom Hoses

JCB Special Slide Lubricant

ISO VG32

†† 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

9803/3600

%

Antifreeze

Starts to Freeze

55

9.35 litres (2.04 gal)

-36° C (-33 °F)

Issue 3*

1

1

General

1-3

1-3

Torque Settings Use only where no torque setting is specified in the text. Values are for dry threads and may be within three per cent of the figures stated. For lubricated threads the values should be REDUCED by one third.

UNF Grade 'S' Bolts Bolt Size in 1

/4

5

/16

3

/8

7

/16

1

/2

9

/16

5

/8

3

/4

7

/8

1 11/4 11/2

(mm) (6.3) (7.9) (9.5) (11.1) (12.7) (14.3) (15.9) (19.0) (22.2) (25.4) (31.7) (38.1)

Hexagon (A/F) in 7

/16

1

/2

9

/16

5

/8

3

/4

13 /16 15 /16

11/8 15/16 11/2 17/8 21/4

Nm 14 28 49 78 117 170 238 407 650 970 1940 3390

Torque Settings kgf m 1.4 2.8 5.0 8.0 12.0 17.3 24.3 41.5 66.3 99.0 198.0 345.0

lbf ft 10 20 36 58 87 125 175 300 480 715 1430 2500

Nm

Torque Settings kgf m

lbf ft

Metric Grade 8.8 Bolts Bolt Size (mm)

*

M5 M6 M8 M10 M12 M16 M20 M24 M30 M36

(5) (6) (8) (10) (12) (16) (20) (24) (30) (36)

Hexagon (A/F) mm 8 10 13 17 19 24 30 36 46 55

7 12 28 56 98 244 476 822 1633 2854

0.7 1.2 3.0 5.7 10 25 48 84 166 291

5 9 21 42 72 180 352 607 1205 2105

Rivet Nut Bolts/Screws Bolt Size M3 M4 M5 M6 M8 M10 M12

(mm) (3) (4) (5) (6) (8) (10) (12)

Torque Settings (for steel rivet nuts) Nm kgf m lbf ft 1.2 0.12 0.9 3.0 0.3 2.0 6.0 0.6 4.5 10.0 1.0 7.5 24.0 2.5 18.0 48.0 4.9 35.5 82.0 8.4 60.5

Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification.

9803/3600

Issue 2*

1

General

1

2-1

Pre-start Cold Checks Service Points and Fluid Levels

2-1

Operation

ENGINE Engine Air Filter Pre-cleaner Clean Coolant Level and Condition Check * Fuel System For Leaks and Contamination Check Oil Level and Condition Check Fuel Filter Drain Fuel Sedimenter Drain and Clean Air Cleaner Dust Valve Clean * Oil and Filter Change Fuel Lift Pump Clean Engine Mounting Bolts Check Fuel Filter Change Air Cleaner Outer Element Change Valve Clearance Check Air Cleaner Inner Element Change Fan Belt Tension/Condition Check * Engine Exhaust for Security Check * Air Inlet for Security Check Radiator Clean All hoses Condition TRANSMISSION AND AXLES Transmission Oil Level Check Tyre Pressures and Condition (see Handbook) Check Tightness of Wheel Nuts Check Axle(s) Oil Level Check Axle(s) Oil Change Hub Oil Levels Check Hub Oil Change Drive Shafts and Universal Joints Grease Steer Axle Pivots and Linkages Grease Wheel Alignment (see Handbook) Check Wheel Bearings Check and Adjust King Pin and Bushes Check and Adjust Transmission Oil Filter Change Transmission Oil Change Transmission Strainer Clean Axle Breathers Check Clear Axle Security Check Transmission Mount Security Check Steering Stops (if fitted) HYDRAULICS Hydraulic Fluid Level System for Leaks Oil Filter Oil (and clean suction strainers)

9803/3600

Check Check Change Sample/Change

Daily Weekly Initial Monthly 6 Monthly Yearly 2 Yearly 10 50 100 250 500 1000 2000 Hr Hr Hr Hr Hr Hr Hr

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Issue 5*

1

General

1

2-2

Pre-start Cold Checks Service Points and Fluid Levels BRAKES Fluid Level Parking Brake Cable Brake System Fluid ELECTRICS Alternator Drive Belt Tension Battery Terminals for Condition and Tightness Wiring Harness for Chafing Battery Electrolyte Level and Condition Starter Motor and Alternator Battery Charge Condition

2-2

Operation

Check Lubricate Change

Daily Weekly Initial Monthly 6 Monthly Yearly 2 Yearly 10 50 100 250 500 1000 2000 Hr Hr Hr Hr Hr Hr Hr

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Check Check Check Check Check Check

ATTACHMENTS Carriage Lock Pins Fork Pivot Pins Optional Attachments (as required) Forks Fit and Check Security

9803/3600

Fill Check Check Clean Check Check

Grease Grease Grease

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BODY AND FRAMEWORK All Pivot Pins Grease Control Lever Linkages Lubricate All Hinges Lubricate * Wear Pad Runways Waxoyl Inner Boom Hoses Grease * Boom Extension Ram Pivot Check and Grease Boom Wear Pad (Machines from S/No. 561001) Check Inner Extension Ram Wear Pad (530-95/110) Replace * Wear Pad Condition Check CAB Windscreen Washer Fluid Level Seat Belt/Seat Security and Condition Fire Extinguisher Cab Heater Filter (if fitted) Wing Mirrors Condition and Security ROPS/FOPS Structure

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Issue 7*

1

General

1

2-3

Functional Test and Final Inspection ENGINE Exhaust Smoke Idle Speed Max Governed Speed Torque Converter Stall Speed Max No Load Speed Throttle System and Control Cable Operation of Stop Control/E.S.O.S. Coolant System for Leaks Engine for Vibration/Noise

2-3

Operation

Daily Weekly Initial Monthly 6 Monthly Yearly 2 Yearly 10 50 100 250 500 1000 2000 Hr Hr Hr Hr Hr Hr Hr

Check Check and Adjust Check and Adjust Check Check Check Check Check Check

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Check Check

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TRANSMISSION AND AXLES Transmission Operation Clutch Pack Pressures * Torque Converter Mainline Pressure Clutch Disconnect/Dump Pedal/Switch Gear Change and Selection 2WD/4WD Selection (if fitted) Forward/Reverse Selection/Operation Neutral Start Operation Reverse Alarm Operation Oil Cooler and Pipework

Check Check Check Check Check Check Check

HYDRAULICS Operation of All Services Steering Operation Main Relief Valve Setting Auxiliary Relief Valve Setting Hose Burst Protection Valves Steer Relief Valve Setting Fan Motor Speed Cooling Pump MRV Pressure * Steer Circuit MRV Pressure Operation of Cooling Fan Motor Servo Remote Operation Hoses/Pipework for Damage or Leaks Piston Rods and Gland Seals Boom Extension Phasing Parallel Lift/Lower Stabiliser Leg Cut-Out Sway Control Main Hydraulic Pump Mounting Load Hold Check Valve

Check Check Check and Adjust Check and Adjust Check Check and Adjust Check and Adjust Check and Adjust Check and Adjust Check Check Check Check Check Check Check Check Check Check Operation

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Check Check and Adjust Check

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BRAKES Foot Brake Operation and Balance Parking Brake Operation Servo Operation (if fitted)

9803/3600

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Issue 8*

1

General

1

2-4

2-4

* Functional Test and Final Inspection ELECTRICS Instrument Readings Warning Lights and Audible Alarm Operation of All Electrical Equipment Operation of Safe Load Indicator Heater Operation Steer Mode Selection Steering Alignment Stabiliser Indication Starter Motor Alternator Cab Switches Proximity Sensors Wiper Motor(s) Safe Load Indicator

Operation

Check Check Check Check Check Check Check Check Check Check Check Check Function Check Calibrate

Daily Weekly Initial Monthly 6 Monthly Yearly 2 Yearly 10 50 100 250 500 1000 2000 Hr Hr Hr Hr Hr Hr Hr

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BODY AND FRAMEWORK Boom Wear Pad Security Inclinometer Operation and Security

Check Check

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CAB Glazing for Correct Fit Tool Kit and Handbook Doors and Hinges Locks and Keys

Check Check Check Check

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PAINTWORK Condition

Check

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ATTACHMENTS Operation Circuit Pressures Optional Equipment (as fitted)

Check Check Check

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9803/3600

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Issue 2*

1 3-2

General

1 3-2

* GREASING (See Section Contents for machine models) For interval see Service Schedule

S146620

9803/3600

Issue 7*

1 3-3

General

1 3-3

* GREASING (See Section Contents for machine models) For interval see Service Schedule

S138700

9803/3600

Issue 7*

1 3-4

General

1 3-4

* GREASING (See Section Contents for machine models) For interval see Service Schedule

S155800

9803/3600

Issue 6*

1

General

1

3-5

3-5

! WARNING

GREASING

Make the machine safe before working underneath it.

Park the machine on level ground, lower the boom.

Apply the parking brake, put the transmission in neutral and stop the engine. Chock both sides of all four wheels.

Front Axle and Driveshaft For interval see Service Schedule Note: Raise the wheels and swing them from lock to lock.

This will ensure full penetration. * All except 530-120

Disconnect the battery, to prevent the engine being started while you are beneath the machine.

GEN-003

1

8 2 3

4

5

9 6

7 0

!

*

530-120 only

1

ÂŁ 2 3

4

9

5 6

@ 7 8 0

!

S138690

9803/3600

Issue 6*

1

General

1

3-6

3-6

! WARNING

GREASING

Make the machine safe before working underneath it.

Park the machine on level ground, lower the boom.

Apply the parking brake, put the transmission in neutral and stop the engine. Chock both sides of all four wheels.

Rear Axle and Driveshaft For interval see Service Schedule Note: Raise the wheels and swing them from lock to lock.

This will ensure full penetration. * All except 530-120

Disconnect the battery, to prevent the engine being started while you are beneath the machine.

GEN-003

*

530-120 only

!

1

7 3

2 9

0

8 6 9803/3600

5

4

Issue 4*

1 3-7

General

1 3-7

GREASING Carriage Lock Pins - Grease Every 50 Hours 2 Grease Points Fork Pivot Pins - Grease Every 250 Hours

138710

9803/3600

Issue 1

1

General

3-8

1 3-8

* GREASING Boom Wear Pad Runways - Every 1000 Hours Remove boom rear cover. With the boom retracted apply Waxoyl to the inner, intermediate and outer boom inner surfaces.

Extend the boom to uncover the inner surfaces as required, refit the boom rear cover.

With the boom fully extended apply Waxoyl evenly over surfaces A. Allow 2-3 hours drying time before retracting the boom.

Apply Slide lubricant to inner hoses and hose runs.

The illustration shown is a 3 stage boom but the procedure applies to all machines.

! CAUTION Waxoyl contains turpentine substitute, which is flammable. Keep flames away when applying Waxoyl.

Waxoyl can take a few weeks to dry completely. Keep flames away during the drying period.

Do not weld near the affected area during the drying period. Take the same precautions as for oil to keep Waxoyl off your skin. Do not breathe the fumes. Apply in a well-ventilated area.

5-3-1-9

S138730

9803/3600

Issue 2*

1

General

3-9

1 3-9

* GREASING (See Section Contents for machine models)

Boom Extension Ram Pivots - Every 1000 Hours Remove inner extension ram pivot pin A and coat with specified grease. Refit pivot pin.

Note: Use another pivot pin to support the ram while greasing the pivot pin.

A

S112050

9803/3600

Issue 2*

1

General

1

3 - 10

3 - 10

* GREASING (See Section Contents for machine models)

Boom Extension Ram Pivots - Every 1000 Hours Remove inner extension ram pivot pin A and coat with specified grease. Refit pivot pin.

Note: Use another pivot pin to support the ram while greasing the pivot pin.

1

A

2

3

S138740

9803/3600

Issue 2*

1

General

1

3 - 11

3 - 11

* GREASING (See Section Contents for machine models) Boom Extension Ram Pivots - Every 1000 Hours Remove inner extension ram pivot pin A and coat with specified grease. Refit pivot pin.

Note: Use another pivot pin to support the ram while greasing the pivot pin.

1

A

2

3

S143500

9803/3600

Issue 2*

1

General

1

3 - 12

3 - 12

OILING The following points should be lightly oiled with engine oil at the periods stated in the service schedule.

3

Control Levers (Not PlaceAce or Servo Machines) Oil the clevis at the bottom of each control lever.

! WARNING Make the machine safe before working underneath it.

Park the machine on level ground, lower the boom. Apply the parking brake, put the transmission in neutral and stop the engine. Chock both sides of all four wheels.

Disconnect the battery, to prevent the engine being started while you are beneath the machine.

GEN-003

1

Parking Brake Cable Oil the clevis at the brake end of the cable. DO NOT allow oil to get on to the brake disc.

S112070

S112070

2

2/4 Wheel Drive Lever (if fitted) Oil the clevis at the end of the lever.

S112070

9803/3600

Issue 2

1

General

1

4-1

4-1

FITTING THE BOOM SAFETY STRUT

! WARNING You could be killed or injured if the boom drops while you are working under it.

Always fit the boom safety strut before working underneath a raised boom.

GEN-004

Fit the boom safety strut as follows: 1

Raise the boom just far enough to fit the strut then stop the engine.

2

Remove the strut from its stowage position and place around the ram piston rod as shown. Fix in place with screw A.

3

Start the engine lower the boom carefully onto the strut.

Stop as soon as the weight of the boom is on the strut.

Remove the boom safety strut as follows: 1

Raise the boom slightly to clear the strut then stop the engine.

2

Remove screw A and remove the strut from the ram.

3

Secure the strut in its stowage position.

A

S138640

9803/3600

Issue 1

2

Hydraulics

2

i

i

Contents Technical Data - 525-58/67, 527-58/67, 530-67 & 535-67 - 530-120 - 530-110 - 530-95 - 537-120 - 537-130 General Description Hydraulic Fluid Level & Filter - All except 530-120, 537-120/130 - 530-120, 537-120/130 Draining Fluid & Cleaning Suction Strainers Hydraulic Tank Removal & Replacement - All except 530-120, 537-120/130 - 530-120, 537-120/130

*

Pump Operation Pump Removal & Replacement - All except 530-120, 537-120/130 - 530-120 up to serial No. 569293 - 530-120 from serial No. 569294 & 537-120/130 Pump Dismantle & Assembly - 530-120, 537-120/130 up to serial No. 577458 - 530-120, 537-120/130 from serial No. 577459 Supplementary Pump (Farm Special Plus, 530-67, 535-67) - Removal & Replacement - Dismantle & Assembly Machine Neutral Circuit (without torsion box cooling) Machine Neutral Circuit (with torsion box cooling) Machine Neutral Circuit (with filter in steer circuit) Machine Neutral Circuit (with supplementary pump) Machine Neutral Circuit (with priority steer/fan pump) Control Valve Block Neutral Circuit Boom Lift Operation (525-67, 527-67, 530-67, & 535-67) Boom Lower Operation (525-67, 527-67, 530-67, & 535-67) Boom Lift Operation (525-58, 527-58) Boom Lower Operation (525-58, 527-58) Hose Burst Operation Boom Extend/Retract Operation (525-58/67, 527-58/67 530-67, 535-67, 530-95) Sway Operation Boom Lift Operation (530-110/120, 537-120/130) Boom Lower Operation (530-110/120, 537-120/130) Boom Extend Regenerative (530-110/120, 537-120/130) Boom Extend High Pressure (530-110/120, 537-120/130) Boom Retract (530-110/120, 537-120/130) Stabiliser Check Valve Operation Stabiliser Operation M.R.V. Operation A.R.V. Operation

9803/3600E

Page No. 1-1 1 - 1A 1 - 1B 1 - 1C 1 - 1D 1 - 1E 1-2

2-1 2 - 1A 2-2 2-3 2-5 3-1 3-3 3-5 3-6 3-7 3 - 8A

3-9 3 - 11 4-1 4 - 2A 4 - 2C 4 - 2E 4 - 2G 4-3 4-5 4-7 4-9 4 - 11 4 - 13 4 - 15 4 - 17 4 - 19 4 - 21 4 - 23 4 - 25 4 - 27 4 - 29 4 - 31 4 - 33 4 - 34

Issue 4*

2

Hydraulics

2

ii

ii

Contents

9803/3600E

Page No.

Control Valve Block Removal & Replacement Control Valve Block Dismantle & Assembly Dual Function Controls Assembly

5-1 5-3 5-5

Pressure Testing

6-1

Lift Rams Removal & Replacement Displacement Rams Removal & Replacement Extension Ram Removal & Replacement (525-58, 527-58) Extension Ram Removal & Replacement - (525-67,527-58, 530-67 & 535-67) Tilt Ram Removal & Replacement Sway Ram Removal & Replacement Tow Hitch Ram Removal & Replacement Inner Extension Ram Removal & Replacement - (530-110/120, 537-120/130) Outer Extension Ram Removal & Replacement - (530-110/120, 537-120/130) Boom Extension Circuit Bleeding Procedure - (530-110/120, 530-120/130) Extension Ram Make Up Valve - (530-110/120, 537-120/130) Boom Hoses Removal & Replacement (530-95) Boom Hoses Chain Track - Removal & Replacement (530-95) Extension Ram Removal & Replacement (530-95) Stabiliser Ram Removal & Replacement Diverter Valve Removal & Replacement Diverter Valve Dismantle & Assembly

7-1 7-3 7-5

Typical Ram Dismantle & Assembly Tow Hitch Ram Dismantle & Assembly Typical Ram with Dowel Head Dismantle & Assembly

8-1 8-3 8-5

Fan Motor Removal, Replacement & Adjustment Fan Motor (Sundstrand) Dismantle & Assembly Fan Motor (Ultra) Dismantle & Assembly

9-1 9-3 9-5

Schematic Hydraulic Circuit - 525-58/67, 527-58/67 & 530-95 up to machine s/n 567217 - 525-58/67, 527-58/67 & 530-95 from machine s/n 567218 - 527-58/67, 535-67 from machine s/n 574296 - All 530-120 & 530-110 up to machine s/n 567217 - 530-110 from machine s/n 567218 - 530-67 & 535-67 - 537-120/130

10 - 1 10 - 3 10 - 4A 10 - 5 10 - 7 10 - 9 10 - 11

7-7 7-9 7 - 11 7 - 13 7 - 15 7 - 17 7 - 19 7 - 20 7 - 21 7 - 23 7 - 25 7 - 27 7 - 29 7 - 30

Issue 4*

2

Hydraulics

2

1-1

1-1

* TECHNICAL DATA (525-58, 67, 527-58, 67, 530-67 & 535-67) Pump Type Flow at max. engine rev/min — at zero pressure — at system pressure

Sundstrand SP/230/40, gear type 88.0 litres/min 84.0 litres/min

19.4 UK gal/min 18.5 UK gal/min

Supplementary Pump (Farm Special Plus & 530-67, 535-67) * Type Ultra IPR/009/CT/DT/BE/8451 Flow at max. engine rev/min — at zero pressure 19.8 litres/min 4.4 UK gal/min — at system pressure 17.8 litres/min 4.0 UK gal/min Control Valves Type Services Operated — Spool 1 — Spool 2 — Spool 3 — Spool 4 — Spool 5 — Spool 6 Relief Valve Operating Pressures Main Relief Valve (MRV) Auxiliary Relief Valves (ARV) — Attachments — Carriage Tilt, head side — Carriage Tilt, rod side — Hydraulic Tow Hitch lower (head side) — Hydraulic Tow Hitch raise (rod side) — Sway, head side — Sway, rod side Note: On later machines the sway ARVs are not fitted

Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer Fan Motor Type Max fan speed at Max engine rev/min NAT ASP engine TURBO engine

5.3 US gal/min 4.8 US gal/min

Kontak, parallel service, double acting spools.

Boom Raise & Lower Boom Extend & Retract Auxiliary (see note) Carriage Tilt Auxiliary (see note) Auxiliary (see note) bar 220

kgf/cm2 224

lbf/in2 3200

138 138 275 96 172 131 165

140 140 281 98 176 133 168

2000 2000 4000 1400 2500 1900 2400

Rams Boom Lift - 525-58, 527-58 Boom Lift - 525-67, 527-58, 530-67, 535-67 Boom Extension - 525-58, 527-58 * Boom Extension - 525-67, 527-58, 530-67, 535-67 Tilt Ram * Displacement * Tow Hitch * Sway Ram Sway Ram (later machines)

23.2 US gal/min 22.2 US gal/min

Bore mm 110 110 70 70 110 110 70 110 110

in 4.3 4.3 2.8 2.8 4.3 4.3 2.8 4.3 4.3

Rod Dia. mm in 60 2.4 60 2.4 50 1.9 50 1.9 50 1.9 50 1.9 30 1.2 50 1.9 50 1.9

Stroke mm 615 807 1700 1968 620 355 220 196 178

in 24.2 31.8 66.9 77.5 24.4 13.9 8.7 7.7 7.0

Partial flow ('spin on') 25 microns (0.001 in) 0.17 bar 125 microns (0.005 in) Sundstrand TFU 200/8, gear type / Ultra 1MR 084C 8784 18 inch fan 20 inch fan 40° C ambient 46° C ambient 40° C ambient 46° C ambient temp. zone temp. zone temp. zone temp. zone 2100 2500 2100 2100 2300 2600

Note: The function of spools 3, 5 & 6 (where fitted) will vary from machine to machine but may include the following: Hydraulic Tow Hitch, Sway Control and Auxiliary Attachment Control.

9803/3600E

Issue 9*

2

Hydraulics

2

1 - 1A

1 - 1A

TECHNICAL DATA (530-120 Only) Pump * Type Flow at max. engine rev/min — at zero pressure — at system pressure

Sundstrand SP/230/50 or Ultra 2PR050, gear type 110.0 litres/min 105.0 litres/min

24.2 UK gal/min 23.0 UK gal/min

29.0 US gal/min 27.6 US gal/min

Control Valves Type Services Operated — Spool 1 — Spool 2 — Spool 3 — Spool 4 — Spool 5 — Spool 6 — Spool 7

Kontak, parallel service, double acting spools.

Boom Raise & Lower Boom Extend & Retract Auxiliary Carriage Tilt Stabiliser Stabiliser Sway

Relief Valve Operating Pressures

bar

kgf/cm2

lbf/in2

Main Relief Valve (M.R.V.) Auxiliary Relief Valves (A.R.V.) — Attachments — Carriage Tilt, head side — Carriage Tilt, rod side — Sway, head side — Sway, rod side Note: On later machines the sway ARVs are not fitted

241

245

3500

138 138 275 131 165

140 140 281 133 168

2000 2000 4000 1900 2400

Rams Boom Lift Boom Outer Extension Boom Inner Extension Tilt Ram Displacement Stabiliser Sway Sway Ram (later machines)

mm 120 120 100 130 130 110 110 110

Bore in 4.7 4.7 3.9 5.1 5.1 4.3 4.3 4.3

Rod Dia. mm in 65 2.5 65 2.5 60 2.3 50 1.9 50 1.9 60 2.3 50 1.9 50 1.9

Stroke mm 1040 3053 3107 695 500 527 196 178

in 40.9 120.1 122.3 27.3 19.6 20.7 7.7 7.0

On machines from serial number 567736 Tilt Ram Displacement

130 130

5.1 5.1

65 65

695 500

27.3 19.6

2.5 2.5

Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer

Partial flow ('spin on') 25 microns (0.001 in) 1.05 bar 125 microns (0.005 in)

Fan Motor Type

Sundstrand TFU 200/8, gear type or Ultra 1MR 084C 8784

Max fan speed at Max engine rev/min

40° C ambient temp. zone 1800 1800

NAT ASP engine TURBO engine

9803/3600E

46° C ambient temp. zone 2500 2500

Issue 5*

2

Hydraulics

2

1 - 1B

1 - 1B

TECHNICAL DATA (530-110 Only) Pump Type Flow at max. engine rev/min — at zero pressure — at system pressure

Sundstrand SP/230/40, gear type 88.0 litres/min 84.0 litres/min

19.4 UK gal/min 18.5 UK gal/min

23.2 US gal/min 22.2 US gal/min

Control Valves Type Services Operated — Spool 1 — Spool 2 — Spool 3 — Spool 4 — Spool 5 — Spool 6

Kontak, parallel service, double acting spools.

Boom Raise & Lower Boom Extend & Retract Auxiliary Carriage Tilt Stabiliser Stabiliser

Relief Valve Operating Pressures

bar

kgf/cm2

lbf/in2

Main Relief Valve (M.R.V.) Auxiliary Relief Valves (A.R.V.) — Attachments — Carriage Tilt, head side — Carriage Tilt, rod side

241

245

3500

138 138 275

140 140 281

2000 2000 4000

Rams Boom Lift Boom Outer Extension Boom Inner Extension Tilt Ram Displacement Stabiliser

Bore mm 110 110 90 120 120 100

in 4.3 4.3 3.5 4.7 4.7 3.9

Rod Dia mm in 60 2.3 60 2.3 60 2.3 65 2.5 65 2.5 60 2.3

Stroke mm 1020 2560 2690 495 495 380

in 40.1 100.7 105.9 19.4 19.4 15

Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer

Partial flow ('spin on') 25 microns (0.001 in) 1.05 bar 125 microns (0.005 in)

Fan Motor Type

Sundstrand TFU 200/8, gear type / Ultra 1MR 084C 8784

Max fan speed at Max engine rev/min

40° C ambient temp. zone 1800 1800

NAT ASP engine TURBO engine

9803/3600E

46° C ambient temp. zone 2100 2100

Issue 3*

2

Hydraulics

2

1 - 1C

1 - 1C

TECHNICAL DATA (530-95 Only) Pump Type Flow at max. engine rev/min — at zero pressure — at system pressure

Sundstrand SP/230/40, gear type 88.0 litres/min 84.0 litres/min

19.4 UK gal/min 18.5 UK gal/min

23.2 US gal/min 22.2 US gal/min

Control Valves Type Services Operated — Spool 1 — Spool 2 — Spool 3 — Spool 4 — Spool 5 — Spool 6

Kontak, parallel service, double acting spools.

Boom Raise & Lower Boom Extend & Retract Auxiliary (see note) Carriage Tilt Auxiliary (see note) Sway

Relief Valve Operating Pressures

bar

kgf/cm2

lbf/in2

Main Relief Valve (M.R.V.) Auxiliary Relief Valves (A.R.V.) — Attachments — Carriage Tilt, head side — Carriage Tilt, rod side — Sway, head side — Sway, rod side Note: On later machines the sway ARVs are not fitted

220

225

3200

138 138 275 131 165

140 140 281 133 168

2000 2000 4000 1900 2400

Rams Boom Lift Boom Extension Tilt Ram Displacement Sway Sway Ram (later machines)

Bore mm 110 100 120 120 110 110

in 4.3 3.9 4.7 4.7 4.3 4.3

Rod Dia. mm in 60 2.3 60 2.3 65 2.5 65 2.5 60 1.9 50 1.9

Stroke mm 1020 3860 495 495 196 178

in 40.1 151.9 19.4 19.4 7.7 7.0

Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer

Partial flow ('spin on') 25 microns (0.001 in) 1.05 bar 125 microns (0.005 in)

Fan Motor Type Max fan speed at Max engine rev/min NAT ASP engine TURBO engine

Sundstrand TFU 200/8, gear type / Ultra 1MR 084C 8784 40° C ambient temp. zone 1800 1800

46° C ambient temp. zone 2100 2100

Note: The function of spools 3, 5 (where fitted) will vary from machine to machine but may include the following: Hydraulic Tow Hitch, and Auxiliary Attachment Control.

9803/3600E

Issue 3*

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