JCB 527-58 Telescopic Handler Repair Service Manual

(S/N: 1473000 - 1473999)
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This service manual PDF download for the 527-58 JCB Telescopic Handler has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.


APPLICABLE MODELS :

JCB Telescopic Handler 527-58 - from S/N: 1473000 - 1473999


TABLE OF CONTENTS :

Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Routine Maintenance
Section B - Body and Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section H - Steering
Section K - Engine
Section M - Electronic Data Systems


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Publication No. : 9813/0200-1
Total Pages : 1084


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9813-0200-1

Section 1 - General Information
General Information
Use
Introduction
Scope
Using the Service Manual
Units of Measurement
Left Side, Right Side
Cross References
Applications
Newest Data
Format
Hydraulic Schematic Codes
Colour Codes
Applications
Introduction
Machine Identification
Introduction
Related Topics
Identifying Your Machine
Machine Identification Plate
Component Identification Plates
Fuel
Introduction
Related Topics
Acceptable and Unacceptable Fuels
Additives
Service Requirements for use of B20 Biodiesel
Warranty
Fuel Types
Usage and Effects of Fuels
Sulphur Content
Effects of Fuel Contaminates
Torque Settings
Introduction
Zinc Plated Fasteners and Dacromet Fasteners
Introduction
Bolts and Screws
Hydraulic Connections
'O' Ring Face Seal System
'Torque Stop' Hose System
`Positional Type' Hydraulic Adaptors
Fitting Procedure
Service Tools
Introduction
Numerical List
Tool Detail Reference
Rivet Nuts
Fitting Procedure
Slide Hammer Kit
Fitting Procedure
Service Consumables
Introduction
Sealing and Retaining Compounds

Section 2 - Care and Safety
Care and Safety
Safety Notices
Introduction
Important Information
The Operator Manual
Safety Warnings
Safety Check List
Safety - Yours and Others
General Safety
Operating Safety
Maintenance Safety
Introduction
General Procedures
Introduction
Related Topics
Parking the Machine and Making it Safe
Maintenance Strut
Installing the Maintenance Strut
Removing the Maintenance Strut
Releasing the Hydraulic Pressure
Connecting/Disconnecting Hydraulic Hoses
Introduction
Connecting the Hydraulic Hoses
Disconnecting the Hydraulic Hoses
Quick Release Couplings
Quick Release Couplings
Connecting and Disconnecting
Hydraulic Contamination
Hydraulic Fluid Quality
Effects of Contamination
Cleaning Operation
Contaminant Standards
Filters
Battery Disconnection/Connection
Disconnection
Connection
Battery Isolation
Removing and Replacing Components
Battery Charging System Precautions
Hydraulic Rams
Installation
Caution During Use
Maintenance, Inspection Points

Section 3 - Routine Maintenance
Routine Maintenance
Routine Maintenance
Related Topics
Service Requirements
Introduction
Owner/Operator Support
Service/Maintenance Agreements
Initial Service and Inspection (100 Hours)
Fit for Purpose Tests for Lifting Equipment
Obtaining Replacement Parts
Health and Safety
Lubricants
Battery
Service Schedules
Introduction
How to Use the Service Schedules
Calendar Equivalents
Pre-start Cold Checks, Service Points and Fluid Levels
Functional Test and Final Inspection
Fluids, Lubricants and Capacities
Coolant Mixtures
Fuel
Prepare the Machine for Maintenance
Cleaning the Machine
Introduction
Preparing the Machine for Cleaning
Cleaning the Machine
Fan Reverse (if fitted)
Checking for Damage
Check the Machine Body and Structure
Check the Tyres
Check the Seat and Seat Belt
Check the Hydraulic Hoses and Fittings
Checking the ROPS/FOPS Structure
Greasing
Introduction
Preparing the Machine for Greasing
Every 50 Hours
Every 500 Hours
Every 1000 Hours
Oiling
Park Brake Cable
Access Panels
Battery Covers
Engine Cover
Rear Cover
Deck Plate
Chaff Guard
Engine Compartment Undershield
Front Undershield
Centre Undershield
Rear Undershield
Cab Undershield
Cab Heater and Air Conditioning
Changing the Air Intake Filter
Brakes
Park Brake
Foot Brake
Electrical System
Battery
Jump Starting the Engine
Secondary Fuses
Primary Fuses
Relays
Engine
Oil and Filter
Cooling System
Front End Accessory Drive Belt
Air Filter
Fuel System
Introduction
Water Separator and Engine Fuel Filter
Bleeding the System
Hydraulic System
Introduction
Releasing the Hydraulic Pressure
Oil and Filter
Hose Burst Protection Valves
Transmission
Axles
Transmission Motor Gear Train
Tyres and Wheels
Tyre Inflation
Checking the Wheel Nut Torques
Wheel Alignment
Introduction
Variations
Permanent 4-Wheel Steer Machines
Non Indicated Manual Steer Mode Selector
Indicated Manual Steer Mode Selector
Electronic Steer Mode Selector
Wear Pads
Boom Wear Pad Clearance
Windscreen Washer
Checking the Level
Fire Extinguisher (if fitted)
Checking the Fire Extinguisher

Section B - Body and Framework
Body and Framework
Fork Carriage
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Cab Heating and Ventilation SYSTEM
Introduction
Related Topics
Operation Overview
Electrical Operation and Schematics
Fault Finding
Tables
Cab Air Conditioning SYSTEM
Introduction
Related Topics
Specifications
R134a Refrigerant
PAG Type Refrigerant Oil
Operation Overview
Component Location
System Operation
System Control
Electrical Operation and Schematics
Safety Procedures
Service Checks
Off-Season Operation
Fault Finding
Introduction
Tables
System Diagnosis using Test Gauges
Test Procedures
Leak Testing
Tightening Leaking Hoses
Binary Switch
Refrigerant
Refrigerant Charging and Discharging
Compressor Drive Belt - Adjustment
Longitudinal Load Moment SYSTEM
Introduction
Related Topics
Operation Overview
Longitudinal Load Moment
Longitudinal Load Moment Indicator (LLMI)
Longitidinal Load Moment Control System (LLMC)
Hydraulic Operation and Schematics
LLMI System
LLMC System
LLMC Isolation
Electrical Operation and Schematics
LLMI System
LLMC System
LLMI - Calibration
Fault Finding
LLMI Fault Codes
LLMI Fault Finding
LLMC Fault Codes
LLMC Fault Finding Tables
LLMI Tests
LLMI Self Test Function
LLMI Diagnostic Tests
LLMC Tests
LLMC Functional Check
Cab
Introduction
Related Topics
Removal and Replacement
Roller Blind
Roof Liner
Floor Mat
Instrument Panels
Door Handle
Door
Screen Guard
Roof Guard
Wiper Motor Front
Wiper Motor Rear
Wiper Motor Roof
Cab
Air Conditioning Condenser - Cab Roof Mounted
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Air Conditioning Binary Switch
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Cab HV and HVAC Unit
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Heater Valve
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Fuel Tank
Introduction
Related Topics
Specifications
Removal and Replacement
Removal
Replacement
Fuel Level Sender
Chassis Panels
Introduction
Related Topics
Removal and Replacement
Engine Cover
Mudguard Assembly
Rear Cover
Battery Cover
Chassis Undershields
Engine Undershield
Chaff Guard
Deck Plate
Chassis Side Cover
Boom
Introduction
Related Topics
Wear Pads and Shims
Wear Pad Clearance
Typical Shimming Procedure
Angle Indicator Removal and Replacement
Removal
Replacement
Pivot Shims
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Dismantling
Assembly
Boom Hoses and Pipework
Auxiliary and Tilt Hoses
LMI Axle Transducer
Introduction
Related Topics
Removal and Replacement
Removal
Replacement

Section C - Electrics
Electrics
Fuses and Relays
Introduction
Fuses
Link Box Fuses
Relays
Schematics
Introduction
Electrical Schematic
Sheets
Component Keys
Electrical Harness SYSTEM
Introduction
Related Topics
Earth Points
Wire Numbers and Functions
Wires 000-199
Wires 200-399
Wires 400-599
Wires 600-799
Wires 800-999
Wires In Splices
General Points
Harness Interconnections and Drawings
Interconnections
Harness Identification
Drawings
Test Procedures
How to Use a Multimeter
Measuring DC Voltage
Measuring Resistance
Measuring Continuity
Measuring Frequency
Testing a Diode or a Diode Wire
Wiring Harness Repair
Introduction
Repair Procedure
Battery Charging SYSTEM
Introduction
Related Topics
Specifications
Operation Overview
Electrical Operation and Schematics
Test Procedures
Charging Circuit Test
Alternator Charging Test
Alternator
Introduction
Related Topics
Specifications
Electrical Operation and Schematics
Removal, Inspection and Replacement
Removal
Inspection
Replacement
Dismantle and Assemble
Renewing the Voltage Regulator and Brushes
Renewing the Drive Pulley
Battery
Introduction
Related Topics
Maintenance
Battery
Test Procedures
Battery Load Testing
Specific Gravity Testing
Disconnection and Connection
Removal and Replacement
Removal
Replacement

Section E - Hydraulics
Hydraulics
Schematics
527-58
LSP Electro Servo Hydraulic SYSTEM
Introduction
Related Topics
Specifications
Control Valve Block
Pump
Cooling Fan Motor
Trailer Brakes
Operation Overview
Hydraulic Pump
Load Sensing
Electronic Servo Proportional Control
Electro Servo Control Valve
Pressure Compensation (Flowshare)
Electro Servo Control Lever
Hose and Pipework
Hydraulic Operation and Schematics
No Services Operated
Service Operation
Multiple Service Operation
Main System Pressure Relief
Auxiliary Relief Valve (ARV) Operation
Pressure Compensator Valves Operation
Parallel Lift
Electrical Operation and Schematics
Electro Servo Control
Hydraulic Control ECU
Fault Finding
Electronic Fault Codes
Tables
Test Procedures
Checking Pump Flow
Load Sense Relief Valve (LSRV)
Auxiliary Relief Valve Pressure (ARV) - ARV’s set lower than the LSVR
Auxiliary Relief Valve Pressure (ARV) - ARV’s set higher than the LSRV
Auxiliary Relief Valve Replacement
Smooth Ride SYSTEM (SRS) - Electro Servo
Introduction
Related Topics
Specifications
Accumulators
Operation Overview
Hydraulic Operation and Schematics
Hydraulic Schematic
Electrical Operation and Schematics
Fault Finding
Tables
Accumulator Charging and Discharging
Charging and Discharging
Accumulator Removal and Replacement
Removal
Replacement
Electro Servo (LSP) Control Valve
Introduction
Related Topics
Removal and Replacement
Handling
Removal
Replacement
Dismantle and Assemble
Valve Block Sections
Proportional Solenoids
Load Sense Relief Valve
Auxiliary Relief Valves (ARV’s)
Accumulator Check Valve and Filter
Dump Solenoid
Main Pump - Gearpump
Introduction
Related Topics
Operation Overview
Hydraulic Operation and Schematics
Removal and Replacement
Removal
Replacement
Dismantle, Inspection and Assemble
Control Lever - Electro Servo
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Cooling Fan Motor
Introduction
Related Topics
Operation Overview
Hydraulic Operation and Schematics
Removal and Replacement
Removal
Replacement
Dismantle, Inspection and Assemble
Dismantle
Inspection
Assemble
Extension Ram
Introduction
Related Topics
Removal and Replacement
Extension Ram
Hose Burst Check Valve
Lift Ram
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Tilt Ram
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Displacement Ram
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Ram Maintenance
Introduction
Related Topics
Dismantle
Assemble
JCB Ram Sealing Procedure
Piston Head Retention
Existing piston head and rod
New piston head and rod
Existing piston head and new rod
New piston head and existing rod
Drilling Dimensions
Hydraulic Control ECU
Introduction
Related Topics
Removal and Replacement
Removal
Replacement

Section F - Transmission
Transmission
Wheels and Tyres
Introduction
Related Topics
Specifications
Removal and Replacement
Front Wheels
Rear Wheels
Wheel Studs
Front Axles
Introduction
Related Topics
Specifications
Component Identification
Removal and Replacement
Removal
Replacement
Dismantle, Inspection and Assembly
Rear Axles
Introduction
Related Topics
Specifications
Component Identification
Removal and Replacement
Removal
Replacement
Dismantle, Inspection and Assembly
Hydrostatic Transmission SYSTEM
Introduction
Related Topics
Specifications
Transmission Pump
Transmission Motor
Component Identification
Operation Overview
General Description
Hydraulic Operation and Schematics
Transmission Pump
Transmission Motor
Hose and Pipework
Electrical Operation and Schematics
Transmission ECU
Forward/Reverse Drive Control
High/Low Speed Range
Ground Speed
Speed Limit
Varispeed
Inching Pedal
Overheat
Trailer Present
Fault Finding
Transmission `Limp Modes'
Electronic Fault Codes
Fault Finding Tables
Test Procedures
Flow and Pressure Tests
Priming Procedure
Moving A Disabled Machine
Towing
Dual Control SYSTEM
Introduction
Related Topics
Component Identification
Operation Overview
Electrical Operation and Schematics
Electrical Schematics
Hydrostatic Drive Motor
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Component Replacement
High/Low Speed Solenoid
Direction Valve Solenoid
Displacement Valve Block
Break Pressure Defeat Valve
Flushing Relief Valve
Flushing Valve Spool
PCOR Cartridge
Hydrostatic Drive Pump
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Pump and Engine Coupling
Component Replacement
Shaft Seal
High Pressure Relief Valves
DA/EP Control Valve
DA/EP Control Valve Solenoid
Pressure Cut Off Valve
Charge Pump
Propshafts
Introduction
Related Topics
Removal and Replacement
Propshaft Removal and Replacement
Speed Sensors
Introduction
Related Topics
Transmission Speed Sensor
Testing
Removal and Replacement
Engine Speed Sensor
Testing
Removal and Replacement
Transmission ECU
Introduction
Related Topics
Removal and Replacement
Removal
Replacement

Section G - Brakes
Brakes
Single Axle Service Brakes SYSTEM
Introduction
Related Topics
Specifications
Operation Overview
Fault Finding
Test Procedures
Brake Piston Seal Leakage
Axle Breather (Braked Axles) - Inspection
Bleeding
Dismantling and Assembly
Brake Light Switch
Operation
External Park Brake SYSTEM
Introduction
Related Topics
Specifications
Operation Overview
Test Procedures
Adjustment
Lever Adjustment
Cable Adjustment
Switch Adjustment
Renewing the Brake Pads
Pad Removal
Pad Inspection
Pad Replacement
Renewing the Parkbrake Cable
Removal
Replacement
Park Brake Disc
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Park Brake Calliper
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Park Brake Switch
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Master Cylinder
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Fluid Reservoir
Introduction
Related Topics
Removal and Replacement
Removal
Replacement

Section H - Steering
Steering
Steering SYSTEM
Introduction
Related Topics
Specifications
Steering Pump
Hydraulic Steering Unit
Priority Valve
Operation Overview
Component Location
Hydraulic Operation and Schematics
Priority Valve Operation
Hose and Pipework
Fault Finding
Tables
Test Procedures
Checking for Internal Hydraulic Leakage
Hydraulic Pressure Tests
Steer Priority Valve - Cleaning
Re-phasing the Road Wheels
Bleeding the System
Machines with Permanent Four Wheel Steer
Machines with Auto Steer Mode System
Machines with Manual Steer Mode System
Manual Steer Mode SYSTEM
Introduction
Related Topics
Operation Overview
Hydraulic Operation and Schematics
Operation - 2-Wheel Steer Selected
Operation - 4-Wheel Steer Selected
Operation - Crab Steer Selected
Schematics
Hose and Pipework
Electrical Operation and Schematics (Indicated System Only)
2 Wheel Steer Selected
4 Wheel Steer/Crab Steer Selected
Fault Finding
Test Procedures
Bleeding the System
Re-phasing the Road Wheels
Proximity Switch - Setting (Indicated machines Only)
Auto Steer Mode SYSTEM
Introduction
Related Topics
Operation Overview
Hydraulic Operation and Schematics
Operation - 2-Wheel Steer Selected
Operation - 4-Wheel Steer Selected
Operation - Crab Steer Selected
Schematics
Hose and Pipework
Electrical Operation and Schematics
2 Wheel Steer Selected
4 Wheel Steer Selected
Crab Steer Selected
Test Procedures
Steer Mode Valve - Checking Solenoid Operation
Bleeding the System
Re-phasing the Road Wheels
Proximity Switch - Setting
Hydraulic Steering Unit
Introduction
Related Topics
Hydraulic Operation and Schematics
Removal and Replacement
Removal
Replacement
Priority Valve
Introduction
Related Topics
Hydraulic Operation and Schematics
Neutral
Turning
Cleaning
Removal and Replacement
Removal
Replacement
Power Track Rod
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Link Arms
Dismantle and Assemble
Rams
Steering Column
Introduction
Related Topics
Removal and Replacement
Steering Wheel
Steering Column Switches
Steering Column
Manual Steer Mode Valve
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Dismantle and Assemble
Dismantle
Assemble
Auto Steer Mode Valve
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Dismantle and Assemble
Dismantle
Assemble

Section K - Engine
Engine
Start and Stop SYSTEM (Mechanical F.I. Engines)
Introduction
Related Topics
Operation Overview
Electrical Operation and Schematics
Cold Start Heater SYSTEM
Introduction
Related Topics
Operation Overview
Electrical Operation and Schematics
Fault Finding
Electronic Fault Codes
JCB Dieselmax (Mechanical F. I. Engines)
Introduction
Related Topics
Specifications
Removal and Replacement
Removal
Replacement
Starter Motor
Introduction
Related Topics
Removal, Inspection and Replacement
Removal
Inspection
Replacement
Renewing the Brush Gear
Renewing the Starter Solenoid
Cooling Pack
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Dismantle and Assemble
Coolant Expansion Tank
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Coolant Level Sensor
Exhaust Silencer
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Air Filter Vacuum Switch
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Throttle Pedal and Cable
Introduction
Related Topics
Removal and Replacement
Throttle Pedal Assembly
Throttle Cable
Throttle Pedal Switch
Hand Throttle
Introduction
Related Topics
Operation Overview
Calibration
Electrical Operation and Schematics
Removal and Replacement
Removal
Replacement
Adjustment

Section M - Electronic Data Systems
Electronic Data Systems
CANbus SYSTEM
Introduction
Related Topics
Operation Overview
CANbus Communications System
Electrical Operation and Schematics
Loadall Monitoring SYSTEM
Introduction
Related Topics
Operation Overview
Fault Code Display
Electrical Operation and Schematics
Service Hours Reset
Introduction
Using the Machine LCD Display
Using JCB Servicemaster 2
Fault Code SYSTEM
Introduction
Related Topics
Operation Overview
CAN Enabled Display
Malfunction Indicator Light (MIL)
CANbus Connected Computer
Fault Code Log
Loadall Monitoring System ECU Fault Codes
General “D” Codes
Transmission “T” Codes
Hydraulic Control ECU “L” Codes
Servicemaster SYSTEM
Introduction
Related Topics
Why Use Servicemaster?
Introduction
Fault Finding
Identify Poor Maintenance
Access Machine Set Up Data
Re-Programming ECU’s
Summary
What is Servicemaster?
Introduction
CANbus Communications System
Servicemaster Structure
How to Set Up Servicemaster
Install Servicemaster
Start Servicemaster
Load the DLA Laptop Driver Software
Configure the DLA Type and Communications Port
Check the DLA Firmware File
Connect Servicemaster to the Machine CANbus
Servicemaster Tools
Introduction
Related Topics
Summary
Loadall LMS Setup - User Guide
Introduction
Care and Safety
Installing
Connection
Starting Loadall LMS Setup
Navigating within Loadall LMS Setup
Menu Bar - File Menu
Menu Bar - Utilities Menu
Menu Bar - Help Menu
Build Options
Hydraulic Options
Service Options
Language Options
Write
Read
Connection Problems
Loadall Machine Diagnostics - User Guide
Introduction
Care and Safety
Installing
Connection
Starting Loadall Machine Diagnostics
Navigating within Loadall Machine Diagnostics
Menu Bar - File Menu
Menu Bar - Options Menu
Menu Bar - Window Menu
Menu Bar - Help Menu
Machine System Tabs and Page List
Status bar
LED Status Key
Hydraulics ECU Diagnostic Pages
Vehicle Can - Diagnostic Pages
Connection Problems
Electronic Control Unit Theory
Introduction
Related Topics
Operation Overview
ECU Inputs
ECU Outputs
Pulse Width Modulation Theory
Introduction
Related Topics
Operation Overview

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