- This service manual PDF download for the 528-70 & 528S JCB Telescopic Forklift 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 :
This Service Manual covers the following machines: - JCB Loadall 528-70 AWS (All Wheel Steering) - from machine S/N: 796000 - JCB Loadall 528S (All Wheel Steering) - from machine S/N: 796102
TABLE OF CONTENTS :
General Information Care & Safety Routine Maintenance Body & Framework Electrics Hydraulics Transmission Brakes Steering Engine
MANUAL SPECIFICATION :
File Format : PDF Language : English Printable : Yes Searchable : Yes Bookmarked : Yes Publication No. : 9803/3650 Issue 4 Total Pages : 400
This complete JCB Telescopic Handler | Loadall | Telescopic Loader service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!
Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail! You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.
-
Cover Contents
General Information Machine Identification Engine Identification Transmission and Axle Identification Torque Settings Service Tools Numerical List Section B Section C Section E Section F Section H Section K Sealing and Retaining Compounds
Care and Safety Safety Notices General Safety Operating Safety Maintenance Safety Lubricants - Health and Safety
Routine Maintenance Lubricants and Capacities New Engines Lubrication Chart (528-70 & 528S Machines) Machine Safety Working with Boom Raised Service Schedules Grease Every 50 Hours Every 500 Hours Lubricate Every 500 Hours Every 1000 Hours Oiling Tyres and Wheels Checking the Footbrake Fluid Level Engine Air Filter Cleaning the Pre-Cleaner Changing the Air Filter Outer Element Changing the Inner Element Engine Oil and Filter Changing the Oil and Filter Engine Cooling System Checking the Coolant Level Coolant Mixtures Changing the Engine Coolant Cleaning the Cab Heater Filter Fuel System Types of Fuel Filling the Tank Cleaning the Lift Pump Gauze Draining the Fuel Filter Changing the Filter Element Draining the Sediment Bowl Cleaning the Sediment Bowl Prime the System Fire Extinguisher Synchro Shuttle Transmission Checking the Oil Level Changing the Oil and Filter Front and Rear Axle Checking the Axle Oil Level Changing the Axle Oil Front and Rear Hub Checking/Filling the Hub Oil Levels Oil Immersed Brakes Changing the Hub Oil Hydraulic System Checking the Fluid Level Changing the Filter Element Hose Burst Protection Valves Boom Lift Ram Boom Extension Ram Carriage Tilt Ram Battery Warning Symbols Checking the Electrolyte Level
Body & Framework Cab Removal and Replacement Direct Glazing Combined Fuel and Hydraulic Tank Removal and Replacement Boom Wear Pads - Removal and Replacement Inner and Outer - Removal and Replacement Rivet Nuts - Fitting Procedure Air Conditioning Option Technical Data Safety Procedures Operation Control Wiring Diagram Fault Finding Refridgerant Charging and Discharging Leak Testing Tightening Leaking Hoses Air Conditioning Unit Removal and Replacement Thermostat Removal and Replacement Pressure Switch Assembly
Electrics Technical Data Fuses and Relays Fuse Identification (528-70 Machines) Relay Identification (528-70 Machines) Fuse Identification (528S Machines) Relay Identification (528S Machines) Fuse Links Test Methods Use of Multimeter Measuring DC Voltage Measuring Resistance Measuring Continuity How to Test a Diode or a Diode Wire Wire/Harness Numbers Schematics 528-70 from 79600 (Synchro Shuttle Transmission) 528S Machines (Powershift Transmission) 528S Machines (Synchro Shuttle Transmission) Batteries Safety Maintenance Testing - Specific Gravity Battery Testing Alternator Charging Circuit Test Alternator Charging Test Terminal 'W' OUtput (Tachometer) Test Removal and Replacement Dismantling and Assembling Starter Motor Starting Circuit Test Removal and Replacement Dismantling and Assembling Safe Load Indicator and Load Moment Indicator Introduction Calibration - SLI System Calibration - LMI System Fault Finding Testing Transducer Removal and Replacement Parking Brake Switch Adjustment
Hydraulics Technical Data Schematic Circuits Dual Lever Controls 528S Machines with Single Lever Control Descriptions Basic Machine Neutral Circuit Hydraulic Hitch and Twin Auxilliary Circuit Fault Finding Contents Introduction to Hydraulic Schematic Symbols Fault Finding Chart Main Hydraulic Pump Removal and Replacement Dismantling, Inspecting and Assembling Testing Valves Valve Block Removal and Replacement Dismantling and Assembling Valve Block Spools Dismantling and Assembling Valve Block 528S Machines with Single Lever Control Joystick Dismantling and Assembling Valve Block Spools 528S Machines with Single Lever Control Joystick Dismantling and Assembling Main Relief Valve (MRV) Testing Auxiliary Relief Valve (ARV) Testing Pilot Pressure Reducing Valve Inspection Checking Servo Pressure Diverter Valve - Removal and Replacement Rams Lift Ram - Removal and Replacement Displacement Ram - Removal and Replacement Extension Ram - Removal and Replacement Tilt Ram - Removal and Replacement Typical Ram - Dismantling and Assembly
Transmission Technical Data 528-70 & 528S Syncro Shuttle Powershift Towing Procedure Descriptions Syncro Shuttle and Powershift Axle View Front and Rear Syncro Shuttle - Section Views and Torque Figures Synchromesh - Manual Gearbox Powershift Transmission General Description and Operation Gear Drivepaths Fault Finding Syncro Shuttle Powershift Torque Converter Removal and Replacement Testing Syncro Shuttle Powershift Syncro Shuttle Section Views and Torque Figures Dismantling Assembling Reverser Unit Dismantling Assembling Powershift Section Views and Torque Figures List of Components Dismantling Assembly Input and Reverser Clutch Dismantling Assembly Mainshaft Dismantling Assembly Layshaft Dismantling Assembly Permanent 4 Wheel Drive Unit Dismantling and Assembly Solenoid Valve Collapsible Spacer Assembly Polytetraflouroethene (PTFE) Piston Ring Seals Fitting Procedure Transmission Oil Cooling Fault Finding Propshafts Removal and Replacement Axles General Description Removal and Replacement Front Axle - SD70 Rear Axle - SD55 Hubs Dismantling Assembly Brakes - Front Axle SD70 Dismantling and Assembly Drive Head - Front Axle SD70 Dismantling Assembly Limited Slip DIfferential Option (SD70) Drive Head - Rear Axle SD55 Dismantling and Assembly Crown Wheel and Pinion Renewing the Pinion OIl Seal Drive Shaft - Salvage After Oil Seal Failure Axle and Gearbox Drive Shaft Flange - Salvage After Oil Seal Failure Drop Box Removal and Replacement Dismantling and Assembling
Brakes Technical Data Parking Brake Testing the Parking Brake Adjustment Caliper - Removal and Replacement Checking Brake Pad Wear Caliper - Dismantling and Assembly Fault Finding Break Seal or Component Leakage Bleeding Master Cylinder Removal and Replacement
Steering Technical Data Descriptions General Description Steer Modes Steer Unit Operation (AWS) Steer Unit Operation (3 Steer Modes) Priority Valve Operation - Neutral Priority Valve Operation - Turn Fault Finding Re-aligning the Road Wheels (AWS) Realigning the Road Wheels (3 Steer Modes) Powered Track Rod Removal and Replacement Valves Hydraulic Steering Unit Dismantling and Assembling Pressure Relief Valve Cartridge Shock Valves
Engine Technical Data Radiator - Removal & Replacement Engine and Transmission - Removal and Replacement Preparing the Machine Preparing the ENgine for Removal Preparing the Transmission for Removal Engine and Transmission Removal and Replacement Seperating the Engine and Transmission