JCB 504, 526 Loadall Repair Service Manual (N.America)
JCB 504, 526 Loadall Repair Service Manual (N.America)
(S/N: 277001 Onwards) - This service manual PDF download for the 504B, 526 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 :
This Service Manual covers the following machines: JCB Loadall 504B - from Machine Serial Number 277001 JCB Loadall 526 - from Machine Serial Number 279289
TABLE OF CONTENTS :
General Information Care & Safety Routine Maintenance Body & Framework Electrics Controls Hydraulics Transmission Brakes Steering Engine
MANUAL SPECIFICATION :
File Format : PDF Language : English Printable : Yes Searchable : Yes Bookmarked : Yes Publication No. : 9803/3610U-4 (N.America) Total Pages : 587
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 !!!!
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Cover Contents
General Information 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 Charts 504B (Rear Steer) Machines 504B AWS Machines (Type AA and AB Engine Builds) 526 Machines (AA and AB Engine Builds) 504B AWS Machines - Low Emission Engines (Type AR and AK Engine Builds) 526 Machines - Low Emission Engines (Type AR and AK Engine Builds) Machine Safety Service Schedules Grease 50 Hours 500 Hours 1000 Hours Oiling Tyres and Wheels Foot Brake (520-55 Machines Only) Engine Air Filter Cleaning the Pre-Cleaner Changing the Outer Element Changing the Inner Element Engine Oil and Filter Checking the Oil Level Changing the Oil and Filter Engine Cooling System Checking the Coolant Level Coolant Mixtures Changing the Coolant Cab Heater Filter Fuel System Fuel Types Filling the Tank Cleaning the Lift Pump Gauze Draining the Filter (up to S/N 280299) Changing the Filter Element (up to S/N 280299) Drainging the Filter (from S/N 280300) Changing the Filter Element (from S/N 280300) Draining the Sediment Bowl Cleaning the Sediment Bowl Bleed 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 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 Checking the Hose Burst Protection Valves Battery
Body and Framework Cab Removal and Replacement Direct Glazing Combined Fuel/Hydraulic Tank - 520-55 & 526-55 up to S/N 279000 Removal and Replacement Fuel/Hydraulic Tanks - 526-55 from S/N 279001 & 526, 526S Removal and Replacement Wear Pads Wear Pads - Removal and Replacement Inner and Outer - Removal and Replacement Air Conditioning Option Technical Data Safety Precautions Operation Wiring Diagram Fault Finding Refrigerant Charging and Discharging Leak Testing Tightening Leaking Hoses Air Conditioning Removal and Replacement Thermostat Removal and Replacement Pressure Switch Removal and Replacement Rivet Nuts
Electrics Technical Data Relay Identification 504B From Machine 277001 to 279014 504B from Machine 279015 onwards 526 to Machine 280576 (Powershift) 526 to Machine 280573 (Syncro Shuttle) 526 from 280577 (Powershift) 526 from 280574 (Synchro Shuttle) Fuse Identification 504B from Machine 277001 to 279014 526 from Machine 278966 to 280576 (Powershift) 526 from Machine 278966 to 280573 (Synchro Shuttle) 504B from 279015 onwards 526 from 280577 (Powershift), 280574 (Synchro Shuttle) Test Methods Use of Multimeter Measuring DC Voltage Measuring Resistance Measuring Continuity How to Test a Diode or a Diode Wire Proximity Switches Adjustment Schematics 504B up to 277535 504B from 277536 to 278817 504B from 278966 on, 526 from 278966 to 2280299 (not Machines with ECU Gearbox Control) 526 from 280300 to 280576 (Powershift and ECU Gearbox control) 526 from 280300 (Syncro Shuttle gearbox) 526 from 280300 (Powershift gearbox) Description Wire Harness Numbers Wire Number Identification Batteries Warning Symbols Safety Maintenance Testing - Specific Gravity Battery Testing Alternator Precautions Charging Test Removal and Replacement Dismantling and Assembling Starter Motor Starter Circuit Test Removal and Replacement Dismantling and Assembling Parking Brake Switch Adjustment Electronic Control Unit General Description ECU Mounting Fault Finding Checking Solenoid Operation Checking for (+VE) Supply to the Solenoids Solenoid Identification Checking the Panel Harness Checking the Park Brake Switch Checking the Transmission Dump Switch Checking Speed Sensor Operation Simplified ECU Installation Fault Finding Guide Handheld Mark II Test Unit
Controls 2/4 Wheel Disconnect Adjustment
Hydraulics Technical Data 504B Schematic Circuit 504B 504B 4 Wheel Machines from Serial No. 278611 to 280299 526 Machines from Serial Number 280300 with Dual Lever Control 526 from Serial No. 280300 with Single Lever Control Option Descriptions Basic Machine Neutral Circuit (504B) Basic Machine Neutral Circuit (526) Control Valve Block Neutral Circuit Boom Lower Operation Boom Lift Operation Boom Extend/Retract Operation Hose Burst Valve Operation Main Relief Valve Operation Auxilliary Relief Valve Operation Fault Finding Contents Introduction to Hydraulic Symbols Probable Causes - Action Pump Main Pump Removal and Replacement Main Pump Dismantling, Inspecting and Assembling Main Pump Testing Valves Valve Block Removal and Replacement - All Machines with Dual Lever Control Option Removal and Replacement - 526 Machines with Single Lever Control Option Dismantling and Assembly - All Machines with Dual Lever Control Option Dismantling and Assembly - 526 Machines with Single Lever Control Option Main Relief Valve (MRV) Testing Auxiliary Relief Valve (ARV) Testing 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 - Fitting New Rod Seal Typical Ram - Dismantling & Assembly
Transmission Technical Data 504B 526 Tyres and Pressures Syncro Shuttle Powershift Product Change Towing Procedure Descriptions General Description (Syncro Shuttle and Powershift) Axle View Front and Rear 504B RS 504B AWS 526 (from Serial No. 280300) Syncro Shuttle General Description and Operation Syncromesh - 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 SS640 Section Views and Torque Figures Dismantling Assembly Reverser Unit (Earlier Type) Dismantling Assembly Reverser Unit (Later Type) - Dismantling Reverser Unit (Later Type) - Assembly Mechanical 4 Wheel Drive Unit - Dismantling Mechanical 4 Wheel Drive Unit - Assembly Powershift Summary of Changes PS700 Section Views and Torque Figures PS750 Section Views and Torque Figures Dismantling (With Reverser Shaft Cover Plate) Assembling (With Reverser Shaft Cover Plate) Dismantling (With Reverser Shaft Plug & PS750) Assembling (With Reverser Shaft Plug & PS750) Input and Reverser Clutch (PS700) Location of Components Dismantling Assembly Mainshaft (PS700) Location of Components Dismantling Assembly Layshaft (PS700) Location of Components Dismantling Assembly Input and Reverser Clutch Dismantling Assembly Mainshaft (PS750) Dismantling Assembly Layshaft (PS750) Dismantling Assembly Hydraulic 2/4 Wheel Drive Unit Dismantling and Assembly Permanent 4 Wheel Drive Unit Dismantling and Assembly Solenoid Valve Dismantling and Assembly Polytetraflouroethene (PTFE) Piston Ring Seals Fitting Procedure Collapsible Spacer - Assembly Output Shaft Removal - Lareger Diameter Gears Propshafts Removal and Replacement Axles Removal and Replacement Front Axle Rear Axle Dismantling and Assembling (All 504B RS Machines & 504B 4 Wheel Steer Machines up to Serial No. 278610) Front Hub Rear Hub (Unbraked) Front Wheel Shaft and Brakes Steer Axle Brakes Swivel Housing Differential Pinion Dismantling and Assembling (504B 4 Wheel Steer Machines from Serial No. 278611 & 526 to Serial No. 280299) Hub & Driveshafts Drive Head Dismantling Pinion Depth Drive Head with Limited Slip Differential Dismantling Friction Plate Wear Assembly Crown Wheel and Pinion Adjustment Dismantling and Assembling (Front Axle 526 Machines from Serial No. 280300) Hub Brakes Drive Head SD55 Splined Hub and Drive Shaft Dismantling and Assembling Salvage After Oil Seal Failure Drive Shaft Axle and Gearbox Drive Shaft Flange Pinion Oil Seal Replacement Drop Box Removal and Replacement All 504B RS Machines & 504B 4 WHeel Steer Machines up to Serial No. 278610) 504B 4 Wheel Steer Machines from Serial No. 278611 & 526 Dismantling and Assembling All 504B RS Machines & 504B 4 Wheel Steer Machines up to Serial No. 278610) 504B 4 Wheel Steer Machines from Serial No. 278611 & 526 2/4 Wheel Disconnect - Dismantling and Assembling Transmission Oil Cooler Oil Contamination Testing Oil Cooler Flushing System Checking Transmission Oil Level Axle Operating Temperature Fault Finding
Brakes Technical Data 504B RS (Rear Steer) Machines up to Serial No. 279119 504B 4 Wheel Steer Machines up to Serial No. 279119 504B 4 Wheel Steer Machines from Serial Number 279120 526 Machines from Serial Number 277467 to Serial Number 280299 Descriptions Compensating Master Cylinder 504B RS & 504B 4 Wheel Steer up to Serial No. 279119 Power Brake Circuit 504B AWS from Serial No. 279120 526 up to Serial No. 280299 Parking Brake Testing the Parking Brake Parking Brake Adjustment Brake Discs Removal, Inspecting & Replacement Fault Finding Probable Causes - Action 504B RS & 4 Wheel Steer up to Serial No. 279119 Bleeding 504B RS (Rear Steer) 504B 4 Wheel Steer up to Serial No. 279119 504B AWS from Serial No. 279120 526 up to Serial No. 280299 526 from Serial No. 280300 Testing Brake Seal or Component Leakage Brake System Pressure Testing 504B AWS from Serial No. 279120 526 up to Serial No. 280299 With Power Brakes Residual Brake System Pressure 504B AWS Master Cylinder Removal and Replacement 504B RS 504B AWS up to Serial No. 279119 504B AWS from Serial No. 279120 526 up to Serial No. 280299 Dismantling and Assembly 504B RS & 504B AWS up to Serial No. 279119 Accumulator Charge Valve 504B AWS from Serial No. 279120 and 526 up to Serial No. 280299 Removal and Replacement Dismantling and Assembly
Steering Technical Data 504B, 526 Descriptions Steer Valve Operation, Neutral Steer Valve Operation, Left Turn Steer Valve Operation, Shock Valve Priority Valve Operation, Neutral Priority Valve Operation, Turn Steer System, Left Turn All Wheel Steer, Left Turn 2 Wheel Steer, Left Turn 4 Wheel Steer, Left Turn Crab Steer Fault Finding Contents Probable Causes - Action Re-aligning the Road Wheels 504B 4 Wheel Steer Machines 526 Powered Track Rod Removal and Replacement Checking Energiser Seals Link Arms - Removal and Replacement Valves Hydraulic Steering Unit, Dismantling and Assembling Priority Valve, Cleaning & Testing Bleeding
Engine Technical Data Radiator Removal and Replacement Engine and Transmission Removal and Replacement Seperating the Engine and Transmission