JCB 526, 528 Rear Engine Loadalls Repair Service Manual
JCB 526, 528 Rear Engine Loadalls Repair Service Manual
(S/N: 1182000 Onwards) - This service manual PDF download for the 526, 526S, 528-70, 528S JCB Rear Engine Loadalls 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.
Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine
MANUAL SPECIFICATION :
File Format : PDF Language : English Printable : Yes Searchable : Yes Bookmarked : Yes Publication No. : 9803/3710-3 Total Pages : 610
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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9803-3710
Section 1 - General Information Introduction About This Manual Machine Model and Serial Number Using the Service Manual Units of Measurement Section Numbering Left Side, Right Side Cross References Identifying Your Machine Machine Identification Plate Typical Vehicle Identification Number (VIN) Typical Product Identification Number (PIN) Component Identification Plates Typical Engine Identification Number Transmission Identification Numbers ROPS/FOPS Certification Plate Standard Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Introduction Bolts and Screws Condition 1 Condition 2 Verbus Ripp Bolts Hydraulic Connections 'O' Ring Face Seal System Adaptors Screwed into Valve Blocks Hoses Screwed into Adaptors Adaptors into Component Connections with Bonded Washers 'Torque Stop' Hose System Service Tools Numerical List Tool Detail Reference Section B - Frame and Bodywork Section C - Electrics Section E - Hydraulics Section F - Transmission Section H - Steering Section K - Engine Service Consumables Sealing and Retaining Compounds Terms and Definitions Colour Coding Hydraulic Schematic Colour Codes
Section 2 - Care and Safety Section 2 Safety Notices Important Information The Operator Manual Safety Warnings Safety Checklist Safety - Yours and Others General Safety Operating Safety Maintenance Safety Safety Decals Introduction Safety Decal Recognition
Section 3 - Routine Maintenance Section 3 Routine Maintenance Health and Safety Lubricants Introduction Hygiene Storage Waste Disposal Handling New Oil Used Oil First Aid - Oil Eyes Swallowing Skin Spillage Fires Battery First Aid - Electrolyte GETS INTO YOUR EYES IS SWALLOWED GETS ONTO YOUR SKIN Warning Symbols Service Schedules Introduction How to Use the Service Schedules Pre-start Cold Checks, Service Points and Fluid Levels Functional Test and Final Inspection Fluids, Lubricants and Capacities Coolant Mixtures Cleaning the Machine Introduction Detergents Pressure Washing and Steam Cleaning Preparing the Machine for Cleaning Cleaning the Machine Cleaning the Cab Heater Filter Checking for Damage Seat Belt Checking the Seat Belt Condition and Security ROPS/FOPS Structure Checking the ROPS/FOPS Structure Boom Safety Strut Installing Removing Greasing Every 50 Hours Every 500 Hours Boom Wear Pad Runways Every 1000 Hours Boom Extension Ram Pivot Pin Oiling Park Brake Cable Control Levers Access Panels Battery Cover Opening and Closing 526, 526S 528-70, 528S Engine Cover Opening and Closing Brakes Park Brake Adjustment Checking the Foot Brake Fluid Level Electrical System Battery Battery Disconnection/Connection Disconnection Connection Checking the Electrolyte Level Battery Isolator (if fitted) Jump Starting the Engine Engine Air Filter Cleaning the Air Filter Dust Valve Changing the Elements Engine Checking the Oil Level Changing the Oil and Filter Checking the Coolant Level Changing the Coolant Front End Accessory Drive Belt Inspecting the Drive Belt Changing the Drive Belt Fuel System Types of Fuel Recommended Fuel Specification Acceptable Fuel Specification Sulphur Content Aviation Kerosene Fuels Low Temperature Fuels Fatty Acid Methyl Ester Fuels as a Replacement for diesel Fuels Petrol Filling the Tank 526, 526S 528-70, 528S Draining the Water Seperator and Engine Fuel Filter Changing the Water Seperator Filter Changing the Engine Fuel Filter Element Bleeding the System Hydraulic System Checking the Hydraulic Fluid Level Changing the Filter Element Changing the Pilot Filter Element (if applicable). Checking the Hose Burst Protection Valves Introduction Boom Lift Rams Boom Extension Ram Carriage Tilt Ram Stabiliser Ram (if fitted) Transmission Checking the Transmission Oil Level Changing the Transmission Oil and Filter Tyres and Wheels Tyre Inflation Checking the Wheel Nut Torques Axles Front and Rear Axle Checking the Axle Oil Level Changing the Axle Oil Oil Immersed Brakes Checking the Hub Oil Levels Changing the Hub Oil Checking the Front Axle Breather Windscreen Washer Checking the Level Fire Extinguisher (if fitted) Checking the Fire Extinguisher
Section A - Attachments Section A Service Procedures Quick Release Couplings Connecting and Disconnecting Quick Release Couplings - Do's and Don'ts Connecting Quick Release Couplings Disconnecting Quick Release Couplings Venting Hydraulic Pressure
Section B - Body and Framework Body and Framework Technical Data Air Conditioning (Option) Basic Operation Air Conditioning (Option) Safety Procedures R134a Refrigerant PAG Type Refrigerant Oil System Operation System Control Load Moment Indicator (LMI) Electrical Connections Air Conditioning (Option) Load Moment Indicator (LMI) Fault Finding Air Conditioning (Option) General Fault Indications System Diagnosis using Test Gauges Load Moment Indicator (LMI) Fault Codes General Fault Finding Diagnostic Tests Service Procedures Rivet Nuts Fitting Procedure Slide Hammer Kit Fitting Procedure Air Conditioning (Option) Service Checks Leak Testing Tightening Leaking Hoses Refrigerant Charging and Discharging Binary Pressure Switch Testing Compressor Drive Belt - Adjustment Condenser Matrix Cleaning Cab ROPS, FOPS Structure - Checks Direct Glazing Load Moment Indicator (LMI) Calibration Procedure Calibration Charts Boom Wear Pad Renewal Air Conditioning (Option) Removal and Replacement Air Conditioning Unit (HVAC) Freeze Protection Thermostat Binary Pressure Switch Load Moment Indicator (LMI) Removal and Replacement Axle Transducer Boom Removal and Replacement 2 Stage Boom Cab Removal and Replacement Combined Fuel, Hydraulic Tank Removal and Replacement 526 Machines 528 Machines Engine Cover Removal and Replacement
Section C - Electrics Section C Technical Data General Electrical Data Fuses and Relays Fuses Link Box Fuses Relays Machines with Synchro Shuttle Transmission Machines with Powershift Transmission Schematic Circuits Machines with Synchro Shuttle Transmission Machines with Powershift Transmission Service Procedures Using a Multimeter Measuring DC Voltage Measuring Resistance Measuring Continuity Measuring Frequency Testing a Diode or a Diode Wire Battery Maintenance First Aid - Electrolyte GETS INTO YOUR EYES IS SWALLOWED GETS ONTO YOUR SKIN Testing Specific Gravity Testing Alternator General Description Service Precautions Charging Circuit Test Check 1 Check 2 Alternator Charging Test Starter Motor Starting Circuit Test Wire and Harness Number Identification Introduction Wire Numbers and Functions Wires 000-199 Wires 200-399 Wires 400-599 Wires 600-799 Wires 800-999 Wires In Splices General Points Wiring Harness Repair Introduction Repair Procedure Alternator Removal, Inspection and Replacement Dismantle and Assembly Starter Motor Removal, Inspection and Replacement Dismantle and Assembly Earth Points Location Harness Data Drawings and Interconnection Harnesses Access Details Drawings Engine - CAD 721/11835 Issue 1 Panel/Cab - CAD 721/11875 Issue 4 Panel/Cab - CAD 721/11877 Issue 4 Chassis - CAD 721/11874 Issue 2 Chassis - CAD 721/11876 Issue 2 Transmission - Synchro Shuttle - CAD 721/ 10929 Issue 2 Transmission - Powershift - CAD 721/11669 Issue 1 Cold Start System - CAD 721/11975 Issue 1 Smooth Ride System (SRS) - CAD 721/11117 Issue 1 Smooth Ride System (SRS) - CAD 721/11118 Issue 2
Section E - Hydraulics Hydraulics Technical Data Hydraulic Pump Control Valve Block Hydraulic Rams Smooth Ride System (SRS) Accumulator Basic Operation Component Location and Neutral Circuit Description Introduction to Hydraulic Schematic Symbols General (Basic and Functional Symbols) Control Valves Example of Schematic Circuit Schematic Circuits Machines with Dual Lever Controls Machines with Single Lever Controls Circuit Descriptions Pump Operation Control Valve Block Neutral Circuit Boom Lift Operation Boom Lower Operation Boom Extend and Retract Operation Hose Burst Protection Valve Operation Main Relief Valve (MRV) Operation Auxiliary Relief Valve (ARV) Operation Parallel Lift Smooth Ride System (SRS) Microswitches Hydraulic Schematic Electrical Connections Smooth Ride System (SRS) Fault Finding General Parallel Lift Smooth Ride System (SRS) Service Procedures Hydraulic Contamination Hydraulic Fluid Quality Effects of Contamination Cleaning Operation Contaminant Standards Filters `Positional Type' Hydraulic Adaptors Fitting Procedure Flow and Pressure Tests Checking Pump Flow Testing Main Relief Valve (MRV) Testing Auxiliary Relief Valves (ARV’s) Checking the Servo Pilot Pressure Smooth Ride System (SRS) Accumulators Charging and Discharging Main Pump Removal and Replacement Dismantle, Inspection and Assemble Control Valve Block Removal and Replacement Machines with Dual Lever Controls Machines with Single Lever Controls Dismantle and Assemble Tie Rods Valve Block Sections Spools and Load Hold Check Valves Servo Pilot Pressure Reducing Valve Dismantle and Assemble Solenoid Diverter Valve Removal and Replacement Hydraulic Rams Precautions During Use Installation Caution During Use Maintenance, Inspection Points Removal and Replacement Lift Ram Displacement Ram Extension Ram Tilt Ram Dismantle and Assemble Typical Ram JCB Ram Sealing Procedure Piston Head Retention Smooth Ride System (SRS) Accumulators Removal and Replacement
Section F - Transmission Transmission Technical Data Tyre Pressures Front Axles Unit Identification Rear Axles Unit Identification Synchro Shuttle Gearbox Unit Identification Powershift Gearbox Unit Identification Engine Stall Speed Combinations Basic Operation General Description Front Axle - Steer Drive Type SD70 Component Identification Rear Axle - Steer Drive Type SD55 Component Identification Synchro Shuttle Gearbox Component Identification Principle of Operation Hydraulic and Electrical Operation Powershift Gearbox Component Identification Principle of Operation Hydraulic and Electrical Operation - 4 Speed Gearbox Drivepaths Torque Converter Component Identification Principle of Operation Systems Description Synchro Shuttle Gearbox Synchromesh (Blocking Pin Type) Synchromesh Operation Forward and Reverser Clutch Operation Powershift Gearbox Forward and Reverser Clutch Operation Mainshaft and Layshaft Clutch Operation Electrical Connections Synchro Shuttle Gearbox Introduction Quick Reference Wires and Connectors Powershift Gearbox Introduction Quick Reference Wires and Connectors Service Procedures Rear Axle SD55 Renewing the Pinion Oil Seal Front Axle SD70 Renewing the Drop Box Input and Output Shaft Oil Seals Testing for Brake Piston Seal Leakage Synchro Shuttle Gearbox Flushing the Transmission Oil Torque Converter Stall Test Pressure and Flow Tests Powershift Gearbox Flushing the Transmission Oil Torque Converter Stall Test Pressure and Flow Tests Solenoid Identification Fault Finding Synchro Shuttle Gearbox Introduction Fault Finding Tables Powershift Gearbox Introduction Fault Finding Tables Propshafts Removal and Replacement Front Axle SD70 Removal and Replacement Dismantle and Assemble Rear Axle SD55 Removal and Replacement Dismantle and Assemble Synchro Shuttle Gearbox Removal and Replacement Dismantle, Inspection and Assembly Powershift Gearbox Removal and Replacement Dismantle, Inspection and Assembly Torque Converter Removal and Replacement Oil Cooler Removal and Replacement
Section G - Brakes Brakes Technical Data Service Brakes Park Brake Basic Operation General Description Fault Finding Brake System Service Procedures Service Brakes Brake Light Switch - Adjustment Bleeding Brake Piston Seal Leakage Axle Breather (Braked Axles) - Inspection Park Brake Testing Adjustment Switch Adjustment Renewing the Brake Pads Master Cylinder Removal and Replacement Service Brakes Dismantling and Assembly Park Brake Synchro Shuttle and Powershift Machines Torque Figures Caliper - Removal and Replacement Caliper - Dismantle, Inspection and Assemble
Section H - Steering Steering Technical Data Steer Unit Priority Valve Basic System Operation General Description Steer System Schematics Machines with All Wheel Steering Only Machines with 3 Steer Modes (Option) Circuit Descriptions Steer System Operation Machines with All Wheel Steering Only Machines with 3 Steer Modes (Option) Priority Valve Operation Neutral Turning Electrical Connections Steer Alignment Indicators Fault Finding Steering System Introduction Fault Finding Tables Service Procedures Testing the Standby Pressure Testing the System Pressure Steer Priority Valve - Cleaning Re-phasing the Road Wheels Machines with All Wheel Steering Only Machines with 3 Steer Modes (Option) Bleeding the System Machines with All Wheel Steering Only Machines with 3 Steer Modes (Option) Proximity Switch - Setting Checking for Internal Hydraulic Leakage Checking Energiser Seals Priority Valve Removal and Replacement Power Track Rod Removal and Replacement Link Arms Removal and Replacement Rams Dismantle and Assemble Steer Mode Valve (Option) Removal and Replacement Hydraulic Steer Unit Removal and Replacement Dismantle and Assemble
Section K - Engine Engine Technical Data JCB 444 Series Unit Identification Specifications Electrical Connections Cold Start Heater Introduction Wires and Connectors Cooling Pack JCB 444 Series Removal and Replacement Removal and Replacement JCB 444 Series Component Key Removal Replacement