JCB 520, 526 Loadall Service Manual – 9803/3610-10

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JCB 520, 526 Loadall Service Manual – 9803/3610-10
(S/N: 277001 Onwards)

This service manual PDF download for the 520,526 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 520-55 RS (Rear Steering) Farm Special & Construction
JCB 520-55 AWS (All Wheel Steering) Farm Special & Construction
JCB 526-55 Farm Special & Construction
JCB 526-55 AWS (All Wheel Steering) Farm Special & Construction
JCB 526S AWS (All Wheel Steering) Farm Special & Construction

JCB 520-55 – From S/N 277001 – 280299
JCB 526, 526S – From S/N 279289 – 280299
JCB 526-55 – From S/N 277468 – 279288

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. : 9803/3610 Issue 10
Total Pages : 586

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
520-55 (Rear Steer) Machines
520-55 AWS Machines (Type AA and AB Engine Builds)
526-55, 526 & 526S Machines (AA and AB Engine Builds)
520-55AWS Machines – Low Emission Engines (Type AR and AK Engine Builds)
526-55, 526 & 526S Machines (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
Chekcing 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
Boom
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
520-55, 526-55, 520-55RS up to 278965
504B (N.Am.) up to 279014
520-55, 520S from 278966 onwards
504B (N.Am.) from 279015 onwards
526, 526S up to 280576 (Powershift)
526 & 526S up to 280573 (Synchro Shuttle)
526, 526S from 280577 (Powershift)
526 & 526S from 280574 (Synchro Shuttle)
Fuse Identification
520-55, 526-55, 520-55RS up to 278965
504B N.Am. up to 279014
526 & 526S up to 280576 (Powershift)
526 & 526S up to 280573 (Synchro Shuttle)
520-55, 520S from 278966 onwards
526, 526S from 280577 (Powershift)
526, 526S from 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
520-55RS, 520-55 up to 277535
520-55 from 277536 and 526-55 up to 278965
520-55, 520S from 278966 on, 526-55, 526S from 280300 to 280576 (not Machines with ECU Gearbox Control)
526-55, 526, 526S from 280300 to 280576 (Powershift and ECU Gearbox control)
520-55 Machines from Serial Number 281847, 526, 526S Machines from Serial Number 280300 With Sybchro Shuttle Transmission
526, 526S Machines from Serial Number 280577 with Powershift Transmission
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
Safe Load Indicator & Load Moment Indicator
Introduction
Calibration – SLI System
Calibration – LMI System
Fault Finding
Testing Pre EMC Machines up to Serial Number 278777
Testing – EMC Machines From Serial Number 278778
Transducer – Removal and Replacement
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
520-55, 526-55, 526 & 526S
Schematic Circuit
520-55 RS & 4 Wheel Steer up to 278610
520-55 4 Wheel Steer from Serial No. 278611 & 526-55, 526, 526S Machines up to Serial No. 280299
526, 526S Machines from Serial Number 280300 with Dual Lever Control
526, 526S Machines from Serial No. 280300 with Single Lever Control Option
Descriptions
Basic Machine Neutral Circuit (520-55)
Basic Machine Neutral Circuit (526-55, 526 & 526S)
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, 526S Machines with Single Lever Control Option
Dismantling and Assembly – All Machines with Dual Lever Control Option
Dismantling and Assembly – 526, 526S 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
520-55
526-55, 526 & 526S
Tyres and Pressures
Pump/Transmission Stall Speed Combinations
Syncro Shuttle
Powershift
Product Change
Towing Procedure
Descriptions
General Description (Syncro Shuttle and Powershift)
Axle View Front and Rear
520-55 RS
520-55 AWS
526-55
526, 526S (from Serial Number 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 520-55 RS Machines & 520-55 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 (526-55 & 520-55 4 Wheel Steer Machines from Serial No. 278611 & 526, 526S 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, 526S 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 520-55 RS Machines & 520-55 4 WHeel Steer Machines up to Serial No. 278610)
526-55 & 520-55 4 Wheel Steer Machines from Serial No. 278611 & all 526, 526S
Dismantling and Assembling
All 520-55 RS Machines & 520-55 4 WHeel Steer Machines up to Serial No. 278610)
526-55 & 520-55 4 Wheel Steer Machines from Serial No. 278611 & all 526, 526S
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
520-55 RS (Rear Steer) Machines up to Serial No. 279119
520-55 4 Wheel Steer Machines up to Serial No. 279119
526-55, 526, 526S Machines from Serial No. 277467 to Serial No. 280299
520-55 4 Wheel Steer Machines from Serial No. 279120
Descriptions
Compensating Master Cylinder
520-55 RS & 520-55 4 Wheel Steer up to Serial No. 279119
Power Brake Circuit
520S and 520-55 AWS from Serial No. 279120
526 and 526S up to Serial No. 280299
Parking Brake
Testing the Parking Brake
Parking Brake Adjustment
Brake Discs
Removal, Inspecting & Replacement
Fault Finding
Probable Causes – Action
520-55 RS & 4 Wheel Steer up to Serial No. 279119
Bleeding
520-55 RS (Rear Steer)
520-55 4 Wheel Steer up to Serial No. 279119
526-55, 520-55 AWS and 520S from Serial No. 279120
526, 526S up to Serial No. 280299
526, 526S from Serial No. 280300
Testing
Brake Seal or Component Leakage
Brake System Pressure Testing
520S, 520-55 AWS from Serial No. 279120
526, 526S up to Serial No. 280299 With Power Brakes
Residual Brake System Pressure
520-55 AWS and 526-55
Master Cylinder
Removal and Replacement
520-55 RS
502-55 AWS up to Serial No. 279119
520-55 AWS, 520S from Serial No. 279120
526, 526S up to Serial No. 280299
Dismantling and Assembly
520-55 RS & 520-55 AWS up to Serial No. 279119
Accumulator Charge Valve
520-55 AWS, 520S from Serial No. 279120 and 526, 526S up to Serial No. 280299
Removal and Replacement
Dismantling and Assembly

Steering
Technical Data
520-55, 526-55, 526 & 526S
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
520-55
526-55, 526 & 526S
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

 

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JCB 520, 526 Loadall Service Manual – 9803/3610-10.pdf

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