JCB 500 Series Loadall Service Manual – 9803/3600

(S/N: 561001 Onwards)
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This workshop repair service manual PDF download for the 500 Series 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 525-58 and 525-58 Farm Special – from machine S/N: 561001
JCB 525-67 and 525-67 Farm Special – from machine S/N: 561001
JCB 525-58 and 525-67 Farm Special Plus
JCB 525-58 and 525-67 Basic Servo Options
JCB 527-58 and 527-67 – from machine S/N: 572775
JCB 530-95 – from machine S/N: 564980
JCB 530-110 – from machine S/N: 563359
JCB 530-110 and 530-120 – PlaceAce
JCB 530-110 and 530-120 Servo Options
JCB 530-120 – from machine S/N: 562601
JCB 530-67 and 530-67 Farm Special – from machine S/N: 571001
JCB 535-67 – from machine S/N: 572775
JCB 537-120 and 537-130 from machine S/N: 572900
Information covers two stage and three stage boom machines.

JCB 525-58 (Includes Basic Servo Option) – from S/N: 561001 Onwards
JCB 525-67 (Includes Basic Servo Option) – from S/N: 561001 Onwards
JCB 527-58 – from S/N: 572775 Onwards
JCB 527-67 – from S/N: 572775 Onwards
JCB 530-67 – from S/N: 571001 Onwards
JCB 530-95 – from S/N: 564980 Onwards
JCB 530-110 (Includes PlaceAce & Servo Options) – from S/N: 563359 Onwards
JCB 530-120 (Includes PlaceAce & Servo Options) – from S/N: 562601 Onwards
JCB 535-67 – from S/N: 572775 Onwards
JCB 537-120 – from S/N: 572900 Onwards
JCB 537-130 – from S/N: 572900 Onwards

TABLE OF CONTENTS :

General
Hydraulics
Body and Framework
PlaceAce Control System
Servo Control System
Engine
Transmission
Axles
Brakes
Hydraulic Steering
Electrics
Service Tools
Index

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9803/3600
Total Pages : 736

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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Front Cover
Contents
Introduction

1-General
Fluids, Lubricants, Capacities & Specifications
(525-58, 67, 527-58, 67, 530-95)
(530-110)
(530-120, 537-120 & 537-130)
(525-58 Farm Special Plus, 530-67, 535-67)
Torque Settings
Identifing Your Machine
Service Schedules
Greasing
OILING
FITTING THE BOOM SAFETY STRUT

2-Hydraulics
Technical Data
TECHNICAL DATA (530-120 Only)
TECHNICAL DATA (530-110 Only)
TECHNICAL DATA (530-95 Only)
TECHNICAL DATA (537-120 Only)
TECHNICAL DATA (537-130 Only)
GENERAL DESCRIPTION
HYDRAULIC FLUID LEVEL & FILTER
HYDRAULIC FLUID LEVEL & FILTER||(530-120 Later Machines)
HYDRAULIC TANK
PUMP OPERATION
HYDRAULIC PUMP
HYDRAULIC PUMP (Sundstrand SP/230/50)
Main Hydraulic Pump (Ultra 2PR050)
SUPPLEMENTARY PUMP (See Section Contents for
MACHINE NEUTRAL CIRCUIT (without Torsion Box Cooling
MACHINE NEUTRAL CIRCUIT (with Torsion Box Cooling
MACHINE NEUTRAL CIRCUIT (With Filter In Steer Circuit)
Machine Neutral Circuit (with supplementary pump & oil cooler)
MACHINE NEUTRAL CIRCUIT (with priority steer/fan pump)
CONTROL VALVE NEUTRAL CIRCUIT
BOOM LIFT OPERATION
BOOM LOWER OPERATION (525 – 67)
BOOM LIFT OPERATION (525-58 only)
BOOM LOWER OPERATION (525-58 only)
HOSE BURST OPERATION
BOOM EXTEND/RETRACT OPERATION
AY OPERATION
BOOM LIFT OPERATION
BOOM LOWER OPERATION
BOOM EXTEND REGENERATIVE
BOOM EXTEND HIGH PRESSURE
BOOM RETRACT
STABILISER CHECK VALVE OPERATION
STABILISER OPERATION
MRV OPERATION
ARV OPERATION
CONTROL VALVE
PRESSURE TESTING
LIFT RAMS
DISPLACEMENT RAM
EXTENSION RAM (525 – 58)
EXTENSION RAM
TILT RAM
SWAY RAM (OPTIONAL)
TOW HITCH (OPTIONAL)
INNER EXTENSION RAM
OUTER EXTENSION RAM
BOOM EXTENSION CIRCUIT BLEEDING
EXTENSION RAM MAKEUP VALVE
BOOM HOSES (530-95)
BOOM HOSES CHAIN TRACK (530-95)
EXTENSION RAM (530-95)
STABILISER RAM (OPTIONAL)
DIVERTER VALVE (Stabiliser/Sway Machines)
TYPICAL LOADALL RAM
TOW HITCH RAM (OPTIONAL)
TYPICAL RAM (with dowelled piston head)
Dismantling and Assembly
FAN MOTOR
FAN MOTOR (SUNDSTRAND)
FAN MOTOR (ULTRA)
SCHEMATIC HYDRAULIC CIRCUITS
(525-58,67 and 530-95 up to Machine serial number 567217)
(525-58,67 and 530-95 from Machine serial number 567218 and 527-58, 67 machines)
(527-58, 527-67, 530-95 & 535-67 from Machine Serial No.574296)
(All 530-120 and 530-110 up to Machine serial number 567217)
(530-110 from Machine serial number 567218)
(530-67, 535-67 up to Machine Serial No. 574295)
(537-120 and 537-130)

3-Body & Framework
BOOM SHIMMING – TYPICAL METHOD
BOOM SHIMMING – 525-58/67, 527-58/67, 530-67, 535-67
BOOM SHIMMING – 530-95
BOOM SHIMMING – 530-110
BOOM SHIMMING – 530-120, 537-120/130
INNER EXTENSION RAM WEAR PADS
INNER BOOM
BOOM (525-58)
BOOM (530-120 & 530-110)
CAB
FRONT WINDSCREEN (hinged)
REAR WINDOW (Fixed)
SIDE WINDOWS
REAR WINDOW (HINGED)
Q-FIT CARRIAGE
FUEL TANK
AIR CONDITIONING OPTION
Technical Data
Description of Operation
Control
Safety Procedures
Wiring Diagram
Fault Finding
Leak Testing
Receiver-Drier
Binary Switch
Evaporator Unit and Thermostat
Blower Motor
Expansion Valve
Adjusting the Compressor Drive Belt

4-PlaceAce Control System
Technical Data
Control System Description
Valve Block Operation
Pulsar Description & Operation
Valve Block Removal & Replacement
Pulsar Solenoid Removal & Replacement
Main Spool Removal & Replacement
Boom Angle Sensor Removal & Replacement
Boom Extension Sensor Removal & Replacement
Attitude Sensor Removal & Replacement
Motion Pac Control Unit Removal & Replacement
Driver Cards Removal & Replacement
Display Unit Removal & Replacement
Joystick Removal & Replacement
Lever Control (Stabilisers) Removal & Replacement
Control Valve Dismantle & Assembly
Valve Stack Dismantle & Assembly
Pressure Testing
Full System Calibration
Vehicle Attitude & Tachometer Signal Calibration
Pulsar Solenoid Calibration
Driver Card Calibration/Adjustment
Functional Checks
Fault Finding
Schematic Hydraulic Circuit 530-110/120
Schematic Electrical Circuit 530-110/120

4A-Servo & Basic Servo Control System
TECHNICAL DATA (Basic Servo 525-58, 67, 527-58, 67, 530-67 & 535-67)
TECHNICAL DATA (Servo 530-110, 530-120)
Servo Control System Description- 530-110/120
Basic Servo Control System Description- 525-58/67, 527-58/67, 530-67 & 535-67
Valve Block Operation
Valve Block Main Spool Operation
Joystick Control Lever Operation
Cab & Chassis Electrical Circuits Description
– 530-110/120
– 525-58/67, 527-58/67, 530-67 & 535-67
JOYSTICK CONTROL LEVER
Valve Block Removal & Replacement
Control Valve Section Dismantle & Assembly
CONTROL VALVE INLET & OUTLET AND SECTIONSEALING
Joystick Removal & Replacement
Lever Control Removal & Replacement
PRESSURE TESTING
BENCH TESTING JOYSTICK CONTROL LEVER
BENCH TESTING SWAY/STABILISER CONTROL LEVERS
Fault Finding Contents (530-110 And 530-120)
SCHEMATIC HYDRAULIC CIRCUIT (530-120,110)
SCHEMATIC HYDRAULIC CIRCUIT(525-58, 67 up to Machine serial number 567217)
SCHEMATIC HYDRAULIC CIRCUIT(525-58, 67 from Machine serial number 567218 and 527-58, 67 up to Machine serial number 574295)
SCHEMATIC HYDRAULIC CIRCUIT(530-67, 535-67 up to Machine serial number 574295)
SCHEMATIC HYDRAULIC CIRCUIT(527-58, 67 and 535-67 from Machine Serial No. 574296)
WIRING DIAGRAM (530-110, 120)
WIRING DIAGRAM (525-58/67, 527-58/67, 530-67 &||535-67)

5-Engine
Technical Data
General Description
Engine Cover
Engine Oil Filter
Fuel Filter
Fuel Pump
Bleeding
Cooling System
Alternator Drive Belt
Pre-Cleaner
Air Filter
Radiator
Engine Removal & Replacement
Exhauster Removal & Replacement
Turbo Charger Engine Insulation
Naturally Aspirated Engine Insulation

6-Transmission
Technical Data
Recovery Procedure
Syncro Shuttle Oil
General Description
Forward and Reverse Solenoid Operation
Syncromesh
Four-Wheel Drive Clutch Operation
Powershift Transmission
Powershift Drivepaths
Fault Finding
Synjcro Shuttle Removal and Replacement
Torque Converter
Syncro Shuttle Dismantling
Syncro Shuttle Assembly
Solenoid Valve D&A
Reverser Unit Dismantling
Reverser Unit Assembly
Reverser Unit (Later Type) Dismantling
Reverser Unit (Later Type) Assembly
Mechanical 4 Wheel Drive Unit Dismantling
Mechanical 4 Wheel Drive Unit Assembly
Hydraulic 4 Wheel Drive Unit Dismantling
Hydraulic 4 Wheel Drive Unit Assembly
Hydraulic 2/4 Wheel Drive Unit IP67 Machines
2/4 Wheel Drive Clutch Fault Finding Finding
Torque Converter Stall Test
Polytetrafluoroethene (PTFE) Piston Ring Seals – Fitting Procedure
PROPSHAFTS
Powershift Removal and Replacement
Powershift Dismantling
Powershift Assembly
Clutch – Dismantling
Clutch -Assembly
Mainshaft – Dismantling
Mainshaft -Assembly
Layshaft- Dismantling
Layshaft -Assembly
Solenoid Identification
Torque Converter Stall Test
Testing For Clutch Leakage
Pressure and Flow Testing

7-Axles
CUTAWAY OF FRONT AXLE
TECHNICAL DATA (525-58/67, 527-58/67, 530-67/95 & 535-67)
TECHNICAL DATA (530-120, 537-120/130)
TECHNICAL DATA (530-110)
ROAD WHEEL
FRONT AXLE BREATHER
AXLE OIL LEVEL
CUTAWAY OF FRONT AXLE
CUTAWAY OF REAR AXLE
FRONT AXLE (FIXED) – REMOVING AND REPLACING
FRONT AXLE (SWAY) – REMOVING AND REPLACING
REAR AXLE – REMOVING AND REPLACING
HUB (DOWEL) AND DRIVESHAFT – DISMANTLING
HUB (DOWEL) AND DRIVESHAFT – ASSEMBLY
FRONT HUB (Splined) and DRIVE SHAFT- DISMANTLING
FRONT HUB (Splined) AND DRIVESHAFT – ASSEMBLY
REAR HUB (Splined), BRAKES AND DRIVESHAFT – DISMANTLING
REAR HUB (Splined), BRAKES AND DRIVESHAFT – ASSEMBLY
BRAKES – DISMANTLING
BRAKES – ASSEMBLY
FRONT DRIVE HEAD – DISMANTLING
FRONT DRIVE HEAD – ASSEMBLY
RENEWING THE AXLE PINION OIL SEAL
REAR DRIVE HEAD – DISMANTLING
REAR DRIVE HEAD – ASSEMBLY
LIMITED SLIP DIFFERENTIAL OPTION

8-Brakes
TECHNICAL DATA (525-58/67, 527-58/67, 530-67 & 535-67)
TECHNICAL DATA (530-120, 537-120/
TECHNICAL DATA (530-95, 110)
Parking Brake
Testing
525 & 528 Machines530-110 Machines to Serial No. 586871
530-110 Machines from Serial No. 586872
Torque Figures
Bleeding Procedure (Front Axle)
Bleeding Procedure (Rear Axle)
SINGLE MASTER CYLINDER WITHOUT SERVO
SINGLE MASTER CYLINDER WITH SERVO
TANDEM MASTER CYLINDER WITH SERVO
SINGLE MASTER CYLINDER WITHOUT SERVO
SINGLE MASTER CYLINDER WITH SERVO
TANDEM MASTER CYLINDER WITH SERVO

9-Hydraulic Steering
TECHNICAL DATA
GENERAL DESCRIPTION
FLOW REGULATING VALVE OPERATION
TANDEM STEERING/FAN MOTOR PUMP
STEERING/FAN MOTOR PUMP
SINGLE STEERING/FAN MOTOR PUMP
SYSTEM OPERATION – 2 WHEEL STEER (Machines without IP67 Electrics)
SYSTEM OPERATION – 4 WHEEL STEER (Machines without IP67 Electrics)
SYSTEM OPERATION – CRAB STEER (Machines without IP^& Electrics)
SYSTEM OPERATION – 2 WHEEL STEER (Machines witH IP67 Electrics)
SYSTEM OPERATION – 4 WHEEL STEER (Machines with IP67 Electrics)
SYSTEM OPERATION – CRAB STEER (Machines with IP67 Electrics)
STEERING UNIT OPERATION 1
STEERING UNIT OPERATION 2
STEERING SHOCK VALVE OPERATION – NORMAL OPERATION
STEERING SHOCK VALVE OPERATION – SHOCK CONDITION
Priority Valve Operation
STEERING UNIT
HYDRAULIC STEERING UNIT
STEERING MODE VALVE(Machines without IP67 electrics)
STEERING MODE VALVE(Machines with IP67 electrics)
STEERING RAM
STEERING RAM Up to m/c no M561929 (525-58,67 Only)
STEERING RAM From m/c no M561930
STEERING RAM
TYPICAL STEER RAM (with dowelled piston head)
BLEEDING
PRESSURE TESTING

10-Electrics
INTRODUCTION
Wire/harness numbers – explanation of:
TECHNICAL DATA
FUSES
RELAYS
TEST METHODS
BATTERIES
ALTERNATOR
ALTERNATOR – A127
STARTING CIRCUIT TEST
STARTER MOTOR – LUCAS M127
CURVES
SAFE LOAD INDICATOR
HARNESS REPAIR
WIRING DIAGRAM ( Machines without IP 67 electrics )
WIRING DIAGRAM ( Machines with IP 67 electrics )
WIRING DIAGRAM(All 527, 535, 537 machines; 525-58/67, 530-95/110 from Serial No. 572168; 530-120 from Serial No. 572242)
WIRING DIAGRAM(530-120 from serial No. 576404 & all 537-120/130)
WIRING DIAGRAM(All machines from serial No. 576404 except 530-120 &537-120/130 machines)

11-Service Tools
SERVICE TOOLS NUMERICAL LIST
SECTION 2 – HYDRAULICS
SECTION 5 – ENGINE
SECTION 6 – TRANSMISSION
SECTION 7 – AXLES
SECTION 9 – STEERING
SECTION 10 – ELECTRICS
SEALING AND RETAINING COMPOUNDS

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