JCB 526, 528 Rear Engine Loadalls Service Manual – 9803/3710-3

(S/N: 1182000 Onwards)
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This workshop repair 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.

APPLICABLE MODELS :

– JCB Loadall 526-55 (JCB 444 Engine) – from S/N: 1182000 Onwards
– JCB Loadall 526S (JCB 444 Engine) – from S/N: 1182000 Onwards
– JCB Loadall 528-70 (JCB 444 Engine) – from S/N 1182000 Onwards
– JCB Loadall 528S (JCB 444 Engine) – from S/N: 1182000 Onwards

TABLE OF CONTENTS :

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
P/N : 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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More Info : http://www.sitelux.com

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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

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