JCB 525-50 loadall telehandler service and repair manual

General Information 1 Care & Safety 2 Routine Maintenance 3 Attachments A Body & Framework B Electrics C Controls D Hydraulics E Transmission F Brakes G Steering H Engine K R Service Manual Loadall Models: 520-50 from Serial No. 754001 525-50 from Serial No. 789308 525-50S from Serial No. 1037581 PUBLISHED BY THE TECHNICAL PUBLICATIONS DEPARTMENT OF JCB SERVICE; © WORLD PARTS CENTRE, WATERLOO PARK, UTTOXETER, ST14 5PA, ENGLAND Tel. 01889 - 590312 PRINTED IN ENGLAND Publication No. 9803/3620 Issue 9

Introduction This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training by JCB Technical Training Department. These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated with the maintenance and repair of hydraulic earthmoving equipment. Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt. Finally, please remember above all else SAFETY MUST COME FIRST! The manual is compiled in sections, the first three are numbered and contain information as follows: 1 = General Information - includes torque settings and service tools. 2 = Care & Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc. 3 = Routine Maintenance - includes service schedules and recommended lubricants for all the machine. The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for example: A = Attachments B = Body & Framework ...etc. The page numbering in each alphabetically coded section is not continuous. This allows for the insertion of new items in later issues of the manual. Section contents, technical data, circuit descriptions, operation descriptions etc are inserted at the beginning of each alphabetically coded section. READ the section contents to locate machine types, machine type indentification IS NOT listed on individual pages. All sections are listed on the front cover; tabbed divider cards align directly with individual sections on the front cover for rapid reference. Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry threads, hence for lubricated threads may be reduced by one third. 'Left Hand' and 'Right Hand' are as viewed from the rear of the machine facing forwards. This Service Manual covers the following machines: 520-50 (520 N. Am.) - from Machine Serial Number 754001 525-50 - from Machine Serial Number 789308 525-50S - from Machine Serial Number 1037581 9803/3620 Issue 5*

i Section 1 General Information 9803/3620 Section 1 i Issue 2* Contents Page No. Identification 1 - 1 Torque Settings 2 - 1 Service Tools - Numerical List 3 - 1 - Section C 4 - 1 - Section E 5 - 1 - Section F 6 - 1 - Section H 7 - 1 - Section K 7 - 1 Sealing and Retaining Compounds 8 - 1

1 - 1 Identification Plate Your machine has an identification plate V mounted as shown. The serial numbers of the machine and its major units are stamped on the plate. Explanation of Vehicle Identification Number (VIN) SLP52050RE0754001 A B C D E A World Manufacturer Identification SLP = JCB B Machine Model 520-50 C Year of Manufacture S P = 1993 V = 1997 1 = 2001 R = 1994 W = 1998 2 = 2002 S = 1995 X = 1999 3 = 2003 T = 1996 Y = 2000 4 = 2004 D Manufacturing Location E = England E Machine Serial Number 0754001 Machine Model Explanation 520 - 50 FG H F 500 Series machine range G 2.0 tonnes lift capacity H 5.0 metres lift height The serial number of each major unit is also stamped on the unit itself. If a major unit is replaced by a new one, the serial number on the identification plate will be wrong. Either stamp the new number of the unit on the identification plate, or simply stamp out the old number. This will prevent the wrong unit number being quoted when replacement parts are ordered. The machine and engine serial numbers can help identify exactly the type of equipment you have. General Information 9803/3620 1 - 1 Issue 4* Section 1 Section 1 Unit Identification The engine serial number is stamped on label W which is fastened to the right side of the cylinder block, near the fuel filter. Explanation of Engine Identification Number AA 50261 U 500405 P A B C D E A Engine Type: A series AK = 4 cylinder turbo - low emission, stage 1 AR = 4 cylinder naturally aspirated - low emission, stage 1 R Series RE = 4 cylinder naturally aspirated, low emission, stage 2 RG = 4 cylinder turbo, low emission stage 2 RJ = 4 cylinder air to air charge cooled, low emission, stage 2 B Build Number C Country of Manufacture D Engine Serial Number E Year of Manufacture If service information or parts are required, the complete engine number should be quoted. If there is also a number marked ‘TPL No’, this should be quoted also. If a short engine has been fitted in service, two engine serial numbers and a TPL No. are stamped on the serial number plate as at Z. All the numbers should be quoted when requiring parts or information. Note: Where the procedures in this manual differ according to engine types, the text and/or illustrations will specify which engine types apply. Transmission and axle identification is shown on the next page. W S181760 V 430250

The Transmission serial number is stamped on label Y which is mounted on the rear face. The rear axle serial number is stamped on plate X mounted to the front face of the axle. The front axle serial number is stamped on plate Z mounted on the rear face of the arm. 1 - 2 Section 1 General Information 9803/3620 Section 1 1 - 2 Issue 1 X S241310 S241320 S241330 Y Z

2 - 1 Section 1 General Information 9803/3620 Section 1 2 - 1 Issue 1 Torque Settings Use only where no torque setting is specified in the text. Values are for dry threads and may be within three per cent of the figures stated. For lubricated threads the values should be REDUCED by one third. UNF Grade 'S' Bolts Bolt Size Hexagon (A/F) Torque Settings in (mm) in Nm kgf m lbf ft 1 /4 (6.3) 7 /16 14 1.4 10 5 /16 (7.9) 1 /2 28 2.8 20 3 /8 (9.5) 9 /16 49 5.0 36 7 /16 (11.1) 5 /8 78 8.0 58 1 /2 (12.7) 3 /4 117 12.0 87 9 /16 (14.3) 13 /16 170 17.3 125 5 /8 (15.9) 15 /16 238 24.3 175 3 /4 (19.0) 1 1 /8 407 41.5 300 7 /8 (22.2) 1 5 /16 650 66.3 480 1 (25.4) 1 1 /2 970 99.0 715 1 1 /4 (31.7) 1 7 /8 1940 198.0 1430 1 1 /2 (38.1) 2 1 /4 3390 345.0 2500 Metric Grade 8.8 Bolts Bolt Size Hexagon (A/F) Torque Settings (mm) mm Nm kgf m lbf ft M5 (5) 8 7 0.7 5 M6 (6) 10 12 1.2 9 M8 (8) 13 28 3.0 21 M10 (10) 17 56 5.7 42 M12 (12) 19 98 10 72 M16 (16) 24 244 25 180 M20 (20) 30 476 48 352 M24 (24) 36 822 84 607 M30 (30) 46 1633 166 1205 M36 (36) 55 2854 291 2105 Rivet Nut Bolts/Screws Bolt Size Torque Settings (for steel rivet nuts) (mm) Nm kgf m lbf ft M3 (3) 1.2 0.12 0.9 M4 (4) 3.0 0.3 2.0 M5 (5) 6.0 0.6 4.5 M6 (6) 10.0 1.0 7.5 M8 (8) 24.0 2.5 18.0 M10 (10) 48.0 4.9 35.5 M12 (12) 82.0 8.4 60.5 Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification.

3 - 1 Service Tools Numerical List Page No 1406/0011 Bonded Washer 5-1 1406/0014 Bonded Washer 5-1 1406/0021 Bonded Washer 5-1 1406/0029 Bonded Washer 5-1 1604/0003 Adapter 5-3 1604/0004 Adapter 5-3 1604/0006 Adapter 5-1 1606/0003 Adapter 5-3 1606/0004 Adapter 5-3 1606/0007 Adapter 5-3 1606/0008 Adapter 5-3 1606/0009 Adapter 5-3 1606/0012 Adapter 5-3 1606/0014 Adapter 5-3 1606/0015 Adapter 5-3 1606/0017 Adapter 5-3 1612/0006 Adapter 5-1 4101/0251 Threadlocker and Sealer 8-1 4101/0451 Threadlocker 8-1 4101/0552 Threadlocker and Sealer (High Strength) 8-1 4101/0651 Retainer (High Strength) 8-1 4102/0551 High Strength Threadlocker 8-1 4102/1201 Multi-Gasket 8-1 4102/1951 Threadseal 8-1 4104/0251 Activator (Aerosol) 8-1 4104/0253 Activator (Bottle) 8-1 4104/1557 Cleaner/Degreaser 8-1 816/00189 Blanking Cap 5-2 816/00190 Blanking Cap 5-2 816/00193 Blanking Cap 5-2 816/00196 Blanking Cap 5-2 816/00197 Blanking Cap 5-2 816/00294 Blanking Cap 5-2 816/15118 Pressure Test Adapter 5-3 816/20008 Adapter 5-1 816/55038 Pressure Test Adapter 5-1 816/55040 Pressure Test Adapter 5-1 816/50043 'T' Adapter 5-2 892/00039 Spool Clamp 5-2 892/00041 De-glazing Tool 7-1 892/00047 'T' Adapter 5-2 892/00048 'T' Adapter 5-2 892/00049 'T' Adapter 5-2 892/00051 'T' Adapter 5-2 892/00055 Blanking Plug 5-2 892/00056 Blanking Plug 5-2 892/00057 Blanking Plug 5-2 892/00058 Blanking Plug 5-2 892/00059 Blanking Plug 5-2 892/00060 Blanking Plug 5-2 892/00071 Adapter 5-3 892/00074 Female Connector 5-2 892/00075 Female Connector 5-2 892/00076 Female Connector 5-2 892/00077 Female Connector 5-2 892/00121 Discharge Tester 4-1 892/00137 Micro-Bore Hose 5-3 892/00179 Bearing Press 6-1 892/00180 Seal Fitting Tool 7-1 892/00181 Plastic Boss 7-1 Page No 892/00223 Hand Pump 5-3 892/00225 Adapter - Impulse Extractor 6-2 892/00253 Pressure Test Kit 5-1 892/00255 1 /4'' BSP Test Point 5-3 892/00256 3 /8'' BSP Test Point 5-3 892/00257 1 /2'' BSP Test Point 5-3 892/00258 5 /8'' BSP Test Point 5-3 892/00259 1'' BSP Test Point 5-3 892/00260 1 1 /4'' BSP Test Point 5-3 892/00261 5 /8'' UNF Test Point 5-3 892/00262 1 /4'' M BSP 1/4'' F BSP 5-1 892/00263 5 /8'' M BSP 5/8'' F BSP 5-1 892/00264 3 /4'' M BSP 3/4'' F BSP 5-1 892/00265 1'' M BSP 1'' F BSP 5-1 892/00268 Flow Monitoring Unit 5-1 892/00269 Sensor Head 5-1 892/00270 Load Valve 5-1 892/00271 Adapter 5-1 892/00272 Adapter 5-1 892/00274 Adapter 5-3 892/00275 Adapter 5-1 892/00276 Adapter 5-1 892/00277 Adapter 5-1 892/00279 Gauge 5-3 892/00281 AVO Meter 4-1 892/00282 Shunt 4-1 892/00283 Tool Kit Case 4-1 892/00284 Digital Tachometer 4-1 892/00285 Hyd. Oil Temperature Probe 4-1 892/00286 Surface Temperature Probe 4-1 892/00295 End Float Setting Tool 6-1 892/00301 Flow Test Adapter 6-1 892/00302 Flow Test Adapter 6-1 892/00304 Flow Test Adapter 6-1 892/00333 Heavy Duty Socket 6-2 892/00706 Test Probe 5-3 892/00817 Heavy Duty Socket 6-2 892/00818 Heavy Duty Socket 6-2 892/00819 Heavy Duty Socket 6-2 892/00836 Lifting Wire Assembly 7-2 892/00891 Seal Fitting Adaptor 6-2 892/00923 Test Block for ARV 5-3 892/00936 Timing Pin 7-2 892/01054 Compression Adaptor 7-2 892/01111 Rocker Assembly Tool 7-2 892/01112 Timing Case Alignment Tool 7-2 892/01113 Thermostat Fitting & Removal Tool 7-2 892/01114 Camshaft Gear Timing Pin 7-2 892/01115 Crankshaft Timing Pin 7-2 992/02800 ARV Extractor 5-2 992/04000 Torque Multiplier 6-2 992/04800 Drive Coupling Spanner 6-1 992/07603 Replacer- Bearing Cup 6-1 992/07608 Bearing Adapter 6-1 992/07609 Bearing Adapter 6-1 992/07610 Bearing Adapter 6-1 992/07611 Bearing Adapter 6-1 992/07612 Bearing Adapter 6-1 992/07613 Bearing Adapter 6-1 Section 1 General Information 9803/3620 Section 1 3 - 1 Issue 4* *

3 - 2 Service Tools (cont'd) Numerical List Page No 992/09500 Spanner 5-2 992/09700 Spanner 5-2 992/10100 Spool Clamp 5-2 992/10900 Test Harness for S.L.I 4-1 993/59300 2/4 Wheel Pressure Tester & Clamp 6-2 993/59500 Adapter - Impulse Extractor 6-2 993/99412 Adaptor Harness 4-1 The following parts are replacement items for kits and would normally be included in the kit numbers above. Replacement item for kit no. 892/00180 892/00181 Replacement Boss 7-1 Replacement item for kit no. 892/00253 892/00201 Replacement Gauge 5-1 892/00202 Replacement Gauge 5-1 892/00203 Replacement Gauge 5-1 892/00254 Replacement Hose 5-1 Section 1 General Information 9803/3620 Section 1 3 - 2 Issue 2* *

JCB 525-50 loadall telehandler service and repair manual

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