JCB 526/528 Telescopic Handlers OEM Service & Repair Manual

Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE. World Class Customer Support 9803/3710-3 Publication No. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400 Service Manual Rear Engine Loadalls 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 D - Controls Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine

Section 0 - Service Manual 0 - 0 0 - 0 9803/3710-3 Notes:

Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE. World Class Customer Support 9803/3710-3 Publication No. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400 Section 1 General Information Service Manual - Rear Engine Loadalls 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 D - Controls Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine

Section 1 - General Information 1 - 0 1 - 0 9803/3710-3 Notes:

Page No. Contents Section 1 - General Information 1 - i 1 - i Introduction About This Manual ................................................................................... 1 - 1 Machine Model and Serial Number ..................................................... 1 - 1 Using the Service Manual ................................................................... 1 - 1 Units of Measurement ......................................................................... 1 - 1 Section Numbering .............................................................................. 1 - 1 Left Side, Right Side ............................................................................ 1 - 2 Cross References ................................................................................ 1 - 2 Identifying Your Machine ......................................................................... 1 - 3 Machine Identification Plate ................................................................ 1 - 3 Component Identification Plates .......................................................... 1 - 5 Standard Torque Settings Zinc Plated Fasteners and Dacromet Fasteners ..................................... 1 - 8 Introduction .......................................................................................... 1 - 8 Bolts and Screws ................................................................................. 1 - 8 Hydraulic Connections ........................................................................... 1 - 12 'O' Ring Face Seal System ................................................................ 1 - 12 'Torque Stop' Hose System ............................................................... 1 - 15 Service Tools Numerical List ........................................................................................ 1 - 16 Tool Detail Reference ............................................................................ 1 - 19 Section B - Frame and Bodywork ...................................................... 1 - 19 Section C - Electrics .......................................................................... 1 - 23 Section E - Hydraulics ....................................................................... 1 - 24 Section F - Transmission ................................................................... 1 - 30 Section H - Steering .......................................................................... 1 - 32 Section K - Engine ............................................................................. 1 - 33 Service Consumables Sealing and Retaining Compounds ....................................................... 1 - 34 Terms and Definitions Colour Coding ........................................................................................ 1 - 35 Hydraulic Schematic Colour Codes ................................................... 1 - 35

Section 1 - General Information Page left intentionally blank 1 - ii 1 - ii

Section 1 - General Information 1 - 1 1 - 1 9803/3710-3 Introduction About This Manual Machine Model and Serial Number This manual provides information for the following model(s) in the JCB machine range: – 526 from SN 1182000 – 526S from SN 1182000 – 528-70 from SN 1182000 – 528S from SN 1182000 Using the Service Manual T11-004 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. The illustrations in this publication are for guidance only. Where the machines differ, the text and/or the illustration will specify. General warnings in Section 2 are repeated throughout the manual, as well as specific warnings. Read all safety statements regularly, so you do not forget them. 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. 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. The manufacturer's policy is one of continuous improvement. The right to change the specification of the machine without notice is reserved. No responsibility will be accepted for discrepancies which may occur between specifications of the machine and the descriptions contained in this publication. Finally, please remember above all else safety must come first! Units of Measurement T1-001_2 In this publication, the S.I. system of units is used. For example, liquid capacities are given in litres. The Imperial units follow in parentheses ( ) eg 28 litres (6 gal). Section Numbering T11-005 The manual is compiled in sections, the first three are numbered and contain information as follows: The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for example: Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each alphabetically coded section. 1 General Information - includes torque settings and service tools. 2 Care and Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc. 3 Maintenance - includes service schedules and recommended lubricants for all the machine. A Attachments B Body and Framework, etc.

Section 1 - General Information Introduction About This Manual 1 - 2 1 - 2 9803/3710-3 Left Side, Right Side In this manual, 'left' A and 'right' B mean your left and right when you are seated correctly in the machine. Fig 1. Cross References T1-004_2 In this publication, page cross references are made by presenting the subject title printed in bold, italic and underlined. It is preceeded by the 'go to' symbol. The number of the page upon which the subject begins, is indicated within the brackets. For example: K Cross References ( T 1-2) .

Section 1 - General Information Introduction Identifying Your Machine 1 - 3 1 - 3 9803/3710-3 Identifying Your Machine Machine Identification Plate Your machine has an identification plate mounted as shown. K Fig 2. ( T 1-3) . The serial numbers of the machine and its major units are stamped on the plate. Note: The machine model and build specification is indicated by the VIN (earlier machines) or PIN (later machines). A detailed description of the VIN/PIN numbering system is included later in this section. 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. Fig 2. Typical Vehicle Identification Number (VIN) T011101-2 1 World Manufacturer Identification (3 Digits) 2 Machine Model (3 Digits) 3 Engine Type (1 Digit) 4 Gearbox Model (1 Digit) 5 Year of Manufacture (1 Digit) 6 Manufacturer Location (1 Digit) E = England 7 Machine Serial Number (7 Digits) Each machine has a unique serial number. 5BA = 526 5BC = 526 USA 5BB = 528-70 5BD = 528S JCB Dieselmax: J = SA Build L = SC Build K = SB Build A = 3 Speed C = 4 Speed B = 5 Speed 5 = 2005 7 = 2007 6 = 2006

Section 1 - General Information Introduction Identifying Your Machine 1 - 4 1 - 4 9803/3710-3 Typical Product Identification Number (PIN) T011100-2 1 World Manufacturer Identification (3 Digits) 2 Machine Model (3 Digits) 3 Engine Type (1 Digit) 4 Gearbox Model (1 Digit) 5 Randomly generated check letter (1 Digit) 6 Year of Manufacture (1 Digit) 7 Machine Serial Number (7 Digits) Each machine has a unique serial number. 5BA = 526 5BC = 526 USA 5BB = 528-70 5BD = 528S JCB Dieselmax: J = SA Build L = SC Build K = SB Build A = 3 Speed C = 4 Speed B = 5 Speed 5 = 2005 7 = 2007 6 = 2006 8 = 2008

JCB 526/528 Telescopic Handlers OEM Service & Repair Manual

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