JCB 520-55 RS, 520-55 AWS, 526-55, 526-55 AWS, 526S AWS Telescopic Handler Service Repair Manual Instant Download

1
General Information 1
R
Service Manual LOADALL PUBLISHED
BY THE TECHNICAL PUBLICATIONS DEPARTMENT OF JCB
SERVICE WATERLOO PARK, UTTOXETER, ST14 5PA,
ENGLAND Tel. 01889 - 590312 PRINTED IN
ENGLAND Publication No. 9803/3610 Issue 10
2
Care Safety
Routine Maintenance 3
A
Attachments
Body Framework B
C
Electrics
D
Controls
E
Hydraulics
F
Transmission
G
Brakes
H
Steering
K
Engine
2
Introduction This publication is designed for the
benefit of JCB Distributor Service Engineers who
are receiving, or have received, training by JCB
International Training Centre. 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! How to use
this manual The manual is compiled in sections,
the first three are numbered and contain
information as follows
1 2 3
General Information - includes torque settings
and service tools. Care Safety - includes
warnings and cautions pertinent to aspects of
workshop procedures etc. 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 B
Attachments 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
identification IS NOT listed on individual
pages. All sections are listed on the title
page 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, from Serial Number 277001
520-55 RS (Rear Steering) Farm Special
Construction 520-55 AWS (All Wheel Steering) Farm
Special Construction 526-55 Farm Special
Construction 526-55 AWS (All Wheel Steering) Farm
Special Construction 526S AWS (All Wheel
Steering) Farm Special Construction
9803/3695
Issue 5
3
Machine History Date Machine Description
1993 520-55 RS The machine incorporated twin brake
Serial No. (277001 - 279114) pedals to operate an independent brake circuit controlling each of the front
277001 Machine introduction wheels. This allowed single wheel braking
to reduce the turning circle. The pedals
could be locked together for road use.
The machine was also equipped with
manually selectable 2/4-wheel drive.
1994 520-55 AWS (504B N.Am) The machine was fitted with permanent
Serial No. (277386 - 278966) four wheel steering and four-wheel braking.
277386 Machine introduction
278610 JCB axles, drop box and 4 wheel power
brakes fitted.
1994 526-55 Introduced as a development of the 520-
Serial No. (277467 - 278966) 55 with a stronger inner boom and larger lift, tilt and displacement rams. The
machine was fitted with JCB
277468
Machine introduction
manufactured axles and drop box, and
incorporated four-wheel power brakes. The
machine was equipped with three manually
selectable steering modes and an optional
turbo-charged engine was available.
1996
520 526 520 (278967 onwards) 526 (278967 -
279567)
520-55 and 526-55 machines re-named 520 and 526.
These machines incorporated a revised hydraulic
tank, plastic fuel tank, fenders and engine
cover.
Serial No. 278967
Machine introduction
1996
526, 526S (526 Am.N) (279289 onwards)
The 526 and 526S machine incorporated a longer
wheelbase to allow for 24in. wheels and tyres on
the 526S machine only.
Serial No. 279289
Machine introduction
280300
ECU controlled powershift available as an
option. Single lever control and trailer
braking. Power brakes replaced by inboard, front
axle brakes.
Drop box fitted with helical gears from axle
serial number 453/275/00005.
280577
ECU control was replaced by relay controlled
transmission.
1996
520S (279598 onwards)
Introduced as a 90 hp turbo-charged engine
version of the 520 machine. The stronger inner
boom on the 526 was introduced to cope with the
increased engine power.
Serial No. 279598
Machine introduction
9803/3630
Issue 1
4
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5
Section 1 General Information Section 1
i i
Contents Page No.
Identification 1 - 1
Torque Settings 2 - 1
Service Tools
- Numerical List 3 - 1
- Section B 3 - 3
- 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
9803/3610
Issue 2
6
General Information
Section 1
Section 1
1 - 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.
Unit Identification The engine serial number is
stamped on label W which is fastened to the
right side of the cylinder block at Y, near the
fuel filter. Explanation of Engine Identification
Number
W Y Z
V
Typical Engine Identification Number AA 50261 U
500405 P A B C D E A Engine Type A series AA
4 cylinder naturally aspirated AB 4 cylinder
turbo 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
S195340
Explanation of Vehicle Identification Number (VIN)
SLP52655RE0277001 A B C D E

1. World Manufacturer Identification
2. Machine Model
3. Year of Manufacture

SLP JCB 526-55 S 1 2001 2 2002 3 2003 4
2004 E England 0277001
P 1993 R 1994 S 1995 T 1996
V 1997 W 1998 X 1999 Y 2000
B Build Number

1. Manufacturing Location
2. Machine Serial Number

C Country of Manufacture
Machine Model Explanation
D Engine Serial Number

• 526 - 55
• FG H
• 500 Series machine range
• 2.6 tonnes lift capacity
• 5.5 meters lift height

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.
With the introduction of the longer wheel base
machine the lift height has been deleted from
the serial number.
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.
526 FG

1. 500 Series machine range
2. 2.6 tonnes lift capacity

Note Where the procedures in this service 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.
9803/3610
Issue 4
7
Section 1
General Information
Section 1
1 - 2
1 - 2
Y
S088470
S196280
Z
S196290
The Syncro Shuttle serial number is stamped on
label Y as shown. The rear axle serial number
is stamped on plate X as shown. The front axle
serial number is stamped on plate Z as shown.
9803/3610
Issue 2
8
Section 1
General Information
Section 1
2 - 1
2 - 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 in (mm) Hexagon (A/F) in Nm Torque Settings 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
(14.3) (15.9)
13 /16 15 /16
170 17.3 125
238 24.3 175
9/16 5/8
3/4 (19.0) 11 /8 407 41.5 300
7/8 (22.2) 15 /16 650 66.3 480
11 /2 17 /8 21 /4
1 11 /4 11 /2
(25.4) (31.7) (38.1)
970 99.0 715
1940 198.0 1430
3390 345.0 2500
Metric Grade 8.8 Bolts Bolt Size (mm) Hexagon (A/F) mm Nm Torque Settings 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.
9803/3610
Issue 2
9
Section 1
General Information
Section 1
8 - 1
8 - 1
Sealing and Retaining Compounds
JCB Multi-Gasket A medium strength sealant suitable for all sizes of gasket flanges, and for hydraulic fittings
of 25-65mm diameter. 4102/1212 50ml
JCB High Strength Threadlocker A high strength locking fluid for use with threaded components. Gasketing for all sizes of flange where the strength of the joint is important. 4102/0551 50ml
JCB Retainer (High Strength) For all retaining parts which are unlikely to be dismantled. 4101/0651 50ml
JCB Threadlocker and Sealer A high strength locking fluid for sealing 4101/0250 10ml
and retaining nuts, bolts, and screws up to 50mm diameter, and for hydraulic fittings up to 25mm diameter. 4101/0251 50ml
Threadseal A medium strength thread sealing compound. 4102/1951 50ml
Threadlocker A locking fluid for use on threads larger than 50mm dia. 4101/0451 50ml
Activator A cleaning primer which speeds the curing rate 4104/0251 (1ltr)
of anaerobic products. (200ml) 4104/0253 Bottle
Cleaner / Degreaser For degreasing components prior to use of anaerobic adhesives and sealants. 4104/1557 400ml
Direct Glazing Kit For one pane of glass, comprises items marked below plus applicator nozzle etc. 993/55700
Ultra Fast Adhesive For direct glazing 4103/2109 310 ml
Active Wipe 205 For direct glazing 4104/1206 30 ml
4104/1203 250 g
Black Primer 206J For direct glazing 4201/4906 30 ml
Clear Silicone Sealant To seal butt jointed glass 4102/0933
Black Polyurethane Sealant To finish exposed edges of laminated glass 4102/2309 310 ml
JCB Cleaner Degreaser For degreasing components prior to use of anaerobic adhesives and sealants. 4104/1538 Aerosol
9803/3610
Issue 6
10
Care Safety
Section 2
Section 2
i
i
Contents
Page No.
Safety Notices
1 - 1
General safety
2 - 1
Operating safety
2 - 2
Maintenance safety
2 - 3
Lubricants - Health and Safety
3 - 1
9803/3610
Issue 1
11
Care Safety
Section 2
Section 2
1 - 1
1 - 1
Safety Notices In this handbook and on the
machine there are safety notices. Each notice
starts with a signal word. The signal word
meanings are given below. 8 DANGER Denotes an
extreme hazard exists. If proper precautions are
not taken it is highly probable that the
operator (or others) could be killed or seriously
injured. INT-1-2-1 8 WARNING Denotes a hazard
exists. If proper precautions are not taken, the
operator (or others) could be killed or
seriously injured. INT-1-2-2 8 CAUTION Denotes a
reminder of safety practices. Failure to follow
these safety practices could result in injury to
the operator (or others) and possible damage to
the machine. INT-1-2-3
9803/3610
Issue 1
12
Care Safety
Section 2
Section 2
2 - 1
2 - 1
All construction and agricultural equipment can
be hazardous. When a JCB machine is correctly
operated and properly maintained, it is a safe
machine to work with. But when it is carelessly
operated or poorly maintained it can become a
danger to you (the operator) and others.
As well as the warnings in this chapter, specific
warnings are given throughout the book. This
section is designed to give a safety code for
use of the machine generally and for maintenance
practices.
Do not work with the machine until you are sure
that you can control it. Do not start any job
until you are sure that you and those around you
will be safe. If you are unsure of anything,
about the machine or the job, ask someone who
knows. Do not assume anything. Remember BE
CAREFUL BE ALERT BE SAFE
GEN-1-6
General Safety
8 WARNING Care and Alertness All the time you are
working with or on the machine, take care and
stay alert. Always be careful. Always be alert
for hazards. INT-1-3-5 8 WARNING Raised Boom A
raised boom can fall or be lowered accidentally.
Do not walk under a raised boom which is not
fitted with a safety strut, or you could be
injured. 5-1-1-1 8 WARNING Lifting Equipment You
can be injured if you use faulty lifting
equipment. Make sure that lifting equipment is
in good condition. Make sure that lifting tackle
complies with all local regulations and is
suitable for the job. Make sure the lifting
equipment is strong enough for the job. INT-1-3-7
8 WARNING Decals You can be injured if you do not
obey the decal safety instructions. Keep decals
clean. Replace unreadable or missing decals with
new ones before operating the machine. Make sure
replacement parts include warning decals where
necessary. INT-1-3-4 8 WARNING Clothing You can
be injured if you do not wear proper clothing.
Loose clothing can get caught in the machinery.
Wear protective clothing to suit the job.
Examples of protective clothing are a hard
hat, safety shoes, safety glasses, a well-fitting
overall, ear-protectors and industrial gloves.
Keep cuffs fastened. Do not wear a necktie or
scarf. Keep long hair restrained. INT-1-3-6
9803/3610
Issue 1
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Care Safety
Section 2
Section 2
2 - 2
2 - 2
8 WARNING Engine Panels The engine has exposed
rotating parts. Do not open the bonnet while the
engine is running. Keep other people clear while
you raise the engine cover using the boom. Do not
use the machine with the bonnet open or the
cover raised. 5-1-2-1 8 WARNING ROPS/FOPS
Structure The machine is fitted with a Roll Over
Protection Structure (ROPS) and a Falling
Objects Protection Structure (FOPS). You could
be killed or seriously injured if you operate the
machine with a damaged or missing ROPS/FOPS. If
the ROPS/FOPS has been in an accident, do not
use the machine until the structure has been
renewed. Modifications and repairs that are not
approved by the manufacturer may be dangerous
and will invalidate the ROPS/ FOPS
certification INT-2-1-9/3 8 WARNING Reversing Rev
ersing at high speed can cause accidents. Do not
reverse in third or fourth (if fitted) gear with
full throttle. Always drive at a safe speed to
suit working conditions. INT-2-2-9 8
WARNING Communications Bad communications can
cause accidents. Keep people around you informed
of what you will be doing. If you will be
working with other people, make sure any hand
signals that may be used are understood by
everybody. Work sites can be noisy, do not rely
on spoken commands. INT-2-2-3 8
WARNING Sparks Explosions and fire can be caused
by sparks from the exhaust or the electrical
system. Do not use the machine in closed areas
where there is flammable material, vapour or
dust. INT-2-2-10 8 CAUTION Overhead Clearance A
raised boom can strike overhead objects. Always
check for overhead clearance before raising the
boom. 5-1-5-1
Operating Safety 8 WARNING Controls You or others
can be killed or seriously injured if you operate
the control levers from outside the cab. Operate
the control levers only when you are correctly
seated inside the cab. INT-2-1-3 8
WARNING Entering/Leaving Always face the machine
when entering and leaving the cab. Use the
step(s) and handrails. Make sure the step(s),
handrails and your boot soles are clean and dry.
Do not jump from the machine. Do not use the
machine controls as handholds, use the
handrails. INT-2-1-7 8 WARNING Passengers Passeng
ers in or on the machine can cause accidents. The
JCB Loadall is a one man machine. Do not carry
passengers. INT-2-2-2 8 WARNING Exhaust
Gases Breathing the machine exhaust gases can
harm and possibly kill you. Do not operate the
machine in closed spaces without making sure
there is good ventilation. If possible, fit an
exhaust extension. If you begin to feel drowsy,
stop the machine at once. Get out of the cab into
fresh air.
INT-2-1-10
8 WARNING
Ramps and Trailers Water, mud, ice, grease and
oil on ramps or trailers can cause serious
accidents. Make sure ramps and trailers are
clean before driving onto them. Use extreme
caution when driving onto ramps and
trailers. INT-2-2-6 8 WARNING Fires If your
machine is equipped with a fire extinguisher,
make sure it is checked regularly. Keep it in
the operator's cab until you need to use it.
Do not use water to put out a machine fire, you
could spread an oil fire or get a shock from an
electrical fire. Use carbon dioxide, dry
chemical or foam extinguishers. Contact your
nearest fire department as quickly as possible.
Firefighters should use self-contained breathing
apparatus INT-3-2-7/1
9803/3610
Issue 1
14
Care Safety
Section 2
Section 2
2 - 3
2 - 3
Maintenance Safety 8 WARNING Metal Splinters You
can be injured by flying metal splinters when
driving metal pins in or out. Use a soft-faced
hammer or drift to remove and fit metal pins.
Always wear safety glasses. INT-3-1-3 8
WARNING Boom Safety Strut A raised boom can drop
suddenly and cause serious injury. Before
working under a raised boom, fit the boom safety
strut. See Boom Safety Strut (MAINTENANCE
section). 5-1-5-7 8 WARNING Communications Bad
communictions can cause accidents. If two or more
people are working on the machine, make sure
each is aware of what the others are doing.
Before starting the engine make sure the others
are clear of danger areas examples of danger
areas are the rotating blades and belt on the
engine, the attachments and linkages, and
anywhere beneath or behind the machine. People
can be killed or injured if these precautions
are not taken. INT-3-1-5 8 WARNING Asbestos Asbes
tos dust can damage your lungs. Some engine
gaskets contain asbestos. Do not dismantle the
engine or exhaust system get these jobs done by
a qualified person who has a copy of the engine
service manual. 5-1-6-1 8 WARNING Battery
Gases Batteries give off explosive gases. Keep
flames and sparks away from the battery. Do not
smoke close to the battery. Make sure there is
good ventilation in closed areas where batteries
are being used or charged. Do not check the
battery charge by shorting the terminals with
metal use a hydrometer or voltmeter. INT-3-1-8
8 DANGER Electrolyte Battery electrolyte is toxic
and corrosive. Do not breathe the gases given
off by the battery. Keep the electrolyte away
from your clothes, skin, mouth and eyes. Wear
safety glasses. See Battery (MAINTENANCE
section) for First Aid treatments. INT-3-2-1/2
8 WARNING Jacking A machine can roll off jacks
and crush you unless the wheels have been
chocked. Always chock the wheels at the opposite
end of the machine that is to be jacked. Do not
work underneath a machine supported only by
jacks. Always support a jacked-up machine on
axle stands before working underneath it.
INT-3-2-8
8 WARNING
Diesel Fuel Diesel fuel is flammable keep naked
flames away from the machine. Do not smoke while
refuelling the machine or working on the engine.
Do not refuel with the engine running. There
could be a fire and injury if you do not follow
these precautions. INT-3-2-2 8 WARNING Hot
Coolant The cooling system is pressurised when
the engine is hot. Hot coolant can spray out
when you remove the radiator cap. Let the system
cool before removing the radiator cap. To remove
the cap turn it to the first notch and let the
system pressure escape, then remove the
cap. INT-3-2-9 8 WARNING Petrol Do not use
petrol in this machine. Do not mix petrol with
the diesel fuel in storage tanks the petrol
will rise to the top and form flammable
vapours. INT-3-1-6 8 WARNING Oil Oil is toxic.
If you swallow any oil, do not induce vomiting,
seek medical advice. Used engine oil contains
harmful contaminants which can cause skin
cancer. Do not handle used engine oil more than
necessary. Always use barrier cream or wear
gloves to prevent skin contact. Wash skin
contaminated with oil thoroughly in warm soapy
water. Do not use petrol, diesel fuel or
paraffin to clean your skin. INT-3-2-3 8
WARNING Electrical Circuits Understand the
electrical circuit before connecting or
disconnecting an electrical component. A wrong
connection can cause injury and/or
damage. INT-3-1-4
9803/3610
Issue 1
15
Section 2
Care Safety
Section 2
2 - 4
2 - 4
8 WARNING Battery Terminals The machine is
negatively earthed. Always connect the negative
pole of the battery to earth.
8 WARNING Hydraulic Fluid Fine jets of hydraulic
fluid at high pressure can penetrate the skin.
Do not use your fingers to check for hydraulic
fluid leaks. Do not put your face close to
suspected leaks. Hold a piece of cardboard close
to suspected leaks and then inspect the
cardboard for signs of hydraulic fluid. If
hydraulic fluid penetrates your skin, get
medical help immediately. INT-3-1-10/1 8
WARNING Hydraulic Pressure Hydraulic fluid at
system pressure can injure you. Before
disconnecting or connecting hydraulic hoses, stop
the engine and operate the controls to release
pressure trapped in the hoses. Make sure the
engine cannot be started while the hoses are
open. INT-3-1-11/1
When connecting the battery, connect the earth
(-) lead last.
When disconnecting the battery, disconnect the
earth (-) lead first. INT-3-1-9 8
WARNING Fluoroelastomeric Materials Certain
seals and gaskets (e.g. crankshaft oil seal)
on JCB machines contain fluoroelastomeric
materials such as Viton, Fluorel and Technoflon.
Fluoroelastomeric materials subjected to high
temperatures can produce highly corrosive
hydrofluoric acid. THIS ACID CAN SEVERELY BURN.
New fluoroelastomeric components at ambient
temperature require no special safety
precautions.
8 WARNING Battery A battery with frozen
electrolyte can explode if it is used or
charged. Do not use a machine with a frozen
battery. To help prevent the battery from
freezing, keep the battery fully
charged. INT-3-1-7 8 CAUTION Cleaning Cleaning
metal parts with incorrect solvents can cause
corrosion. Use only recommended cleaning agents
and solvents. INT-3-2-11 8 CAUTION 'O' rings,
Seals and Gaskets Badly fitted, damaged or rotted
'O' rings, seals and gaskets can cause leakages
and possible accidents. Renew whenever disturbed
unless otherwise instructed. Do not use
Triochloroethane or paint thinners near 'O' rings
and seals. INT-3-2-12 8 WARNING Soft Ground A
machine can sink into soft ground. Never work
under a machine on soft ground. INT-3-2-4 8
WARNING Hydraulic Hoses Damaged hoses can cause
fatal accidents. Inspect the hoses regularly
for Damaged end fittings Chafed outer covers
Ballooned outer covers Kinked or crushed
hoses Embedded armouring in outer covers
Displaced end fittings. INT-3-3-2
Used fluoroelastomeric components whose
temperatures have not exceeded 300C require no
special safety precautions. If evidence of
decomposition (e.g. charring) is found, refer to
the next paragraph for safety instructions DO
NOT TOUCH COMPONENT OR SURROUNDING AREA.
Used fluoroelastomeric components subjected to
temperatures greater than 300C (e.g. engine
fire) must be treated using the following safety
procedure. Make sure that heavy duty gloves and
special safety glasses are worn
1 Ensure that components have cooled then remove
and place material into plastic bags.
2 Thoroughly wash contaminated area with 10
calcium hydroxide or other suitable alkali
solution, if necessary use wire wool to remove
burnt remains.
3 Thoroughly wash contaminated area with
detergent and water.
4 Contain all removed material, gloves etc. used
in this operation in sealed plastic bags and
dispose of in accordance with Local Authority
Regulations.
DO NOT BURN FLUOROELASTOMERIC MATERIALS.
If contamination of skin or eyes occurs, wash the
affected area with a continuous supply of clean
water or with calcium hydroxide solution for
15-60 minutes. Get medical attention
immediately. INT - 3 - 3 - 5/1
9803/3610
Issue 2
16
Care Safety
Section 2
Section 2
3 - 1
3 - 1
Lubricants - Health and Safety
Hygiene
JCB lubricants are not a health risk when used
properly for their intended purposes.
2 Apply a barrier cream to the skin before
handling used engine oil.
However, excessive or prolonged skin contact can
remove the natural fats from your skin, causing
dryness and irritation.
3 Note the following when removing engine oil
from skin a Wash your skin thoroughly with soap
and water.
b Using a nail brush will help.
Low viscosity oils are more likely to do this, so
take special care when handling used oils, which
might be diluted with fuel contamination.
c Use special hand cleansers to help clean dirty
hands.
Whenever you are handling oil products you should
maintain good standards of care and personal and
plant hygiene. For details of these precautions
we advise you to read the relevant publications
issued by your local health authority, plus the
following.

• Never use petrol, diesel fuel, or paraffin for
  washing.
• Avoid skin contact with oil soaked clothing.
• Don't keep oily rags in pockets.
• Wash dirty clothing before re-use.
• Throw away oil-soaked shoes.
• First Aid - Oil

Storage
Always keep lubricants out of the reach of
children.
Never store lubricants in open or unlabelled
containers.
Waste Disposal
Eyes
All waste products should be disposed of in
accordance with all the relevant regulations.
In the case of eye contact, flush with water for
15 minutes. If irritation persists, get medical
attention.
The collection and disposal of used engine oil
should be in accordance with any local
regulations. Never pour used engine oil into
sewers, drains or on the ground.
Swallowing
If oil is swallowed do not induce vomiting. Get
medical advice.
Handling
Skin
New Oil
In the case of excessive skin contact, wash with
soap and water.
There are no special precautions needed for the
handling or use of new oil, beside the normal
care and hygiene practices.
Spillage
Used Oil
Absorb on sand or a locally approved brand of
absorbent granules. Scrape up and remove to a
chemical disposal area.
Used engine crankcase lubricants contain harmful
contaminants.
Fires
Here are precautions to protect your health when
handling used engine oil
Extinguish with carbon dioxide, dry chemical or
foam extinguishers. Do not use water.
Fire-fighters should use self-contained
breathing apparatus.
1 Avoid prolonged, excessive or repeated skin
contact with used engine oils.
9803/3610
Issue 1
17
Routine Maintenance
Section 3
Section 3
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Contents
Page No.

• 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)
• 520-55 AWS Machines - Low Emission Engines (Type
  AR and AK Engine Builds)
• 526-55, 526 526S Machines Low Emission Engines
  (Type AR and AK Engine Builds)
• 526-55, 526 526S Machines Low Emission Engines
  (Type RE and RG Engine Builds)

1 - 1 1 - 1 1 - 2
1 - 3
1 - 4
1 - 5
1 - 6
1 - 7
Machine Safety
2 - 1
Service Schedules
3 - 1

• Grease
• 50 Hours
• 500 Hours
• 1000 Hours

4 - 1 4 - 2 4 - 4
Oiling
5 - 1
Tyres and Wheels
6 - 1
Foot Brake (520-55 machines only)
7 - 1

• Engine Air Filter
• Cleaning the Pre-Cleaner
• Changing the Outer Element
• Changing the Inner Element

7 - 1 7 - 2 7 - 3

• Engine Oil and Filter
• Checking the Oil level
• Changing the Oil and Filter

8 - 1 8 - 1

• Engine Cooling System
• Checking the Coolant Level
• Coolant Mixtures
• Changing the Coolant

9 - 1 9 - 1 9 - 2
Cab Heater Filter
10 - 1
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Issue 6
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Section 3
Routine Maintenance
Section 3
ii
ii
Contents
Page No.

• 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)
• Draining the Filter (from S/N 280300)
• Changing the Filter Element
• A series engines (from S/N 280300) R series
  engines
• Draining the Sediment Bowl
• Cleaning the Sediment Bowl
• Bleed the System
• Fuel Pipes- Removal and Replacement

11 - 1 11 - 2 11 - 2 11 - 3 11 - 3 11 - 4
11 - 4 11 - 5 11 - 6 11 - 6 11 - 8 11 - 11
Fire Extinguisher
12 - 1

• Syncro Shuttle Transmission
• Checking the Oil Level
• Changing the Oil and Filter

12 - 1 12 - 2

• Front and Rear Axle
• Checking the Axle Oil Level
• Changing the Axle Oil

13 - 1 13 - 1

• Front and Rear Hub
• Checking the Hub Oil Levels
• Oil Immersed Brakes
• Changing the Hub Oil

14 - 1 14 - 1 14 - 1

• Hydraulic System
• Checking the Fluid Level
• Changing the Filter Element

15 - 1 15 - 1
Hose Burst Protection Valves - Checking the Hose
Burst Protection Valves
16 - 1
Battery
17 - 1
9803/3610
Issue 3
19
Section 3
Routine Maintenance
Section 3
1 - 1
1 - 1
Lubricants Capacities
New Engines New engines DO NOT require a
running-in period. The engine/machine should be
used in a normal work cycle immediately glazing
of the piston cylinder bores, resulting in
excessive oil consumption, could occur if the
engine is gently run-in. Under no circumstances
should the engine be allowed to idle for extended
periods (e.g. warming up without load). Engines
of new machines are filled at the factory with
JCB 10W/30 Multigrade oil. This oil should be
drained after the first 100 hours operation and
the engine filled with the appropriate
recommended grade as shown in the lubrication
chart. JCB 10W/30 Multigrade should also be used
for the first 100 hours operation whenever a new
or reconditioned engine is fitted to the
machine. After the first 100 hours operation, it
is essential that the 10W/30 oil is replaced by
the lubricant recommended in the lubrication
charts.
Lubrication Charts Lubrication charts are
included on the following pages for all machine
models. Note that there are some differences in
specifications for machines operating in North
America. Be sure you identify the machine and its
lubricant requirements correctly.
Note 1
This is nominal machine capacity. The total
hydraulic system capacity depends on the
equipment being used. Fill and check with all
rams closed. Watch level sight glass when filling.
Note 2
If JCB Special MPL Grease is used, all 50 hour
greasing operations must be carried out at TEN
(10) HOUR intervals. All 500 hour greasing
operations must be carried out at FIFTY (50) HOUR
intervals
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Issue 5
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Section 3
Routine Maintenance
Section 3
1 - 2
1 - 2
Lubricants Capacities 520-55 RS (Rear Steer)
Machines
ITEM CAPACITY CAPACITY CAPACITY FLUID/LUBRICANT INTERNATIONAL SPECIFICATION
ITEM Litres UK Gal US Gal FLUID/LUBRICANT INTERNATIONAL SPECIFICATION
Fuel Tank
Up to serial No. 279000 120 26.4 31.7 Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
From serial No. 279001 160 35.2 42.2
Engine (Oil) 10 2.2 JCB High Performance Engine Oil -10 C to 50 C (14 F to 122 F) SAE15W/40 API CF4/SG (ACEA E2B2A2)
JCB Super Universal Agricultural -15 C to 30 C (5 F to 86 F) SAE10W/30 API CD/SF
JCB Torque Converter Fluid -18 C to 0 C (0 F to 32 F) SAE10W API CD/SF
2.6 NORTH AMERICA JCB 15W/40 Engine Oil 14F to 122F (-10C to 50C) SAE 15W/40 API CF4/SG
JCB 10W Engine Oil -4F to 50 F (-20C to 10C) SAE 10W API CF4/SG
Engine (Coolant) 20 4.4 JCB Four Seasons Antifreeze ASTM D3306-74
55 Antifreeze 11 2.4 And Summer Coolant
Starts to freeze -36 C (-33 F)
NORTH AMERICA
5.3 Permanent Antifreeze ASTM D3306-74
2.9 Starts to freeze -33 F (-36 C)
Syncro Shuttle Transmission 17 3.7 4.5 JCB High Performance Transmission Fluid JCB 4000/0900 Friction modified oils MUST NOT be used (eg Dexron ATF type).
Front Axle JCB High performance Gear Oil Plus JCB 4000/2200
Housing 9.7 2.1 2.5 JCB High performance Gear Oil Plus MUST be suitable for use with
Hubs (x2) 0.6 0.1 0.16 JCB High performance Gear Oil Plus oil immersed brakes and limited
JCB High performance Gear Oil Plus slip differentials (LSD).
JCB High performance Gear Oil Plus slip differentials (LSD).
Rear Axle JCB High performance Gear Oil Plus
Housing 5.0 1.1 1.3 JCB High performance Gear Oil Plus
Hubs (x2) 1.5 0.3 0.4 JCB High performance Gear Oil Plus
Hydraulic Tank (1) Up to serial No. 279000 From serial No. 279001 100 110 22.0 24.2 26.4 29.0 JCB High Performance Hydraulic Fluid 46 (Above 38 C, 100 F) JCB High Performance Hydraulic Fluid 32 (Below 38 C, 100 F) JCB Light Hydraulic Fluid ISO VG46 ISO VG32 ISO VG15
Up to serial No. 279000 From serial No. 279001 26.4 29.0 NORTH AMERICA (All Machines) JCB Hydraulic Fluid ISO VG46
Grease Points (2) JCB HP Grease JCB Special MPL-EP Grease Lithium complex NLGI No. 2 constsituency including extreme pressure additives. Lithium based NLGI No. 2 constsituency including extreme pressure additives.
Wear Pad Runways JCB Waxoyl
Boom Hoses JCB Special Slide Lubricant
9803/3610
Issue 4
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Section 3
Routine Maintenance
Section 3
1 - 3
1 - 3
Lubricants Capacities
520-55 AWS Machines (Type AA and AB Engine Builds)
ITEM CAPACITY CAPACITY CAPACITY FLUID/LUBRICANT INTERNATIONAL SPECIFICATION
ITEM Litres UK Gal US Gal FLUID/LUBRICANT INTERNATIONAL SPECIFICATION
Fuel Tank
Up to serial No. 279000 120 26.4 31.7 Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
From serial No. 279001 160 35.2 42.2
Engine (Oil) 10 2.2 JCB High Performance Engine Oil -10 C to 50 C (14 F to 122 F) SAE15W/40 API CF4/SG (ACEA E2B2A2)
JCB Super Universal Agricultural -15 C to 30 C (5 F to 86 F) SAE10W/30 API CD/SF
JCB Torque Converter Fluid -18 C to 0 C (0 F to 32 F) SAE10W API CD/SF
2.6 NORTH AMERICA JCB 15W/40 Engine Oil 14F to 122F (-10C to 50C) SAE 15W/40 API CF4/SG
JCB 10W Engine Oil -4F to 50 F (-20C to 10C) SAE 10W API CF4/SG
Engine (Coolant) 20 4.4 JCB Four Seasons Antifreeze ASTM D3306-74
55 Antifreeze 11 2.4 And Summer Coolant
Starts to freeze -36 C (-33 F)
NORTH AMERICA
5.3 Permanent Antifreeze ASTM D3306-74
2.9 Starts to freeze -33 F (-36 C)
Syncro Shuttle Transmission 17 3.7 4.5 JCB High Performance Transmission Fluid JCB 4000/0900 Friction modified oils MUST NOT be used (eg Dexron ATF type).
Front Axle JCB High performance Gear Oil Plus JCB 4000/2200
Housing 5.5 1.2 1.4 JCB High performance Gear Oil Plus MUST be suitable for use with
Hubs (x2) 1.5 0.3 0.4 JCB High performance Gear Oil Plus oil immersed brakes and limited
JCB High performance Gear Oil Plus slip differentials (LSD).
JCB High performance Gear Oil Plus slip differentials (LSD).
Rear Axle JCB High performance Gear Oil Plus
Housing 5.0 1.1 1.3 JCB High performance Gear Oil Plus
Hubs (x2) 1.5 0.3 0.4 JCB High performance Gear Oil Plus
Hydraulic Tank (1) Up to serial No. 279000 From serial No. 279001 100 110 22.0 24.2 26.4 29.0 JCB High Performance Hydraulic Fluid 46 (Above 38 C, 100 F) JCB High Performance Hydraulic Fluid 32 (Below 38 C, 100 F) JCB Light Hydraulic Fluid ISO VG46 ISO VG32 ISO VG15
Up to serial No. 279000 From serial No. 279001 26.4 29.0 NORTH AMERICA (All Machines) JCB Hydraulic Fluid ISO VG46
Grease Points (2) JCB HP Grease JCB Special MPL-EP Grease Lithium complex NLGI No. 2 constsituency including extreme pressure additives. Lithium based NLGI No. 2 constsituency including extreme pressure additives.
Wear Pad Runways JCB Waxoyl
Boom Hoses JCB Special Slide Lubricant
9803/3610
Issue 4
22
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Section 3
Routine Maintenance
Section 3
1 - 4
1 - 4
Lubricants Capacities
526-55, 526 526S Machines (AA and AB Engine
Builds)
ITEM CAPACITY CAPACITY CAPACITY FLUID/LUBRICANT INTERNATIONAL SPECIFICATION
ITEM Litres UK Gal US Gal FLUID/LUBRICANT INTERNATIONAL SPECIFICATION
Fuel Tank
Up to serial No. 279000 120 26.4 31.7 Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
From serial No. 279001 160 35.2 42.2
Engine (Oil) 10 2.2 JCB High Performance Engine Oil -10 C to 50 C (14 F to 122 F) SAE15W/40 API CF4/SG (ACEA E2B2A2)
JCB Super Universal Agricultural -15 C to 30 C (5 F to 86 F) SAE10W/30 API CD/SF
JCB Torque Converter Fluid -18 C to 0 C (0 F to 32 F) SAE10W API CD/SF
2.6 NORTH AMERICA JCB 15W/40 Engine Oil 14F to 122F (-10C to 50C) SAE 15W/40 API CF4/SG
JCB 10W Engine Oil -4F to 50 F (-20C to 10C) SAE 10W API CF4/SG
Engine (Coolant) 20 4.4 JCB Four Seasons Antifreeze ASTM D3306-74
55 Antifreeze 11 2.4 And Summer Coolant
Starts to freeze -36 C (-33 F)
NORTH AMERICA ASTM D3306-74
5.3 Permanent Antifreeze
2.9 Starts to freeze -33 F (-36 C)
Syncro Shuttle Transmission 17 3.7 4.5 JCB High Performance Transmission Fluid JCB 4000/0900 Friction modified oils MUST NOT be used (eg Dexron ATF type).
Front Axle JCB High performance JCB 4000/2200
Housing 9 1.98 2.4 Gear Oil Plus MUST be suitable for use with
Hubs (x2) 2 0.44 0.5 oil immersed brakes and limited
slip differentials (LSD).
slip differentials (LSD).
Rear Axle
Housing 8.4 1.85 2.2
Hubs (x2) 2 0.44 0.5
Brake System From serial No. 280300 JCB Light Hydraulic Fluid Do not use ordinary brake fluid ISO VG15
Hydraulic Tank (1) Up to serial No. 279000 From serial No. 279001 100 110 22.0 24.2 26.1 29.0 JCB High Performance Hydraulic Fluid 46 (Above 38 C, 100 F) JCB High Performance Hydraulic Fluid 32 (Below 38 C, 100 F) JCB Light Hydraulic Fluid ISO VG46 ISO VG32 ISO VG15
Up to serial No. 279000 From serial No. 279001 26.1 29.0 NORTH AMERICA (All Machines) JCB Hydraulic Fluid ISO VG46
Grease Points (2) JCB HP Grease JCB Special MPL-EP Grease Lithium complex NLGI No. 2 constsituency including extreme pressure additives. Lithium based NLGI No. 2 constsituency including extreme pressure additives.
Wear Pad Runways JCB Waxoyl
Boom Hoses JCB Special Slide Lubricant
9803/3610
Issue 3
24
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