Month: August 2018

Pages from 9803-3690 – JCB Compact Loadalls (520-40, 524-50, 527-55) Service Manual

Complete workshop & service manual with electrical wiring diagrams for JCB Loadall (520-40, 520-50, 524-50, 525-50, 525-50S, 520-55 RS, 520-55 AWS, 526-55, 526-55 AWS, 526S AWS, 527-55). It’s the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

This JCB Loadall (520-40, 520-50, 524-50, 525-50, 525-50S, 520-55 RS, 520-55 AWS, 526-55, 526-55 AWS, 526S AWS, 527-55) service & repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

FILELIST:
9803-3610 – JCB Loadall (520-55 RS/AWS, 526-55, 526-55 AWS, 526S AWS) Service Manual.pdf
9803-3620 – JCB Loadall (520-50, 525-50, 525-50S) Service Manual.pdf
9803-3690 – JCB Compact Loadalls (520-40, 524-50, 527-55) Service Manual .pdf
Loadalls 2000_2010 Electrical Wiring Diagrams (BONUS MATERIAL).pdf

EXCERPT:
Service Manual
Compact Loadalls
Section 1 – General Information
Section 2 – Care and Safety
Section 3 – Maintenance
Section A – Attachments
Section B – Body and Framework
Section C – Electrics
Section D – Controls
Section E – Hydraulics
Section F – Transmissions
Section G – Brakes
Section H – Steering
Section K – Engine
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Fire Extinguisher (if fitted)
Checking the Fire Extinguisher
Check the fire extinguisher for damage, security and signs of leaking.
Check that the gauge A indicates that the extinguisher is charged i.e. the needle is in the GREEN segment.
Note: If the needle is in or very near the RED segment at either end of the gauge, the extinguisher must be serviced or replaced.
Make sure the safety pin B is fitted and secure.
The extinguisher should be serviced every 12 months by a suitably qualified person.
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Pages from 9803-3300 – JCB Telescopic Handler 520 (Up to SN270587) Service Manual

Complete workshop & service manual with electrical wiring diagrams for JCB Telescopic Handler 520. It’s the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

This JCB Telescopic Handler 520 service & repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

9803-3300 – JCB Telescopic Handler 520 (Up to SN270587) Service Manual.pdf

EXCERPT:
PRESSURE MAINTAINING VALVE
Dismantling and Assembly
Use the numerical sequence as a guide to Dismantling.
For Assembly reverse the sequence.
When Dismantling
Ensure that all work surfaces and components are clean.
Identify springs for correct replacement.
When Assembling
Renew seals and gaskets, lubricate all components with transmission fluid before fitting.
If low clutch pressure has previously been diagnosed renew both springs.
Remove burrs or light markings from pistons or bores by polishing. If scoring or damage is evident components must be renewed.
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Pages from 9803-9900 – JCB Telescopic Handler 515-40 Service Manual

Complete workshop & service manual with electrical wiring diagrams for JCB Telescopic Handler 515-40. It’s the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

This JCB Telescopic Handler 515-40 service & repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

FILELIST:
9803-9900 – JCB Telescopic Handler 515-40 Service Manual.pdf

Machine Model and Serial Number
This manual provides information for the following
model(s) in the JCB machine range:
– 515-40 from SN 1627500 to 1769999

EXCERPT:
Service Manual
515-40
Section 1 – General Information
Section 2 – Care and Safety
Section 3 – Maintenance
Section A – Attachments
Section B – Body and Framework
Section C – Electrics
Section D – Controls
Section E – Hydraulics
Section F – Transmissions
Section G – Brakes
Section H – Steering
Section K – Engine
…
Front Wiper
Removal and Replacement
Removal
1 Remove the left instrument panel. K Left Instrument Panel ( T B-79)
2 Remove the right instrument panel.K Right Instrument Panel ( T B-80)
3 Remove the screen guard (if fitted). K Screen Guard ( T B-97)
4 Remove the fuel sender guard plate (if fitted). K Fuel Sender Guard Plate ( T B-96)
5 Disconnect the wiper motor electrical connector A.
6 Remove the tube B at the cab bulkhead adapter.
7 Remove the nuts C and pull the wiper arm assembly D off the motor shafts.
8 Remove the screws G and cover H.
9 With the aid of one more person hold the wiper motor E and at the same time remove the nuts F.
10 Remove the wiper motor E.
Replacement
Note: If the wiper motor is defective it must be replaced. It is not possible to repair a defective wiper motor.
Replacement is the opposite of the removal procedure.
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Pages from 9803-3640U – JCB 506C, 506CHL, 508C Loadalls Service Manual

Complete workshop & service manual with electrical wiring diagrams for JCB 506C, 506CHL, 508C Loadalls. It’s the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

This JCB 506C, 506CHL, 508C Loadalls service & repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

FILELIST:
9803-3640U – JCB 506C, 506CHL, 508C Loadalls Service Manual.pdf

EXCERPT:
Service Manual
506C, 506CHL, 508C
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 – Transmissions
Section G – Brakes
Section H – Steering
Section K – Engine
…
Layshaft – Location of Components
ITEM DESCRIPTION
1 Piston (aluminium)
2 Piston liner
3 Counter plates
4 Bolt
5 Spring
6 Oil baffle ring
7 Spring retainer
8 ‘O’ ring
9 Circlip
10 Bearing
11 Ring seal
12 Spacer
13 Shim kit
14 Pressure plate (inner – 4 mm)
15 Circlip
16 ‘O’ ring
17 Layshaft gear
18 Needle roller bearing
19 Washer
20 Thrust bearing
21 Layshaft clutch housing
22 ‘O’ ring
23 Gear
24 Washer
25 Spacer†
26 ‘O’ ring
27 Toothed plate shim
28 Gasket
29 Friction plates
30 Pressure plate (Outer – 6 mm)
† 2 Wheel Drive machines only. 4 Wheel Drive machines have a gear instead of a spacer.
…

Pages from 9803-3740 – JCB Telescopic Handler 506-36, 507-42, 509-42, 510-56, 512-56 Service Manual

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INSTANT DOWNLOAD

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Complete workshop repair & service manual with electrical wiring diagrams for JCB Telescopic Handler 505-19, 505-22, 506-36, 506B, 507-42, 508-40, 509-42, 510-40, 510-56, 512-56. It’s the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

This JCB Telescopic Handler 505-19, 505-22, 506-36, 506B, 507-42, 508-40, 509-42, 510-40, 510-56, 512-56 service & repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

FILE LIST:
9803-3600U – JCB Telescopic Handler 500-Series (505-19, 505-22, 506-36, 506B, 508-40, 510-40) Service Manual.pdf
9803-3740 – JCB Telescopic Handler 506-36, 507-42, 509-42, 510-56, 512-56 Service Manual.pdf

Applications
This manual contains topics that relate to some or all JCB Loadall machines in the 5C group. There are several machine model codes in the family.
Machine Group Model Code Model Name
5C D 506-36
5C E 507-42
5C F 509-42
5C G 510-56
5C H 512-56
…
This Service Manual covers the following Machines:-
505-19 – Serial Number 561001 – 579365
505-22 – Serial Number 561001 – 579365
508-40 – Serial Number 562601 – 579365
506-36 – Serial Number 563359 – 579999
510-40 – Serial Number 564542 – 579365
508-40, 508-40 – PlaceAce
505-19, 505-22 – Basic Servo Options
506-36, 508-40 – Servo Options
506B – Serial Number 570000 – 579766
Information covers two stage and three stage boom machines.

EXCERPT:
Service Manual
506-36, 507-42, 509-42, 510-56, 512-56
Section 1 – General Information
Section 2 – Care and Safety
Section 3 – Routine Maintenance
Section B – Body and Framework
Section C – Electrics
Section E – Hydraulics
Section F – Transmission
Section G – Brakes
Section H – Steering
Section K – Engine
Section M – Electronic Network
…
Removal and Replacement
Before removing and dismantling the pump, check the flow and pressure. If either of these are low and cannot be corrected at the relief valve, the appropriate pump section must be renewed completely.
Renewal of components such as gears, bearings and housings will not effect a permanent cure. If the pump output is satisfactory but there is external leakage, the pump should be removed and dismantled for re-sealing only.
Before removing or dismantling the pump, make sure the exterior of the pump and working area is thoroughly cleaned and free of possible sources of contamination.
!MWARNING
Make the machine safe before working underneath it.
Park the machine on level ground, lower the attachments to the ground. Apply the park brake, put the transmission in neutral and stop the engine. Block both sides of all four wheels.
Disconnect the battery, to prevent the engine being started while you are beneath the machine.
!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose, residual hydraulic pressure trapped in the service hose line must be vented. Make sure the hose service line has been vented before connecting or removing hoses. Make sure the engine cannot be started while the hoses are open.
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INSTANT DOWNLOAD

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