JCB 520-55 TELESCOPIC HANDLER Service Repair Manual ALL277001-280299.pdf

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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. 9803/36 10 Issue 10

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

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, 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 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*

Machine History Date

Machine

Description

1993

520-55 RS

The machine incorporated twin brake pedals to operate an independent brake circuit controlling each of the front 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.

(277001 - 279114) Serial No. 277001

Machine introduction

1994

520-55 AWS (504B N.Am) (277386 - 278966)

Serial No. 277386


278610

JCB axles, drop box and 4 wheel power brakes fitted.

1994

526-55 (277467 - 278966)

Serial No. 277468


1996

520 & 526 520 (278967 onwards) 526 (278967 - 279567)

Serial No. 278967


1996

526, 526S (526 Am.N) (279289 onwards)

Serial No. 279289


280300

ECU controlled powershift available as an option. Single lever control and trailer braking. Power brakes replaced by inboard, front axle brakes.

280577

ECU control was replaced by relay controlled transmissio transmission. n.

1996

520S (279598 onwards)

Serial No. 279598

9803/3630

The machine was fitted with permanent four wheel steering and four-wheel braking.


Introduced as a development of the 52055 with a stronger inner boom and larger lift, tilt and displacement rams. The machine was fitted with JCB 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. 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.

The 526 and 526S machine incorporated a longer wheelbase to allow for 24in. wheels and tyres on the 526S machine only. Drop box fitted with helical gears from axle serial number 453/275/00005.

Introduced as a 90 hp turbo-charged engine version version of the the 520 machine. machine. The stronger inner boom on the 526 was introduced to cope with the increased engine power.

Issue 1

General Information

Section 1

Section 1

i

i

Contents Identification

1-1

Torque Settings

2-1

Service Tools - Numerical List * - Section B - Section C - Section E - Section F - Section H - Section K

3-1 3-3 4-1 5-1 6-1 7-1 7-1

Sealing and Retaining Compounds

9803/3610

Page No.

8-1

Issue 2*

General Information

Section 1

Section 1

1-1

1-1 * Unit Identification

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.

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 V

Y Z S195340

Explanation of Vehicle Identification Number (VIN)

SLP52655RE0277001 A A B C

D E

B

C D

World Manu World Manufac factur turer er Iden Identif tifica icatio tion n Machine Model Year of Manufacture P = 1993 V = 1997 R = 1994 W = 1998 S = 1995 X = 1999 T = 1996 Y = 2000 Manufacturing Location Machine Serial Number

E

SLP = JCB JCB 526-55 S 1 = 2001 2 = 2002 3 = 2003 4 = 2004 E = England 0277001

Typical Engine Identification Number AA 50261 U 500405 P A B C D E * A Engine Type: A series AA = 4 cylinder naturally naturally aspirated AB = 4 cylinder turbo AK = 4 cylinder turbo - low emission, stage stage 1 AR = 4 cylinder naturally aspirated aspirated - low emission, stage 1 R Series RE = 4 cylinder naturally aspirated, low emission, stage 2 RG = 4 cylinder turbo, low emission stage 2 B Build Number C Country of Manufacture

Machine Model Explanation D Engine Serial Number

526 - 55 FG H F 500 Series machine range G 2.6 tonnes lift capacity H 5.5 meters lift height With the introduction of the longer wheel base machine the lift height has been deleted from the serial number.

526 FG F 500 Series machine range G 2.6 tonnes lift capacity

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 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 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*

General Information

Section 1 1-2

Section 1 1-2

Y S088470

X

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

Section 1

Section 1

General Information

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 1 /4 5 /16 3 /8 7 /16 1 /2 9 /16 5 /8 3 /4 7 /8

1 11 /4 11 /2

(mm) (6.3) (7.9) (9.5) (11.1) (12.7) (14.3) (15.9) (19.0) (22.2) (25.4) (31.7) (38.1)

Hexagon (A/F) in 7 /16 1 /2 9 /16 5 /8 3 /4 13 /16 15 /16

11 /8 * 15 /16 11 /2 17 /8 21 /4

Nm 14 28 49 78 117 170 238 407 650 970 194 0 339 0

Torque Settings kgf m 1 .4 2 .8 5 .0 8 .0 1 2 .0 1 7 .3 2 4 .3 4 1 .5 6 6 .3 9 9 .0 19 8 . 0 34 5 . 0

l b f ft 10 20 36 58 87 125 175 300 480 715 14 30 25 00

Nm

Torque Settings kgf m

l b f ft

Metric Grade 8.8 Bolts Bolt Size (mm) M5 M6 M8 M 10 M 12 M 16 M 20 M 24 M 30 M 36

(5) (6) (8) (10) (12) (16) (20) (24) (30) (36)

Hexagon (A/F) mm 8 10 13 17 19 24 30 36 46 55

7 12 28 56 98 244 476 822 163 3 285 4

0 .7 1 .2 3 .0 5 .7 10 25 48 84 166 291

5 9 21 42 72 18 0 35 2 60 7 120 5 210 5

Rivet Nut Bolts/Screws Bolt Size M3 M4 M5 M6 M8 M 10 M 12

(mm) (3) (4) (5) (6) (8) (10) (12)

Torque Settings (for steel rivet nuts) Nm kgf m l bf f t 1 .2 0 . 12 0. 9 3 .0 0. 3 2. 0 6 .0 0. 6 4. 5 1 0 .0 1. 0 7. 5 2 4 .0 2. 5 18 . 0 48 . 0 4 .9 35 . 5 82 . 0 8 .4 60 . 5

Note: 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*

Section 1

General Information

3-1

3-1

Service Tools Numerical List

1406/0011 1406/0014 1406/0018 1406/0021 1406/0029 1604/0003 1604/0004 1604/0006 1606/0003 1606/0004 1606/0007 1606/0008 1606/0009 1606/0012 1606/0014 1606/0015 1606/0017 1612/0006 816/00189 816/00190 816/00193 816/00196 816/00197 816/00294 816/15118 816/20008 816/ 81 6/55 5503 038 8 816/ 81 6/55 5504 040 0 816/50043 892/00039 892/00041 892/00047 892/00048 892/00049 892/00051 892/00055 892/00056 892/00057 892/00058 892/00059 892/00060 892/00071 892/00074 892/00075 892/00076 892/00077 892/00121 892/00137 892/00179 892/00180 892/00181 892/00223 892/00224 892/00225 892/00254 892/00255 892/00256 892/00257 892/00258 892/00259 892/00260 9803/3610

Section 1

Page No

Bonded Washer Bonded Washer Bonded Washer Bonded Washer Bonded Washer Adapter Adapter Adapter Adapter Adapter Adapter Adapter Adapter Adapter Adapter Adapter Adapter Adapter Blanking Cap Blanking Cap Blanking Cap Blanking Cap Blanking Cap Blanking Cap Pressure Test Adapter Adapter Pres Pr essu sure re Te Test st Ad Adap apte terr Pres Pr essu sure re Te Test st Ad Adap apte terr 'T' Adapter Spool Clamp De-glazing Tool 'T' Adapter 'T' Adapter 'T' Adapter 'T' Adapter Blanking Plug Blanking Plug Blanking Plug Blanking Plug Blanking Plug Blanking Plug Adapter Female Connector Female Connector Female Connector Female Connector Discharge Tester Micro-Bore Hose Bearing Press Seal Fitting Tool Plastic Boss Hand Pump Impulse Extractor Adapter - Impulse Extractor Hose 1 /4'' BSP Test Point 3 /8'' BSP Test Point 1 /2'' BSP Test Point 5 /8'' BSP Test Point 1'' BSP Test Point

5-1 5-1 5-1 5-1 5-1 5-3 5-3 5-1 5-3 5-3 5-3 5-3 5-3 5-3 5-3 5-3 5-3 5-1 5-2 5-2 5-2 5-2 5-2 5-2 5-3 5-1 5-1 51 5-1 51 5-2 5-2 7-1 5-2 5-2 5-2 5-2 5-2 5-2 5-2 5-2 5-2 5-2 5-3 5-2 5-2 5-2 5-2 4-1 5-3 6-1 7-1 7-1 5-3 6-2 6-2 5-1 5-3 5-3 5-3 5-3 5-3

11 /4'' BSP Test Point

5-3

Numerical List Page No 5 /8'' UNF Test Point 892/00261 5-3 1 /4'' M BSP 1/4'' F BSP 892/00262 5-1 5 /8'' M BSP 5/8'' F BSP 892/00263 5-1 3 /4'' M BSP 3/4'' F BSP 892/00264 5-1 892/ 89 2/00 0026 265 5 1''' M BS 1' BSP P 1' 1''' F BS BSP P 5-1 51 892/00268 Flow Monitoring Unit 5-1 892/00269 Sensor Head 5-1 892/00270 Load Valve Lo 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 2 892/00 892 /00279 279 Press Pr essure ure Gau Gauge ge 0-4 0-400 00 bar bar (0(0-600 6000 0 lbf/i lbf/in n ) 5-1 892/00 892 /00280 280 Press Pr essure ure Gau Gauge ge 0-6 0-600 00 bar bar (0(0-900 9000 0 lbf/i lbf/in n2 ) 5-1 892/00282 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 6-1 892/00298 Fluke Meter 4-1 892/00301 Flow Test Adapter 6-1 892/00302 Flow Test Adapter 6-1 892/00304 Flow Test Adapter 6-1 892/00333 Heavy Duty Socket 6-2 892/00334 Seal Fitting Tool 5-4 892/00 892 /00346 346 Press Pr essure ure Gau Gauge ge 0-7 0-70 0 bar bar (0(0-100 1000 0 lbf/ lbf/in in2 ) 6-1 892/00706 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 7-2 892/00842 Glass Lifter 3-3 892/00843 Glass Stand 3-3 892/00844 Long Knife 3-4 892/00846 Glass Extractor (Handles) 3-4 892/00847 Nylon Spatula 3-3 892/00848 Wire Starter 3-4 892/ 89 2/00 0084 849 9 Brai Br aide ded d Cu Cutt ttin ing g Wi Wire re 3-4 34 892/00891 Seal Fitting Adapter 6-3 892/00893 Torque Converter Alignment Bar 6-2 892/00902 Spanner, Track Rod End 6-3 892/00903 Spanner, Differential 6-3 892/00904 Spanner, Differential 6-3 892/00905 SLI Test Box 4-1 892/00906 Seal Fitting Adapter 6-3 892/00916 Spring Compression Tool 6-4 892/00918† Setting Tool Kit 6-5 892/00920 Flow Test Adaptor 6-1 892/00923 Test Block for A.R.V. 5-3 Timing Pin for fuel injection pump 7-2 * 892/00936 892/00943 Hand Held Test Unit 4-3 892/00964 Test Point (1/8 BSP) PS700 6-4 892/00965 Test Point (3/8 BSP) PS700 6-4 892/00966 Test Point (1/4 BSP) SS400, SS600 6-4 * 892/01054 Adaptor for compression testing 7-2 * 892/01111 Rocker Assembly Tool 7-2 * 892/01112 Timing Case Alignment Tool 7-2 * 892/01113 Thermostat Fit & Removal Tool 7-2 Camshaft Gear Timing Pin 7-2 * 892/01114 Crankshaft Timing Pin 7-2 * 892/01115 921/52600† Spacer Kit 6-5 926/15500 Rubber Spacer Blocks 3-3 Issue 9*

Section 1

General Information

Section 1

3-2

3-2 Numerical List 921/52626 Spacer 14.00 mm

Service Tools (cont’d) Numerical List Page No 992/02800 ARV Extractor 5-2 992/04000 Torque Multiplier 6-2 992/04800 Drive Coupling Spanner 6-1 992/07000 Ram End Cap Peg Spanner 5-3 992/07603 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 6-1 992/09500 Spanner 5-2 992/09700 Spanner 5-2 992/10100 Spool Clamp 5-2 992/10900 Test Harness for SLI 4-1 992/12800 Cut-Out Knife 3-4 992/12801 ‘L’ Blades 3-4 993/59300 2/4 Wheel Pressure Tester & Clamp 6-2 993/70100 Powershift Endfloat Checking Kit 6-8 993/70111 Breakback Torque Wrench 6-5 993/78200 Mainshift Airline Adaptor 6-4 993/99412 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 items for kit no. 892/00253 892/00201 Replacement Gauge 892/00202 Replacement Gauge 892/00203 Replacement Gauge 892/00254 Replacement Hose

5-1 5-1 5-1 5-1

Replacement items for kit no. 993/70100 993/70101 Base Plate and Bolts 993/70104 Mainshaft Pillar 993/70106 Layshaft/Reverser Pillar 993/70112 Input Shaft Pillar 993/70120 Setting Assembly 993/70130 Mainshaft Adapter 993/70140 Setting Assembly 993/70160 Yoke Assembly

9803/3610

6-5 6-5 6-5 6-5 6-5 6-5 6-5 6-5 6-5 6-5 6-5 6-5 6-5 6-5 6-5 6-5 6-5 6-5 6-5 6-5 6-5 6-5 6-5 6-5 6-5

6-8 6-8 6-8 6-8 6-8 6-8 6-8 6-8

Note: To maintain a complete kit, order a replacement spacer for the one used.

† Identifies items required for all JCB Gearboxes from September 1996, when solid spacers replaced collapsible spacers. Ram Seal Protection Sleeves

5-4

892/01 892/ 0101 016 6 892/ 89 2/01 0101 017 7 892/ 89 2/01 0101 018 8 892/ 89 2/01 0101 019 9 892/01 892 /01020 020 892/ 89 2/01 0102 021 1 892/01 892 /01022 022 892/ 89 2/01 0102 023 3 892/ 89 2/01 0102 024 4 892/ 89 2/01 0102 025 5 892/ 89 2/01 0102 026 6

For 25 mm Ro For Rod d Dia Diame mete terr Forr 30 mm Ro Fo Rod d Dia Diame mete terr Forr 40 mm Ro Fo Rod d Dia Diame mete terr Forr 50 mm Ro Fo Rod d Dia Diame mete terr Forr 50 Fo 50 mm mm Rod Rod Dia Diamet meter er (sl (slew ew ram ram)) Forr 60 mm Ro Fo Rod d Dia Diame mete terr Forr 60 Fo 60 mm mm Rod Rod Dia Diamet meter er (sl (slew ew ram ram)) Forr 65 mm Ro Fo Rod d Dia Diame mete terr Forr 70 mm Ro Fo Rod d Dia Diame mete terr Forr 75 mm Ro Fo Rod d Dia Diame mete terr Forr 80 mm Ro Fo Rod d Dia Diame mete terr

892/ 89 2/01 0102 027 7

Pist Pi ston on Sea Seall Asse Assemb mbly ly Too Tooll

* Hub Service Kit Replacement items for spacer kit no. 921/52600 921/52601 Spacer 12.75 mm 921/52602 Spacer 12.80 mm 921/52603 Spacer 12.85 mm 921/52604 Spacer 12.90 mm 921/52605 Spacer 12.95 mm 921/52606 Spacer 13.00 mm 921/52607 Spacer 13.05 mm 921/52608 Spacer 13.10 mm 921/52609 Spacer 13.15 mm 921/52610 Spacer 13.20 mm 921/52611 Spacer 13.25 mm 921/52612 Spacer 13.30 mm 921/52613 Spacer 13.35 mm 921/52614 Spacer 13.40 mm 921/52615 Spacer 13.45 mm 921/52616 Spacer 13.50 mm 921/52617 Spacer 13.55 mm 921/52618 Spacer 13.60 mm 921/52619 Spacer 13.65 mm 921/52620 Spacer 13.70 mm 921/52621 Spacer 13.75 mm 921/52622 Spacer 13.80 mm 921/52623 Spacer 13.85 mm 921/52624 Spacer 13.90 mm 921/52625 Spacer 13.95 mm

Page No 6-5

998/10 998/ 1062 623 3 998/ 99 8/10 1060 607 7 1315 13 15/3 /373 731Z 1Z 1370/0601Z 998/10614 998/ 99 8/10 1062 624 4 998/10615 1370/0701Z 1420 14 20/0 /001 012Z 2Z 998/10610 1370 13 70/0 /040 401Z 1Z 1420 14 20/0 /000 009Z 9Z 998/ 99 8/10 1060 608 8 1315/3414Z 1370 13 70/0 /030 301Z 1Z 998/10606 998/ 99 8/10 1061 616 6 1315 13 15/3 /383 835Z 5Z 445/12303 917/02800 892/00891

892/01092

6-9

Pul ulle lerr Be Bea am Inne In nerr Bear Bearin ing g Pla Plate te Bolt Bo lt M16x M16x22 220 0 Nut M16 Tube Modi Mo difi fied edWh Whee eell Stud Stud Wheel Bearing CarrierPuller Nut M20 Wash Wa sher er M2 M20 0 Puller Rod Rod Nutt M12 Nu M12 Wash Wa sher er M1 M12 2 Bear Be arin ing g Ce Cent ntre re Pu Pull ller er Bolt M10x60 Nutt M10 Nu M10 Bearing Fitting Tube Pull Pu ller er Ha Hand ndle le Nu Nutt Bolt Bo lt M20x M20x30 300 0 Washer Bearing Seal Dolly

Issue 7*

General Information

Section 1

Section 1

3-3

3-3

Service Tools Section B - Body and Framework Framework

826/01176 826/01106 826/01177 826/01176 826/01333

M6 x 16mm Rivet Nut M6 x 19mm Rivet Nut M8 x 18mm Rivet Nut M10 x 23mm Rivet Nut M10 x 26mm Rivet Nut

Installation Tool Available from: Bollhoff Fastenings Ltd. Midacre The Willenhall Estate Rose Hill Willenhall West Midlands, WV13 2JW S150970

Glass Lifter - minimum 2 off - essential for glass installation, 2 required to handle large panes of glass. Ensure suction cups are protected from damage during storage. Folding Stand for Holding Glass essential for preparing new glass prior to installation. JCB part 892/00843

number

JCB part number - 892/00842

-

S186280

S186300

Rubber Spacer Blocks - used to provide the correct set clearance between glass edge and cab frame. JCB part number - 926/15500 (unit quantity = 500 off)

Nylon Spatula - general tool used for smoothing sealants - also used to re-install glass in rubber glazing because metal tools will chip the glass edge. JCB part number - 892/00847 S186470

9803/3610

S186550

Issue 1*

Section 1

General Information

Section 1

3-4

3-4

Servic Service e Tools (cont'd) Section Section B - Body &Framework

Wire Starter - used to access braided cutting wire (below) through original polyurethane seal. Cut-Out Knife - used to remove broken glass. JCB part number - 992/12800 JCB part number - 892/00848 S186340

S186310

'L' Blades - 25 mm (1 in) cut - replacement blades for cut-out knife (above). JCB part number - 992/12801 (unit quantity = 5 off)

Glass Extractor (Handles) - used with braided cutting wire (below) to cut out broken glass. JCB part number - 892/00846

S186350

S186320

Braided Cutting Wire - consumable heavy duty cut-out wire used with the glass extraction tool (above).

Long Knife - used to give extended reach for normally inaccessible areas. JCB part number - 892/00844

JCB part number - 892/00849 (approx 25 m length)

S186330

9803/3610

S186360

Issue 1*

General Information

S ec tion tion 1

S ec tion tion 1

4- 1

4 -1

Service Tools Section C - Electrics

AVO AVO Te Te s t Kit 1

8 9 2 /0 0 2 8 3

To o l Kit C a se se

2

8 9 2 /0 0 2 9 8

Flu ke Me t e r

3

8 9 2 /0 0 2 8 6

S ur urfa c e Te mp mp e ra ra tu t u re P ro ro be be

4

8 9 2 /0 0 2 8 4

Ve nt nt ur ure Mi Mic ro ro ta ta c h D ig it it a l Ta c ho h o me me te te r

5

8 9 2 /0 0 2 8 2

1 0 0 a mp m p S hu hu n t - o p e n t y p e

6

8 9 2 /0 0 2 8 5

Hy dr d ra ul ulic Te mp mp e ra ra tu t u re P ro ro be be

8 92 92 /0 01 01 21 21

Hig h Ra Ra t e D is is c h a rg rg e Te Te s t e r (4 00 00 a m ps ps ) for testing testing b a ttery cond ition tion

S188230

S188240

9 9 2 /1 0 9 0 0 9 93 93 /9 94 94 12 12

Te st s t Ha rn rn e s s fo r S a fe fe Lo ad a d In In d ic ic a to to r Ad a p t o r Ha r ne ne s s

Fro m m a c hi hin e S er e ria l No . 2 7 8 8 18 u s e: e: 892/0090 00905 5 * 892/

S188250

9803 /3610

Test Bo x For For Sa fe Loa Loa d Indi Indica ca tor (SLI) SLI) and Load Moment Indicator (LMI) S244692

Issue 3*

S ec tion tion 1

General Information

S ec tion tion 1

4- 2

4 -2

Service Tools Section C - Electrics Reco mmende d Electri Electrica ca l Repa ir Kit Kit 2 A : 7 2 1 2 /0 00 2 2 Wa y P in in H o us us in in g 2 B : 7 2 1 2 /0 00 4 2 Wa y Pi P in R e ta ta in in e r 2 C : 7 2 1 2 /0 00 3 2 Wa y S o cck ke t R e ta ta in in e r 2 D : 7 2 1 2 /0 00 1 2 Wa y S o cck ke t C on o n n e ct cto r 3 A : 7 2 1 3 /0 00 2 3 Wa y P in in H o us us in in g 3 B : 7 2 1 3 /0 00 4 3 Wa y Pi P in R e ta ta in in e r 3 C : 7 2 1 3 /0 00 3 3 Wa y S o cck ke t R e ta ta in in e r 3 D : 7 2 1 3 /0 00 1 3 Wa y S o cck ke t C on o n n e ct cto r 4 A : 72 72 1 3 /0 00 6 3 Wa Wa y P in in Ho Ho us us in in g (D (D T) 4 B : 72 72 1 3 /0 00 8 3 Wa Wa y P in in Re Re ta ta in in e r (D T) 4 C : 72 72 1 3 /0 00 7 3 Wa y S o c ke ke t R et et a in in er er (D T) 4 D : 72 72 1 3 /0 00 5 3 Wa Wa y S o c ke ke t Co C o nn nn e c to to r (D T) 5 A : 7 2 1 4 /0 00 2 4 Wa y P in in H o us us in in g 5 B : 7 2 1 4 /0 00 4 4 Wa y Pi P in R e ta ta in in e r 5 C : 7 2 1 4 /0 00 3 4 Wa y S o cck ke t R e ta ta in in e r 5 D : 7 2 1 4 /0 00 1 4 Wa y S o cck ke t C on o n n e ct cto r

6A 6B 6C 6D 7A 7B 7C 7D 8A 8B 8C 8D 9A 9B 9C 9D 10 11 12

: 7 2 1 6 /00 0 2 : 7 2 1 6 /00 0 4 : 7 2 1 6 /00 0 3 : 7 2 1 6 /00 0 1 : 7 2 1 8 /00 0 2 : 7 2 1 8 /00 0 4 : 7 2 1 8 /00 0 3 : 7 2 1 8 /00 0 1 : 7 2 1 9 /00 0 2 : 7 2 1 9 /00 0 4 : 7 2 1 9 /00 0 3 : 7 2 1 9 /00 0 1 : 7 2 1 9 /00 0 6 : 7 2 1 9 /00 0 8 : 7 2 1 9 /00 0 7 : 7 2 1 9 /00 0 5 : 7 2 1 0 /00 0 1 : 72 72 1 0 /00 0 2 : 72 72 1 0 /00 0 3

6 Wa y P in in H o us us in in g 6 Wa y Pi P in Re Re ta ta in in e r 6 Wa y S o cck ke t R e ta ta in in e r 6 Wa y S o cck ke t C on o n n e ct cto r 8 Wa y P in in H o us us in in g 8 Wa y Pi P in Re Re ta ta in in e r 8 Wa y S o cck ke t R e ta ta in in e r 8 Wa y S o cck ke t C on o n n e ct cto r 1 0 Wa y P in in Ho us us in in g 1 0 Wa y P in in R e ta ta in in e r 1 0 Wa y S oc oc ke ke t R e ta ta in in e r 1 0 Wa y S o cck ke t C o nn nn e ct cto r 1 4 Wa y P in in Ho us us in in g 1 4 Wa y P in in R e ta ta in in e r 1 4 Wa y S oc oc ke ke t R e ta ta in in e r 1 4 Wa y S o cck ke t C o nn nn e ct cto r D u m m y P lu lu g Wire S e a l (1. 4 - 2. 2 m m d ia ia . ) Wire S e a l (2. 2 - 2. 9 m m d ia ia . )

S188380

9803 /3610

Iss ue 1

S ec tion tion 1

General Information

S ec tion tion 1

4- 3

4 -3

Servic Service e Tools (cont'd) Section C - Electrics

8 92 92 /0 09 09 43 43

Ha n d H e ld ld Te Te s t U ni nit MK MK II II (EC U )

299920

9803 /3610

Issue 1*

General Information

S ec tion tion 1

Section 1

5- 1

5 -1

Service Tools (cont'd) Section E - Hydraulics * Hydrauli Hydraulic Circui Circuitt Tes Tes t G aug es a nd C onnec tions tions 1 2 3 4 5

8 9 2 /0 0 2 7 9 8 9 2 /0 0 3 4 6 8 9 2 /0 0 3 4 7 8 9 2 /0 0 2 5 4 8 9 2 /0 0 2 8 0

P re re ss ss u urre G a ug ug e 00-4 00 ba b a r (0 -6 0 00 lb lb f/ f/in2) P re re ss ss u urre G a ug ug e 00-70 ba ba r (0 -1 0 0 0 lb f/ f/in2) C o nne c t o r Ho s e P re re ss ss u urre G a ug ug e 00-6 00 ba b a r (0 -9 0 00 lb lb f/ f/in2)

4

3 1,2,5

S188130

S188140

P re s s u re Te s t ' T' Ad a p t o rs

B o n d e d Wa s h e rs

892/002 892/00262 62 1/4 in M BSP x 1/4 in F B S P x Te s t P o in t 816/550 816/55038 38 3/8 in M BSP x 3/8 in F B S P x Te s t P o in t 816/550 816/55040 40 1/2 in M BSP x 1/2 in F B S P x Te s t P o in t 892/002 892/00263 63 5/8 in M BSP x 5/8 in F B S P x Te s t P o in t 892/002 892/00264 64 3/4 in M BSP x 3/4 in F B S P x Te s t P o in t 892/ 892/0026 00265 5 1 in in M BSP x 1 in in F BS P x Test Test P oint oint

1 40 6 /0 0 1 1 1 40 6 /0 0 1 8 1 40 6 /0 0 1 4 1 40 6 /0 0 2 1 1 40 6 /0 0 2 9

1

in. BS P in. BS P 5 /8 in. BS P 3 /4 in. BS P 11/4 in. BS P 1

/4 /2

Flow Flow Tes t Eq uipment uipment 892/ 892/00268 00268 892/00269 892/ 892/0027 00270 0 1406 1406/ /0021 0021 1604 1604/ /0006 0006 1612 1612/ /0006 0006 892/ 892/0027 00271 1 892/ 892/0027 00272 2 816/ 816/2000 20008 8 892/ 892/0027 00275 5 892/ 892/0027 00276 6 892/ 892/0027 00277 7

9803 /3610

Flow Flow Monitori Monitoring ng U nit nit S ens or Hea d 0 to 100 l/ l/min (0 to 22 UK ga l/min) Loa d Valv Valvee Bonded Was Was her Ada pter 3/4 in M x 3/4 M BS P Ada pter 3/4 in F x 3/4 M BS P Ada pter 3/4 in F x 5/8 M BS P Ada pter 5/8 in F x 3/4 M BS P Ada pter 3/4 in F x 1/2 M BS P Ada pter 1/2 in F x 3/4 M BS P Ada pter 3/4 in F x 3/8 M BS P Ada pter 3/4 in F x 3/4 M BS P

S188150

Iss ue 2*

General Information

S ec tion tion 1

S ec tion tion 1

5- 2

5 -2

Servic Service e Tools (cont'd) Section E - Hydraulics

S193880

S193870

Fe m a le C o n e B la n kin g C a p 892/ 892 /00055 000 55 892/ 892 /00056 000 56 892/ 892 /00057 000 57 892/ 892 /00058 000 58 892/ 892 /00059 000 59 8 9 2 /0 0 0 6 0

1

Ma le C o n e B la n kin g C a p

in . B S P /8 in . B S P 1 /2 in . B S P 5 /8 in . B S P 3 /4 in . B S P 1 in . B S P

8 1 6 /0 0 2 9 4 8 1 6 /0 0 1 8 9 8 1 6 /0 0 1 9 0 8 1 6 /0 0 1 9 7 8 1 6 /0 0 1 9 6 8 1 6 /0 0 1 9 3

/4

3

1

in. BS P in. BS P 1 /2 in. BS P 5 /8 in. BS P 3 /4 in. BS P 1 in . B S P 3

/4 /8

S193900

S193890

T' Ad a p t e rs

Fe m a le C o n n e c t o rs

892/ 892 /00047 000 47 3/8 in. B S P (A) x 1/4 in . B S P (B ) 892/ 892 /00048 000 48 1/2 in. B S P (A) x 1/4 in . B S P (B ) 892/ 892 /00049 000 49 5/8 in. B S P (A) x 1/4 in . B S P (B ) 816/ 816 /50043 500 43 3/4 in. B S P (A) x 1/4 in . B S P (B ) 892/ 892/00051 00051 1 in. in. BS P (A) x 1/4 in. BSP (B)

8 9 2 /0 0 0 7 4 8 9 2 /0 0 0 7 5 8 9 2 /0 0 0 7 6 8 9 2 /0 0 0 7 7

3 1 5 3

/8 /2 /8 /4

in. in. in. in.

BS P BS P BS P BS P

x x x x

3 1 5 3

/8 /2 /8 /4

BS P BS P BS P BS P

S192410

S193930

He x a g o n S p a n n e rs fo r R a m P is t o n s a n d En d C a p s

S p o o l C la m p s

9 9 2 /0 9 5 0 0 75 7 5 m m A/F 9 9 2 /0 9 7 0 0 95 9 5 m m A/F

8 9 2 /0 0 0 3 9 9 9 2 /1 0 1 0 0 9 92 92 /0 28 28 00 00

9803 /3610

in. in. in. in.

S p o o l C la m p S p o o l C la m p AR V E xt xt ra ra c t o r

Iss ue 1

General Information

S ec tion tion 1

S ec tion tion 1

5- 3

5 -3


Male Ada Ada pters pters - BS P x BS P 1606/ 160 6/0003 000 3 3/8 in. x 1/4 in. 1604 /0003 000 3 3/8 in. x 3/8 in. 892/000 892/00071 71 3/8 in. x 3/8 in. tape r 1606 /0004 000 4 1/2 in. x 1/4 in. 1606 /0007 000 7 1/2 in. x 3/8 in. 1604 /0004 000 4 1/2 in. x 1/2 in. 1606 /0017 001 7 5/8 in. x 1/2 in. 1606 /0008 000 8 3/4 in. x 3/8 in. 1606 /0009 000 9 3/4 in. x 1/2 in. 1604 /0006 000 6 3/4 in. x 3/4 in. 1606 /0012 001 2 3/4 in. x 1 in. 1606/ 160 6/0014 001 4 3/4 in. x 11/4 in. 1606 1606/ /0015 0015 1 in. in. x 11/4 in.

S193860

S193850

P ress ure Tes t Ada Ada pters 892/ 892 /00255 002 55 1/4 in . B S P x Te s t P o in t 892/ 892 /00256 002 56 3/8 in. BS P x Tes Tes t P oint oint 1 892/ 892 /00257 002 57 /2 in . B S P x Te s t P o in t 892/ 892 /00258 002 58 5/8 in . B S P x Te s t P o in t 816/151 816/15118 18 3/4 in . B S P x Te s t P o in t 8 9 2/0 0 2 5 9 1 in . B S P x Te s t P o in t 892/ 892/0026 00260 0 1.1/4 in . B S P x Te s t P o in t 892/002 892/00261 61 5/8 in . U NF x Te s t P o in t

Ha n d P u m p Eq u ip m e n t

S200141

8 9 2 /0 0 2 2 3 8 9 2 /0 0 1 3 7 8 9 2 /0 0 2 7 4 8 9 2 /0 0 2 6 2 8 9 2 /0 0 7 0 6 8 9 2 /0 0 2 7 9

Ha n d P u m p Mic ro -b o re Ho s e 1/4 in BS P x 5 metres metres Ad a p t e r 1/4 in M BSP x 3/8 in M BS P Ta per 1 1 /4 in M BSP x /4 in F BS P x Test Test P oint oint Te s t P ro b e G a u g e 0 - 4 0 0 b a r (0 -6 0 0 0 lb f/in2)

S270650

*8 9 2 /0 0 9 2 3

S216060

Te s t B lo c k fo r A. R . V

9 92 92 /0 70 70 00 00

9803 /3610

R a m En En d C a p P e g S p a n n er er

Issue 3*

General Information

S ec tion tion 1

S ec tion tion 1

5- 4

5 -4


7mm 11 o 20mm

10mm

5mm R

m 3 m

338410

Ram Se al Protection Protection S leeves 110mm 175mm 3o

R

8 9 2/0 1 0 2 7

1 . 4 m m

P is is to to n S e a l As s em e m b ly ly To ol ol

338500

8 9 2/0 0 3 3 4

9803 /3610

892/ 892/0101 01016 6 892/ 892/0101 01017 7 892/ 892/0101 01018 8 892/ 892/0101 01019 9 892/ 892/0102 01020 0 892/ 892/0102 01021 1 892/ 892/0102 01022 2 892/ 892/0102 01023 3 892/ 892/0102 01024 4 892/ 892/0102 01025 5 892/ 892/0102 01026 6

For 25 mm For 30 mm For 40 mm For 50 mm For 50 mm For 60 mm For 60 mm For 65 mm For 70 mm For 75 mm For 80 mm

Rod Rod Rod Rod Rod Rod Rod Rod Rod Rod Rod

Di Diameter Di Diameter Di Diameter Di Diameter Di Diameter (slew (slew ram) ram) Di Diameter Di Diameter (slew (slew ram) ram) Di Diameter Di Diameter Di Diameter Di Diameter

S ea e a l Fit t in g To ol ol

Iss ue 1

General Information

S ec tion tion 1

S ec tion tion 1

6- 1

6 -1

Servic Service e Tools (cont'd) Section F - Transmission

S188160

992/ 992/0760 07608 8 992/ 992/0760 07609 9 992/ 992/0761 07610 0 992/ 992/0761 07611 1 992/ 992/0761 07612 2 9 9 2/0 7 6 1 3

Bea ring Bea ring Bea ring Bea ring Bea ring B e a rin g

Ada pter Ada pter Ada pter Ada pter Ada pter Ad a p t e r

S188170

9 9 2 /0 7 6 0 3

R e p la c e r- B e a rin g C u p

S188190

S188200

8 9 2/0 0 2 9 5 En d Flo a t S e t t in g To o l

8 9 2 /0 0 1 7 9

B e a rin g P re s s

C

A

S188220

B

S083252

D A B C *D

8 9 2 /0 0 3 0 4 8 9 2 /0 0 3 0 1 8 9 2 /0 0 3 0 2 8 9 2 /0 0 9 2 0

9803 /3610

Flo w Flo w Flo w Flo w

Te Te s t Te Te s t Te Te s t Te Te s t

Ad Ad a p te te r Ad Ad a p te te r Ad Ad a p te te r Ad Ad a p te te r

992/ 992/04800 04800 Flang Flang e S pa nner For locking pinion flange while nut is slackened or torq torq ue set

Issue 2*

S ec tion tion 1

General Information

S ec tion tion 1

6- 2

6 -2


*892/00893 Torq ue C onverter Al Alignment B a r 992/04000 Torq ue Multipl Multipliier S228921

Use in co njuncti njunction on w ith a torque w rench to give a 5:1 multiplication when tightening pinion nuts etc.

S197030

892 /00224 002 24 * 892/ Impulse mpulse Extracto r S et for Hub Hub Be a ring ring S ea ts S197250

S197070

Heavy Duty Sockets for Durlok bolts 892/00817 17mm A/ A/F x 3/4in sq ua re d rive rive 892/00818 22mm A/ A/F x 3/4in sq ua re d rive rive 1 892/00819 15mm A/ A/F x /2in sq ua re d rive rive 3 892/00333 19mm A/ A/F x /4in sq ua re d rive rive

B

D C A

S197080

*993/59300 2/4 Wheel Wheel Drive Drive C lutch P ress ure ure Tes t Ada ptor &C la mp S196750

9803 /3610

8 9 2 /0 0 2 2 5

Ad a p te te r - Im pu pu ls e E x t ra ra c to to r A S ma ll 17mm 17mm to 25mm B Medium 25mm to 45mm C La rge 45mm to 80mm

9 9 3 /5 9 5 0 0

Ad a p te te r - Im pu pu ls e Ex Ex t ra ra c to to r D (sync (sync ro shuttle shuttle a nd pow ershift ershift transmission)

Issue 3*

General Information

S ec tion tion 1

S ec tion tion 1

6- 3

6 -3


S250350

892/ 892 /0090 2 S pa nner, nner, Track Track Rod End

892/ 892 /0090 6 S ea l Fi Fitting tting Ada ptor

S250340

S250370

892/ 892 /0090 3 Spanner, Differential

892/ 892 /0090 4 Spanner, Differential

S250360

*

892/ 892 /00891 008 91 S ea l Fi Fitting tting Ada ptor S227760

9803 /3610

Issue 2*

General Information

S ec tion tion 1

S ec tion tion 1

6- 4

6 -4


S267310

8 9 2 /0 0 9 1 6

S261230

Sp prrin g C o mp mp re ss ss o orr To ol ol Forwa rd/Revers e Clutches

Torq ue Mea s uring uring Too Too l for Whee Whee l Hub S ea ls Manufacture locally, procedures in this manual show chec king king the whee l hub hub s ea l using using a rolli olling force. However, the torque can be measured using using above loc ally ally ma nufa nufa ctured too l. B e a r in in g r o ll ll in g t o r q u e i s 1 2 t o 2 2 N m (9 (9 t o 1 6 lb lb f f t ) excluding seal drag. Maximum permissible including seal drag is 40 Nm (29.5 lbf ft)

S316250

Tes t P oint 1

8 9 2 /0 0 9 64

Te s t p o in in t (1 /8 B S P ) P S 7 00 00

2

8 9 2 /0 0 9 65

Te s t p o in in t (3 /8 B S P ) P S 7 00 00

3

8 9 2 /0 0 9 66

Te s t p o in in t (1 /4 B S P ) S S 4 00 00 , S S 60 60 0

S197010

993/ 993/7820 78200 0

Mainshaft ainshaft Ai Airline Adaptor Adaptor (P ow ershift Trans Trans miss ion Only) Only)

These tes t points ca n be left in in pos ition tion a fter tes tes ting. ting.

9803 /3610

Issue 3*

General Information

S ec tion tion 1

S ec tion tion 1

6- 5

6 -5


Solid Spacer Setting Kit

1

1 2 3

3

2 S316260

9803 /3610

8 9 2 /0 0 9 1 8 9 9 3 /7 0 1 1 1 9 2 1 /5 2 6 0 0 Comprises: 9 2 1 /5 2 6 0 1 9 2 1 /5 2 6 0 2 9 2 1 /5 2 6 0 3 9 2 1 /5 2 6 0 4 9 2 1 /5 2 6 0 5 9 2 1 /5 2 6 0 6 9 2 1 /5 2 6 0 7 9 2 1 /5 2 6 0 8 9 2 1 /5 2 6 0 9 9 2 1 /5 2 6 1 0 9 2 1 /5 2 6 1 1 9 2 1 /5 2 6 1 2 9 2 1 /5 2 6 1 3 9 2 1 /5 2 6 1 4 9 2 1 /5 2 6 1 5 9 2 1 /5 2 6 1 6 9 2 1 /5 2 6 1 7 9 2 1 /5 2 6 1 8 9 2 1 /5 2 6 1 9 9 2 1 /5 2 6 2 0 9 2 1 /5 2 6 2 1 9 2 1 /5 2 6 2 2 9 2 1 /5 2 6 2 3 9 2 1 /5 2 6 2 4 9 2 1 /5 2 6 2 5 9 2 1 /5 2 6 2 6

S et e t t in g To To o l Kit B re re a kb kb a ck c k To rrqq ue u e Wre nc nc h Sp paa c e r Kit S p ac a c er e r 12. 75 S p ac a c er e r 12. 80 S p ac a c er e r 12. 85 S p ac a c er e r 12. 90 S p ac a c er e r 12. 95 S p ac a c er e r 13. 00 S p ac a c er e r 13. 05 S p ac a c er e r 13. 10 S p ac a c er e r 13. 15 S p ac a c er e r 13. 20 S p ac a c er e r 13. 25 S p ac a c er e r 13. 30 S p ac a c er e r 13. 35 S p ac a c er e r 13. 40 S p ac a c er e r 13. 45 S p ac a c er e r 13. 50 S p ac a c er e r 13. 55 S p ac a c er e r 13. 60 S p ac a c er e r 13. 65 S p ac a c er e r 13. 70 S p ac a c er e r 13. 75 S p ac a c er e r 13. 80 S p ac a c er e r 13. 85 S p ac a c er e r 13. 90 S p ac a c er e r 13. 95 S p ac a c er e r 14. 00

Issue 1*

S ec tion tion 1

General Information

6- 6

S ec tion tion 1 6 -6


Fixture for Syncro Shuttle &Powershift Gearbox remova l &replace &replace ment.

Note: When removing/ removing/repl replaa cing a S yncro S huttle huttle Gea rbox, use items items 1, 2 a nd 3. When removing/ removing/repl replaa cing a P ow ershift ershift G ea rbox, use items 1 and 4.

S162580

Fixture - Item 1

9803 /3610

Issue 1*

S ec tion tion 1

General Information

Section 1

6- 7

6 -7

Service Tools (cont'd) Section F - Transmission Fixture Fixture - Item 2

Fixture Fixture - Item 3

9803 /3610

Fixture - Item 4

Iss ue 1*

General Information

S ec tion tion 1

S ec tion tion 1

6- 8

6 -8

Servic Service e Tools (cont'd) Section F - Transmission Transmission

1

9 9 3 /7 01 0 0

P o w e rs rs h ifift En En d fl flo a t C he he c ki kin g Ki Kit (Include Include s items 2 to 13)

1 4

2

9 9 3 /7 01 0 1

B as a s e P la la te te

3

9 9 3 /7 01 6 0

Yo ke As sy sy

7

11

3

12

4

9 9 3 /7 01 3 0

Ma in in s ha h a ft ft Ad a p te te r As s y

10 8

5

9 9 3 /7 01 0 4

6

5

Ma in in s ha ha ft ft P il illa r

6 13 2

6

9 9 3 /7 01 0 6

La y s ha ha f t/ t/R ev e v e rs rs e r P il illa r 9

7

9 9 3 /7 01 2 0

La ys y s ha ha ft ft S e tt tt in g As As s y A191642

8

9 9 3 /7 01 4 0

R e ve ve rs rs er e r S e tt tt in g As As s y

9

1 3 9 1 /33 0 5

C a ps ps cr c re w (M (M8 x 2 0 )

1 0 8 26 26 /0 14 14 17 17

S e t s c re re w (M (M1 0x 0x 30 30 ) Fla n g e d

11 993/ 993/7011 70111 1

Setting Setting Wr Wrench (th (thiis is not part part of the the kit) kit)

1 2† 2† 9 93 93 /7 01 01 12 12

In pu put S h a ft ft P il illa r

1 3† 3† 9 93 93 /7 01 01 50 50

In pu put S e t ti tin g As As s y

A191642

† If these items a re not in in your kit kit they ca n be ordered s epa rately but the the ba se pla pla te 2 will have to be drilled to secure item 12, see A a n d B. Mea surements are in mm. Appl Applyy J CB Threa hrea dlocker And And S ea ler and tighten tighten item 9 to 25-30 Nm (18-22 lbf ft).

8.5

10

20

15 12

A B

36 17 81.75 96.35

9

9803 /3610

A191643

Issue 1*

General Information

Section 1

Section 1

6-9

6-9

Service Tools (cont'd) Section F - Transmissi Transmission on (cont’d) Wheel Hub Service Tool A B C

5

A

Bearing Puller Bearing Press Hub Seal Dolly

1

Item Description A , B & C Hub Service Kit

Part No. 892/01092

Qty 1

6

comprises of: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

8,9

Puller Beam Inne In nerr Be Bear arin ing g Pla latte Bolt M16x220 Nut M16 Reaction Tube Mod Mo dif ifie iedW dWhe heel el Stu tud d Wheel Bearing Carrier Puller Nut M20 Washer M20 Puller Rod Nut M12 Washer M12 Bear Be arin ing g Ce Cent ntre re Pu Pull ller er Bolt M10x60 Nut M10 Bearing Fitting Tube Pul ulle lerr Han and dle Nut Bolt Bo lt M2 M20x 0x30 300 0 Washer Bearing Seal Dolly

B

998/10623 998/ 99 8/10 1060 607 7 1315/3731Z 1370/0601Z 998/10614 998/ 99 8/10 1062 624 4

1 1 2 2 1 2

998/10615 1370/0701Z 1420/0012Z 998/10610 1370 13 70/0 /040 401Z 1Z 1420/0009Z 998/ 99 8/10 1060 608 8 1315/3414Z 1370/0301Z 998/10606 998/ 99 8/10 1061 616 6 1315 13 15/3 /383 835Z 5Z 445/12303 917/02800 892/00891

2 4 2 2 2 2 1 1 1 1 1 2 2 1 1

15

7 2

10

4

11,12

3

13 16

14

18

C

19, 20

8

21

17

A439160

9803/3610

Issue 1*

Section 1

General Information

Section 1

7-1

7-1

Service Tools (cont'd) Section H - Steering

892/00180 892/00180 Seal Fitting Fitting Tool Tool for for fitting fitting 'O' ring ring and and back-up ring to Danfoss Orbitrol Unit 892/00 892 /00181 181 Rep Replace lacemen mentt Plast Plastic ic Boss Boss

S191750

Section K - Engine

892/00 892 /00041 041 De-gla De-glazin zing g Tool for for Cylinde Cylinderr Bores Bores (to assist bedding-in of new piston rings)

S192390

For details of other engine service tools refer to Perkins Service Manual Publication No. 9806/0100

9803/3610

Issue 1

Section 1

General Information

7-2

Section 1 7-2

Service Tools (cont'd) Section K - Engine Note: “R” Series Engines only

1 2 3 4 5

892/01111 892/ 89 2/0 011 1112 12 980/ 98 0/0 011 1113 13 892/ 89 2/0 011 1114 14 892/01115

3

Rocker assembly tool Tim imin ing g ca cas se al alig ignm nme ent tool The herrmos osttat fi fitt & re remov ova al to tool Cam ams sha haft ft gea earr ti tim min ing g pi pin n Crankshaft tim imiing pin

1

4

2

5

892/00836 Lifting Wire Assembly (for engine removal only) A314530

892/ 89 2/00 0093 936 6

Timi Ti ming ng pin pin for for fuel fuel injec injecti tion on pum pump p (AK, AR)

892/ 89 2/01 0105 054 4

Adap Ad apto torr for comp compre ress ssio ion n testi testing ng (AK, AR)

9803/3610

S219080

Issue 1*

Section 1

General Information

Section 1

8-1 * Sealing

8-1

and Retaining Compounds

JCB Multi-Gasket

JCB High Strength Threadlocker

JCB Retainer (High Strength)

A medium strength strength sealant suitable suitable for all sizes of gasket flanges, and for hydraulic fittings of 25-65mm diameter.

4102/1212

50ml

A high strength locking locking fluid for use with threaded threaded components. Gasketing for all sizes of flange where the strength of the joint is important.

4102/0551

50ml

For all retaining parts which are unlikely to be dism di sman antl tled ed..

4101 41 01/0 /065 651 1

50ml 50 ml

JCB Threadlocker and Sealer

A high strength locking locking fluid for sealing and retaining nuts, bolts, and screws up to 50mm diameter, and for hydraulic fittings up to 25mm diameter.

4101/0250 4101/0251

10ml 50ml

Threadseal

A medium strength strength thread sealing compound.

4102/1951

50ml

Threadlocker

A locking fluid for use use on threads larger larger than 50mm dia.

4101/0451

50ml

4104/0251 4104/0253

(1ltr) Bottle

400ml

Activator

A cleaning primer which which speeds the curing rate of anaerobic products. (200ml)

Cleaner / Degreaser

For degreasing components prior to use of anaerobic adhesives and sealants.

4104/1557

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 4104/1203

30 ml 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

Direct Glazing Kit

9803/ 3610 3 610

Issue 6*

Care & Safety

S e c t io n 2

S e c t io n 2

i

i

Contents

9803 /3610

Page No.

S a fe t y No t ic e s

1-1

G e n e ra l s a fe t y

2-1

O p e ra t in g s a fe t y

2-2

Ma in t e n a n c e s a fe t y

2-3

Lub ric a n t s - He a lt h a n d S a fe t y

3-1

Iss ue 1

Care & Safety

S e c t io n 2 1- 1

S e c t io n 2 1 -1

Safety Notices In this handbook and on the machine there are safety notices. Each notice starts with a signa l wo rd. The The signa l wo rd mea nings nings are g iven below.

! 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

! 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

! CAUTION Denotes a reminder of safety practices. Failure to follow these safety practices could result result in inj injur uryy to the ope rator (or (or others) and pos sible sible d a ma ge to the ma chine. INT-1-2-3

9803 /3610

Iss ue 1

Care & Safety

S e c t io n 2

S e c t io n 2

2- 1

2 -1

All construction and agricultural equipment can be haza rdous. When When a J CB mac hine hine is is c orrectl orrectlyy operated a nd 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 w ell a s the w arnings arnings in this this c hapte r, specific specific w a rnings nings a re given throughout throughout the boo k. Thi Thiss sec tion tion is d es igned to g ive a safety code for use of the machine generally and for maintenance maintenance prac prac tices tices .

Do not w ork with the mac hine hine until until you are sure that yo u ca n co ntrol it. it. Do not start any job until you are sure that you and those around yo u will will be s a fe. If you are unsure of anything, about the machine or the job, as k someone w ho knows knows . Do not ass ume anything. anything. R emember emember

BE CAREFUL BE ALERT BE SAFE GEN-1-6

General Safet Safety y

! WARNING ! 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

! WARNING Clothing You ca n be injur njured ed if you do not w ea r proper proper clothing. clothing. Loos e 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 w ea r a nec ktie ktie or sc a rf. Keep long long hair restrained. restrained. INT-1-3-6

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

! 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

! 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. job. INT-1-3 -7

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Iss ue 1

Care & Safety

S e c t io n 2

S e c t io n 2

2- 2

2 -2

! WARNING

Operating Safety

! 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.

Engine Panels The eng ine ha s exposed rotating rotating pa rts. rts. Do not open the bonnet while the engine is running. Keep other people clear while while you raise the eng ine co ver using the boo m. Do not use the ma chine chine w ith the bonnet ope n or the the co ver ra ra ise d. 5-1-2-1

! WARNING

INT-2-1-3

! 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

! WARNING Passengers Pa ss engers in in or on the the ma chine chine ca n ca use a ccidents. The The J C B L o a d a l l i s a o n e m a n m a c h i ne ne . D o n o t c a r r y passengers. INT-2-2-2

! 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 fres fres h a ir. INT-2-1-10

! 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 drivi driving ng onto ramps a nd trailers. trailers. INT-2-2-6

! 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

ROPS/FOPS Structure The ma chine is fitted fitted w ith a Roll Over Prote ction S tructure (ROPS) and a Falling Objects Protection Structure (FOPS). You could be killed or seriously injured if you operate the mac hine hine with a da ma ge d or miss miss ing ROP S /FOPS . If If the the R O P S /F OP O P S h a s b e e n in in a n a c c i d e n t , d o n o t u s e t h e ma chine chine until until the the s tructur tructuree ha s bee n renewed . Modifi Modifica tions tions and repairs that are not approved by the manufacturer may b e d a n g e r o u s a n d w i l l in in v a li l i d a t e t h e R O P S /F O P S certification INT-2-1-9/3

! WARNING Reversing R e v e rs rs in i n g a t h ig ig h s p e e d c a n c a u s e a c c id id e n t s . D o n o t reverse in third or fourth (if fitted) gear with full throttle. Alwa ys d rive rive at a sa fe spee d to s uit uit wo rki rking c onditions. onditions. INT-2-2-9

! 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 rely on spoken comma nds. INT-2-2-3

! WARNING Sparks E xp x p lo lo s i o n s a n d f ir ir e c a n b e c a u s e d b y s p a r ks ks f r o m t h e 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

! CAUTION Overhead Clearance A raised boom can strike overhead objects. Always check for overhead clearance before raising the boom. 5-1-5-1

INT-3-2-7/1

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Iss ue 1

Care & Safety

S e c t io n 2

S e c t io n 2

2- 3

2 -3

Maintenance Maintenance Safety

! WARNING

! 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.

J acki cking A ma chine ca n roll roll off jac jac ks a nd c rush you unless unless the w heels have been chocked. Always chock the wheels at the opposite end of the machine that is to be jacked. Do not wo rk underneath underneath a ma chine supported only by jac jac ks. Al Alwa ys support a jacked-up machine on axle stands before working underneath it.

INT-3-1-3

! 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. S ee B oo m S a fety S trut (MA (MAIN INT TENANCE ENANCE s ec tion). tion). 5-1-5-7

! 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, engine, the a ttachments a nd link linkag ag es, a nd a nywhere nywhere beneath or behind the machine. People can be killed or injur njured ed if these preca utions utions a re not ta ken. INT-3-1-5

! WARNING Asbestos As b e s t o s d u s t c a n d a m a g e y o u r l u ng n g s . S o m e e n g in in e gaskets contain asbestos. Do not dismantle the engine or exhaust system; get these jobs done by a qualified person who ha s a copy of the engine engine s ervi ervice ce manual. 5-1-6-1

INT-3-2-8

! WARNING Diesel Fuel Diesel fuel is flammable; keep naked flames away from the machine. Do not smoke while refuelling the machine or w o r ki kin g o n t h e e n g in e . D o n o t r e f u e l w it it h t h e e n g i n e runni running. ng. There c ould be a fire fire a nd injury njury ifif you d o no t follow follow these precautions. INT-3-2-2

! WARNING Hot Coolant The co oling oling s yste m is is pres surise surise d w hen the eng ine is hot. Hot coolant can spray out when you remove the radiator cap. Let the system cool before removing the radiator cap. To remove t he c a p; turn itit to the first first no tch a nd let the system pressure esca pe, then remove remove the cap. INT-3-2-9

! 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 form fla fla mma ble vapours. INT-3-1-6

! 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

! DANGER Electrolyte Battery electrolyte is toxic and corrosive. Do not breathe the gases given off by the battery. Keep the electrolyte away f ro ro m y o u r c l o t h e s , s k in in , m o u t h a n d e y e s . We a r s a f e t y gla ss es . S ee B a ttery (MA (MAINT INTENANCE ENANCE s ec tion) for First First Aid treatments. INT-3-2-1/2

9803 /3610

! WARNING Oil 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

! WARNING Electrical Circuit C ircuits s U n d e r s t a n d t h e e le l e c t r ic ic a l c ir ir c u it it b e f o re re c o n n e c t i n g o r disconnecting an electrical component. A wrong connection ca n ca use injur injuryy and /or dama ge . INT-3-1-4

Iss ue 1

Care & Safety

S ec tion tion 2

S ec tion tion 2

2- 4

2 -4

! WARNING Hydraulic 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

! WARNING Battery Terminals The ma chine is is neg a tivel tivelyy ea rthed. Al Alwa ys c onnec t the nega tive tive pole of the the ba ttery to earth. When co nnecting the ba ttery, connec t the ea rth rth (-) (-) lea d las t. When disconnecting the battery, disconnect the earth (-) lead first. INT-3-1-9

! WARNING Hydraulic 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 a re open. INT-3-1-11/1

! WARNING Battery A battery with frozen electrolyte can explode if it is used or cha rged. Do no t use a mac hine hine with a frozen frozen b atte ry. To help prevent the battery from freezing, keep the battery fully charged.

! WARNING Fluoroelastomeric Materials Certain sea ls and ga skets (e.g. (e.g. c rankshaft oil oil seal) on J CB * Certain machines contain fluoroelastomeric materials such as Viton, F lu lu o r e l a n d Te c h n o f l o n . F lu lu o r o e l a s t o m e r ic ic m a t e r ia ia l s subjected to high temperatures c an p rod uce highly highly co rros rros ive hyd rofluoric rofluoric a cid . THIS THIS ACID CAN S EVERELY EVERELY BUR N. New fluoroelastomeric components at ambient temperature req uir uire no s pec ia l sa fety preca preca utions. utions. Used fluoroelastomeric components whose temperatures have not exceeded 300°C require no special safety precautions. If evidence of decomposition (e.g. charring) is found, refer to the next paragraph for safety instructions DO NOTTOUC NOTTOUC H COMP ONENTOR S URR OUNDING OUNDING AREA. AREA.

INT-3-1-7

! CAUTION Cleaning Cleaning metal parts with incorrect solvents can cause corrosion. Use only recommended cleaning agents and solvents.

Used fluoroelastomeric components subjected to temperatures greater than 300°C (e.g. engine fire) must be treated using the following safety procedure. Make sure that heavy duty gloves gloves a nd spec ial safety glas glas ses are worn: 1

E ns ns u re re th th a t c o mp mp o ne ne n ts ts h a v e c o o le le d t he he n re m o ve ve a n d place material into plastic bags.

2

Thoroughl horoughlyy wash contaminated contaminated area area with with 10% 10% calcium calcium hydroxide or other suitable alkali solution, if necessary use wire wire w ool to remove burnt rema rema ins.

3

Th o ro ro ug ug h ly ly w a s h c o n t a m in in a t ed ed a re a w it h d et et e rg rg e n t a nd nd water.

4

C o n t a in in a ll ll re m o ve ve d m a t e ri ria l, l, g lo lo v es es e t c . u s e d in in t hi his operation in sealed plastic bags and dispose of in a cc orda nce with Loc Loc a l Author Authoriity Reg ula ula tions. tions.

INT-3-2-11

! CAUTION 'O' rings, Seals and Gaskets Badly fitted, damaged or rotted 'O' rings, seals and gaskets c a n c a u s e le a k a g e s a n d p o s s i b le le a c c id id e n t s . R e n e w whenever disturbed unless otherwise instructed. Do not use Trioc rioc hloroetha hloroetha ne or pa int thinners thinners nea r 'O' rings rings a nd s ea ls. INT-3-2-12

! WARNING Soft Ground A machine can sink into soft ground. Never work under a machine on soft ground. INT-3-2-4

! WARNING Hydraulic Hydraulic Hoses Damaged hoses can cause fatal accidents. Inspect the hoses regularly for: Dama ged end fitti fittings ngs Chafed outer covers Ba llooned outer covers Kinked Kinked or crushed hos es Embedd ed armouring armouring in outer covers Displac Displac ed end fitti fittings .

DO NOT B URN FLUO ROELASTOMERIC ROELASTOMERIC MAT MATERIALS ERIALS . If contamination of skin or eyes occurs, wash the affected area with a c ontinuous ontinuous supply of clea clea n wa ter or with ca lcium hydroxide solution for 15-60 minutes. Get medical attention immediately. INT- 3 - 3 - 5/1

INT-3-3-2

9803 /3610

Issue 2*

Care & Safety

S e c t io n 2 3- 1

S e c t io n 2

Lubri ubrica nts - Health Health a nd S a fety

3 -1

Hygiene J CB lubrica ubrica nts a re not a hea lth ri risk whe n used properl properly for their their intended intended purpos purpos es .

2

Apply a barrier cream to the skin before handling used eng ine oil. oil.

However, excessive or prolonged skin contact can remove t h e n a t u r a l fa f a t s f ro ro m y o u r s k iin n , c a u s in i n g d r y ne ne s s a n d irri irrita ta tion.

3

Note the following when removing engine oil from skin: skin thoroughly thoroughly w ith so ap a nd w ate r. a Was h your skin

b 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. l, d i e s e l f ue u e l , o r p a r a f f in in f o r d N e v e r u s e p e t r o l, washing.

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.

Storage Alwa ys keep lubri lubrica ca nts out of the rea ch o f children. children. Never store lubricants in open or unlabelled containers.

Us ing a na il brush brush will will help. help.

e

Avoid skin contact with oil soaked clothing.

f

Don't keep oily oily rag s in poc kets.

g

Wash dirty clothing before re-use.

h

Throw hrow a wa y oil oil-soa ked shoes .

First Aid - Oil

Waste Disposal

Eyes All waste products should be disposed of in accordance with all the relevant regulations. The c ollection ollection a nd d ispo sa l of used engine oil should be in accordance with any local regulations. Never pour used engine oil into s ew ers, dra ins o r on the g round. round.

In the ca se of eye c onta ct, flush flush w ith wa ter for for 15 minutes. minutes. If irri rrita tion tion persists persists , g et medica l attention.

Swallowing

Handling

If oil is swallowed do not induce vomiting. Get medical advice.

New Oil

Skin

There are no spe cial preca preca utions utions neede d for the ha ndling ndling o r u s e o f n e w o il i l , b e s i d e t h e n o rm r m a l c a r e a n d h y g ie n e practices.

In the case of excessive skin contact, wash with soap and water.

Used Oil Used engine crankcase lubricants contain harmful contaminants. Here are precautions to protect your health when handling used engine oil: oil:

1

Avoid prolonged, excessive or repeated skin contact with used engine oils. oils.

9803 /3610

Spillage Absorb on sand or a locally approved brand of absorbent granules. Scrape up and remove to a chemical disposal area.

Fires E x t in in g u is i s h w i t h c a rb o n d i o x id id e , d r y c h e m i c a l o r fo fo a m extinguishers. Do not use water. Fire-fighters should use self-contained breathing apparatus.

Iss ue 1

Routine Maintenance

Section 3

Section 3

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i

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)

1-3 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

9803/3610

1-1 1-1 1-2

10 - 1

Issue 6*

Routine Maintenance

Section 3

Section 3

ii

ii

Contents

Page No.

Fuel System - Fuel Types 11 - 1 - Filling the Tank 11 - 2 - Cleaning the Lift Pump Gauze 11 - 2 - Draining the Filter (up to S/N 280299) 11 - 3 - Chan Changin ging g the the Filte Filterr Eleme Element nt (up (up to S/N 2802 280299) 99) 11 - 3 - Draining the Filter (from S/N 280300) 11 - 4 - Changing the Filter Element “A” series engines (from S/N 280300) 11 - 4 “R” series engines 11 - 5 - Draining the Sediment Bowl 11 - 6 - Cleaning the Sediment Bowl 11 - 6 - Bleed the System 11 - 8 - Fuel Pipes- Removal and Replacement 11 - 11

9803/3610

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 - Check heckin ing g the the Hose ose Burs Burstt Prote rotect ctio ion n Valve alves s

16 - 1

Battery

17 - 1

Issue 3*

S ec tion tion 3

Routine Maintenance Lubricants &Capacities

1- 1


New Engines New e ngines DO NOTreq uire uire a running-in running-in period period . The The eng ine/ma ne/ma chine sho uld uld b e us ed in a no rmal work cyc le immed immed ia tely; 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 ma chines a re fil filled a t the fa cto ry with J CB 10W/ 10W/30 Mul Multigrad tigrad e o il. Thi Thiss oil sho uld uld b e d rained a fter the first first 100 hours op eration a nd the engine fil filled with the a ppropri ppropria te reco mmende d g rade a s s how n in in the lubri lubrica ca tion tion c hart. J CB 10W/ 10W/30 Mul Multi tigrad grad e should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first first 100 hours hours o pera tion, it it is is es se ntial that the 10W/ 10W/30 oil is repla repla ce d b y the lubrica lubrica nt reco mmend ed in the lubrica lubrica tion charts.

Lubrication Char Charts ts Lubrication charts are included on the following pages for all machine models. Note that there are some diff erences in specifications for machines operating in North America. Be sure you identify the machine and its lubricant requirements correctly.

Note 1:

This his is is nominal nominal machine ca pa city. The total hydrauli hydraulic sys tem ca pa city dep ends o n the the eq uipment uipment being being used . Fi Fill and chec k with all ra ms closed . Watc Watc h level level sight sight g las s when fil filling.

Note 2:

If J CB S pec ia l MPL G reas e is is use d, a ll 50 hour grea sing operations must be ca rri rried out at TEN TEN (10) HOUR intervals. All 500 hour grea sing ope rations must be ca rri rried out a t FIFT FIFTY (50) (50) HOUR intervals

9803 /3610

Issue 5*

Routine Maintenance

S ec tion tion 3 1- 2


Lubricants &Capacities

520-55 RS (Rear Steer) Machines ITEM

CAPACITY FLUID/LUBRICANT Litres UK Gal US Gal

Fuel Tank U p t o s er e ria l No . 2 7 90 0 0 Fro m s e ria l No . 2 79 0 0 1

120 160

26. 4 35. 2

Engine (Oil)

10

2. 2

3 1. 7 4 2. 2

D ie s el e l O il (S ee e e Types of Fuel)

J CB High igh Per Perform ormance Eng Engine Oil Oil -1 0 ° C t o 50 50 °C °C (1 (1 4 ° F t o 12 12 2 ° F) F) J CB Sup Super Universal sal Agricultural -15 °C to 30 °C (5 °F to 86 °F)

2.6

Engine (Coolant (Coolant)) 5 5 % An t ifre e z e

20 11

5.3 2. 9

Syncro Shuttle Transmission

17

3. 7

4. 5

Front Axle Housing Hubs (x2)

9. 7 0. 6

2. 1 0. 1

2. 5 0. 16

Rear Axle Housing Hubs (x2)

5. 0 1. 5

1. 1 0. 3

1. 3 0. 4

Hydraulic Tank (1) Up to serial serial No. 2790 279000 00 Fro m s e ria l No . 2 79 0 0 1

100 100 110

22.0 22.0 24. 2

U p t o s e ria l No . 2 7 90 0 0 Fro m s e ria l No . 2 79 0 0 1

Grease Points (2)

S AE10W/30 AP I CD/S CD/S F

NORTH AMERICA J CB 15W/40 /40 Eng Engine Oil Oil 1 4 ° F t o 12 12 2 ° F (-1 0 ° C to t o 50 50° C )

S AE 15W/40 AP I C F4 F4 /S G

J CB 10W Eng Engine Oil Oil -4 ° F t o 50 50° F (-2 0 ° C to to 1 0 ° C )

SAE 10W AP I C F4 F4 /S G

NORTH AMERICA Permanent Antifreeze S t a rt rt s t o fre ez e z e -3 3 ° F (-3 6 ° C ) J CB High igh Per Perform ormance Transmission Fluid J CB High performance Gear Oil Plus

NORTH AMERICA (All Mac Ma c hines ) J CB Hydraulic Fluid J CB HP Grease

J CB Spe Specia cial MPL-EP PL-EP Gre Grease

Wear Pad Runways

J CB Waxoyl

Boom Hoses

J CB Special Slide Lubricant

9803 /3610

S AE15W/40 AP I C F4 F4 /S G (AC E A E2 :B :B 2 :A :A2 )

SAE10W AP I C D /S F

J CB High Performance Hydraulic Fluid 46 (Ab o v e 3 8 ° C , 1 00 ° F) J CB High igh Per Perform ormance Hydraulic Fluid 32 (Below 38 °C, 100 °F) J CB Lig Light Hydraulic Fluid 2 6. 4 2 9. 0

AS TM D 9 7 5 -6 6 T No s . 1 D , 2 D

J CB Tor Torque Conv Converter Fluid -1 8 ° C to to 0 ° C (0 (0 ° F t o 3 2 ° F)

J CB Four Season sons Antifreeze And Summer Coolant Starts to freeze -36 °C (-33 °F)

4. 4 2. 4

INTERNATIONAL SPECIFICATION

AS TM D3306 -74

AS TM D3306 -74 J C B: 4000/0900 Fri Friction mo dified dified oils oils MUST NOT be us ed (eg Dexron ATF type ). J C B: 4000/2200 MUSTb e s uitab uitab le for use use with o il im m e rs e d b ra ke s a n d lim it e d slip differentials (LSD).

ISO VG VG 46

ISO VG VG 32

ISO VG VG 15

ISO VG VG 46 Lithium complex NLGI No. 2 co nsts ituency including ncluding e xtreme xtreme pressure additives. Lithium based NLGI No. 2 co nsts ituency including ncluding e xtreme xtreme pressure additives.

Issue 4*

Routine Maintenance

S ec tion tion 3

S ec tion tion 3


1- 3

1 -3

520-55 AWS Machines (Type AA and AB Engine Builds) ITEM



120 160

26. 4 35. 2

Engine (Oil)

10

2. 2

3 1. 7 4 2. 2


J CB High igh Per Perform ormance Eng Engine Oil Oil -1 0 ° C t o 50 50 °C °C (1 (1 4 ° F t o 12 12 2 ° F) F) J CB Sup Super Universal sal Agricultural -15 °C to 30 °C (5 °F to 86 °F)

2.6


20 11

5.3 2. 9


17

3. 7

4. 5


5. 5 1. 5

1. 2 0. 3

1. 4 0. 4


5. 0 1. 5

1. 1 0. 3

1. 3 0. 4

Hydraulic Tank (1) Up to serial serial No. 2790 279000 00 Fro m s e ria l No . 2 79 0 0 1

100 100 110

22.0 22.0 24. 2


Grease Points (2)

S AE10W/30 AP I CD/S CD/S F





NORTH AMERICA Permanent Antifreeze S t a rt rt s t o fre ez e z e -3 3 ° F (-3 6 ° C ) J CB High igh Per Perform ormance Transmission Fluid J CB High performance Gear Oil Plus



Wear Pad Runways

J CB Waxoyl

Boom Hoses


9803 /3610



J CB High Performance Hydraulic Fluid 46 (Ab o v e 3 8 ° C , 1 00 ° F) J CB High igh Per Perform ormance Hydraulic Fluid 32 (Below 38 °C, 100 °F) J CB Lig Light Hydraulic Fluid 2 6. 4 2 9. 0

AS TM D 9 7 5 -6 6 T No s . 1 D , 2 D



4. 4 2. 4


AS TM D3306 -74

AS TM D3306 -74 J C B: 4000/0900 Fri Friction mo dified dified oils oils MUST NOT be us ed (eg Dexron ATF type ). J C B: 4000/2200 MUSTb e s uitab uitab le for use use with o il im m e rs e d b ra ke s a n d lim it e d slip differentials (LSD).

ISO VG VG 46

ISO VG VG 32

ISO VG VG 15


Issue 4*

Routine Maintenance

S ec tion tion 3

S ec tion tion 3


1- 4

1 -4

526-55, 526 & 526S Machines (AA and AB Engine Builds) ITEM



120 160

26. 4 35. 2

Engine (Oil)

10

2. 2

3 1. 7 4 2. 2

2.6


20 11

4. 4 2. 4

5.3 2. 9


17

3. 7

4. 5


9 2

1. 98 0. 44

2. 4 0. 5


8. 4 2

1. 85 0. 44

2. 2 0. 5

Brake System Fro m s e ria l No . 2 80 3 0 0 Hydraulic Tank (1) Up to serial serial No. 2790 279000 00 Fro m s e ria l No . 2 79 0 0 1


Grease Points (2)

100 100 110


2 6. 1 2 9. 0


J CB Sup Super Universal sal Agricu icultural -1 5 ° C to to 30 30 ° C (5 (5 ° F t o 8 6 ° F)

S AE10W/30 AP I C D/ D/S F








AS TM D3306 -74

NORTH AMERICA Permanent Antifreeze S t a rt rt s t o fre ez e z e -3 3 ° F (-3 6 ° C )

AS TM D3306 -74

J CB High igh Per Perform ormance Transmission Fluid

J C B 4000/0900 Fri Friction mo dified dified oils oils MUST NOT be us ed (eg Dexron ATF type ).

J CB High performance Gear Oil Plus

J C B 4000/2200 MUSTb e s uitab uitab le for use use with o il im m e rs e d b ra ke s a n d lim it e d slip differentials (LSD).

J CB Light Hydraulic Fluid D o n o t u s e o rd in a ry b ra ke flu id

ISO VG VG 15



Wear Pad Runways

J CB Waxoyl

Boom Hoses


9803 /3610

AS TM D 9 7 5 -6 6 T No s . 1 D , 2 D

J CB High igh Per Perform ormance Eng Engine Oil Oil -1 0 ° C t o 50 50 °C °C (1 (1 4 ° F t o 12 12 2 ° F) F)

J CB High Performance Hydraulic Fluid 46 (Ab o v e 3 8 ° C , 1 00 ° F) J CB High igh Per Perform ormance Hydraulic Fluid 32 (Below 38 °C, 100 °F) J CB Lig Light Hydraulic Fluid

22.0 22.0 24. 2


ISO VG VG 46

ISO VG VG 32

ISO VG VG 15


Issue 3*

Routine Maintenance

S ec tion tion 3

S ec tion tion 3


1- 5

1 -5

520-55 AWS Machines (Type AR and AK Engine Builds) ITEM



Fuel Tank

Engine (Oil)

160

35. 2

10

2. 2

4 2. 2

2.6


20 11

17

3. 7

4. 5


5. 5 1. 5

1. 2 0. 3

1. 4 0. 4


5. 0 1. 5

1. 1 0. 3

1. 3 0. 4

Hydraulic Tank (1)

110

24. 2

Grease Points (2)


J CB High igh Per Perform ormance Eng Engine Oil Oil -15 °C °C t o 40 40 °C °C (5 (5 °F °F t o 10 10 4 ° F) F)

S AE10W/30 AP I C F4 F4 /S G (A (AC EA E A E2 : B 2: 2: A2 A2 )





NORTH AMERICA Permanent Antifreeze S t a rt rt s t o fre ez e z e -3 3 ° F (-3 6 ° C ) J CB High igh Per Perform ormance Transmission Fluid J CB High Performance Gear Oil Plus

J CB High igh Per Perform ormance Hydraulic Fluid 46 (Above 38 °C, 100 °F) J CB High igh Per Perform ormance Hydraulic Fluid 32 (Below 38 °C, 100 °F) J CB Lig Light Hydraulic Fluid 29.0



Wear Pad Runways

J CB Waxoyl

Boom Hoses


9803 /3610

AS TM D 9 7 5 -6 6 T No s . 1 D , 2 D



4. 4 2. 4

5.3 2. 9


D ie s e l O il (S e e Types of Fuel)

AS TM D3306 -74

AS TM D3306 -74 J C B 4000/0900 Fri Friction mo dified dified oils oils MUST NOT be us ed (eg Dexron ATF type ). J C B 4000/2200 MUSTb e s uitab uitab le for use use with o il im m e rs e d b ra ke s a n d lim it e d slip differentials (LSD).

ISO VG VG 46

ISO VG VG 32

ISO VG VG 15


Issue 2*

Routine Maintenance

S ec tion tion 3

S ec tion tion 3


1- 6

1 -6

526-55, 526 & 526S Machines (Type AR and AK Engine Builds) ITEM



Fuel Tank

Engine (Oil)

160

35. 2

10

2. 2

4 2. 2

2.6


20 11

17

3. 7

4. 5


9. 0 2. 0

1. 98 0. 44

2. 4 0. 5


8. 4 2. 0

1. 85 0. 44

2. 2 0. 5

Hydraulic Tank (1)

110

24. 2

Grease Points (2)


J CB High igh Per Perform ormance Eng Engine Oil Oil -15 °C °C t o 40 40 °C °C (5 (5 °F °F t o 10 10 4 ° F) F)

S AE10W/30 AP I C F4 F4 /S G (A (AC EA E A E2 : B 2: 2: A2 A2 )





NORTH AMERICA Permanent Antifreeze S t a rt rt s t o fre ez e z e -3 3 ° F (-3 6 ° C ) J CB High igh Per Perform ormance Transmission Fluid J CB High Performance Gear Oil Plus

J CB High igh Per Perform ormance Hydraulic Fluid 46 (Above 38 °C, 100 °F) J CB High igh Per Perform ormance Hydraulic Fluid 32 (Below 38 °C, 100 °F) J CB Lig Light Hydraulic Fluid 29.0



Wear Pad Runways

J CB Waxoyl

Boom Hoses


9803 /3610

AS TM D 9 7 5 -6 6 T No s . 1 D , 2 D



4. 4 2. 4

5.3 2. 9


D ie s e l O il (S e e Types of Fuel)

AS TM D3306 -74

AS TM D3306 -74 J C B 4000/0900 Fri Friction mo dified dified oils oils MUST NOT be us ed (eg Dexron ATF type ). J C B 4000/2200 MUSTb e s uitab uitab le for use use with o il im m e rs e d b ra ke s a n d lim it e d slip differentials (LSD).

ISO VG VG 46

ISO VG VG 32

ISO VG VG 15


Issue 2*

Section 3

Hydraulics

1-7

Section 3 1-7

Fault Finding

526-55, 526 & 526S Machines (Type RE and RG Engine Builds) ITEM

CAPACITY Litres UK Gal US Gal

FLUID/LUBRICANT


Diesel Oil (See Types of Fuel ) )

ASTM D975-66T Nos. 1D, 2D

JCB Extreme Performance Engine Oil 15W/40 -10 °C to +50 °C (14 °F to 122 °F)

CH4/SJ (ACEA E5-B3-A3)

Fuel Tank

Engine (Oil)

160

35.2

10

(2.2)

42.2

2.6

Engine (Coolant) 55% Antifreeze

20 11

JCB Four Seasons Antifreeze And Summer Coolant Starts to freeze -36 °C (-33 °F)

4.4 2.4

5.3 2.9 Syncro Shuttle Transmission

17

3.7

4.5


9.0 2.0

1.98 0.44

2.4 0.5


8.4 2.0

1.85 0.44

2.2 0.5

Hydraulic Tank (1)

110

24.2

29.0 Grease Points (2)

NORTH AMERICA JCB Genuine Engine Oil 15W/40 -10 °C to +50 °C (14 °F to 122 °F)

NORTH AMERICA Permanent Antifreeze Star St artts to fr fre eez eze e -3 -33 3 °F ((-36 36 °C)

ASTM D3306-74

ASTM D3306-74

JCB High Performance Transmission Fluid

JCB 4000/0900 Friction modified oils MUST NOT be used (eg Dexron ATF type).

JCB High Performance Gear Oil Plus

JCB 4000/2200 MUST be suitable for use with oil immersed brakes and limited slip differentials (LSD).

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

NORTH AMERICA (All Machines) JCB Hydraulic Fluid JCB HP Grease

JCB Special MPL-EP Grease

Wear Pad Runways

JCB Waxoyl

Boom Hoses

JCB Special Slide Lubricant

9803/3610

CH4/SJ (ACEA E5-B3-A3)

ISO VG32

ISO VG15

ISO VG46 Lithium complex NLGI No. 2 constsituency including extreme pressure additives. Lithium based NLGI No. 2 constsituency including extreme pressure additives.

Issue 1*

Routine Maintenance

Section 3

Section 3

2-1

2-1

When working on a Loadall the machine must be made safe before carrying out any servicing.

General Safet Safety y

Working with Boom Raised

Read Section 2, Care and Safety.

Carry out General Safety and the following procedure:

Position the machine on firm level ground. Apply the parking brake. Chock both sides of all four wheels. Make sure the transmission selector and gear lever are in the neutral position.

! WARNING You You cou could be kil kille led d or or in injur jured if if th the boo boom m dr drops ops wh while ile you are working under it. Install the safety strut as instructed below before doing any maintenance work with the boom raised. 5-3-1-2

*

Fully retract the boom and lower to the ground. Switch OFF the engine and remove the starter key.

Before fitting the safety strut remove any load on the forks and empty buckets or attachments. Fully retract the boom (unless it needs to be extended for maintenance). Raise the boom just far enough to install the strut.

Operate the controls to vent residual pressure. Release the hydraulic tank filler cap to release residual tank pressure. When welding electrically disconnect the alternator.

Make sure the parking brake is engaged and the transmission is in neutral. Switch Switch OFF the engine and remove the starter key.

! CAUTION You You will have to clim climb onto the machin chine to fit or remove the safety strut. Take care, especially if the machine is wet. Remove mud and oil before climbing onto the machine.

A

5-3-1-11

! WARNING You You cou could be be kil kille led d or inju injure red d if the boo boom m is is low lowered while you are under it. Keep people away from the machine while you fit the strut. 5-3-1-3

Remove the strut from its stowage position A. Place the strut around the ram piston rod as shown. Fix it in place with strap B. S195470

The strap fitted to the safety strut must be in a serviceable condition, if not fit a new strap. To prevent any chance of the boom creeping down and trapping your fingers, the boom should be lowered onto the strut.

Note: Lower the boom carefully, to prevent possible damage to the strut. Stop as soon as the weight of the boom is on the strut.

B

S195740

9803/3610

Issue 3*

Routine Maintenance

Section 3

Section 3

2-2

2-2

Working with Boom Raised (continued) Remove Safety Strut Raise the boom to take the weight off of the strut. Stop the Engine. Make sure the parking brake is engaged and the transmission is in neutral. Remove the starter key.

! CAUTION You You wil willl hav have e to to clim climb ont onto th the mach machin ine e to to inst instal alll or remove the safety strut. Take care, especially if the machine is wet. Remove mud and oil before climbing onto the machine.

A

5-3-1-11

! WARNING You You cou could be be kil kille led d or inju injure red d if the boo boom m is is lowe lower red while you are under it. Keep people away from the machine while you remove the safety strut.

S195470

5-3-1-10

Start the engine and raise the boom to take the weight off the strut. Stop the engine and remove the starter key. Undo the strap B, then remove the strut. Place the strut in its stowage position A.

B

S195740

9803/3610

Issue 1

Section 3 3-1

Pre-start Cold Checks Service Points and Fluid Levels

Routine Maintenance

3-1

Service Schedules

Operation

ENGINE Engine Air Filter Pre-cleaner Clean Oil Level and Condition Check Oil and Filter (AA - AS build) (1) Change Oil and Filter (RE - RG build) (1) Change Hydraulic Tank Filler Cap Change Air Cleaner Dust Valve Clean Air Cleaner Outer Element Element Change Air Cleaner Inner Element Element Change Fuel Sy System Fo For Le Leaks an and Co Contaminatio ion n Check Fuel Filter Drain Change * Fuel Filter (AA - AS build) * Fuel Filter (RE - RG build) Change Coolant Level an and An Antifreeze St Strength Check Fuel Sedimenter (AA - AS build) Drain and clean Drain and clean * Fuel Sedimenter (RE - RG build) (5)Check * Fan/ AC Belt Tension/Condition Valve Clearances (AA - AC codes) codes) Check and Adjust# Adjust# and Adjust# * Valve Clearances (AJ-AS,RE-RG codes)Check and Engine Mount Security Check Rain Cap/Pre-cleaner Installed if fitted Check Radiator Clean TRANSMISSION AND AXLES Transmission Oil Level Transmission Oil Transmission Oil Filter Axle(s) Oil Level Axle(s) Oil Hub Oil Level Hub Oil Drive Dr ive Sha Shafts fts and Uni Univer versal sal Joi Joints nts Axle Pivots and Linkages Axle Breather(s) Breather(s) Tyre Pressures/Condition Hub Wheel Bearings Transmission Strainer Wheel Nut Security Wheel Alignment Trunnion Bearings Steering Stops (if fitted) Transmission Mount Security Axle Mount Security Security

Section 3

Check (2) Change Change Check Change Check (3) Change (4) Se Secur curity ity/Gr /Greas ease e Grease Check Check Check Clean Check Check Check/Adjust# Security Check Check

Daily 10 Hr

Weekly 50 Hr

100 Hr

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6 Monthly Yearly 500 1000 Hr Hr

2 Yearly 2000 Hr

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In arduous conditions conditions (eg. refuse rehandling, rehandling, waste paper paper reclamation etc). etc). Change the oil and and filter every 250 hours or three months (whichever comes first). (2) After a major major transmission transmission repair, the new oil should be run to operating operating temperature temperature and changed changed again to to remove any contamination which entered entered during the repair. Change the oil and filter after a further 100 hours if the oil was heavily contaminated because of, or from the failure (e.g. water contamination). (3) After a hub repair, repair, the new oil oil should be be run to temperature temperature and and changed changed again to remove remove any contam contamination ination which which entered during the repair. Change the oil again after a further 100 hours to remove any bedding-in wear. This is particularly important if new brake plates have been fitted. (4) In arduous arduous conditi conditions, ons, grease grease the the driveshaft driveshaft and and universal universal joints joints at 250 Hours or 3 months (whichever comes first). fitted check check tension tension and and conditio condition n after first first 20 hours hours of operatio operation. n. * (5) If a new belt is fitted Note Jobs which should be be done by a specialist are shown by #. First 100 Hours Service only to be completed by JCB Distributor. (1)

9803/3610

Issue 6*

Thank you very much for your reading. Please Click Here Then

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JCB 520-55 TELESCOPIC HANDLER Service Repair Manual ALL277001-280299.pdf

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