jcb 526-56 Service Manual

jcb 526-56 Service Manual

Loadall (rough terrain variable reach truck)
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SERVICE MANUAL
LOADALL (ROUGH TERRAIN
VARIABLE REACH TRUCK)
526-56, 531-70, 531-T70, 533-105,
535-95, 535-T95, 536-60, 536-70,
536-70LC, 536-T70, 536-T70LP,
541-70, 541-T70, 550-80
EN - 9813/5600 - ISSUE 4 - 05/2018
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
Copyright 2018 © JCB SERVICE
All rights reserved. No part of this publication may
be reproduced, stored in a retrieval system, or
transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise,
without prior permission from JCB SERVICE.
www.jcb.com
Foreword
The Operator's Manual
You and others can be killed or seriously injured
if you operate or maintain the machine without
first studying the Operator's Manual. You must
understand and follow the instructions in the
Operator's Manual. If you do not understand
anything, ask your employer or JCB dealer to
explain it.
Do not operate the machine without an Operator's
Manual, or if there is anything on the machine you
do not understand.
Treat the Operator's Manual as part of the machine.
Keep it clean and in good condition. Replace the
Operator's Manual immediately if it is lost, damaged
or becomes unreadable.
Contents
01 - Machine
03 - Attachments, Couplings and Load
Handling
06 - Body and Framework
09 - Operator Station
12
-
Heating,
Conditioning (HVAC)
15 - Engine
18 - Fuel and Exhaust System
21 - Cooling System
24 - Brake System
25 - Steering System
27 - Driveline
30 - Hydraulic System
33 - Electrical System
72 - Fasteners and Fixings
75 - Consumable Products
78 - After Sales
Ventilating
and
Air-

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Table of Contents
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Summary of Contents for jcb 526-56

  • Page 1 Operator's Manual. You must understand and follow the instructions in the Operator's Manual. If you do not understand anything, ask your employer or JCB dealer to explain it. SERVICE MANUAL Do not operate the machine without an Operator's Manual, or if there is anything on the machine you do not understand.
  • Page 2 Notes: 9813/5600-4...
  • Page 3 Spine Cards SERVICE MANUAL SERVICE MANUAL Volume 1 Volume 2 526-56, 531-70, 531-T70, 533-105, 526-56, 531-70, 531-T70, 533-105, 535-95, 535-T95, 536-60, 535-95, 535-T95, 536-60, 536-70, 536-70LC, 536-T70, 536-70, 536-70LC, 536-T70, 536-T70LP, 541-70, 541-T70, 550-80 536-T70LP, 541-70, 541-T70, 550-80 EN 9813/5600...
  • Page 4 Notes: 9813/5600-4...
  • Page 5: Table Of Contents

    01 - Machine Contents Page No. Acronyms Glossary ............................ 01-2 01-03 Safety 01-03-03 Safety - Yours and Others ....................01-3 01-03-06 Safety Warnings ....................... 01-4 01-03-09 General Safety ......................... 01-5 01-03-12 Maintenance Safety ......................01-6 01-03-18 Operating Safety ......................01-8 01-03-21 Worksite Safety ......................
  • Page 6: Acronyms Glossary

    Acronyms Glossary FOPS Falling Object Protective Structure Parts Identification List ROPS Roll-Over Protective Structure 9813/5600-4 2018-05-25...
  • Page 7 01 - Machine 03 - Safety 03 - Safety Contents Page No. 01-03-03 Safety - Yours and Others ....................01-3 01-03-06 Safety Warnings ....................... 01-4 01-03-09 General Safety ......................... 01-5 01-03-12 Maintenance Safety ......................01-6 01-03-18 Operating Safety ......................01-8 01-03-21 Worksite Safety ......................
  • Page 8 Notes: 01 - 2 9813/5600-4 01 - 2...
  • Page 9: Safety

    They inform you of potential hazards and how to avoid them. If you do not fully understand the warning messages, ask your employer or JCB dealer to explain them. Safety is not just a matter of responding to the warnings.
  • Page 10: Safety Warnings

    01 - Machine 03 - Safety 06 - Safety Warnings 06 - Safety Warnings Introduction In this manual there are safety notices. Each notice starts with a signal word. The signal word meanings are given below. The signal word 'DANGER' indicates a hazardous situation which, if not avoided, will result in death or serious injury.
  • Page 11: General Safety

    Keep long hair restrained. Remove altered in any way which could affect or invalidate its rings, watches and personal jewellery. compliance. For advice consult your JCB dealer. Alcohol and Drugs It is extremely dangerous to operate machinery when under the influence of alcohol or drugs.
  • Page 12: Maintenance Safety

    Repairs pressure must be discharged by a JCB dealer, as the sudden release of the hydraulic fluid or gas may If your machine does not function correctly in cause serious injury or death.
  • Page 13 Chemicals Certain seals and gaskets (e.g. crankshaft oil seal) on JCB machines contain fluoroelastomeric materials such Viton®, FluorelTM Technoflon®.
  • Page 14: Operating Safety

    Your doing. If you will be working with other people, local JCB distributor will be glad to advise you. make sure any hand signals that may be used are understood by everybody. Worksites can be noisy, do Fuel not rely on spoken commands.
  • Page 15 01 - Machine 03 - Safety 18 - Operating Safety Regulations clearly. Modification of the machine's configuration by the user (e.g. the fitting of large and non- approved attachments) may result in a restriction of Obey all laws, worksite and local regulations which the machine visibility.
  • Page 16 01 - Machine 03 - Safety 18 - Operating Safety has passed. Do not attempt to mount or enter the machine. If the machine is struck by lightning do not use the machine until it has been checked for damage and malfunction by trained personnel. 01 - 10 9813/5600-4 01 - 10...
  • Page 17: Worksite Safety

    01 - Machine 03 - Safety 21 - Worksite Safety 21 - Worksite Safety An applicable worksite organisation is required in order to minimise hazards that are caused by restricted visibility. The worksite organisation is a Introduction collection of rules and procedures that coordinates the machines and people that work together in WARNING You or others can be killed or seriously the same area.
  • Page 18: Risk Assessment

    If you are unsure of the suitability of the machine for • Are any other machines or persons likely to be a specific task, contact your JCB dealer who will be in or to enter the area while operations are in pleased to advise you.
  • Page 19: Maintenance Positions

    01 - Machine 03 - Safety 27 - Maintenance Positions 27 - Maintenance Positions Introduction Introduction ............ 01-13 Lift arm lowered Health and Safety .......... 01-15 Figure 2. A Lift arm lowered 1. Park the machine on level, solid ground. 2.
  • Page 20 01 - Machine 03 - Safety 27 - Maintenance Positions 5. Remove the maintenance strut from its stowage 4. Secure the strut in its stowage position. position. 5. Lower the lift arm to the ground. Figure 4. A Maintenance strut 6.
  • Page 21 01 - Machine 03 - Safety 27 - Maintenance Positions Health and Safety WARNING Maintenance must be done only by suitably qualified and competent persons. Before doing any maintenance make sure the machine is safe, it must be correctly parked on solid, level ground.
  • Page 22: About This Manual

    01 - Machine 06 - About this Manual 06 - About this Manual Contents Page No. 01-06-03 Model and Serial Number ....................01-17 01-06-06 Using the Manual ......................01-18 01 - 16 9813/5600-4 01 - 16...
  • Page 23: Model And Serial Number

    01 - Machine 06 - About this Manual 03 - Model and Serial Number 03 - Model and Serial Number Introduction This manual provides information for the following model(s) in the JCB machine range: Model From: 526-56 2336575 531-70 2336575...
  • Page 24: Using The Manual

    06 - Using the Manual Introduction Information in this manual conforms to a standard List). These headings are assigned numerical JCB service manual format. The format uses section identification references. headings taken from a PIL (Parts Identification Table 1. Example...
  • Page 25: Description

    01 - Machine 09 - Description 09 - Description Contents Page No. 01-09-00 General ........................... 01-21 01-09-03 Log Moving/Object Handling ..................01-23 01-09-06 Optional Equipment and Attachments ................01-24 01-09-12 Main Component Locations ................... 01-25 01-09-15 Service Point Locations ....................01-26 01 - 19 9813/5600-4...
  • Page 26 Notes: 01 - 20 9813/5600-4 01 - 20...
  • Page 27: General

    00 - General 00 - General Introduction Introduction ............ 01-21 The JCB Loadall is a self propelled, seated operator, Operation ............01-22 wheeled machine for operation on unimproved natural terrain and disturbed terrain. A main structural support is designed to carry an...
  • Page 28 01 - Machine 09 - Description 00 - General Operation The machine is intended to be used in normal conditions for the applications described in this manual. If the machine is used for other applications or in dangerous environments, for example in a flammable atmosphere or in areas with dust containing asbestos, special safety regulations must be obeyed and the machine must be equipped for...
  • Page 29 Introduction Do not use the machine to move or handle logs unless sufficient log protection is installed. You could cause serious injury to yourself and damage to the machine. For more information, contact your JCB dealer. 01 - 23 9813/5600-4...
  • Page 30 A wide range of optional attachments are available to increase the versatility of your machine. Only the JCB approved attachments are recommended for use with your machine. Contact your JCB dealer for the full list of approved attachments available. 01 - 24...

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