JCB 504B TELESCOPIC HANDLER Service Repair Manual SN 277001 Onwards PDF

Open front screen
General Information 1
Care & Safety 2
R
Routine Maintenance 3
Attachments A
Body & Framework B
Electrics C
Service
Controls D
Manual Hydraulics E
LOADALL Transmission F
Brakes G
PUBLISHED BY THE
TECHNICAL PUBLICATIONS DEPARTMENT
Steering H
OF JCB SERVICE;
WATERLOO PARK, UTTOXETER,

ST14 5PA, ENGLAND
Tel. 01889 - 590312
Engine K
PRINTED IN ENGLAND
Publication No. 9803/3610U-4

Introduction
This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training
by JCB Technical Training Department.
These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated
with the maintenance and repair of hydraulic earthmoving equipment.
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!
The manual is compiled in sections, the first three are numbered and contain information as follows:
1 = General Information - includes torque settings and service tools.

2 = Care & Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc.
3 = 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 = Attachments
B = 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 indentification IS NOT listed on individual pages.
All sections are listed on the front cover; 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:
504B - from Machine Serial Number 277001

*526 - from Machine Serial Number 279289
9803/3610U Issue 2*
Section 1 General Information Section 1
i i
Contents Page No.
Identification 1-1
Torque Settings 2-1
Service Tools
- Numerical List 3-1
* - Section B 3-3
- Section C 4-1
- Section E 5-1
- Section F 6-1
- Section H 7-1
- Section K 7-1
Sealing and Retaining Compounds 8-1
9803/3610 Issue 2*
1-1 1-1
Identification Plate Unit Identification

Your machine has an identification plate V mounted as The engine serial number is stamped on a label W which is
shown. The serial numbers of the machine and its major fastened to the right side of the cylinder block, near the fuel
units are stamped on the plate. filter.
S195340
S195600
Explanation of Vehicle Identification Number (VIN)

Typical Engine Identification Number
AA 50261 U 500405 P
SLP504BRE0277001 A B C D E
A B C D E
A Engine Type
A World Manufacturer Identification SLP = JCB AA = 4 cylinder naturally aspirated
AB = 4 cylinder turbo
*B Machine Model 504B
C Year of Manufacture S
P = 1993 V = 1997 1 = 2001 B Build Number
R = 1994 W = 1998 2 = 2002
S = 1995 X = 1999 3 = 2003 C Country of Origin
T = 1996 Y = 2000 4 = 2004
D Manufacturing Location E = England D Engine Sequence Number
E Machine Serial Number 0277001
E Year of Manufacture
Machine Model Explanation
504B
F G
F 500 Series machine range

G 4,000 lbs lift capacity
The serial number of each major unit is also stamped on the

unit itself. If a major unit is replaced by a new one, the serial
number on the identification plate will be wrong. Either
stamp the new number of the unit on the identification plate,
or simply stamp out the old number. This will prevent the
wrong unit number being quoted when replacement parts
are ordered.
The machine and engine serial numbers can help identify

exactly the type of equipment you have.
9803/3610U Issue 3*
1-2 1-2
S088470
S196280
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
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 Hexagon (A/F) Torque Settings

in (mm) in Nm kgf m lbf ft
1 7
/4 (6.3) /16 14 1.4 10
5 1
/16 (7.9) /2 28 2.8 20
3 9
/8 (9.5) /16 49 5.0 36
7 5
/16 (11.1) /8 78 8.0 58
1 3
/2 (12.7) /4 117 12.0 87
9 13
/16 (14.3) /16 170 17.3 125
5 15
/8 (15.9) /16 238 24.3 175
3
/4 (19.0) 11/8 407 41.5 300
7
/8 (22.2) * 15/16 650 66.3 480
1 (25.4) 11/2 970 99.0 715
11/4 (31.7) 17/8 1940 198.0 1430
11/2 (38.1) 21/4 3390 345.0 2500
Metric Grade 8.8 Bolts
Bolt Size Hexagon (A/F) Torque Settings

(mm) mm Nm kgf m lbf ft
M5 (5) 8 7 0.7 5
M6 (6) 10 12 1.2 9
M8 (8) 13 28 3.0 21
M10 (10) 17 56 5.7 42
M12 (12) 19 98 10 72
M16 (16) 24 244 25 180
M20 (20) 30 476 48 352
M24 (24) 36 822 84 607
M30 (30) 46 1633 166 1205
M36 (36) 55 2854 291 2105
Rivet Nut Bolts/Screws
Bolt Size Torque Settings (for steel rivet nuts)

(mm) Nm kgf m lbf ft
M3 (3) 1.2 0.12 0.9
M4 (4) 3.0 0.3 2.0
M5 (5) 6.0 0.6 4.5
M6 (6) 10.0 1.0 7.5
M8 (8) 24.0 2.5 18.0
M10 (10) 48.0 4.9 35.5
M12 (12) 82.0 8.4 60.5
Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification.
9803/3610 Issue 2*
3-1 3-1
Service Tools
Numerical List Page No Numerical List Page No
1406/0011 Bonded Washer 5-1 892/00260 11/4'' BSP Test Point 5-3
5
1406/0014 Bonded Washer 5-1 892/00261 /8'' UNF Test Point 5-3
1
1406/0018 Bonded Washer 5-1 892/00262 /4'' M BSP 1/4'' F BSP 5-1
5
3
1604/0003 Adapter 5-3 892/00265 1'' M BSP 1'' F BSP 5-1
1604/0004 Adapter 5-3 892/00268 Flow Monitoring Unit 5-1
1604/0006 Adapter 5-1 892/00269 Sensor Head 5-1
1606/0003 Adapter 5-3 892/00270 Load Valve 5-1
1606/0004 Adapter 5-3 892/00271 Adapter 5-1
1606/0007 Adapter 5-3 892/00272 Adapter 5-1
1606/0008 Adapter 5-3 892/00274 Adapter 5-3
1606/0009 Adapter 5-3 892/00275 Adapter 5-1
1606/0012 Adapter 5-3 892/00276 Adapter 5-1
1606/0014 Adapter 5-3 892/00277 Adapter 5-1
1606/0015 Adapter 5-3 * 892/00279 Pressure Gauge 0-400 bar (0-6000 lbf/in2) 5-1
1606/0017 Adapter 5-3 * 892/00280 Pressure Gauge 0-600 bar (0-9000 lbf/in2) 5-1
1612/0006 Adapter 5-1 892/00282 Shunt 4-1
816/00189 Blanking Cap 5-2 892/00283 Tool Kit Case 4-1
816/00190 Blanking Cap 5-2 892/00284 Digital Tachometer 4-1
816/00193 Blanking Cap 5-2 892/00285 Hyd. Oil Temperature Probe 4-1
816/00196 Blanking Cap 5-2 892/00286 Surface Temperature Probe 4-1
816/00197 Blanking Cap 5-2 892/00295 End Float Setting Tool 6-1
816/00294 Blanking Cap 5-2 892/00298 Fluke Meter 4-1
816/15118 Pressure Test Adapter 5-3 892/00301 Flow Test Adapter 6-1
816/20008 Adapter 5-1 892/00302 Flow Test Adapter 6-1
816/55038 Pressure Test Adapter 5-1 892/00304 Flow Test Adapter 6-1
816/55040 Pressure Test Adapter 5-1 892/00333 Heavy Duty Socket 6-2
816/50043 'T' Adapter 5-2 892/00334 Seal Fitting Tool 5-4
892/00039 Spool Clamp 5-2 * 892/00346 Pressure Gauge 0-70 bar (0-1000 lbf/in2) 6-1
892/00041 De-glazing Tool 7-1 892/00706 Test Probe 5-3
892/00047 'T' Adapter 5-2 892/00817 Heavy Duty Socket 6-2
892/00051 'T' Adapter 5-2 892/00842 Glass Lifter 3-3
892/00055 Blanking Plug 5-2 892/00843 Glass Stand 3-3
892/00056 Blanking Plug 5-2 892/00844 Long Knife 3-4
892/00057 Blanking Plug 5-2 892/00846 Glass Extractor (Handles) 3-4
892/00058 Blanking Plug 5-2 892/00847 Nylon Spatula 3-3
892/00059 Blanking Plug 5-2 892/00848 Wire Starter 3-4
892/00060 Blanking Plug 5-2 892/00849 Braided Cutting Wire 3-4
892/00071 Adapter 5-3 892/00891 Seal Fitting Adapter 6-3
892/00074 Female Connector 5-2 892/00893 Torque Converter Alignment Bar 6-2
892/00075 Female Connector 5-2 892/00902 Spanner, Track Rod End 6-3
892/00076 Female Connector 5-2 892/00903 Spanner, Differential 6-3
892/00077 Female Connector 5-2 892/00904 Spanner, Differential 6-3
892/00121 Discharge Tester 4-1 892/00905 SLI Test Box 4-1
892/00137 Micro-Bore Hose 5-3 892/00906 Seal Fitting Adapter 6-3
892/00179 Bearing Press 6-1 892/00916 Spring Compression Tool 6-4
892/00180 Seal Fitting Tool 7-1 892/00918 Setting Tool Kit 6-5
892/00181 Plastic Boss 7-1 892/00920 Flow Test Adaptor 6-1
892/00223 Hand Pump 5-3 892/00923 Test Block for A.R.V. 5-3
892/00224 Impulse Extractor 6-2 892/00943 Hand Held Test Unit 4-3
892/00225 Adapter - Impulse Extractor 6-2 892/00964 Test Point (1/8 BSP) PS700 6-4
* 892/00254 Hose 5-1 892/00965 Test Point (3/8 BSP) PS700 6-4
1
892/00255 /4'' BSP Test Point 5-3 892/00966 Test Point (1/4 BSP) SS400, SS600 6-4
3
892/00256 /8'' BSP Test Point 5-3 921/52600 Spacer Kit 6-5
1
892/00257 /2'' BSP Test Point 5-3 926/15500 Rubber Spacer Blocks 3-3
5
892/00258 /8'' BSP Test Point 5-3 992/02800 ARV Extractor 5-2
892/00259 1'' BSP Test Point 5-3 992/04000 Torque Multiplier 6-2
9803/3610 Issue 8*
3-2 3-2
* Service Tools (cont'd)

Numerical List Page No Numerical List Page No
992/04800 Drive Coupling Spanner 6-1 Replacement items for kit no. 993/70100
992/07000 Ram End Cap Peg Spanner 5-3 993/70101 Base Plate and Bolts 6-8
992/07603 Replacer- Bearing Cup 6-1 993/70104 Mainshaft Pillar 6-8
992/07608 Bearing Adapter 6-1 993/70106 Layshaft/Reverser Pillar 6-8
992/07609 Bearing Adapter 6-1 993/70112 Input Shaft Pillar 6-8
992/07610 Bearing Adapter 6-1 993/70120 Setting Assembly 6-8
992/07611 Bearing Adapter 6-1 993/70130 Mainshaft Adapter 6-8
992/07612 Bearing Adapter 6-1 993/70140 Setting Assembly 6-8
992/07613 Bearing Adapter 6-1 993/70160 Yoke Assembly 6-8
992/09500 Spanner 5-2
992/09700 Spanner 5-2 Note: To maintain a complete kit, order a replacement
992/10100 Spool Clamp 5-2 spacer for the one used.
992/10900 Test Harness for SLI 4-1
992/12800 Cut-Out Knife 3-4 Identifies items required for all JCB Gearboxes from
992/12801 L Blades 3-4 September 1996, when solid spacers replaced collapsible
993/59300 2/4 Wheel Pressure Tester & Clamp 6-2 spacers.
993/70100 Powershift Endfloat Checking Kit 6-8
993/70111 Breakback Torque Wrench 6-5
993/78200 Mainshift Airline Adaptor 6-4 Ram Seal Protection Sleeves 5-4
993/99412 Adaptor Harness 4-1
892/01016 For 25 mm Rod Diameter
The following parts are replacement items for kits and would 892/01017 For 30 mm Rod Diameter
normally be included in the kit numbers above. 892/01018 For 40 mm Rod Diameter
892/01019 For 50 mm Rod Diameter
Replacement item for kit no. 892/00180 892/01020 For 50 mm Rod Diameter (slew ram)
892/00181 Replacement Boss 7-1 892/01021 For 60 mm Rod Diameter
892/01022 For 60 mm Rod Diameter (slew ram)
Replacement items for kit no. 892/00253 892/01023 For 65 mm Rod Diameter
892/00201 Replacement Gauge 5-1 892/01024 For 70 mm Rod Diameter
892/00254 Replacement Hose 5-1
892/01027 Piston Seal Assembly Tool
Replacement items for spacer kit no. 921/52600
921/52601 Spacer 12.75 mm 6-5
921/52602 Spacer 12.80 mm 6-5
921/52603 Spacer 12.85 mm 6-5
921/52604 Spacer 12.90 mm 6-5
921/52605 Spacer 12.95 mm 6-5
921/52606 Spacer 13.00 mm 6-5
921/52607 Spacer 13.05 mm 6-5
921/52608 Spacer 13.10 mm 6-5
921/52609 Spacer 13.15 mm 6-5
921/52610 Spacer 13.20 mm 6-5
921/52611 Spacer 13.25 mm 6-5
921/52612 Spacer 13.30 mm 6-5
921/52613 Spacer 13.35 mm 6-5
921/52614 Spacer 13.40 mm 6-5
921/52615 Spacer 13.45 mm 6-5
921/52616 Spacer 13.50 mm 6-5
921/52617 Spacer 13.55 mm 6-5
921/52618 Spacer 13.60 mm 6-5
921/52619 Spacer 13.65 mm 6-5
921/52620 Spacer 13.70 mm 6-5
921/52621 Spacer 13.75 mm 6-5
921/52622 Spacer 13.80 mm 6-5
921/52623 Spacer 13.85 mm 6-5
921/52624 Spacer 13.90 mm 6-5
921/52625 Spacer 13.95 mm 6-5
921/52626 Spacer 14.00 mm 6-5
9803/3610 Issue 6*
3-3 3-3
Service Tools
Section B - Body and Framework
826/01176 M6 x 16mm 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 - JCB part number - 892/00842
essential for preparing
new glass prior to
installation.
JCB part number -

892/00843
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.

S186470 S186550
9803/3610 Issue 1*
3-4 3-4
Service Tools (cont'd)

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.
S186310 S186340
'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.

S186320 S186350
Long Knife - used to give extended reach for normally

Braided Cutting Wire - consumable heavy duty cut-out inaccessible areas.
wire used with the glass extraction tool (above).
(approx 25 m length)
S186330 S186360
9803/3610 Issue 1*
4-1 4-1
Service Tools
Section C - Electrics
AVO Test Kit
1 892/00283 Tool Kit Case
2 892/00298 Fluke Meter
3 892/00286 Surface Temperature Probe
4 892/00284 Venture Microtach Digital Tachometer
5 892/00282 100 amp Shunt - open type
6 892/00285 Hydraulic Temperature Probe
S188230
892/00121 High Rate Discharge Tester (400 amps)

for testing battery condition
S188240
992/10900 Test Harness for Safe Load Indicator From machine Serial No. 278818 use:
993/99412 Adaptor Harness
* 892/00905 Test Box For Safe Load Indicator (SLI)
S188250 and Load Moment Indicator (LMI) S244692
9803/3610 Issue 3*
4-2 4-2
Service Tools
Recommended Electrical Repair Kit

2A :7212/0002 2 Way Pin Housing 6A :7216/0002 6 Way Pin Housing
2B :7212/0004 2 Way Pin Retainer 6B :7216/0004 6 Way Pin Retainer
2C :7212/0003 2 Way Socket Retainer 6C :7216/0003 6 Way Socket Retainer
2D :7212/0001 2 Way Socket Connector 6D :7216/0001 6 Way Socket Connector
4A :7213/0006 3 Way Pin Housing (DT) 8A :7219/0002 10 Way Pin Housing
4B :7213/0008 3 Way Pin Retainer (DT) 8B :7219/0004 10 Way Pin Retainer
4C :7213/0007 3 Way Socket Retainer (DT) 8C :7219/0003 10 Way Socket Retainer
4D :7213/0005 3 Way Socket Connector (DT) 8D :7219/0001 10 Way Socket Connector
10 :7210/0001 Dummy Plug
11 :7210/0002 Wire Seal (1.4 - 2.2 mm dia.)
12 :7210/0003 Wire Seal (2.2 - 2.9 mm dia.)
S188380
9803/3610 Issue 1
4-3 4-3
892/00943 Hand Held Test Unit MK II (ECU)
299920
9803/3610 Issue 1*
5-1 5-1

Section E - Hydraulics
* Hydraulic Circuit Test Gauges and Connections
1 892/00279 Pressure Gauge 0-400 bar (0-6000 lbf/in2)

3 892/00347 Connector
4 892/00254 Hose
4
3
1,2,5
S188130
S188140
PressureTest 'T' Adaptors Bonded Washers
892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point 1406/0011 1

/4 in. BSP
/2 in. BSP
/8 in. BSP

/4 in. BSP
892/00264 3/4 in M BSP x 3/4 in F BSP x Test Point 1406/0029 11/4 in. BSP
892/00265 1 in M BSP x 1 in F BSP x Test Point
Flow Test Equipment
892/00268 Flow Monitoring Unit

892/00269 Sensor Head 0 to 100 l/min (0 to 22 UK gal/min)
892/00270 Load Valve
1406/0021 Bonded Washer
1604/0006 Adapter 3/4 in M x 3/4 M BSP
1612/0006 Adapter 3/4 in F x 3/4 M BSP
892/00277 Adapter 3/4 in F x 3/4 M BSP S188150
9803/3610 Issue 2*
5-2 5-2
S193870 S193880
Female Cone Blanking Cap Male Cone Blanking Cap
892/00055 1/4 in. BSP 816/00294 1

/4 in. BSP
892/00056 3/8 in. BSP 816/00189 3
/8 in. BSP
892/00057 1/2 in. BSP 816/00190 1
/2 in. BSP
892/00058 5/8 in. BSP 816/00197 5

/8 in. BSP
892/00059 3/4 in. BSP 816/00196 3

/4 in. BSP
892/00060 1 in. BSP 816/00193 1 in. BSP
S193890 S193900
T' Adapters Female Connectors
892/00047 3/8 in. BSP (A) x 1/4 in. BSP (B) 892/00074 3
/8 in. BSP x 3/8 in. BSP
892/00048 1/2 in. BSP (A) x 1/4 in. BSP (B) 892/00075 1
/2 in. BSP x 1/2 in. BSP
892/00049 5/8 in. BSP (A) x 1/4 in. BSP (B) 892/00076 5 5
/8 in. BSP x /8 in. BSP
816/50043 3/4 in. BSP (A) x 1/4 in. BSP (B) 892/00077 3 3
/4 in. BSP x /4 in. BSP
892/00051 1 in. BSP (A) x 1/4 in. BSP (B)
S193930 S192410
Hexagon Spanners for Ram Pistons and End Caps Spool Clamps
992/09500 75mm A/F 892/00039 Spool Clamp

992/09700 95mm A/F 992/10100 Spool Clamp
992/02800 ARV Extractor
9803/3610 Issue 1
5-3 5-3

Male Adapters - BSP x BSP
1606/0003 3/8 in. x 1/4 in.

1604/0003 3/8 in. x 3/8 in.
892/00071 3/8 in. x 3/8 in. taper
1606/0004 1/2 in. x 1/4 in.
1606/0007 1/2 in. x 3/8 in.
1604/0004 1/2 in. x 1/2 in.
1606/0017 5/8 in. x 1/2 in.
1606/0008 3/4 in. x 3/8 in.
1606/0009 3/4 in. x 1/2 in.
1604/0006 3/4 in. x 3/4 in.
1606/0012 3/4 in. x 1 in.
1606/0014 3/4 in. x 11/4 in.
1606/0015 1 in. x 11/4 in. S193860
S193850
Pressure Test Adapters
892/00255 1/4 in. BSP x Test Point Hand Pump Equipment

892/00256 3/8 in. BSP x Test Point
892/00257 1/2 in. BSP x Test Point 892/00223 Hand Pump
892/00258 5/8 in. BSP x Test Point 892/00137 Micro-bore Hose 1/4 in BSP x 5 metres
816/15118 3/4 in. BSP x Test Point 892/00274 Adapter 1/4 in M BSP x 3/8 in M BSP Taper
1 1
892/00259 1 in. BSP x Test Point 892/00262 /4 in M BSP x /4 in F BSP x Test Point
892/00260 1.1/4 in. BSP x Test Point 892/00706 Test Probe

892/00261 5/8 in. UNF x Test Point 892/00279 Gauge 0 - 400 bar (0-6000 lbf/in2)
S200141
S270650
S216060
*892/00923 Test Block for A. R. V
992/07000 Ram End Cap Peg Spanner
9803/3610 Issue 3*
6-1 6-1

Section F - Transmission
S188160
992/07608 Bearing Adapter S188170

992/07609 Bearing Adapter
992/07613 Bearing Adapter 992/07603 Replacer- Bearing Cup
S188190
S188200
892/00295 End Float Setting Tool 892/00179 Bearing Press
C
A
S188220
B S083252
D
A 892/00304 Flow Test Adapter 992/04800 Flange Spanner
B 892/00301 Flow Test Adapter For locking pinion flange while nut is
C 892/00302 Flow Test Adapter slackened or torque set
*D 892/00920 Flow Test Adapter
9803/3610 Issue 2*
6-2 6-2

*892/00893
Torque Converter Alignment Bar
992/04000 Torque Multiplier
Use in conjunction with a torque wrench

S228921
to give a 5:1 multiplication when tightening
S197030
pinion nuts etc.
* 892/00224
Impulse Extractor Set for Hub Bearing Seats
S197250
S197070
Heavy Duty Sockets for Durlok bolts
892/00817 17mm A/F x 3/4in square drive

B
C
A
S197080
892/00225 Adapter - Impulse Extractor

A Small 17mm to 25mm
B Medium 25mm to 45mm
C Large 45mm to 80mm
*993/59300
2/4 Wheel Drive Clutch Pressure Test Adaptor & Clamp 993/59500 Adapter - Impulse Extractor
D (syncro shuttle and powershift
S196750
transmission)
9803/3610 Issue 3*
6-3 6-3

S250350
892/00902 892/00903
Spanner, Track Rod End S250340 Spanner, Differential
892/00906 892/00904
S250360
Seal Fitting Adaptor S250370 Spanner, Differential
892/00891
Seal Fitting Adaptor
S227760
9803/3610 Issue 2*
6-4 6-4

S267310
S261230
892/00916 Spring Compressor Tool -
Forward/Reverse Clutches
Torque Measuring Tool for Wheel Hub Seals
Manufacture locally, procedures in this manual show

checking the wheel hub seal using a rolling force.
However, the torque can be measured using using above
locally manufactured tool.
Bearing rolling torque is 12 to 22Nm (9 to 16lbf ft)

excluding seal drag. Maximum permissible including seal
drag is 40 Nm (29.5 lbf ft)
S316250
Test Point
1 892/00964 Test point (1/8 BSP) PS700

S197010
2 892/00965 Test point (3/8 BSP) PS700

993/78200 Mainshaft Airline Adaptor
3 892/00966 Test point (1/4 BSP) SS400, SS600 (Powershift Transmission Only)
These test points can be left in position after testing.
9803/3610 Issue 3*
6-5 6-5

Solid Spacer Setting Kit
1 1 892/00918 Setting Tool Kit

2 993/70111 Breakback Torque Wrench
3 921/52600 Spacer Kit
Comprises:
921/52601 Spacer 12.75
921/52602 Spacer 12.80
921/52603 Spacer 12.85
921/52604 Spacer 12.90
921/52605 Spacer 12.95
921/52606 Spacer 13.00
921/52607 Spacer 13.05
921/52608 Spacer 13.10
921/52609 Spacer 13.15
921/52610 Spacer 13.20
921/52611 Spacer 13.25
921/52612 Spacer 13.30
921/52613 Spacer 13.35
921/52614 Spacer 13.40
921/52615 Spacer 13.45
921/52616 Spacer 13.50
3 921/52617 Spacer 13.55
921/52618 Spacer 13.60
921/52619 Spacer 13.65
921/52620 Spacer 13.70
921/52621 Spacer 13.75
2 921/52622 Spacer 13.80
921/52623 Spacer 13.85
S316260 921/52624 Spacer 13.90
921/52625 Spacer 13.95
921/52626 Spacer 14.00
9803/3610 Issue 1*
6-6 6-6

Fixture for Syncro Shuttle & Powershift Gearbox

removal & replacement.
Note: When removing/replacing a Syncro Shuttle

Gearbox, use items 1, 2 and 3.
When removing/replacing a Powershift Gearbox,

use items 1 and 4.
S162580
Fixture - Item 1
9803/3610 Issue 1*
6-7 6-7

Fixture - Item 2
Fixture - Item 3 Fixture - Item 4
9803/3610 Issue 1*
6-8 6-8

1 993/70100 Powershift Endfloat Checking Kit

(Includes items 2 to 13) 1
7 11
4 3
2 993/70101 Base Plate
3 993/70160 Yoke Assy

12 6
5
4 993/70130 Mainshaft Adapter Assy 10
8 6
5 993/70104 Mainshaft Pillar 13
6 993/70106 Layshaft/Reverser Pillar

9
7 993/70120 Layshaft Setting Assy

A191642
8 993/70140 Reverser Setting Assy
9 1391/3305 Capscrew (M8x20)
10 826/01417 Setscrew (M10x30) Flanged
11 993/70111 Setting Wrench (this is not part of the kit)
12 993/70112 Input Shaft Pillar A191642
13 993/70150 Input Setting Assy
If these items are not in your kit they can be ordered separately but the base plate 2 will have to be drilled to secure
item 12, see A and B. Measurements are in mm. Apply JCB Threadlocker And Sealer and tighten item 9 to 25-30 Nm
(18-22 lbf ft).
8.5
20
10
15
12
36
B 17
81.75
96.35
9 A191643
9803/3610 Issue 1*
7-1 7-1

Section H - Steering
892/00180 Seal Fitting Tool for fitting 'O' ring and

back-up ring to Danfoss Orbitrol Unit
892/00181 Replacement Plastic Boss
S191750
Section K - Engine
892/00041 De-glazing Tool for Cylinder 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
8-1 8-1
* Sealing and Retaining Compounds
JCB Multigasket A medium strength sealant suitable for all

sizes of gasket flanges, and for hydraulic
fittings of 25-65 mm diameter. 4102/1212
JCB High Strength Threadlocker A high strength locking fluid for use with
threaded components. Gasketing for all
sizes of flange where the strength of the
joint is important. 4102/0551
JCB Retainer (High Strength) For all retaining parts which are unlikely to be
dismantled. 4101/0651
JCB Threadlocker and Sealer A high strength locking fluid for sealing
and retaining nuts, bolts, and screws up to
50 mm diameter, and for hydraulic fittings up
to 25 mm diameter. 4101/0252
JCB Threadseal A medium strength thread sealing compound. 4102/1951
JCB Threadlocker and Sealer A medium to high strength locking fluid for
(High Strength) retention and sealing of ram piston heads. 4101/0552
JCB Threadlocker A locking fluid for use on threads larger than

50 mm dia. 4101/0451
JCB Activator A cleaning primer which speeds the curing rate 4104/0251 Aerosol
of anaerobic products. 4104/0253 Bottle
JCB Cleaner/Degreaser For degreasing components prior to use of

anaerobic adhesives and sealants. 4104/1557 Aerosol
9803/3610 Issue 5*
Section 2 Care & Safety Section 2
i i
Contents Page No.
Safety Notices 1-1
General safety 2-1
Operating safety 2-2
Maintenance safety 2-3
Lubricants - Health and Safety 3-1
9803/3610 Issue 1
1-1 1-1
Safety Notices
In this handbook and on the machine there are safety notices. Each notice starts with a
signal word. The signal word meanings are given below.
! 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 in injury to the operator (or others) and possible damage to the machine.
INT-1-2-3
9803/3610 Issue 1
2-1 2-1
All construction and agricultural equipment can be As well as the warnings in this chapter, specific warnings are
hazardous. When a JCB machine is correctly operated and given throughout the book. This section is designed to give
properly maintained, it is a safe machine to work with. But a safety code for use of the machine generally and for
when it is carelessly operated or poorly maintained it can maintenance practices.
become a danger to you (the operator) and others.
Do not work with the machine until you are sure that you can
control it.
Do not start any job until you are sure that you and those
around you will be safe.
If you are unsure of anything, about the machine or the job,

ask someone who knows. Do not assume anything.
Remember
BE CAREFUL
BE ALERT
BE SAFE
GEN-1-6
General Safety
! WARNING
! WARNING Care and Alertness
All the time you are working with or on the machine, take
Decals care and stay alert. Always be careful. Always be alert for
You can be injured if you do not obey the decal safety hazards.
instructions. Keep decals clean. Replace unreadable or INT-1-3-5
missing decals with new ones before operating the machine.
Make sure replacement parts include warning decals where ! WARNING
necessary.
INT-1-3-4
Raised Boom
A raised boom can fall or be lowered accidentally. Do not
! WARNING walk under a raised boom which is not fitted with a safety
strut, or you could be injured.
Clothing 5-1-1-1
You can be injured if you do not wear proper clothing. Loose
clothing can get caught in the machinery. Wear protective ! WARNING
clothing to suit the job. Examples of protective clothing are:
Lifting Equipment
a hard hat, safety shoes, safety glasses, a well-fitting overall,
You can be injured if you use faulty lifting equipment. Make
ear-protectors and industrial gloves. Keep cuffs fastened.
sure that lifting equipment is in good condition. Make sure
Do not wear a necktie or scarf. Keep long hair restrained.
INT-1-3-6
that lifting tackle complies with all local regulations and is
suitable for the job. Make sure the lifting equipment is strong
enough for the job.
INT-1-3-7
9803/3610 Issue 1
2-2 2-2
Operating Safety ! WARNING

Engine Panels
! WARNING The engine has exposed rotating parts. Do not open the
Controls bonnet while the engine is running. Keep other people clear
You or others can be killed or seriously injured if you operate while you raise the engine cover using the boom. Do not use
the control levers from outside the cab. Operate the control the machine with the bonnet open or the cover raised.
5-1-2-1
levers only when you are correctly seated inside the cab.
INT-2-1-3
! WARNING
! WARNING ROPS/FOPS Structure
The machine is fitted with a Roll Over Protection Structure
Entering/Leaving (ROPS) and a Falling Objects Protection Structure (FOPS).
Always face the machine when entering and leaving the cab. You could be killed or seriously injured if you operate the
Use the step(s) and handrails. Make sure the step(s), machine with a damaged or missing ROPS/FOPS. If the
handrails and your boot soles are clean and dry. Do not ROPS/FOPS has been in an accident, do not use the
jump from the machine. Do not use the machine controls as machine until the structure has been renewed. Modifications
handholds, use the handrails. and repairs that are not approved by the manufacturer may
INT-2-1-7
be dangerous and will invalidate the ROPS/FOPS
certification
! WARNING INT-2-1-9/3
Passengers
Passengers in or on the machine can cause accidents. The ! WARNING
JCB Loadall is a one man machine. Do not carry Reversing
passengers. Reversing at high speed can cause accidents. Do not
INT-2-2-2
reverse in third or fourth (if fitted) gear with full throttle.
Always drive at a safe speed to suit working conditions.
! WARNING INT-2-2-9
Exhaust Gases
Breathing the machine exhaust gases can harm and ! WARNING
possibly kill you. Do not operate the machine in closed Communications
spaces without making sure there is good ventilation. If Bad communications can cause accidents. Keep people
possible, fit an exhaust extension. If you begin to feel around you informed of what you will be doing. If you will be
drowsy, stop the machine at once. Get out of the cab into working with other people, make sure any hand signals that
fresh air. may be used are understood by everybody. Work sites can
INT-2-1-10 be noisy, do not rely on spoken commands.
INT-2-2-3
! WARNING
Ramps and Trailers ! WARNING
Water, mud, ice, grease and oil on ramps or trailers can
Sparks
cause serious accidents. Make sure ramps and trailers are
Explosions and fire can be caused by sparks from the
clean before driving onto them. Use extreme caution when
exhaust or the electrical system. Do not use the machine in
driving onto ramps and trailers.
INT-2-2-6
closed areas where there is flammable material, vapour or
dust.
! WARNING INT-2-2-10
Fires ! CAUTION
If your machine is equipped with a fire extinguisher, make
Overhead Clearance
sure it is checked regularly. Keep it in the operator's cab
A raised boom can strike overhead objects. Always check
until you need to use it.
for overhead clearance before raising the boom.
5-1-5-1
Do not use water to put out a machine fire, you could spread
an oil fire or get a shock from an electrical fire. Use carbon
dioxide, dry chemical or foam extinguishers. Contact your
nearest fire department as quickly as possible. Firefighters
should use self-contained breathing apparatus
INT-3-2-7/1
9803/3610 Issue 1
2-3 2-3
Maintenance Safety
! WARNING ! WARNING
Metal Splinters Jacking
You can be injured by flying metal splinters when driving A machine can roll off jacks and crush you unless the wheels
metal pins in or out. Use a soft-faced hammer or drift to have been chocked. Always chock the wheels at the
remove and fit metal pins. Always wear safety glasses. opposite end of the machine that is to be jacked. Do not
INT-3-1-3 work underneath a machine supported only by jacks. Always
support a jacked-up machine on axle stands before working
! WARNING underneath it.
INT-3-2-8
Boom Safety Strut
A raised boom can drop suddenly and cause serious injury.
! WARNING
Before working under a raised boom, fit the boom safety
strut. See Boom Safety Strut (MAINTENANCE section). Diesel Fuel
5-1-5-7 Diesel fuel is flammable; keep naked flames away from the
machine. Do not smoke while refuelling the machine or
! WARNING working on the engine. Do not refuel with the engine
running. There could be a fire and injury if you do not follow
Communications
these precautions.
Bad communictions can cause accidents. If two or more INT-3-2-2
people are working on the machine, make sure each is
aware of what the others are doing. Before starting the
! WARNING
engine make sure the others are clear of danger areas;
examples of danger areas are: the rotating blades and belt Hot Coolant
on the engine, the attachments and linkages, and anywhere The cooling system is pressurised when the engine is hot.
beneath or behind the machine. People can be killed or Hot coolant can spray out when you remove the radiator
injured if these precautions are not taken. cap. Let the system cool before removing the radiator cap.
INT-3-1-5 To remove the cap; turn it to the first notch and let the
system pressure escape, then remove the cap.
! WARNING INT-3-2-9
Asbestos
! WARNING
Asbestos dust can damage your lungs. Some engine
gaskets contain asbestos. Do not dismantle the engine or Petrol
exhaust system; get these jobs done by a qualified person Do not use petrol in this machine. Do not mix petrol with the
who has a copy of the engine service manual. diesel fuel; in storage tanks the petrol will rise to the top and
5-1-6-1 form flammable vapours.
INT-3-1-6
! WARNING
! WARNING
Battery Gases
Batteries give off explosive gases. Keep flames and sparks Oil
away from the battery. Do not smoke close to the battery. Oil is toxic. If you swallow any oil, do not induce vomiting,
Make sure there is good ventilation in closed areas where seek medical advice. Used engine oil contains harmful
batteries are being used or charged. Do not check the contaminants which can cause skin cancer. Do not handle
battery charge by shorting the terminals with metal; use a used engine oil more than necessary. Always use barrier
hydrometer or voltmeter. cream or wear gloves to prevent skin contact. Wash skin
INT-3-1-8 contaminated with oil thoroughly in warm soapy water. Do
not use petrol, diesel fuel or paraffin to clean your skin.
! DANGER INT-3-2-3
Electrolyte ! WARNING
Battery electrolyte is toxic and corrosive. Do not breathe the
Electrical Circuits
gases given off by the battery. Keep the electrolyte away
Understand the electrical circuit before connecting or
from your clothes, skin, mouth and eyes. Wear safety
disconnecting an electrical component. A wrong connection
glasses. See Battery (MAINTENANCE section) for First Aid
can cause injury and/or damage.
treatments. INT-3-1-4
INT-3-2-1/2
9803/3610 Issue 1
2-4 2-4
! WARNING ! WARNING
Battery Terminals
Hydraulic Fluid
The machine is negatively earthed. Always connect the
Fine jets of hydraulic fluid at high pressure can penetrate the
negative pole of the battery to earth.
skin. Do not use your fingers to check for hydraulic fluid
leaks. Do not put your face close to suspected leaks. Hold a
When connecting the battery, connect the earth (-) lead last.
piece of cardboard close to suspected leaks and then
inspect the cardboard for signs of hydraulic fluid. If hydraulic
When disconnecting the battery, disconnect the earth (-)
fluid penetrates your skin, get medical help immediately.
INT-3-1-10/1 lead first.
INT-3-1-9
! WARNING ! WARNING
Hydraulic Pressure
Fluoroelastomeric Materials
Hydraulic fluid at system pressure can injure you. Before
disconnecting or connecting hydraulic hoses, stop the * Certain seals and gaskets (e.g. crankshaft oil seal) on JCB
machines contain fluoroelastomeric materials such as Viton,
engine and operate the controls to release pressure trapped
Fluorel and Technoflon. Fluoroelastomeric materials
in the hoses. Make sure the engine cannot be started while
subjected to high temperatures can produce highly corrosive
the hoses are open.
INT-3-1-11/1 hydrofluoric acid. THIS ACID CAN SEVERELY BURN.
New fluoroelastomeric components at ambient temperature

require no special safety precautions.
! WARNING
Battery Used fluoroelastomeric components whose temperatures
A battery with frozen electrolyte can explode if it is used or have not exceeded 300C require no special safety
charged. Do not use a machine with a frozen battery. To precautions. If evidence of decomposition (e.g. charring) is
help prevent the battery from freezing, keep the battery fully found, refer to the next paragraph for safety instructions DO
charged. NOT TOUCH COMPONENT OR SURROUNDING AREA.
INT-3-1-7
Used fluoroelastomeric components subjected to
! CAUTION temperatures greater than 300C (e.g. engine fire) must be
Cleaning treated using the following safety procedure. Make sure that
Cleaning metal parts with incorrect solvents can cause heavy duty gloves and special safety glasses are worn:
corrosion. Use only recommended cleaning agents and
solvents. 1 Ensure that components have cooled then remove and
INT-3-2-11 place material into plastic bags.
! CAUTION 2 Thoroughly wash contaminated area with 10% calcium

'O' rings, Seals and Gaskets hydroxide or other suitable alkali solution, if necessary
Badly fitted, damaged or rotted 'O' rings, seals and gaskets use wire wool to remove burnt remains.
can cause leakages and possible accidents. Renew
whenever disturbed unless otherwise instructed. Do not use 3 Thoroughly wash contaminated area with detergent and
Triochloroethane or paint thinners near 'O' rings and seals. water.
INT-3-2-12
4 Contain all removed material, gloves etc. used in this
! WARNING operation in sealed plastic bags and dispose of in
accordance with Local Authority Regulations.
Soft Ground
A machine can sink into soft ground. Never work under a
DO NOT BURN FLUOROELASTOMERIC MATERIALS.
machine on soft ground.
INT-3-2-4
If contamination of skin or eyes occurs, wash the affected
! WARNING area with a continuous supply of clean water or with calcium
hydroxide solution for 15-60 minutes. Get medical attention
Hydraulic Hoses immediately.
Damaged hoses can cause fatal accidents. Inspect the INT - 3 - 3 - 5/1
hoses regularly for:
Damaged end fittings
Chafed outer covers
Ballooned outer covers
Kinked or crushed hoses
Embedded armouring in outer covers
Displaced end fittings.
INT-3-3-2
9803/3610 Issue 2*
3-1 Lubricants - Health and Safety 3-1
Hygiene
JCB lubricants are not a health risk when used properly for 2 Apply a barrier cream to the skin before handling used
their intended purposes. engine oil.
However, excessive or prolonged skin contact can remove 3 Note the following when removing engine oil from skin:
the natural fats from your skin, causing dryness and a Wash your skin thoroughly with soap and water.
irritation.
b Using a nail brush will help.
Low viscosity oils are more likely to do this, so take special
care when handling used oils, which might be diluted with c Use special hand cleansers to help clean dirty
fuel contamination. hands.
Whenever you are handling oil products you should maintain d Never use petrol, diesel fuel, or paraffin for
good standards of care and personal and plant hygiene. For washing.
details of these precautions we advise you to read the
relevant publications issued by your local health authority, e Avoid skin contact with oil soaked clothing.
plus the following.
f Don't keep oily rags in pockets.
Storage
g Wash dirty clothing before re-use.
Always keep lubricants out of the reach of children.
h Throw away oil-soaked shoes.
Never store lubricants in open or unlabelled containers.
First Aid - Oil
Waste Disposal
Eyes
All waste products should be disposed of in accordance
with all the relevant regulations. In the case of eye contact, flush with water for 15 minutes. If
irritation persists, get medical attention.
The collection and disposal of used engine oil should be in
accordance with any local regulations. Never pour used Swallowing
engine oil into sewers, drains or on the ground.
If oil is swallowed do not induce vomiting. Get medical
Handling advice.
New Oil Skin
There are no special precautions needed for the handling or In the case of excessive skin contact, wash with soap and
use of new oil, beside the normal care and hygiene water.
practices.
Spillage
Used Oil
Absorb on sand or a locally approved brand of absorbent
Used engine crankcase lubricants contain harmful granules. Scrape up and remove to a chemical disposal
contaminants. area.
Here are precautions to protect your health when handling Fires

used engine oil:
Extinguish with carbon dioxide, dry chemical or foam
1 Avoid prolonged, excessive or repeated skin contact extinguishers. Do not use water. Fire-fighters should use
with used engine oils. self-contained breathing apparatus.
9803/3610 Issue 1
Section 3 Routine Maintenance Section 3
i i
Contents Page No.
* Lubricants and Capacities

- New Engines 1-1
- Lubrication Charts 1-1
- 504B (Rear Steer) Machines 1-2
- 504B AWS Machines (Type AA and AB Builds) 1-3
- 526 Machines (Type AA and AB Builds) 1-4
- 504B AWS Machines - Low Emission Engines
(Type AR and AK Builds) 1-5
- 526 Machines - Low Emission Engines
(Type AR and AK Builds) 1-6
Machine Safety 2-1
Service Schedules 3-1
* Grease
- 50 Hours 4-1
- 500 Hours 4-2
- 1000 Hours 4-4
Oiling 5-1
Tyres and Wheels 6-1
Foot Brake (504B machines only) 7-1
Engine Air Filter

- Cleaning the Pre-Cleaner 7-1
- Changing the Outer Element 7-2
- Changing the Inner Element 7-3
Engine Oil and Filter

- Checking the Oil level 8-1
- Changing the Oil and Filter 8-1
Engine Cooling System

- Checking the Coolant Level 9-1
- Coolant Mixtures 9-1
- Changing the Coolant 9-2
Cab Heater Filter 10 - 1
* 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
- Changing the Filter Element (up to S/N 280299) 11 - 3
- Draining the Filter (from S/N 280300) 11 - 4
- Changing the Filter Element (from S/N 280300) 11 - 4
- Draining the Sediment Bowl 11 - 5
- Cleaning the Sediment Bowl 11 - 5
- Bleed the System 11 - 6
9803/3610U Issue 4*
ii ii
Contents Page No.
Fire Extinguisher 12 - 1
Syncro Shuttle Transmission

- Checking the Oil Level 12 - 1
- Changing the Oil and Filter 12 - 2
Front and Rear Axle

- Checking the Axle Oil Level 13 - 1
- Changing the Axle Oil 13 - 1
Front and Rear Hub

- Checking the Hub Oil Levels 14 - 1
* - Oil Immersed Brakes 14 - 1
- Changing the Hub Oil 14 - 1
Hydraulic System
- Checking the Fluid Level 15 - 1
- Changing the Filter Element 15 - 1
Hose Burst Protection Valves

- Checking the Hose Burst Protection Valves 16 - 1
Battery 17 - 1
9803/3610 Issue 2*
1-1 Lubricants & Capacities 1-1
New Engines
New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately;
glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no
circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new
machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation
and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade
should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After
the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended in the lubrication
charts.
*
Lubrication Charts
Lubrication charts are included on the following pages for all machine models. Be sure you identify the machine and its
lubricant requirements correctly.
9803/3610U Issue 4*
504B (Rear Steer) Machines
ITEM CAPACITY FLUID/LUBRICANT INTERNATIONAL

Litres UK Gal US Gal SPECIFICATION
Fuel Tank
Up to serial No. 279000 120 26.4 31.7 Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
From serial No. 279001 160 35.2 42.2
Engine (Oil) 10 2.2 2.6 JCB 15W/40 Engine Oil SAE 15W/40
14F to 122F (-10C to 50C) API CF4/SG
JCB 10W Engine Oil SAE 10W
-4F to 50 F (-20C to 10C) API CF4/SG
Engine (Coolant) 20 4.4 5.3 Permanent Antifreeze ASTM D3306-74

55% Antifreeze 11 24 2.9 Starts to freeze -33 F (-36 C)
Syncro Shuttle 17 3.7 4.5 JCB Special Transmission ESP-M2C 33G

Transmission Fluid Friction modified oils MUST NOT
be used (eg Dexron ATF type).
Front Axle
Housing 9.7 2.1 2.5 JCB Special Gear Oil Plus API GL4
Hubs (x2) 0.6 0.1 0.16 MUST be suitable for use with
oil immersed brakes and limitedslip
differentials (LSD).
Rear Axle
Housing 5.0 1.1 1.3
Hubs (x2) 1.5 0.3 0.4
Hydraulic Tank
Up to serial No. 279000 100 22.0 26.4 JCB Hydraulic Fluid ISO VG46
From serial No. 279001 110 24.2 29.0
Grease Points JCB HP Grease Lithium based No. 2 consistency
Wear Pad Runways JCB Waxoyl
Boom Hoses JCB Special Slide Lubricant
Note: This is nominal machine capacity. The total hydraulic system capacity depends on the equipment being used. Fill
and check with all rams closed. Watch level sight glass when filling.
Note: If JCB Special MPL Grease is used, all 50 hour greasing operations must be carried out at TEN (10) HOUR intervals.
All 500 hour greasing operations must be carried out at FIFTY (50) HOUR intervals.
9803/3610U Issue 3*
504B AWS Machines (Type AA and AB Builds)

Fuel Tank
From serial No. 279001 160 35.2 42.2

55% Antifreeze 11 2.4 2.9 Starts to freeze -33 F (-36 C)

Front Axle
oil immersed brakes and limited slip
Rear Axle
Housing 5.0 1.1 1.3
Hubs (x2) 1.5 0.3 0.4
Hydraulic Tank
From serial No. 279001 110 24.2 29.0
Note: This is nominal machine capacity. The total hydraulic system capacity depends on the equipment being used. Fill and
check with all rams closed. Watch level sight glass when filling.
9803/3610U Issue 3*
526 Machines (AA and AB Builds)

Fuel Tank
From serial No. 279001 160 35.2 42.2


Front Axle
Housing 9 1.98 2.4 JCB Special Gear Oil Plus API GL4
Hubs (x2) 2 0.44 0.5 MUST be suitable for use with
Rear Axle
Housing 8.4 1.85 2.2
Hubs (x2) 2 0.44 0.5
Brake System JCB Light Hydraulic Fluid ISO VG15

From serial No. 280300
Do not use ordinary brake fluid
Hydraulic Tank
From serial No. 279001 110 24.2 29.0

Note: This is nominal machine capacity. The total hydraulic system capacity depends on the equipment being used. Fill and
check with all rams closed. Watch level sight glass when filling.
All 500 hour greasing operations must be carried out at FIFTY (50) HOUR intervals
9803/3610U Issue 2*
504B AWS Machines - Low Emission Engines (Type AR and AK Builds)

Fuel Tank
160 35.2 42.2 Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D


Front Axle
Rear Axle
Housing 5.0 1.1 1.3
Hubs (x2) 1.5 0.3 0.4
Hydraulic Tank 110 24.2 29.0 JCB Hydraulic Fluid ISO VG46
9803/3610U Issue 1*
526 Machines - Low Emission Engines (Type AR and AK Builds)

Fuel Tank
160 35.2 42.2 Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D


Front Axle
Housing 9 1.98 2.4 JCB Special Gear Oil Plus API GL4
Hubs (x2) 2 0.44 0.5 MUST be suitable for use with
Rear Axle
Housing 8.4 1.85 2.2
Hubs (x2) 2.0 0.44 0.5
Brake System JCB Light Hydraulic Fluid ISO VG15
Do not use ordinary brake fluid
Hydraulic Tank 110 24.2 29.0 JCB Hydraulic Fluid ISO VG46
9803/3610U Issue 1*
2-1 2-1
When working on a Loadall the machine must be made safe

before carrying out any servicing.
General Safety 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.
! WARNING
You could be killed or injured if the boom drops while
Chock both sides of all four wheels. you are working under it. Install the safety strut as
instructed below before doing any maintenance work
Make sure the transmission selector and gear lever are in the with the boom raised.
5-3-1-2
neutral position.
Before fitting the safety strut remove any load on the forks
Fully retract the boom and lower to the ground. *
and empty buckets or attachments.
Switch OFF the engine and remove the starter key.
Fully retract the boom (unless it needs to be extended for
maintenance). Raise the boom just far enough to install the
Operate the controls to vent residual pressure.
strut.
Release the hydraulic tank filler cap to release residual tank
Make sure the parking brake is engaged and the
pressure.
transmission is in neutral. Switch OFF the engine and
remove the starter key.
When welding electrically disconnect the alternator.
! CAUTION
You will have to climb onto the machine to fit or remove
the safety strut. Take care, especially if the machine is
A wet. Remove mud and oil before climbing onto the
machine.
5-3-1-11
! WARNING
You could be killed or injured if the boom is 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.
S195740
9803/3610 Issue 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 will have to climb onto the machine to install or A
remove the safety strut. Take care, especially if the
machine is wet. Remove mud and oil before climbing
onto the machine.
5-3-1-11
! WARNING
You could be killed or injured if the boom is lowered
while you are under it. Keep people away from the S195470
machine while you remove the safety strut.
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.
S195740
9803/3610 Issue 1
3-1 Service Schedules 3-1
Daily Weekly First 6 Monthly Yearly 2 Yearly

Pre-start Cold Checks Operation 10 50 100 500 1000 2000
Service Points and Fluid Levels Hr Hr Hr Hr Hr Hr
ENGINE
Engine Air Filter Pre-cleaner Clean z z z z z z
Oil Level and Condition Check z z z z z z
Oil and Filter (1) Change z z z z
Air Cleaner Dust Valve Clean z z z z
Air Cleaner Outer Element Change z z z
Air Cleaner Inner Element Change z
Fuel System For Leaks and Contamination Check z z z z z z
Fuel Filter Drain z z z z z
Fuel Filter Change z z z z
Coolant Level and Antifreeze Strength Check z z z z z z
Fuel Sedimenter Drain and clean z z z z z
Fan Belt Tension/Condition Check z z z z
Valve Clearances (AA - AC codes) Check and Adjust z
Valve Clearances (AJ - AS codes) Check and Adjust z
Engine Mount Security Check z z z z
Rain Cap/Pre-cleaner Installed if fitted Check z
Radiator Clean z z z
TRANSMISSION AND AXLES

Transmission Oil Level Check z z z z
Transmission Oil (2) Change z z
Transmission Oil Filter Change z z z z
Axle(s) Oil Level Check z z
Axle(s) Oil Change z z z
Hub Oil Level Check z
Hub Oil (3) Change z z z z
Drive Shafts and Universal Joints Security/Grease z z z z
Axle Pivots and Linkages Grease z z z z z
Axle Breather(s) Check z z z z
Tyre Pressures/Condition Check z z z z z z
Hub Wheel Bearings Check z z z z
Transmission Strainer Clean z z
Wheel Nut Security Check z z z z z z
Wheel Alignment Check z z z z z
Trunnion Bearings Check/Adjust z z z z
Steering Stops (if fitted) Security z z z z
Transmission Mount Security Check z
Axle Mount Security Check z
(1) In arduous conditions (eg. refuse re-handling, waste paper reclamation etc.) change the oil after every 250 hours or three months
(whichever comes first).
(2) After a major transmission repair, the new oil should be run to operating temperature and changed again to remove any
contamination which 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 (eg. water contamination).
(3) After a major transmission repair, the new oil should be run to operating temperature and changed again to remove any
contamination which entered during the repair. Change the oil again after a further 100 hours to remove bedding-in wear. This is
particularly important if new brake plates have been fitted.
Note: Jobs which should be done by a specialist are shown by .

First 100 hour service only (and after major re-builds), to be completed by JCB Distributor.
9803/3640U Issue 2
3-2 Service Schedules 3-2
Daily Weekly First 6 Monthly Yearly 2 Yearly

Pre-start Cold Checks Operation 10 50 100 500 1000 2000
Service Points and Fluid Levels Hr Hr Hr Hr Hr Hr
HYDRAULICS
Oil Level Check z z z z
Oil Sample/Change z
Oil Filter Change z z z z
Suction Strainer Clean z
BRAKES
Brake System Fluid (if applicable) Check Level z z z
Brake System Fluid (if applicable) Change z
ELECTRICS
Battery Terminals for Condition & Tightness Check z z z z
Wiring for Chaffing Check z z z z
BODYWORK AND CAB

Lift/Displacement/Tilt/Steer Ram Pivot Pins Grease z z z z
Fire Extinguisher Check z z z z z
Wing Mirrors Condition & Security Check z z z z z
ROPS/FOPS Structure Check z
All Pivot Pins Grease z z z z
Doors and Hinges Lubricate z z z z
Wear Pad Runways Waxoyl z z z
Inner Boom Hoses Grease z z z
Boom Wear Pad Clearance Check/Adjust z z z
Replace if required
Wear Pad Condition/Security Change as required z z z z
Control Lever Linkages Lubricate z z z z
Inner Boom Extension Ram Wear Pad

(if fitted) Change z z
Windscreen Washer Fluid Level Check z z z z z z
Cab Heater Filter (if fitted) Clean z z z
Pre-start Cold Checks Operation 250 500 1000 2000

Service Points and Fluid Levels Hr Hr Hr Hr
BOOM CHAIN SERVICING

Boom Chains Lubricate/Check Tensionl z z z z
Boom Extend & Retract Chain Wear Limit Check z z
Boom Chain Roller Wear Check z z z z
Boom Roller Pivot Pin with Grease Point Grease z z z
Note: Jobs which should be done by a specialist are shown by .

First 100 hour service only (and after major re-builds), to be completed by JCB Distributor.
9803/3640U Issue 3*
Thank you very much
for your reading.
Please Click Here
Then Get More
Information.

JCB 504B TELESCOPIC HANDLER Service Repair Manual SN 277001 Onwards PDF

Caricato da

Informazioni sul documento

Titolo originale

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

JCB 504B TELESCOPIC HANDLER Service Repair Manual SN 277001 Onwards PDF

Caricato da

Copyright:

Formati disponibili

Open front screen

WATERLOO PARK, UTTOXETER,

Publication No. 9803/3610U-4

1 = General Information - includes torque settings and service tools.

This Service Manual covers the following machines:

504B - from Machine Serial Number 277001

Contents Page No.

Torque Settings 2-1

Sealing and Retaining Compounds 8-1

Identification Plate Unit Identification

Explanation of Vehicle Identification Number (VIN)

F 500 Series machine range

The serial number of each major unit is also stamped on the

The machine and engine serial numbers can help identify

The rear axle serial number is stamped on plate X as shown.

UNF Grade 'S' Bolts

Bolt Size Hexagon (A/F) Torque Settings

Metric Grade 8.8 Bolts

Bolt Size Hexagon (A/F) Torque Settings

Rivet Nut Bolts/Screws

Bolt Size Torque Settings (for steel rivet nuts)

* Service Tools (cont'd)

826/01176 M6 x 16mm Rivet Nut

Installation Tool Available from:

Glass Lifter - minimum 2 off - essential for glass

JCB part number -

Rubber Spacer Blocks - used to provide the correct set

JCB part number - 926/15500

Nylon Spatula - general tool used for

JCB part number - 892/00847

Service Tools (cont'd)

Wire Starter - used to

Cut-Out Knife - used to remove

JCB part number - 992/12800

JCB part number - 892/00848

'L' Blades - 25 mm (1 in) cut - replacement blades for

JCB part number - 992/12801 (unit quantity = 5 off)

Glass Extractor (Handles) - used with braided cutting

JCB part number - 892/00846

Long Knife - used to give extended reach for normally

AVO Test Kit

1 892/00283 Tool Kit Case

2 892/00298 Fluke Meter

3 892/00286 Surface Temperature Probe

4 892/00284 Venture Microtach Digital Tachometer

5 892/00282 100 amp Shunt - open type

6 892/00285 Hydraulic Temperature Probe

892/00121 High Rate Discharge Tester (400 amps)

Recommended Electrical Repair Kit

Service Tools (cont'd)

892/00943 Hand Held Test Unit MK II (ECU)

Service Tools (cont'd)

* Hydraulic Circuit Test Gauges and Connections

1 892/00279 Pressure Gauge 0-400 bar (0-6000 lbf/in2)

PressureTest 'T' Adaptors Bonded Washers

892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point 1406/0011 1

892/00263 5/8 in M BSP x 5/8 in F BSP x Test Point 1406/0021 3

Flow Test Equipment

892/00268 Flow Monitoring Unit

Service Tools (cont'd)

Female Cone Blanking Cap Male Cone Blanking Cap

892/00055 1/4 in. BSP 816/00294 1

892/00058 5/8 in. BSP 816/00197 5