Jcb Loadall 525 50 Service Manuals

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JCB LOADALL | 525-50
MAX. PAYLOAD: 2.5 tonnes (5510lb)

MAX. LIFT HEIGHT: 5.0 metres (16ft-5in)

MAX. HORSEPOWER: 57.5 kW (77hp)

F G

H
E J

STATIC DIMENSIONS

Machine model 525-50 Machine model 525-50

m (ft-in) m (ft-in)
A Overall height (std cab) 2.19 (7-2) J Overall length to front carriage 3.62 (11-10)
B Height to top of steering wheel 1.57 (5-2) K Ground clearance 0.36 (1-2)
C Overall width 1.82 (6-0) Outer turn radius over tyres 3.71 (12-1)
D Inside width of cab 0.83 (2-9) Obstruction/departure angle with/without quickhitch degrees 30°/58°
E Width over tyres 1.82 (6-0) Weight kg (lb) 5400 (11002)
F Front track 1.49 (4-11) Power to weight ratio 57.5kW (77hp) Engine 9.8kW/tonne
G Wheelbase 2.00 (6-7) Tyres 12.5 x 18 10pr
H Overall length to front tyres 3.13 (10-3) A Product
of Hard Work

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 JCB LOADALL | 525-50

LIFT PERFORMANCE LOADER PERFORMANCE

Machine Model 525-50

6 Standard GP bucket
Bucket rated capacity m3 (yd3) 0.90 (1.20)
68.5o 1.7m
5 Bucket struck capacity m3 (yd3) 0.76 (1.02)
1.5
60o Breakout force kgf (lbf) 2800 (6172)
Dump height (max) m (ft-in) 4.46 (14-6)
1.0 Dump angle at max height degrees 40°
50o
Loadover height (max) m (ft-in) 5.09 (16-8)
4 0.5

2500kg
Rollback angle at ground degrees 40°
40o Carriage rotation angle (total) degrees 150°
Payload (max) kg (lb) 1620 (3571)
2000kg Bucket width m (ft-in) 1.95 (6-5)
3
30o

ENGINE
1500kg

20o Latest technology and advanced design provides low fuel consumption, reduced noise, high torque and power output,
2
total reliability and minimal maintenance.
500mm Easily replaceable pre-finished dry liners, five bearing, heat treated crankshaft. Expansion controlled pistons.
Two-stage, dry type air filter with primary and safety elements.
10o
Engine conforms with EC mobile off-highway emissions regulations (stage 1).
1
1000kg

Engine 525-50
Displacement ltr (in3) 4.20 (256)
0o No. of cylinders 4
0 Bore size mm (in) 103 (4.06)
-5o Stroke mm (in) 127 (5)
2.82

1.18
2.10

1.53

Aspiration Naturally aspirated

Power rating @ 2000rpm
Gross SAE J1349 kW (HP) 57.5 (77)
m 4 3 2 1 0
Torque rating @ 1200rpm
SAE J1349 Nm (lbf ft) 290 (214)
LIFT PERFORMANCE Noise level directive 2000/14/EC dBA 104

Machine Model 525-50

Lift capacity to full height kg (lb) 2500 (5510)
Lift capacity at full reach kg (lb) 1000 (2204)
Lift height m (ft-in) 5.00 (16-5)
Reach at max lift height m (ft-in) 0.50 (1-8)
Maximum forward reach m (ft-in) 2.82 (9-3)
Reach with 1 tonne load m (ft-in) 2.82 (9-3)
Placing height m (ft-in) 4.60 (15-1)
A Product
Complies with stability test EN 1459 Annex B. of Hard Work
 JCB LOADALL | 525-50

TRANSMISSION HYDRAULICS

JCB Syncro Shuttle transmission incorporating torque converter, reversing shuttle and all synchromesh 4-speed gearbox in one Single gear pump, with suction strainer and filter. One boom end auxiliary hydraulic service fitted as standard.
resiliently mounted unit.
Operating system pressure bar (psi) 241 (3500)
Electro-hydraulic direction control through a steering column mounted switch for modulated forward/reverse shuttling.
Flow at system pressure (@ 2200rpm) ltr/min 65
Gear lever and loader control transmission disconnect switches for fast gearchanging.
Cycle times seconds
Travel speed 30km/h (18mph).
Front and rear axles: Epicyclic hub reduction type with drop box on front axle. 4WS and permanent 4WD. Boom raise 7.4
Boom lower 5.3
Extend 5.7
Retract 3.2
Bucket dump 2.3
Bucket crowd 3.2
BRAKES

Service brakes: Hydraulically activated, power assisted multi disc type brakes. They are oil immersed for long life and fade free
braking. Mounted within the planetary hub means that the brakes are direct acting to each wheel, greatly increasing deceleration ELECTRICS
and eliminating skid potential.
Parking brake: Is an electro/hydraulically operated oil immersed multi disc brake on the transmission output shaft and will hold 12 V negative earth. 92 AH heavy duty battery with isolator. 65 amp alternator. Full road lighting. Direction indicators.
the machine on 1 in 4 gradients. Hazard warning.

CAB

Quiet, safe and comfortable cab conforms to ROPS 86/295/EEC and FOPS 86/296/EEC Directives. Toughened glass all round.
Tinted with laminated roof screen. Roof bars, front screen and roof screen wipers and heater/screen demister. Rear opening
BOOM AND CARRIAGE window with wash/wipe. Audio-visual warning system for coolant temperature, engine oil pressure, air-cleaner, battery charge,
transmission oil temperature and pressure. Hourmeter and tachometer. Multi lever direct acting hydraulic control levers with
Boom is manufactured from high tensile steel.
joystick control of lift and crowd, gear lever, parkbrake. Throttle and brake pedals. Adjustable deluxe suspension seat.
Low maintenance, hard wearing pads.
Load moment indicator: Automatic eye level audio-visual load moment indicator warning system receiving a signal from a load
JCB tool carrier parallel lift carriage with pin locking accepts fork frame with integral pallet forks and a wide range of attachments. sensor housed on the rear axle. This system continuously monitors the machine’s forward stability and leaves the operator in
control at all times.

STEERING
SAFETY CHECK VALVES Full power hydrostatic steering. Permanent 4WS with 32° lock front and rear axles provides exceptional manoeuvrability.
4WS is provided by a steer priority flow from the main hydraulic pump. Flow is directed through a steer alignment valve to double
Fitted to carriage tilt, telescopic and boom lift rams. acting steer rams (1 per axle).
Steering option: Three steer mode options: front wheel steer; all wheel steer; crab steer; operated from in the cab by a selection
switch, with automatic alignment.

OPTIONS AND ACCESSORIES

SERVICE CAPACITIES
Options: Low cab, working lights, reversing light, reverse alarm, rotating flashing beacon, fire extinguisher, front screen guard,
Fuel tank litres (UK gal) 90 (9.5) tinted glass, mechanical or hydraulic tow hitch for maximum gross weight of 5 tonnes. Complete with trailer light socket and trailer
Hydraulic tank litres (UK gal) 70 (15.5) tip hydraulics, hydraulic pin locking for attachments, 2 boom end auxiliary services. Low ground pressure bearing tyres, spark
Coolant litres (UK gal) 20 (4.4) arrester, catalyst, air conditioning, limited slip differential in front and rear axle.
A Product
Attachments: 525-50 is available with hydraulic quickhitch. Contact your local dealer for details of the comprehensive range. of Hard Work
 JCB LOADALL | 525-50

A GLOBAL COMMITMENT TO QUALITY

JCB’s total commitment to its products and customers has helped it grow from a one-man
business into Britain’s largest privately owned manufacturer of backhoe loaders, crawler excavators,
wheeled excavators, telescopic handlers, wheeled loaders, dump trucks,
rough terrain fork lifts, industrial fork lifts, mini/midi excavators, skid steer loaders and tractors.

By making constant and massive investments in the latest production technology, the JCB factories
have become some of the most advanced in Europe.

By leading the field in innovative research and design, extensive testing and stringent quality control,
JCB machines have become renowned all over the world for performance, value and reliability.

And with a global sales and service network of over 400 distributors and agents, the company
exports over 70% of its production to all five continents.

Through setting the standards by which others are judged, JCB has become one of Britain’s
most impressive success stories.

JCB cares for the environment. This paper has been JCB Sales Limited, Rocester, Staffordshire ST14 5JP. Tel: 01889 590312. Fax: 01889 590588. Web: http://www.jcb.com
produced without the use of elemental chlorine A Product
chemicals in the bleaching process. JCB reserves the right to change specifications without notice. Illustrations shown may include optional equipment and accessories. The JCB logo is a registered trademark of J C Bamford Excavators Ltd. 9999/5076 2/05 of Hard Work
 JCB LOADALL FARM SPECIAL | 525-50 /525-50S
MAX. PAYLOAD: 2.5 tonnes (5510lb)

MAX. LIFT HEIGHT: 5.0 metres (16ft-5in)

MAX. HORSEPOWER: 57.5/74.6 kW (77/100hp)

F G
H

E J

STATIC DIMENSIONS

Machine model 525-50/525-50S Machine model 525-50/525-50S

m (ft-in) m (ft-in)
A Overall height (std cab) 2.19 (7-2) J Overall length to front carriage 3.62 (11-10)
B Height to top of steering wheel 1.57 (5-2) K Ground clearance 0.36 (1-2)
C Overall width 1.82 (6-0) Outer turn radius over tyres 3.71 (12-1)
D Inside width of cab 0.83 (2-9) Obstruction/departure angle with/without quickhitch degrees 30°/58°
E Width over tyres 1.82 (6-0) Weight kg (lb) 5400 (11002)
F Front track 1.49 (4-11) Power to weight ratio 57.5kW (77hp) Engine 9.8kW/tonne
G Wheelbase 2.00 (6-7) Tyres 12.5 x 18 10pr
H Overall length to front tyres 3.13 (10-3) High Performance
by Design
 JCB LOADALL FARM SPECIAL | 525-50 /525-50S

LIFT PERFORMANCE LOADER PERFORMANCE

Machine Model 525-50/525-50S

6 Standard GP bucket
Bucket rated capacity m3 (yd3) 0.90 (1.20)
68.5o 1.7m
5 Bucket struck capacity m3 (yd3) 0.76 (1.02)
1.5
60o Breakout force kgf (lbf) 2800 (6172)
Dump height (max) m (ft-in) 4.46 (14-6)
1.0 Dump angle at max height degrees 40°
50o
Loadover height (max) m (ft-in) 5.09 (16-8)
4 0.5
Rollback angle at ground degrees 40°

2500kg
Carriage rotation angle (total) degrees 150°
40o
Payload (max) kg (lb) 1620 (3571)

2000kg
Bucket width m (ft-in) 1.95 (6-5)
3
30o

ENGINE
1500kg

20o Latest technology and advanced design provides low fuel consumption, reduced noise, high torque and power output,
2
total reliability and minimal maintenance.

500mm Easily replaceable pre-finished dry liners, five bearing, heat treated crankshaft. Expansion controlled pistons.
Two-stage, dry type air filter with primary and safety elements.
10o
Engine conforms with EC mobile off-highway emissions regulations (stage 1).
1
1000kg

Engine options 525-50 525-50S

Displacement ltr (in3) 4.20 (256) 3.99 (244)
0o No. of cylinders 4 4

0 Bore size mm (in) 103 (4.06) 100 (3.94)

-5o Stroke mm (in) 127 (5) 127 (5)
2.82

1.18
2.10

Aspiration Naturally aspirated Turbo charged

1.53

Power rating @ 2000rpm

Gross SAE J1349 kW (HP) 57.5 (77) 74.6 (100)
m 4 3 2 1 0 Torque rating @ 1200rpm
SAE J1349 Nm (lbf ft) 290 (214) 402 (297)
LIFT PERFORMANCE Noise level directive 2000/14/EC dBA 104 105

Machine Model 525-50/525-50S

Lift capacity to full height kg (lb) 2500 (5510)
Lift capacity at full reach kg (lb) 1000 (2204)
Lift height m (ft-in) 5.00 (16-5)
Reach at max lift height m (ft-in) 0.50 (1-8)
Maximum forward reach m (ft-in) 2.82 (9-3)
Reach with 1 tonne load m (ft-in) 2.82 (9-3)
Placing height m (ft-in) 4.60 (15-1)
High Performance
Complies with stability test EN 1459 Annex B. by Design
 JCB LOADALL FARM SPECIAL | 525-50 /525-50S

TRANSMISSION HYDRAULICS

JCB Syncro Shuttle transmission incorporating torque converter, reversing shuttle and all synchromesh 4-speed gearbox Single gear pump, with suction strainer and filter. One boom end auxiliary hydraulic service fitted as standard.
(3-speed gearbox in Turbo charged option) in one resiliently mounted unit.
Operating system pressure bar (psi) 241 (3500)
Electro-hydraulic direction control through a steering column mounted switch for modulated forward/reverse shuttling.
Flow at system pressure (@ 2200rpm) ltr/min 65
Gear lever and loader control transmission disconnect switches for fast gearchanging.
Cycle times seconds
Travel speed 30km/h (18mph).
Front and rear axles: Epicyclic hub reduction type with drop box on front axle. 4WS and permanent 4WD. Boom raise 7.4
Boom lower 5.3
Extend 5.7
Retract 3.2
Bucket dump 2.3
Bucket crowd 3.2
BRAKES

Service brakes: Hydraulically activated, power assisted multi disc type brakes. They are oil immersed for long life and fade free
braking. Mounted within the planetary hub means that the brakes are direct acting to each wheel, greatly increasing ELECTRICS
deceleration and eliminating skid potential.
Parking brake: Is an electro/hydraulically operated oil immersed multi disc brake on the transmission output shaft and will hold 12 V negative earth. 92 AH heavy duty battery with isolator. 65 amp alternator. Full road lighting. Direction indicators.
the machine on 1 in 4 gradients. Hazard warning.

CAB

Quiet, safe and comfortable cab conforms to ROPS 86/295/EEC and FOPS 86/296/EEC Directives. Toughened glass all round.
Tinted with laminated roof screen. Roof bars, front screen and roof screen wipers and heater/screen demister. Rear opening
BOOM AND CARRIAGE window with wash/wipe. Audio-visual warning system for coolant temperature, engine oil pressure, air-cleaner, battery charge,
transmission oil temperature and pressure. Hourmeter and tachometer. Multi lever direct acting hydraulic control levers with
Boom is manufactured from high tensile steel.
joystick control of lift and crowd, gear lever, parkbrake. Throttle and brake pedals. Adjustable deluxe suspension seat.
Low maintenance, hard wearing pads.
Load moment indicator: Automatic eye level audio-visual load moment indicator warning system receiving a signal from a load
JCB tool carrier parallel lift carriage with pin locking accepts fork frame with integral pallet forks and a wide range of attachments. sensor housed on the rear axle. This system continuously monitors the machine’s forward stability and leaves the operator in
control at all times.

STEERING
SAFETY CHECK VALVES Full power hydrostatic steering. Permanent 4WS with 32° lock front and rear axles provides exceptional manoeuvrability.
4WS is provided by a steer priority flow from the main hydraulic pump. Flow is directed through a steer alignment valve to
Fitted to carriage tilt, telescopic and boom lift rams. double acting steer rams (1 per axle).
Steering option: Three steer mode options: front wheel steer; all wheel steer; crab steer; operated from in the cab by a
selection switch, with automatic alignment.

OPTIONS AND ACCESSORIES

SERVICE CAPACITIES
Options: Low cab, working lights, reversing light, reverse alarm, rotating flashing beacon, fire extinguisher, front screen guard,
Fuel tank litres (UK gal) 90 (9.5) tinted glass, mechanical or hydraulic tow hitch for maximum gross weight of 5 tonnes. Complete with trailer light socket and
Hydraulic tank litres (UK gal) 70 (15.5) trailer tip hydraulics, hydraulic pin locking for attachments, 2 boom end auxiliary services. Low ground pressure bearing tyres,
Coolant litres (UK gal) 20 (4.4) spark arrester, catalyst, air conditioning, limited slip differential in front and rear axle.
High Performance
Attachments: 525-50 is available with hydraulic quickhitch. Contact your local dealer for details of the comprehensive range. by Design
 JCB LOADALL FARM SPECIAL | 525-50 /525-50S

A GLOBAL COMMITMENT TO QUALITY

JCB’s total commitment to its products and customers has helped it grow from a one-man
business into Britain’s largest privately owned manufacturer of backhoe loaders, crawler
excavators, wheeled excavators, telescopic handlers, wheeled loaders, dump trucks,
rough terrain fork lifts, industrial fork lifts, mini/midi excavators, skid steer loaders and tractors.

By making constant and massive investments in the latest production technology, the JCB factories
have become some of the most advanced in Europe.

By leading the field in innovative research and design, extensive testing and stringent quality control,
JCB machines have become renowned all over the world for performance, value and reliability.

And with a global sales and service network of over 400 distributors and agents, the company
exports over 70% of its production to all five continents.

Through setting the standards by which others are judged, JCB has become one of Britain’s
most impressive success stories.

JCB care for the environment. This paper has been JCB Sales Limited, Rocester, Staffordshire ST14 5JP. Tel: 01889 590312. Fax: 01889 590588. Web: http://www.jcb.co.uk
produced without the use of elemental chlorine High Performance
9999/4791 06/02 by Design
chemicals in the bleaching process. JCB reserves the right to change specifications without notice. Illustrations shown may include optional equipment and accessories. The JCB logo is a registered trademark of J C Bamford Excavators Ltd.
JCB LOADALL | 525-50M FAST FACTS
JCB Military Loadall
● Compact machine designed to work where
access and headroom are restricted
including ISO containers

● Lifts 2,500kg to a height of 5.0 metres and

1,000kg to full forward reach

● Permanent 4 wheel drive and steering on

4 equal sized wheels for great traction and
turning circle

● Military specific options enables correct

specification machine for all applications
 JCB LOADALL | 525-50 MILITARY
MAX. PAYLOAD: 2.5 tonnes (5510lb)

MAX. LIFT HEIGHT: 5.0 metres (16ft-5in)

MAX. HORSEPOWER: 57.5/74.6 kW (77/100hp)

F G
H

E J

STANDARD STATIC DIMENSIONS STANDARD LIFT PERFORMANCE

Machine model 525-50M Machine model 525-50M Machine Model 525-50M

m (ft-in) m (ft-in) Lift capacity to full height kg (lb) 2500 (5510)
A Overall height (std cab) 2.19 (7-2) J Overall length to front carriage 3.62 (11-10) Lift capacity at full reach kg (lb) 1000 (2204)
B Height to top of steering wheel 1.57 (5-2) K Ground clearance 0.36 (1-2) Lift height m (ft-in) 5.00 (16-5)
C Overall width 1.82 (6-0) Outer turn radius over tyres 3.71 (12-1) Reach at max lift height m (ft-in) 0.50 (1-8)
D Inside width of cab 0.83 (2-9) Obstruction/departure angle with/without quickhitch 30°/58° Maximum forward reach m (ft-in) 2.82 (9-3)
E Width over tyres 1.82 (6-0) Weight kg (lb) 5400 (11904) Reach with 1 tonne load m (ft-in) 2.82 (9-3)
F Front track 1.49 (4-11) Power to weight ratio 57.5kW (77hp) Engine 9.8kW/tonne Placing height m (ft-in) 4.60 (15-1)
G Wheelbase 2.00 (6-7) Tyres – Michelin XM37 335 x 80 R18
Complies with stability test EN 1459 Annex B.
H Overall length to front tyres 3.13 (10-3) High Performance
by Design
 JCB LOADALL | 525-50 MILITARY

LIFT PERFORMANCE LOADER PERFORMANCE

Machine Model 525-50M

STANDARD CARRIAGE ONLY FOR MACHINES FITTED WITH 200MM STROKE
Standard GP bucket
SIDESHIFT CARRIAGE
6
Bucket rated capacity m3 (yd3) 0.90 (1.20)
6

68.5o 1.7m 68.5o 1.56m Bucket struck capacity m3 (yd3) 0.76 (1.02)
5 5
1.5 60o 1.24 Breakout force kgf (lbf) 2800 (6172)
60o

1.0 0.66
Dump height (max) m (ft-in) 4.46 (14-6)
50o 50o

4 0.5 4 Dump angle at max height degrees 40°

0.24
2500kg

40o 40o Loadover height (max) m (ft-in) 5.09 (16-8)

Rollback angle at ground degrees 40°
2000kg

2500kg
3
30o 30o Carriage rotation angle (total) degrees 150°
Payload (max) kg (lb) 1620 (3571)

2000kg
20o
Bucket width m (ft-in) 1.95 (6-5)
1500kg

20o 2
2

1500kg
500mm 500mm

10o 10o
ENGINE
1 1
1000kg
1000kg

Latest technology and advanced design provides low fuel consumption, reduced noise, high torque and power output,
0o 0o total reliability and minimal maintenance.
0 0 Easily replaceable pre-finished dry liners, five bearing, heat treated crankshaft. Expansion controlled pistons.
-5o -5o
Two-stage, dry type air filter with primary and safety elements.
2.91

2.59

2.02

1.58
2.82

1.18
2.10

1.53

Engine conforms with EC mobile off-highway emissions regulations (stage 1).

m 4 3 2 1 0 m 4 3 2 1 0
Engine options 525-50M
FOR MACHINES FITTED WITH 1200MM STROKE Displacement ltr (in3) 4.20 (256)
SIDESHIFT CARRIAGE No. of cylinders 4
SWL DATA FOR SIDESHIFT
6 GREATER THAN 100mm Bore size mm (in) 103 (4.06)
68.5o 1.56m
5 1500kg Stroke mm (in) 127 (5)
4.8 60o 1.04
Aspiration Naturally aspirated
50o 0.58 Power rating @ 2000rpm
4
Gross SAE J1349 kW (HP) 57.5 (77)
1900kg
3.68 40o Torque rating @ 1200rpm
1900kg

SAE J1349 Nm (lbf ft) 290 (214)

3
30o Noise level directive 2000/14/EC dBA 104

20o
2 TRANSMISSION
1500kg

500mm

10o
JCB Syncro Shuttle transmission incorporating torque converter, reversing shuttle and all synchromesh 4-speed gearbox in one
1 resiliently mounted unit.
1000kg

Electro-hydraulic direction control through a steering column mounted switch for modulated forward/reverse shuttling.
0o Gear lever and loader control transmission disconnect switches for fast gearchanging.
0
-5o
Travel speed 30km/h (18mph).
Front and rear axles: Epicyclic hub reduction type with drop box on front axle. 4WS and permanent 4WD.
2.98
2.48

2.04

m 4 3 2 1 0 SAFETY CHECK VALVES

High Performance
SWL DATA FOR SIDESHIFT
LESS THAN 100mm
Fitted to carriage tilt, telescopic and boom lift rams. by Design
 JCB LOADALL | 525-50 MILITARY

BRAKES HYDRAULICS

Service brakes: Hydraulically activated, power assisted multi disc type brakes. They are oil immersed for long life and fade free Single gear pump, with suction strainer and filter. One boom end auxiliary hydraulic service fitted as standard.
braking. Mounted within the planetary hub means that the brakes are direct acting to each wheel, greatly increasing deceleration
and eliminating skid potential. Operating system pressure bar (psi) 241 (3500)
Parking brake: Is an electro/hydraulically operated oil immersed multi disc brake on the transmission output shaft and will hold Flow at system pressure (@ 2200rpm) ltr/min 65
the machine on 1 in 4 gradients. Cycle times seconds
Boom raise 7.4
STEERING Boom lower 5.3
Extend 5.7
Full power hydrostatic steering. Permanent 4WS with 32° lock front and rear axles provides exceptional manoeuvrability.
Retract 3.2
4WS is provided by a steer priority flow from the main hydraulic pump. Flow is directed through a steer alignment valve to double
acting steer rams (1 per axle). Bucket dump 2.3
Steering option: Three steer mode options: front wheel steer; all wheel steer; crab steer; operated from in the cab by a selection Bucket crowd 3.2
switch, with automatic alignment.
CAB
SERVICE CAPACITIES
Quiet, safe and comfortable cab conforms to ROPS 86/295/EEC and FOPS 86/296/EEC Directives. Toughened glass all round.
Fuel tank litres (UK gal) 90 (9.5) Tinted with laminated roof screen. Roof bars, front screen and roof screen wipers and heater/screen demister. Rear opening
Hydraulic tank litres (UK gal) 70 (15.5) window with wash/wipe. Audio-visual warning system for coolant temperature, engine oil pressure, air-cleaner, battery charge,
Coolant litres (UK gal) 20 (4.4) transmission oil temperature and pressure. Hourmeter and tachometer. Multi lever direct acting hydraulic control levers with
joystick control of lift and crowd, gear lever, parkbrake. Throttle and brake pedals. Adjustable deluxe suspension seat with
retractable seat belt.
ELECTRICS Load moment indicator: Automatic eye level audio-visual load moment indicator warning system receiving a signal from a load
sensor housed on the rear axle. This system continuously monitors the machine’s forward stability and leaves the operator in
Option 1: 12 V negative earth. 103 AH heavy duty battery with isolator. 65 amp alternator. Full road lighting. Direction indicators. control at all times.
Hazard warning.
Option 2: 24 V negative earth. Twin 115 AH heavy duty battery. 55amp alternator. Full road lighting. Direction indicators.
BOOM AND CARRIAGE
Hazard warning. Lockable battery isolator. Inter-vehicle start socket. heated side and rear screen.
Boom is manufactured from high tensile steel.
Low maintenance, hard wearing pads.
TRANSPORTABILITY
JCB tool carrier parallel lift carriage with pin locking accepts fork frame with integral pallet forks and a wide range of attachments.
Air transportable in C130, C141 and C-5. Can be slung beneath heavy lift helicopter. Recovery points front and rear. Lifting and tie
OPTIONS AND ACCESSORIES
down points.
Options: Low cab, working lights, reversing light, reverse alarm, rotating flashing beacon, fire extinguisher, front screen guard,
ATTACHMENTS tinted glass, mechanical or hydraulic tow hitch for maximum gross weight of 5 tonnes. Complete with trailer light socket and trailer
tip hydraulics, hydraulic pin locking for attachments, 2 boom end auxiliary services. Low ground pressure bearing tyres, spark
Hydraulic or mechanical quickhitch tool carrier allows rapid change of front end attachments. Standard class 2 carriage. 200mm stroke arrester, catalyst, air conditioning, limited slip differential in front and rear axle.
or 1200mm stroke sideshift fork frame allows placement and recovery of loads from either side of an ISO container. 0.9m3 shovel for Category ‘C’ protection, 4 tonne NATO tow pintle, jack box and 5 tonne jack, tool box, spare wheel carrier, gun net rack, rifle
loose material handling. Standard carriage load guard. holder, cab mounted search lights, light guards, winterisation, lifting eyes.

JCB cares for the environment. This paper has been JCB Sales Limited, Rocester, Staffordshire ST14 5JP. Tel: 01889 590312. Fax: 01889 590588. Web: http://www.jcb.co.uk
produced without the use of elemental chlorine High Performance
JCB reserves the right to change specifications without notice. Illustrations shown may include optional equipment and accessories. The JCB logo is a registered trademark of J C Bamford Excavators Ltd. 10/03 by Design
chemicals in the bleaching process.
 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
Steering H
PUBLISHED BY THE
TECHNICAL PUBLICATIONS DEPARTMENT
OF JCB SERVICE; ©
WATERLOO PARK, UTTOXETER,
ST14 5PA, ENGLAND
Engine K
Tel. 01889 - 590312
PRINTED IN ENGLAND

Publication No. 9803/3650

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:

520-50 (520 N. Am.) - from Machine Serial Number 754001

525-50 - from Machine Serial Number 789308

525S - from Machine Serial Number TBA

9803/3620 Issue 3*
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 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

9803/3620 Issue 2*
Section 1 General Information Section 1
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.

S245621 S181760

Explanation of Vehicle Identification Number (VIN) Typical Engine Identification Number

AA 50261 U 500405 P
SLP52050RE0754001 A B C D E
A B C D E
A Engine Type
A World Manufacturer Identification SLP = JCB AA = 4 cylinder naturally aspirated
B Machine Model 520-50 AB = 4 cylinder turbo
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 0754001
E Year of Manufacture
Machine Model Explanation

520 - 50
FG H

F 500 Series machine range

G 2.0 tonnes lift capacity
H 5.0 meters lift height

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.

9803/3620 Issue 2
Section 1 General Information Section 1
1-2 1-2

The Transmission serial number is stamped on label Y which

is mounted on the rear face.

The rear axle serial number is stamped on plate X mounted

to the front face of the axle.

The front axle serial number is stamped on plate Z mounted

on the rear face of the arm.

S241330

X
S241310

S241320

9803/3610E Issue 1
Jcb Loadall 525 50 Service Manuals
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