Page 1

Service Manual Side Engine Loadalls Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine Section M - Electronic Data Systems

Publication No.

9813/0900-2

World Class Customer Support Copyright Š 2004 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. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400


Section 1 - General Information Contents Page No. Applications Introduction ............................................................................................. 1-1-1 Tables ..................................................................................................... 1-1-2 Use Introduction ............................................................................................. 1-2-1 Scope ..................................................................................................... 1-2-2 Format .................................................................................................... 1-2-3 Left and Right Sides ............................................................................... 1-2-4 Hydraulic Schematic Codes ................................................................... 1-2-5 Electrical Device Codes .......................................................................... 1-2-6 Machine Identification Introduction ............................................................................................. 1-3-1 Related Topics ........................................................................................ 1-3-2 Machine Identification Plate .................................................................... 1-3-3 Component Identification Plates ............................................................. 1-3-5 Torque Settings Introduction ............................................................................................. 1-4-1 Zinc Plated Fasteners and Dacromet Fasteners .................................... 1-4-2 Hydraulic Connections ............................................................................ 1-4-6 `Positional Type' Hydraulic Adaptors .................................................... 1-4-10 Service Tools Introduction ............................................................................................. 1-5-1 Numerical List ......................................................................................... 1-5-2 Tool Detail Reference ............................................................................. 1-5-5 Rivet Nuts ............................................................................................. 1-5-24 Slide Hammer Kit .................................................................................. 1-5-26 Service Consumables Introduction ............................................................................................. 1-6-1 Sealing and Retaining Compounds ........................................................ 1-6-2 Fuel Introduction ............................................................................................. 1-7-1 Related Topics ........................................................................................ 1-7-2 Acceptable and Unacceptable Fuels ...................................................... 1-7-3 Stall Speed Combinations Introduction ............................................................................................. 1-8-1 Related Topics ........................................................................................ 1-8-2 Specifications ......................................................................................... 1-8-3

1-i

1-i


Section 1-1 - General Information Applications Introduction

Applications Introduction This manual contains topics that relate to JCB Loadall machines in the 5A and 5T groups. There are several machine model codes in the family. Machine Group

Model Code

Model Name

Serial Number range

5A

A

531-70

1522574 to TBA

5A

B

535-95

1522588 to TBA

5A

C

536-60

1522577 to TBA

5A

D

541-70

1522566 to TBA

5A

H

533-105

1522615 to TBA

5A

R

536-70

1522577 to TBA

5A

S

526-56

1448231 to TBA

5A

W

550-80

1186000 to TBA

5T

A

531-T70

1522570 to TBA

5T

B

541-T70

1522566 to TBA

5T

C

536-T60

1522577 to TBA

5T

D

535-T95

1522569 to TBA

5T

E

536-T70

1522577 to TBA

5T

W

550-T80

1186000 to TBA

Note: This manual is applicable to EN15000 compliant machines only. Machine variants: There are different machine variants within the same model name. This happens because of market requirements, or when the machine specification changes after a period of time. Where applicable information is given to help identify which machine variant is applicable for the given specifications and procedures. Use the applications tables to see which topics relate to which machine models and variants. Where no variant information is given the topic is applicable to all machine models indicated on the table. Important: The machine model names are NOT referred to in the topics. You must refer to the applications tables for the applicable machine model. Table entries shaded grey indicate a topic not included in this issue of the manual. K Tables ( T 1-1-2) K Section 1 - General Information ( T 1-1-2) K Section 2 - Care and Safety ( T 1-1-2) K Section 3 - Routine Maintenance ( T 1-1-3) K Section B - Body and Framework ( T 1-1-4) K Section C - Electrics ( T 1-1-6) K Section E - Hydraulics ( T 1-1-7) K Section F - Transmission ( T 1-1-10) K Section G - Brakes ( T 1-1-12) K Section H - Steering ( T 1-1-13) K Section K - Engine ( T 1-1-14) K Section M - Electronic Data Systems ( T 1-1-15)

1-1-1

9813/0900-2 (1-14-05)

1-1-1


1-1-2

Machine Identification

Torque Settings

Service Tools

Service Consumables

Fuel

1-3

1-4

1-5

1-6

1-7

9813/0900-2 (1-14-05)

Title

Safety Notices

General Procedures

Topic Ref

2-1

2-2

Section 2 - Care and Safety

Stall Speed Combinations

Use

1-2

1-8

Title

Topic Ref

Section 1 - General Information

Variant

Variant

531-70, 531-T70

531-70, 531-T70

Tables

535-95, 535-T95

536-60, 536-T60

535-95, 536-60, 535-T95 536-T60

533-105

All Machines

All Machines

541-70, 541-T70

Machine models

All Machines

All Machines

All Machines

All Machines

All Machines

All Machines

All Machines

533-105

Machine models 541-70, 541-T70

526-56

536-70, 526-56 536-T70

536-70, 536-T70

550-80

550-80

Section 1-1 - General Information Applications Tables

1-1-2


1-1-3

Title

Routine Maintenance (P1)

Routine Maintenance (P2)

Topic Ref

3-1

3-2

Section 3 - Routine Maintenance

Variant 535-95, 535-T95

z

531-70, 531-T70

z

z

536-60, 536-T60

z

541-70, 541-T70

z

533-105

Machine models

z

536-70, 536-T70

z

526-56

z

550-80

Section 1-1 - General Information Applications Tables

9813/0900-2 (1-14-05)

1-1-3


1-1-4

Fork Carriage

Cab Heating and Ventilation SYSTEM

Cab Air Conditioning SYSTEM

Longitidinal Load Moment SYSTEM (S1)

Longitidinal Load Moment SYSTEM (S2)

Cab

Air Conditioning Condenser - Cooling Pack Mounted

Air Conditioning Condenser - Cab Roof Mounted

Cab HV and HVAC Unit

Air Conditioning Binary Switch

Heater Valve

Fuel Tank

Chassis Panels

Boom

Hydraulic Tank

Load Moment Indicator Axle Transducer

Stabilisers

B1

B2

B3

B4

B5

B6

B7

B8

B9

B10

B11

B12

B13

B14

B15

B16

B17

Topic Ref Title

Section B - Body and Framework

9813/0900-2 (1-14-05)

3 Stage

2 Stage

Parallel Gearpump Hydraulic System Machines

Agri Xtra

Agri, Agri Plus, Agri Super

Variant

z

z z z z z z

z

z

z z z z z

z

z

z

z z

533-105

z

z

z

z z

z z

536-70, 536-T70

z

z z z z z z

z

z z z z z z

z z

z

z z z z z

z

z z z z z z

Machines with intercooled engines

Machines with non intercooled engines

z

z

z

z

z

z z

z

z z

z z

z

z z

z z

z z

541-70, 541-T70

z

z z

z z

536-60, 536-T60

z

535-95, 535-T95

531-70, 531-T70

Machine models

z z

z z z z z z

z

z

z

z z

526-56

z

z z z z z z

z

z

z

z z

550-80

Section 1-1 - General Information Applications Tables

1-1-4


1-1-5

Longitidinal Load Moment Indicator Unit

Longitidinal Load Moment Control Sensors

B18

B19

Topic Ref Title

Variant

535-95, 535-T95

z z

531-70, 531-T70

z z

z z

536-60, 536-T60

z z

541-70, 541-T70

z z

533-105

Machine models

z z

536-70, 536-T70

z z

526-56

z z

550-80

Section 1-1 - General Information Applications Tables

9813/0900-2 (1-14-05)

1-1-5


1-1-6

Title

Fuses and Relays

Schematics

Electrical Harness SYSTEM

Battery Charging SYSTEM

Alternator

Battery

Topic Ref

C1

C2

C3

C4

C5

C6

Section C - Electrics

Variant 535-95, 535-T95

z z z z z z

531-70, 531-T70

z z z z z z

z z z z

z z

536-60, 536-T60

z z z z

z z

541-70, 541-T70

z z z z

z z

533-105

Machine models

z z z z

z z z z z z

z z

536-70, 526-56 536-T70

z z z z

z z

550-80

Section 1-1 - General Information Applications Tables

9813/0900-2 (1-14-05)

1-1-6


1-1-7

Parallel Control Valve 4 Section

Parallel Control Valve 6 Section

LSP Electro Servo Control Valve (S1)

LSP Electro Servo Control Valve (S2)

LSP Electro Servo Control Valve (S3)

Servo Pilot Pressure Supply Valve (S1) Agri Xtra

Servo Pilot Pressure Supply Valve (S2) Agri, Agri Plus, Agri Super

Servo Pilot Pressure Supply Valve (S3)

E13

E14

E15

9813/0900-2 (1-14-05)

E16

E17

E18

E19

Agri, Agri Plus, Agri Super

Agri Xtra

Agri, Agri Plus, Agri Super

E12

Agri Xtra

Variable Hydraulic Cooling Fan Control SYSTEM

Smooth Ride SYSTEM (SRS) - Parallel

E7

E11

LSP Electro Servo SYSTEM (S4)

E6

Smooth Ride SYSTEM (SRS) Electro Servo (S3)

LSP Electro Servo SYSTEM (S3)

E5

Agri, Agri Plus, Agri Super

E10

LSP Electro Servo SYSTEM (S2)

E4

Agri Xtra

Smooth Ride SYSTEM (SRS) Electro Servo (S2)

LSP Electro Servo SYSTEM (S1)

E3

E9

Parallel Hydraulic SYSTEM

E2

Smooth Ride SYSTEM (SRS) Electro Servo (S1)

Systems and Schematics

E1

Variant

E8

Title

Topic Ref

Section E - Hydraulics

z z

z z

z

z

z

z

z

z

z

z z

z z

z z

z z

z z

z

z

z z

z

z

535-95, 536-60, 535-T95 536-T60

z z

531-70, 531-T70

z z

z z

z

z

z z

z z

z z

541-70, 541-T70

z

z z

533-105

Machine models

z z

z z

z

z

z z

z z

z z

536-70, 536-T70

z

z

z

z

526-56

z

z

z

z

z

z

550-80

Section 1-1 - General Information Applications Tables

1-1-7


1-1-8

9813/0900-2 (1-14-05)

Displacement Ram

Sway Ram

Stabiliser Rams

Ram Maintenance

Sway/Fan Changeover Valve

Hydraulic Oil Cooler By-Pass SYSTEM Agri, Agri Plus, Agri Super, Agri Xtra

Hydraulic Oil Cooler By-Pass Valve

Internal Hydraulic Tank Filter

E29

E30

E31

E32

E33

E34

E35

E36

Agri, Agri Plus, Agri Super, Agri Xtra

Agri, Agri Plus, Agri Super, Agri Xtra

Tilt Ram

E28

Agri, Agri Plus, Agri Super

Agri Xtra

Lift Rams

Control Lever - Electro Servo - Pod Mounted

E24

Variable Speed Fan

E27

Cooling Fan Motor (P2)

E23

Extension Ram

Cooling Fan Motor (P1)

E22

125 l/min

110 l/min

80 l/min Triple Pump

80 l/min Double Pump

E26

Main Pump - Gearpump

E21

Control Lever - Electro Servo - Cab Mounted

Main Pump - Variflow

E20

Variant

E25

Title

Topic Ref

z z z z z

z z

z z z z z

z z z z z z z z

z

z z

z z z

z

z

z

z

z z z z

z

z

z

z

z

535-95, 536-60, 535-T95 536-T60

z

z

z

z z z z

531-70, 531-T70

z

z

z z z

z z z z z

z

z

z

z z z z

541-70, 541-T70

z z

z z z z

z

z

533-105

Machine models

z

z

z z z

z z z z z

z

z

z

z z z z

536-70, 536-T70

z

z z z z

z

z

526-56

z

z

z z z

z z z z z

z

z

z

550-80

Section 1-1 - General Information Applications Tables

1-1-8


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Title

Ambient Air Temperature Sender

Topic Ref

E37

Variant

531-70, 531-T70

535-95, 536-60, 535-T95 536-T60

541-70, 541-T70

533-105

Machine models 536-70, 536-T70

526-56

1-1-9 z

550-80

Section 1-1 - General Information Applications Tables

9813/0900-2 (1-14-05)

1-1-9


1-1-10

SS700 Gearbox SYSTEM

Lock Up Torque Converter SYSTEM

Dual Control SYSTEM (S1)

Dual Control SYSTEM (S2)

Dual Control SYSTEM (S3)

Shiftmaster ECU

PS750 Mk IV Gearbox

PS760 Gearbox

SS700 Gearbox

Bevel Gearbox

Torque Converter

F12

F13

F14

F15

F16

F17

F18

F19

F20

F21

PS750 Mk IV Gearbox SYSTEM

F7

F11

Rear Axles (S2)

F6

PS766 Gearbox SYSTEM (ECU 2.3)

Rear Axles (S1)

F5

F10

Front Axles (S2)

F4

PS764 Gearbox SYSTEM (S2)

Front Axles (S1)

F3

F9

Wheels and Tyres

F2

PS764 Gearbox SYSTEM (S1)

Configuration

F1

F8

Title

Topic Ref

Section F - Transmission

9813/0900-2 (1-14-05)

Agri, Agri Plus, Agri Super

PS766 System

Variant

z

z

z z

z z z

z z

z

z z

z z

z z z

z z

z

z z

z

z z

z z

z

535-95, 535-T95

531-70, 531-T70

z z

z z z

z z

z

z z

z

z

z z

536-60, 536-T60

z z

z z z

z z

z

z z

z

z

z z

541-70, 541-T70

z z

z

z

z

z

z z

533-105

Machine models

z z

z z z

z z

z

z z

z

z

z z

536-70, 536-T70

z z z

z

z

z

z

z

z

z z

526-56

z z

z

z

z

z

z

z z

550-80

Section 1-1 - General Information Applications Tables

1-1-10


Title

Transmission Oil Cooler - Liquid to Liquid

Transmission Oil Cooler - Air Blast

Propshafts (S1)

Propshafts (S2)

Transmission Speed Sensor

Engine Speed Sensor

Speedometer

SS700 Cable Shift

Topic Ref

F22

F23

F24

F25

F26

F27

F28

F29

Variant

1-1-11 z z z

z

531-70, 531-T70

z z z

z

535-95, 535-T95

541-70, 541-T70

533-105

536-70, 536-T70

z z z

z z z z

z z z z

z z z z

z

Machines with intercooled engines

Machine with non intercooled engines

536-60, 536-T60

Machine models

z z z z

z

526-56

z z z

550-80

Section 1-1 - General Information Applications Tables

9813/0900-2 (1-14-05)

1-1-11


1-1-12

Title

Single Axle Service Brakes SYSTEM

Power Braking SYSTEM

External Park Brake SYSTEM

Internal Park Brake SYSTEM

Park Brake Calliper

Park Brake Disc

Park Brake Switch

Servo Exhauster Unit

Servo Unit - Single Axle Brakes

Master Cylinder

Fluid Reservoir

Power Brake Valve

Power Brake Accumulator

Power Brake Charge Valve

Topic Ref

G1

G2

G3

G4

G5

G6

G7

G8

G9

G10

G11

G12

G13

G14

Section G - Brakes

PS750 and SS700 Gearbox System

PS750 and SS700 Gearbox System

PS760 Gearbox Systems

PS750 and SS700 Gearbox System

Variant

z z z z z z z z z

z z z z z z z z

z

z z

535-95, 535-T95

531-70, 531-T70

z z z z z

z

z

z

z

z

536-60, 536-T60

z z z z z

z

z

z

z

z

541-70, 541-T70

z z z z z

z

z

z

z

533-105

Machine models

z z z z z

z

z

z

z

z

536-70, 536-T70

z z z z z

z

z

z

z

526-56

z z z

z

z

z

550-80

Section 1-1 - General Information Applications Tables

9813/0900-2 (1-14-05)

1-1-12

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JCB 536-60 TELESCOPIC HANDLER Service Repair Manual SN:1522577 to TBA  

JCB 536-60 TELESCOPIC HANDLER Service Repair Manual SN:1522577 to TBA  

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