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.
9803/3760-07
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 ............................................................. 1-3-6 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 Machine Group machines in the 5A and 5T groups. There are several machine model codes in the family.
Model Code
Model Name
5A
A
531-70
5A
B
535-95
5A
C
536-60
5A
D
541-70
5A
H
533-105
5A
R
536-70
5A
S
526-56
5T
A
531-T70
5T
B
541-T70
5T
C
536-T60
5T
D
535-T95
5T
E
536-T70
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. For machines with LLMC built after October 2010 refer to the service manual 9813/0900. 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 1-1-5) K Section E - Hydraulics ( T 1-1-6) K Section F - Transmission ( T 1-1-9) K Section G - Brakes ( T 1-1-11) K Section H - Steering ( T 1-1-12) K Section K - Engine ( T 1-1-13) K Section M - Electronic Data Systems ( T 1-1-14)
1-1-1
9803/3760-06 (1-14-02)
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
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
Tables
531-70, 531-T70
531-70, 531-T70
535-95, 535-T95
535-95, 535-T95
533-105
536-60, 536-T60
9803/3760-06 (1-14-02)
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
541-70, 541-T70
Machine models 536-60, 536-T60
536-70, 536-T70
536-70, 536-T70
526-56
526-56
Section 1-1 - General Information Applications Tables
1-1-2
1-1-3
Title
Introduction
Service Schedules - Machines with SD and SF Engines
Service Schedules - Machines with SE Engines
Fluids, Lubricants and Capacities
Cleaning the Machines
Inspection
Seat Belts
ROPS/FOPS (and OECD) Structure
Greasing
Heater and Air Conditioning
Brakes
Electrical System
Engine
Engine Air FIlter
Fuel System
Hydraulic System
Transmission
Tyres and Wheels
Wear Pads
Windscreen Washer
Access Panels
Fire Extinguisher
Topic Ref
3-1
3-2
3-3
3-4
3-5
3-6
3-7
3-8
3-9
3-10
3-11
3-12
3-13
3-14
3-15
3-16
3-17
3-18
3-19
3-20
3-21
3-22
Section 3 - Routine Maintenance
Electronic F.I. engines
Mechanical F.I. engines
Variant
z z
z
535-95, 535-T95
z
531-70, 531-T70
z
z
536-60, 536-T60
9803/3760-06 (1-14-02)
All Machines
All Machines
All Machines
All Machines
All Machines
All Machines
All Machines
All Machines
All Machines
All Machines
All Machines
All Machines
All Machines
All Machines
All Machines
All Machines
All Machines
All Machines
All Machines
z
z
z
533-105
All Machines
541-70, 541-T70
Machine models
z
z
536-70, 536-T70
z
526-56
Section 1-1 - General Information Applications Tables
1-1-3
1-1-4
9803/3760-06 (1-14-02)
Cab Heating and Ventilation SYSTEM
Cab Air Conditioning SYSTEM
Load Moment Indicator (LMI) SYSTEM
Longitidinal Load Moment SYSTEM
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
B2
B3
B4
B5
B6
B7
B8
B9
B10
B11
B12
B13
B14
B15
B16
Stabilisers
Longitudinal Load Moment Indicator Unit
B17
B18
Electric Inclinometers
Fork Carriage
B1
Topic Ref Title
Section B - Body and Framework
Agri, Agri Plus, Agri Super November 2009 to October 2010
Agri, Agri Plus, Agri Super November 2009 to October 2010
Agri, Agri Plus, Agri Super November 2009 to October 2010
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
536-60, 536-T60
z
z z z
z z
541-70, 541-T70
z
z z
z z
533-105
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
z z z z z z
Machines with intercooled engines
z
z z
z z z z z z
Machines with non intercooled engines
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
Section 1-1 - General Information Applications Tables
1-1-4
1-1-5
Schematics
Electrical Harness SYSTEM
Battery Charging SYSTEM
Alternator
Battery
Machine Control ECU (S1)
C2
C3
C4
C5
C6
C7
Agri, Agri Plus, Agri Super Nov 2009 to October 2010(1)
SLC machines without LLMC, LLMC machines up to October 2010(1)
Variant
(1) For details of LLMC machines from October 2010 refer to the Service Manual 9813/0900
Machine Control ECU (S2)
Fuses and Relays
C1
C8
Title
Topic Ref
Section C - Electrics
z
z z z z
z z z z
z
z z
z z
531-70, 535-95, 531-T70 535-T95
z
z z z z
z z
536-60, 536-T60
z
z z z z
z z z z z z
z z
541-70, 533-105 541-T70
Machine models
z
z z z z
z z
536-70, 536-T70
z z z z z
z z
526-56
Section 1-1 - General Information Applications Tables
9803/3760-06 (1-14-02)
1-1-5
1-1-6
Smooth Ride SYSTEM (SRS) Electro Servo (S1) Agri Xtra
Smooth Ride SYSTEM (SRS) Electro Servo (S2) Agri, Agri Plus, Agri Super November 2009 to October 2010(1)
Smooth Ride SYSTEM (SRS)Servo Parallel
Parallel Control Valve 4 Section
Parallel Control Valve 6 Section
Flowshare (LSP) Control Valve
LSP Electro Servo Control Valve (S1)
E11
E12
9803/3760-06 (1-14-02)
E13
E14
E15
E16
Agri Xtra
Non LLMC machines, LLMC machines up to October 2010(1)
Non LLMC machines, LLMC machines up to October 2010(1)
SLC machines up to October 2010(1)
Up to November 2009
SLC machines up to October 2010(1)
Agri, Agri Plus, Agri Super November 2009 to October 2010(1)
E10
LSP Electro Servo SYSTEM (S2)
E6
Agri Xtra
Smooth Ride SYSTEM (SRS) LSP
LSP Electro Servo SYSTEM (S1)
E5
Up to November 2009
E9
LSP Variflow Hydraulic SYSTEM
E4
Up to November 2009
Smooth Ride SYSTEM (SRS) - Parallel
LSP Gearpump Hydraulic SYSTEM
E3
Non LLMC machines, LLMC machines up to October 2010(1)
E8
Parallel Hydraulic SYSTEM
E2
Servo Parallel Hydraulic SYSTEM
Systems and Schematics
E1
Variant
E7
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
535-95, 535-T95
531-70, 531-T70
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
541-70, 541-T70
z
z z
533-105
Machine models
z
z
z
z z z z
z z z z
z z
536-70, 536-T70
z
z
z
z
z z
526-56
Section 1-1 - General Information Applications Tables
1-1-6
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1-1-7
9803/3760-06 (1-14-02)
Cooling Fan Motor
Control Lever - Electro Servo (S1)
Control Lever - Electro Servo (S2)
Control Lever - Servo Parallel
Extension Ram
Lift Rams
E25
E26
E27
E28
E29
E30
Tilt Ram
Main Pump - Gearpump
E24
E31
Main Pump - Variflow
Servo Pilot Pressure Supply Valve (S2)
E21
E23
Servo Pilot Pressure Supply Valve (S1)
E20
Pilot Manifold Block
Servo Pilot Valve
E19
E22
Inloader Valve
E18
SLC
Agri, Agri Plus, Agri Super November 2009 to October 2010(1)
Agri Xtra
125 l/min
110 l/min
80 l/min Triple Pump
80 l/min Double Pump
SLC machines up to October 2010(1)
Agri, Agri Plus, Agri Super November 2009 to October 2010(1)
Agri Xtra up to October 2010(1)
LSP Hydraulic Systems - Up to November 2009
Gearpump Systems
SLC machines up to October 2010(1)
Agri, Agri Plus, Agri Super November 2009 to October 2010(1)
LSP Electro Servo Control Valve (S2)
Servo Parallel Control Valve
Variant
Title
E17
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
536-60, 536-T60
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
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
z z
z
536-70, 536-T70
z z z z
z
z
z
z
526-56
Section 1-1 - General Information Applications Tables
1-1-7
1-1-8
Displacement Ram
Sway Ram
Stabiliser Rams
Ram Maintenance
Sway/Fan Changeover Valve
E32
E33
E34
E35
E36
Variant
(1) For details of LLMC machines from October 2010 refer to the Service Manual 9813/0900
Title
Topic Ref
z z
z z
z z z z
535-95, 535-T95
531-70, 531-T70
z
z
536-60, 536-T60
z z
z z
541-70, 541-T70
z z
z
533-105
Machine models
z z
z z
536-70, 536-T70
z
z
526-56
Section 1-1 - General Information Applications Tables
9803/3760-06 (1-14-02)
1-1-8
1-1-9
Dual Control SYSTEM (S1)
Dual Control SYSTEM (S2)
Dual Control SYSTEM (S3)
Shiftmaster ECU
PS750 Gearbox
PS750 Mk IV Gearbox
PS760 Gearbox
SS700 Gearbox
Bevel Gearbox
Torque Converter
Transmission Oil Cooler - Liquid to Liquid
F12
F13
F14
F15
F16
F17
F18
F19
F20
F21
PS764 Gearbox SYSTEM
F7
F11
PS750 Mk IV Gearbox SYSTEM
F6
Lock Up Torque Converter SYSTEM
PS750 Gearbox SYSTEM
F5
F10
Rear Axles
F4
SS700 Gearbox SYSTEM
Front Axles
F3
F9
Wheels and Tyres
F2
PS766 Gearbox SYSTEM (ECU 2.3)
Configuration
F1
F8
Title
Topic Ref
Section F - Transmission
9803/3760-06 (1-14-02)
SLC
Agri, Agri Plus, Agri Super November 2009 to October 2010(1)
LSP Hydraulic System Up to November 2009
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 z z
z z
z z
z
z
z 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 z
z z
z
z
z z
z z z z
z z
541-70, 533-105 541-T70
z
z
z z z z
z
z z
z z z z z z
z z
536-70, 536-T70
Machine with non intercooled engines
531-70, 535-95, 531-T70 535-T95
Machine models
z
z z
z z
z
z
z z z z
z z
526-56
Section 1-1 - General Information Applications Tables
1-1-9
1-1-10
Transmission Oil Cooler - Air Blast
Propshafts
Transmission Speed Sensor
Engine Speed Sensor
Speedometer
SS700 Cable Shift
F22
F23
F24
F25
F26
F27
Variant
(1) For details of LLMC machines from October 2010 refer to the Service Manual 9813/0900
Title
Topic Ref
z z z z
z z z z
531-70, 535-95, 531-T70 535-T95
541-70, 533-105 541-T70
z z z z
z z z z z
z
z z z z
536-70, 536-T70
Machines with intercooled engines
536-60, 536-T60
Machine models
z z
z
526-56
Section 1-1 - General Information Applications Tables
9803/3760-06 (1-14-02)
1-1-10
1-1-11
Servo Unit - Single Axle Brakes
Master Cylinder
Fluid Reservoir
G9
G10
Park Brake Disc
G5
G8
Park Brake Calliper
G4
Servo Exhauster Unit
Internal Park Brake SYSTEM
G3
G7
External Park Brake SYSTEM
G2
Park Brake Switch
Single Axle Service Brakes SYSTEM
G1
G6
Title
Topic Ref
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
Section 1-1 - General Information Applications Tables
9803/3760-06 (1-14-02)
1-1-11
1-1-12
Hydraulic Steering Unit
Priority Valve
Power Track Rod
Steering Column
H4
H5
H6
H7
Auto Steer Mode Valve
Auto Steer Mode SYSTEM
H3
H9
Manual Steer Mode SYSTEM
H2
Manual Steer Mode Valve
Steering SYSTEM
H1
H8
Title
Topic Ref
Section H - Steering
Variant 535-95, 535-T95
z z 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 z
536-60, 536-T60
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
536-70, 536-T70
z z z z z z z
z z
526-56
Section 1-1 - General Information Applications Tables
9803/3760-06 (1-14-02)
1-1-12