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.

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

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