JCB 532H, 537H Loadalls Service Manual (Supplement) – 9803/3641 – PDF DOWNLOAD

General Information Care & Safety Routine Maintenance R

Electrics

Service Manual (Supplement)

Hydraulics Transmission Brakes Steering

532H, 537H

PUBLISHED BY THE TECHNICAL PUBLICATIONS DEPARTMENT OF JCB SERVICE; © WATERLOO PARK, UTTOXETER, ST14 5PA, ENGLAND Tel. 01889 - 590312 PRINTED IN ENGLAND Publication No. 9803/3641

Engine

1 2 3 C E F G H K

Overall Contents i

i

Section 1 General Information Introduction Care and Safety * Service Tools

1-1 1-2

Section 2 Care and Safety Operating Safety Maintenance Safety

1-1 1-1

Section 3 Routine Maintenance Introduction Fluids, Lubricants, Capacities and Specifications

1-1

Service Schedules

2-1

Towing a Machine

4-1

Checking the Drop Box Oil Level

5-1

Changing the Transmission Charge Filter

6-1

Testing the Parking Brake

7-1

Section C Electrics Introduction

1-1

Fuses and relays Fuse Identification Relay Identification

1-2 1-3

* Transmission Controller

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Diagnostic LED’s

2-1

Schematic Diagrams

4 - 1 to 4 - 8

Issue 2*

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ii

Section E Hydraulics Technical Data

1-1

Hydraulic Contamination

2-1

Fault Finding

3-1

Schematic Diagrams and Circuit Descriptions Schematic Diagrams Circuit Descriptions Drive Pump Drive Motor

4-5 4-6

Engine/Drive Pump Coupling

5-1

Drive Pump Removal and Replacement Minor Repairs Location of Components Shaft Seal Multi-Function Valves Charge Pressure Relief Valve Coupling Removal and Replacement Servo Piston Cover Seals Renewal Control Valve Speed Sensor Removal and Replacement Pump Cover Servo Control Valve

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4-1

6-1 6-3 6-4 6-5 6-5 6-6 6-7 6-8 6-9 6 - 10 6 - 10

Drive Motor/Drop Box Assembly Removal and Replacement Minor Repairs Location of Components Shaft Seal Loop Flushing Valve Charge Pressure Relief Valve Multi-Function Block/Pressure Compensator Valve

7-3 7-4 7-5 7-5 7-6

Fan Pump Removal and Replacement Dismantling and Assembly

8-1 8-2

Fan Motor Removal and Replacement Dismantling and Assembly

9-1 9-2

Main Service Pump Removal and Replacement Dismantling and Assembly

11 - 1 11 - 2

7-1

Issue 2*

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Overall Contents iii

iii

Section E Hydraulics (continued) Priority Valve Description and Operation Removal and Replacement To Machine Serial Number 775548 Dismantling and Assembly To Machine Serial Number 775548 Removal and Replacement From Machine Serial Number 775549 Dismantling and Assembly From Machine Serial Number 775549

12 - 1 12 - 2 12 - 3 12 - 4 12 - 5

Transmission Oil Cooler Bypass Valve Removal and Replacement

13 - 1

Start-up procedure

15 - 1

Section F Transmission Introduction Technical Data

1-1 1-1

Description and Operation Introduction Drive Circuit Fan (Charge) Pump and Fan Motor Circuit Brake Pressure Defeat Valve Case Drain Circuit Oil Cooling Circuit Test Points Sensors

2-1 2-2 2-3 2-3 2-4 2-5 2-6 2-7

Drop Box Removal and Replacement Dismantling and Assembly

4-1 5-1

Propshafts Removal and Replacement

6-1

Section G Brakes Introduction Technical Data

1-1 1-1

Parking Brake Adjustment

2-1

Section H Steering

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Introduction

1-1

Technical Data

1-1

Issue 2*

Overall Contents iv

iv

Section K Engine

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Introduction Technical Data

1-1 1-1

Engine Removal and Replacement Renewing the Coupling Drive Flange Replacement Engine Mounting Bracket And Bushes

2-1 2-5 2-6 2-6

Machine Start-up Procedure

2-7

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Section 1

General Information

Section 1

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Contents

Introduction Care and Safety Service Tools

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Page No.

1-1 1-2

Issue 3*

Section 1

General Information Introduction

1-1

Section 1 1-1

* This manual is a supplement to the Loadall Service Manual.

The information covers the 532H machine from serial number 770970 and the 537H machine from serial number 773560, unless specified otherwise. * Note: Only those areas of the machines which are different from the non-hydrostatic version are dealt with here. For all other aspects refer to the Service Manual.

Unless specified otherwise, all references to ‘Service Manual’ in this supplement are to be taken as meaning the appropriate publication listed below.

9803/3660 9803/3661 9803/3662

Loadall Service Manual (English) Loadall Service Manual (French) Loadall Service Manual (German).

! CAUTION Hydraulic cleanliness is absolutely essential when working on hydrostatic drive systems. Orifices in the pump and motor can be blocked by even the tiniest particle - e.g. a thread from a cloth. You must maintain the highest level of cleanliness when working on any part of the system.

5-3-4-7

Care and Safety * Before carrying out any maintenance procedures on this machine, make sure you read the Care and Safety information in Section 2 of the Service Manual. The relevant information in that Section should be observed as well as any care and safety information contained in this supplement.

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Issue 3*

Section 1

General Information

1-2

Section 1 1-2

Service Tools Section C - Electrics 892/00931

Communication Cable

346520

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Section 2

Care and Safety

Section 2

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Contents

Operating Safety Maintenance Safety

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1-1 1-1

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Section 2

Care and Safety

Section 2

1-1

1-1

* Before carrying out any maintenance procedures on this machine, make sure you read the Care and Safety information in Section 2 of the Service Manual. The relevant information in that Section should be observed as well as any care and safety information contained in this manual.

Operating Safety ! CAUTION Parking Brake The parking brake must not be used to slow the machine from travelling speed, except in an emergency, otherwise the efficiency of the brake will be reduced. Whenever the parking brake has been used in an emergency, always renew the brake pads.

4-2-1-1/1

Maintenance Safety ! WARNING Parking Brake Before adjusting the parking brake, make sure that the machine is on level ground. Put chocks each side of all four wheels. Disconnect the battery so that the engine cannot be started. If you do not take these precautions the machine could run over you.

BRAK 1-5

! CAUTION Hydraulic Cleanliness Hydraulic cleanliness is absolutely essential when working on hydrostatic drive systems. Orifices in the pump and motor can be blocked by even the tiniest particle - e.g. a thread from a cloth. You must maintain the highest level of cleanliness when working on any part of the system.

5-3-4-7

! WARNING Hydraulic Fluid Pressure Fine jets of hydraulic fluid at high pressure can penetrate the skin. Do not use your fingers to check for hydraulic fluid leaks. Do not put your face close to suspected leaks. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of hydraulic fluid. If hydraulic fluid penetrates your skin, get medical help immediately.

INT-3-1-10/1

! WARNING Hydraulic Fluid Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses or couplings, vent the pressure trapped in the hoses in accordance with the instructions given in this publication.

HYD 1-5

! WARNING Working Beneath the Machine Make the machine safe before getting underneath it. Park the machine on level ground. Make sure the engine is stopped, the parking brake is engaged and the transmission is in neutral. Disconnect the battery. Chock all four wheels.

5-3-2-1

! WARNING Lifting Equipment You can be injured if you use faulty lifting equipment. Make sure that lifting equipment is in good condition. Make sure that lifting tackle complies with all local regulations and is suitable for the job. Make sure that lifting equipment is strong enough for the job.

INT-1-3-7

9803/3641

Issue 2*

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DOWNLOAD THE COMPLETE MANUAL

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL