JCB 535-140 Hi Viz Telescopic Handler Service Repair Manual from 1522591 to TBA

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

Applications

Introduction

This manual contains topics that relate to some or all JCB Loadall machines in the 5A group. There are several machine model codes in the family.

Machine GroupModel CodeModel NameSerial Number range:

5AF 540-170 from 1522578 to TBA

5AL 540-140 TBA

5AN 535-125 Hi Viz from 1522579 to TBA

5AP 535-140 Hi Viz from 1522591 to TBA

5AX 540-200 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. Information relating specifically to different variants of the same model is given in the applications tables and in the Topics throughout the manual where applicable.

Use the applications tables to see which topics relate to which machine models and variants.

Important: The machine model names are NOT referred to in the topics. You must refer to the applications tables for the applicable machine models.

Note: For full details of machine identification refer to Section 1 - Machine Identification

K Tables ( T 1-1-2)

K Section 1 - General Information ( T 1-1-2)

K Section 2 - Care and Safety ( T 1-1-3)

K Section 3 - Routine Maintenance ( T 1-1-4)

K Section B - Body and Framework ( T 1-1-5)

K Section C - Electrics ( T 1-1-7)

K Section E - Hydraulics ( T 1-1-8)

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)

Section 1 - General Information

Tables

Section 2 - Care and Safety

Section 3 - Routine Maintenance

Section B - Body and Framework

B1 Fork Carriage

B2 Cab Heating and Ventilation SYSTEM

B3 Cab Air Conditioning SYSTEM

B4 Longitudinal Load Moment System (B-19-10)

B5 Longitudinal Load Moment System (B-19-11)

B6 Longitudinal Load Moment System (B-19-15)

B7 Cab

B8 Air Conditioning CondensorCooling Pack Mounted

B9 Air Conditioning Condensor - Roof Mounted

B10 Cab HV and HVAC Unit

B11 Air Conditioning Binary Switch

B12 Heater Valve

B13 Fuel Tank

B14 Engine Cover

B15 Valve Block Covers B16

B24 Longitudinal Load Moment Indicator Unit

B25 Longitudinal Load Moment Control Sensors

Section C - Electrics

C1 Fuses and Relays

C2 Schematics

C3 Electrical Harness SYSTEM

C4 Battery Charging SYSTEM

C5 Alternator (C-04-01) Engine serial number up to U0193211

C6 Alternator (C-04-02) Engine serial number from U0193212

C7 Battery

Section E - Hydraulics

E1 Systems and Schematics

E2 Parallel Hydraulic SYSTEM

E3 Parallel Servo Hydraulic SYSTEM

E4 LSP Electro Servo Hydraulic SYSTEM

E5 Hydraulic Interlock SYSTEM

E6 Auxiliary Relief Valve (ARV) Operation

E7 Main Relief Valve (MRV)/ Load Sense Relief valve (LSRV) Operation

E8 Pressure Compensator Operation

E9 Parallel Lift Operation

E10 Parallel Circuit Operation

E11 Parallel Servo Circuit Operation

E12 LSP Electro Servo Circuit Operation

E13 Boom Pressure Balance System

E14 Universal Hydraulic Circuit Faults

E15 Parallel Circuit Faults

E16 Parallel Servo Circuit Faults

E17 LSP Electro Servo Circuit Faults

E18 Parallel System Pressure Tests

E19 Pump Flow Tests - Gearpump

E20 Parallel Servo System Pressure Tests

E21 LSP Electro Servo System Pressure Tests

E22 Parallel Control Valve - 6 Section

E23 Parallel Control Valve - 5 Section

E24 Parallel Control Valve - 2 Section

E25 Electro Servo Control Valve

E29

E31

Section F - Transmission

F5 PS750 Mk IV Gearbox SYSTEM

F6 PS764 Gearbox SYSTEM

F7 PS750 Mk IV Gearbox Hydraulic Operation

F8 PS764 Gearbox Hydraulic Operation

F9 Gearbox Systems Fault Finding

F10 PS750 Mk IV Gearbox - Hydraulic Testing

F11 PS760 Gearbox - Hydraulic Testing

F12 Torque Converter Stall Tests

F13 Flushing the Transmission Oil

F14 PS750 Mk IV Gearbox

F15 PS760 Gearbox

F16 Torque Converter Operation

F17 Torque Converter

F18 Bevel Gearbox

F19 Transmission Oil Cooler - Air Blast Intercooled engines

F20 Transmission Oil Cooler - Liquid to Liquid Non intercooled engines

F21 Propshafts

Section G - Brakes Machine

G1 Twin Axle Service Brakes SYSTEM

G2 External Park Brake SYSTEM PS750 gearbox

G3 Internal Park Brake SYSTEM PS760 gearbox

G4 Park Brake Calliper PS750 gearbox

G5 Park Brake Disc PS750 gearbox

G6 Park Brake Switch

G7 Servo Exhauster Unit

G8 Servo Unit - Twin Axle Brakes

G9 Master Cylinder

G10 Fluid Reservoir

Section H - Steering

H1 Steering SYSTEM

H2 Manual Steer Mode SYSTEM

H3 Auto Steer Mode SYSTEM

H4 Hydraulic Steering Unit (H-02-07)

H5 Priority Valve

H6 Power Track Rods (H-07-06)

H7 Steer Rams

H8 Steering Column

H9 Manual Steer Mode Valve

H10 Auto Steer Mode Valve

H11 Steer Proximity Switches

Section K - Engine

K1 Stop and Start SYSTEM (Mechanical F.I. Engines)

K2 Stop and Start SYSTEM (Electronic F.I. Engines)

K3 Cold Start Heater SYSTEM Mechanical F.I. Engines

K4 Starter Motor

K5 Cooling Pack - (Non Intercooled)

K6 Cooling Pack - (Intercooled Mechanical F.I. Engines)

K7 Cooling Pack - (Electronic F.I. Engines)

K8 Coolant Expansion Tank

K9 Air Filter Vacuum Switch

K10 Throttle Pedal and Cable

K11 Throttle Position Sensor (TPS) (K-07-10)

K12 Throttle Position Sensor (TPS) (K-07-11)

K13 Exhaust Silencer

K14 JCB Dieselmax (Mechanical F.I. Engines)

K15 JCB Dieselmax (Electronic F.I. Engines)

Electronic F.I. engines up to March 2011

Electronic F.I. engines from March 2011

Section M - Electronic Data Systems Machine models

M1 CANbus SYSTEM

M2 Loadall Monitoring SYSTEM

M3 Fault Code SYSTEM

M4 Servicemaster SYSTEM

M5 Servicemaster Tool Set

M6 JCB DieselMax (4.4L Tier 3 SE)

Diagnostic Tool - User Guide

M7 JCB DieselMax (4.4L Tier 3 SE)

Engine Setup Tool - User Guide

M8 Cluster (LMS) Setup Tool - User Guide

M9 Loadall Datalogger Tool - User Guide

M10 Loadall Machine Diagnostics Tool - User Guide

M11 Boom Angle Sensor Calibration Tool - User Guide

M12 Immobiliser Diagnostics ToolUser Guide

M13 Immobiliser Setup Tool - User Guide

M14 Pulse Width Modulation Theory

M15 Electronic Control Unit Theory

M16 Livelink ECU

M17 Immobiliser ECU

M18 Hydraulic Control ECU

Use

Introduction

This topic contains information about the structure of the manual and how to use the manual.

K Scope ( T 1-2-2)

K Personnel ( T 1-2-2)

K Applications ( T 1-2-2)

K Newest Data ( T 1-2-2)

K Format ( T 1-2-3)

K Left and Right Sides ( T 1-2-4)

K Hydraulic Schematic Codes ( T 1-2-5)

K Colour Codes ( T 1-2-5)

Scope

Personnel

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. Finally, please remember above all else SAFETY MUST COME FIRST!

Applications

This manual contains data relevant to a range of machines. Make sure you reference the data for the correct machine. Refer to the Applications topic in this section.

Newest Data

From time to time new machines, systems or devices require the manual to be re-issued. Make sure you have the newest issue.

Always check the on-line JCB data system for relevant technical information.

Format

The manual is compiled in sections, the first three are numbered and contain information as follows:

1General Information - Use the Applications Tables at the front of the section to see which topic in the manual is applicable to which machine model. The section also includes general information such as torque settings and service tools.

2Care & Safety - includes warnings, cautions and general procedures related to aspects of workshop procedures contained in the manual.

3Routine 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:

AAttachments

BBody and Framework...etc.

The sections contain topics. Each topic is a self contained set of data about a machine SYSTEM or Device.

Some topics are only applicable to some machine models. Use the Applications Tables in this section to see which topic is applicable to which machine model.

Each topic contains data such as specifications, descriptions, fault finding and test procedures. Device topics also contain removal, replacement, dismantle and assemble procedures.

Some topics contain procedures and specifications for different variants. This happens because of market requirements, or when the machine specification changes after a period of time. Where applicable, a table in the introduction of each topic contains information to help you identify the correct specifications or procedures.

Each topic also contains a Related Topics table. This table lists all the topics that contain related data. For example a hydraulic SYSTEM contains devices such as valves and pumps. These devices have their own topics and they are listed in the SYSTEM related topics table.

Left and Right Sides

Left and Right Sides

'Left Hand' and 'Right Hand' are as viewed from the rear of the machine facing forwards.

Hydraulic Schematic Codes

Hydraulic Schematic Codes

Colour Codes

The following colour coding, used on illustrations to denote various conditions of oil pressure and flow, is standardised throughout JCB Service Publications.

Red Full Pressure: Pressure generated from operation of a service. Depending on application this may be anything between neutral circuit pressure and LSRV operating pressure.

PinkPressure: Pressure that is above neutral circuit pressure but lower than that denoted by Red.

OrangePilot: Oil pressure used in controlling a device (Pilot).

BlueNeural: Neutral circuit pressure.

GreenExhaust:

Light GreenCavitation: Oil subjected to a partial vacuum due to a drop in pressure (cavitation).

YellowLock Up: Oil trapped within a chamber or line, preventing movement of components (lock up).

Machine Identification

Introduction

This topic contains information about a machine identification. On the machine and on the machine devices there are identification data plates.

K Related Topics ( T 1-3-2)

K Machine Identification Plate ( T 1-3-3)

K Typical Product Identification Number (PIN) ( T 1-3-3)

K European Tractor Type Approved Builds ( T 1-3-5)

K Component Identification Plates ( T 1-3-7)

K Typical Engine Identification Number ( T 1-3-7)

K Transmission Identification Numbers ( T 1-3-8)

K ROPS/FOPS and OECD Certification Plates ( T 1-3-11)

Related Topics

Related Topics

Table 1. Related Topics in This Publication

The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correct information. Some machines have different systems and devices. Make sure you refer to the correct topic, refer to Section 1 - Applications.

SectionsTopic TitlesSub Titles

1 Applications ALL

Table 2. Related Topics in Publication 9813/1400 - Personnel Platform Supplement

The table lists topics in another manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correct information. Some machines have different systems and devices. Make sure you refer to the correct topics.

SectionsSection TitlesTopic Titles ALLALL ALL

Section 1-3 - General Information

Machine Identification

Machine Identification Plate

The machine has an identification plate mounted as shown. K Fig 1. ( T 1-3-3). The serial numbers of the machine and its major units are stamped on the plate.

Note: The machine model and build specification is indicated by the PIN.

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.

GETGatersleben, Germany

PUNPune, India

SHAShanghai, China

JBPJCB Branded Products

Typical Product Identification Number (PIN)

420811

Standard Builds

5AA = 531-70

5AB = 535-95

5AC = 536-60

5AD = 541-70

5AF = 540-170

5AG = 550-140

5AH = 533-105

5AL = 540-140

5AM = 550-170

5AN = 535-125 HiViz

5AP = 535-140 HiViz

5AR = 536-70

5AS = 526-56

5AT = 527-58 Low Cab

5AV = 527-58 High Cab

5AW = 550-80

5AX = 540-200

5CD = 506-36

5CE = 507-42

5CF = 509-42

5CG = 510-56

5CH = 512-56

5CJ = 514-56

5MN = 535-125 MP(1)

5MP = 535-140 MP(1)

(1)Man Platform Variant - Refer to Service Manual Supplement9813/1400

T011100-C1

1 World Manufacturer Identification (3 Digits)

JCBUK

GEOGeorgia, US

HARHaryana, India

SORSorocaba, Brazil

European Tractor Type Approved Builds:

5TA = 531-705TD = 535-95

5TB = 541-705TE = 536-70

5TC = 536-605TW = 550-80

5UW = 550U80

Machine Identification Plate 1-3-3 1-3-3

Fig 1.

2 Machine Model (3 Digits)

3 Engine Type (1 Digit)

JCB Dieselmax (Tier 3):

P = Turbocharged and intercooled, 85kW (114Hp)

R = Turbocharged and intercooled, 97kW (130Hp)

S = Turbocharged, 74.2kW (100Hp)

T = Turbocharged, 63kW (85Hp)

V = Turbocharged and intercooled, 108 kW (145Hp)

JCB Ecomax (Tier 4):

W = Turbocharged and intercooled,55kW (74Hp)

X = Turbocharged and intercooled, 81kW (109Hp)

Y = Turbocharged and intercooled,93kW (125Hp)

Z = Turbocharged and intercooled, 108kW (145Hp)

4 Gearbox Model (1 Digit)

E = 3 Speed (PS750)J = 6 Speed (PS760)

F = 3 Speed (PS760)M = 4 Speed (SS700)

G = 4 Speed (PS750)N = 4 Speed (PS750 - 40 KPH)

H = 4 Speed (PS760)

P = 20 Kph

R = 25 Kph

S = 34 kph

T = 40 Kph

5 Randomly generated check letter (1 Digit)

6 Machine Serial Number (8 Digits)

Each machine has a unique serial number.

Section 1-3 - General Information

Machine Identification

Machine Identification Plate

Table 3. Powershift/SyncroShuttle Transmission

Table 4. HydroStatic Transmission

European Tractor Type Approved Builds

Section 1-3 - General Information

Fig 2. Table 5. Machines with SA/SB/SC/SD/SE/SF Engines

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Section 1-3 - General Information

(1)Dependent on tyres option.

(1)Dependent on

option.

Table 6. Machines with SH/SL/DH Engines

Section 1-3 - General Information

Machine Identification

Component Identification Plates

Component Identification Plates

Typical Engine Identification Number

Engine data labels A are located on the cylinder block at position C and rocker cover D (if fitted). The data label contains important engine information and includes the engine identification number E

A typical engine identification number is explained as follows:

SD320/40001U0000104

1 Engine Type

SD = turbocharged

SE = electronic common rail fuel injection, turbocharged and intercooled.

SF = turbocharged and intercooled.

SH = 4.4 litre electronic common rail fuel injection with Variable Geometry Turbocharger (81kW, 93kW)

SL = 4.4 litre electronic common rail fuel injection with Fixed Geometry Turbocharger (55kW)

DH = 4.8 litre electronic common rail fuel injection with Variable Geometry Turbocharger (108kW)

2 Engine part number

3 Country of manufacture

U = United Kingdom

4 Engine Serial Number

5 Year of Manufacture

The last three parts of the engine identification number are stamped on the cylinder block at position B

C007280-C5.jpg

Fig 3. Engine

Transmission Identification Numbers

Axles (Excluding 550-80 Machines)

The transmission components have a serial number stamped on a data plate A as shown.

Section 1-3 - General Information

Machine Identification

Component Identification Plates

Axles (550-80 Machines)

The axles have a serial number stamped on a data plate label A as shown.

To view to the front axle data plate remove the cover B and the plate will be visible through hole C

A710840-C1

Fig 4. Front Axle

A710830-C1

Fig 5. Rear Axle

C107510

Fig 6. Front Axle

C107520

Fig 7. Rear Axle

Gearbox

The transmission components have a serial number stamped on a data plate A as shown.

Section 1-3 - General Information

Machine Identification

Component Identification Plates

263370-C1

Fig 8. PS750 Powershift Transmission

A401030-C2

Fig 9. PS760 Powershift Transmission

C007640

Fig 10. SS700 Transmission