JCB 535, 540, 550 Side Engine Loadalls Service Manual – 9803/3750-05

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JCB 535, 540, 550 Side Engine Loadalls Service Manual – 9803/3750-05
(S/N: 1186000 Onwards)

This service manual PDF download for the 535, 540, 550 JCB Side Engine Loadalls has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

– JCB 540-170 – from S/N: 1186000 Onwards
– JCB 550-140 – from S/N: 1186000 Onwards
– JCB 540-140 – from S/N: 1186000 Onwards
– JCB 550-170 – from S/N: 1186000 Onwards
– JCB 535-125 HiViz – from S/N: 1186000 Onwards
– JCB 535-140 HiViz – from S/N: 1186000 Onwards

TABLE OF CONTENTS :

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

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Publication No. : 9803/3750-05
Total Pages : 1665

This complete JCB Telescopic Handler | Loadall | Telescopic Loader service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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9803-3750
Service Manual
Side Engine Loadalls

Section 1 – General Information
General Information
Applications
Introduction
Tables
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
Use
Introduction
Scope
Personnel
Applications
Newest Data
Format
Left and Right Sides
Hydraulic Schematic Codes
Colour Codes
Electrical Device Codes
Machine Identification
Introduction
Related Topics
Machine Identification Plate
Typical Product Identification Number (PIN)
Component Identification Plates
Typical Engine Identification Number
Transmission Identification Numbers
ROPS/FOPS and OECD Certification Plates
Torque Settings
Introduction
Zinc Plated Fasteners and Dacromet Fasteners
Introduction
Bolts and Screws
Hydraulic Connections
‘O’ Ring Face Seal System
‘Torque Stop’ Hose System
`Positional Type’ Hydraulic Adaptors
Fitting Procedure
Service Tools
Introduction
Numerical List
Tool Detail Reference
Rivet Nuts
Fitting Procedure
Slide Hammer Kit
Fitting Procedure
Service Consumables
Introduction
Sealing and Retaining Compounds
Fuel
Introduction
Related Topics
Acceptable and Unacceptable Fuels
Additives
Service Requirements for use of B20 Biodiesel
Warranty
Fuel Types
Usage and Effects of Fuels
Sulphur Content
Effects of Fuel Contaminates
Stall Speed Combinations
Introduction
Related Topics
Specifications

Section 2 – Care and Safety
Care and Safety
Safety Notices
Introduction
Important Information
The Operator Manual
Safety Warnings
Safety Check List
Safety – Yours and Others
Common Rail (SE Engine) Specific
General Safety
Operating Safety
Maintenance Safety
Safety Labels
Introduction
General Procedures
Introduction
Related Topics
Parking the Machine and Making it Safe
Boom Safety Strut
Installing
Removing
Venting Hydraulic Pressure
Connecting/Disconnecting Hydraulic Hoses
Introduction
Connecting the Hoses
Disconnecting the Hoses
Quick Release Couplings
Connecting and Disconnecting
Hydraulic Contamination
Hydraulic Fluid Quality
Effects of Contamination
Cleaning Operation
Contaminant Standards
Filters
Battery Disconnection/Connection
Disconnection
Connection
Removing and Replacing Components
Battery Charging System Precautions
Hydraulic Rams
Installation
Caution During Use
Maintenance, Inspection Points

Section 3 – Routine Maintenance
Routine Maintenance
Introduction
Health and Safety
Lubricants
Battery
Service Schedules – Machines with SD and SF Engines
Related Topics
Introduction
Fuel System
How to Use the Service Schedules
Calendar Equivalents
Pre-start Cold Checks, Service Points and Fluid Levels
Functional Test and Final Inspection
Service Schedules – Machines with SE Engines
Related Topics
Introduction
Calendar Equivalents
How to Use the Service Schedules
Fuel System
Pre-start Cold Checks, Service Points and Fluid Levels
Functional Test and Final Inspection
Fluids, Lubricants and Capacities
Related Topics
Specifications
Coolant Mixtures
Cleaning the Machine
Related Topics
Introduction
Detergents
Pressure Washing and Steam Cleaning
Preparing the Machine for Cleaning
Cleaning the Machine
Inspection
Checking for Damage
Check the Machine Body and Structure
Check the Tyres
Check the Seat and Seat Belt
Check the Hydraulic Hoses and Fittings
Seat Belts
Checking the Seat Belt Condition and Security
Check the Seat and Seat Belt
ROPS/FOPS (and OECD) Structure
Checking the ROPS/FOPS (and OECD) Structure
Greasing
Related Topics
Greasing
Preparing the Machine for Greasing
Every 50 Hours
Every 500 Hours
Every 1000 Hours
Oiling
Park Brake Cable
Control Levers
Heater and Air Conditioning
Related Topics
Changing the Air Intake Filter
Brakes
Related Topics
Checking the Foot Brake Fluid Level
Electrical System
Related Topics
Battery
Battery Disconnection/Connection
Checking the Electrolyte Level
Battery Isolator
Jump Starting the Engine
Fuses and Relays
Fuses
Link Box Fuses
Relays
Engine
Related Topics
Checking the Oil Level
Changing the Oil and Filter
Checking the Coolant Level
Changing the Coolant
Crankcase Ventilation (SE Engine)
Front End Accessory Drive Belt
Introduction
Inspecting the Drive Belt
Changing the Drive Belt
Engine Air Filter
Related Topics
Cleaning the Air Filter Dust Valve
Changing the Elements
Fuel System
Related Topics
Fuel
Filling the Tank
Water Separator and Engine Fuel Filter
Introduction
Draining the Water Separator and Engine Fuel Filter
Changing the Water Separator Pre-Filter
Changing the Engine Fuel Filter Element
Cleaning Water Separator Pump (if fitted)
Bleeding the System
Machines with SA,SB,SC,SD and SF Engines
Machines with SE Engine
Hydraulic System
Related Topics
Oil and Filters
Checking the Hydraulic Fluid Level
Changing the Filter Element
Hose Burst Protection Valves
Testing
Transmission
Related Topics
Gearbox
Checking the Oil Level
Changing the Oil and Filter
Front and Rear Axle
Checking the Axle Oil Level
Changing the Axle Oil
Oil Immersed Brakes
Hub Oil
Checking the Front Axle Breather
Tyres and Wheels
Tyre Inflation
Checking the Wheel Nut Torques
Wheel Nut Torque Indicators (if fitted)
Wheel Alignment
Introduction
Manual Steer Mode Selector
Electronic Steer Mode Selector
Wear Pads
Related Topics
Wear Pads
Boom Wear Pad Clearance
Windscreen Washer
Related Topics
Checking the Level
Access Panels
Related Topics
Battery Cover
Opening and Closing
Engine Cover
Opening and Closing
Undershield
Removal and Replacement
Fire Extinguisher (if fitted)
Checking the Fire Extinguisher

Section B – Body and Framework
Body and Framework
Applications
Table
Fork Carriage
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Cab Heating and Ventilation SYSTEM
Introduction
Related Topics
Operation Overview
Electrical Operation and Schematics
Electrical Connectors
Fault Finding
Tables
Cab Air Conditioning SYSTEM
Introduction
Related Topics
Specifications
R134a Refrigerant
PAG Type Refrigerant Oil
Operation Overview
Component Location
System Operation
System Control
Electrical Operation and Schematics
Electrical Connectors
Safety Procedures
Service Checks
Off-Season Operation
Fault Finding
Introduction
Tables
System Diagnosis using Test Gauges
Test Procedures
Leak Testing
Tightening Leaking Hoses
Binary Switch
Refrigerant
Refrigerant Charging and Discharging
Compressor Drive Belt – Adjustment
Load Moment Indicator (LMI) SYSTEM
Introduction
Related Topics
Operation Overview
Electrical Operation and Schematics
Electrical Connectors
Fault Finding
Fault Codes
General Fault Finding
Diagnostic Tests
Calibration
Calibration Charts
Cab
Introduction
Related Topics
Removal and Replacement
Roller Blind
Roof Liner
Instrument Panels
Door Handle Removal and Replacement
Door Removal and Replacement
Roof Guard
Wiper Motor Front
Wiper Motor Rear
Wiper Motor Roof
Cab
Air Conditioning Condenser – Cooling Pack Mounted
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Air Conditioning Condenser – Roof Mounted
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Cab HV and HVAC Unit
Introduction
Related Topics
Freeze Thermostat (HVAC Unit)
Removal
Replacement
Removal and Replacement
Removal
Replacement
Air Conditioning Binary Switch
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Heater Valve
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Fuel Tank
Introduction
Related Topics
Specifications
Removal and Replacement
Fuel Tank
Fuel Level Sender – P1
Fuel Level Sender – P2
Chassis Panels
Introduction
Related Topics
Removal and Replacement
Engine Cover
Mudguard Assembly
Boom
Introduction
Related Topics
Operation Overview
3 Stage Boom – Telescopic operation
Parallel Lift
Wear Pads and Shims
Wear Pad Clearance – 3 Stage Boom (P1)
Wear Pad Clearance – 3 Stage Boom (P2)
Wear Pad Clearance – 4 Stage Boom
Typical Method
Carriage Adjustment – (Non Sway Machines)
Angle Indicator Removal and Replacement
Removal
Replacement
Pivot Shims
Boom Rear Cover
Removal and Replacement
Boom Removal and Replacement
Removal
Replacement
Dismantling and Assembly
3 Stage Boom
4 Stage Boom
LMI Axle Transducer
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Stabilisers
Introduction
Related Topics
Leg Removal and Replacement
Removal
Replacement
Checking Pressure Switch Operation

Section C – Electrics
Electrics
Applications
Table
Fuses and Relays
Introduction
Access and Location
Fuses – SD, SE, SF Engines 3 Stage Boom (S1)
Fuses – SD, SE, SF Engines 3 Stage Boom (S2)
Fuses – SD, SE, SF Engines 4 Stage Boom
Link Box Fuses – SD, SF Engines
Link Box Fuses – SE Engines
Relays – SD, SE, SF Engines 3 Stage Boom (S1)
Relays – SD, SE, SF Engines 3 Stage Boom (S2)
Relays – SD, SE, SF Engines 4 Stage Boom
Schematics
Introduction
SD and SF Engines (S1)
Component Keys
SD and SF Engines (S2)
Component Keys
SA, SB, SD and SF Engines (S3)
Sheets
Component Keys
SE Engines (S1)
Component Keys
SE Engines (S2)
Component Keys
SE Engines (S3)
Sheets
Component Keys
Electrical Harness SYSTEM
Introduction
Related Topics
Earth Points
Wire Numbers and Functions
Wires 000-199
Wires 200-399
Wires 400-599
Wires 600-799
Wires 800-999
Wires In Splices
General Points
Harness Interconnections and Drawings
Interconnections
Harness Identification
Drawings
Test Procedures
How to Use a Multimeter
Measuring DC Voltage
Measuring Resistance
Measuring Continuity
Measuring Frequency
Testing a Diode or a Diode Wire
Wiring Harness Repair
Introduction
Repair Procedure
Battery Charging SYSTEM
Introduction
Related Topics
Specifications
Operation Overview
Electrical Operation and Schematics
Electrical Connectors
Test Procedures
Charging Circuit Test
Alternator Charging Test
Alternator
Introduction
Related Topics
Specifications
Electrical Operation and Schematics
Removal, Inspection and Replacement
Removal
Inspection
Replacement
Dismantle and Assemble
Renewing the Voltage Regulator and Brushes
Renewing the Drive Pulley
Battery
Introduction
Related Topics
Specifications
Maintenance
Test Procedures
Battery Load Testing
Specific Gravity Testing
Disconnection and Connection
Removal and Replacement
Removal
Replacement

Section E – Hydraulics
Hydraulics
Applications
Table
Systems and Schematics
Introduction
Systems
Schematics – Machines with Dual Lever Controls
Schematics – Machines with Servo Controls (S1)
Schematics – Machines with Servo Controls (S2)
Parallel Hydraulic SYSTEM
Introduction
Related Topics
Specifications
6 Spool Valve Block (S1)
6 Spool Valve Block (S2)
Hydraulic Pump
Cooling Fan Motor
Operation Overview
Component Location and Identification
Oil Pump
Control Valve Block
Main Relief Valve (MRV) Operation
Auxiliary Relief Valve (ARV) Operation
Hydraulic Operation and Schematics
No Services Operated
Service Operation
Main System Pressure Relief
6 Spool Control Valve with Unloader Section
Parallel Lift
Boom Regenerative Valve (if fitted)
Fault Finding
Tables
Test Procedures
Checking Pump Flow
Testing Main Relief Valve (MRV)
Testing ARV’s Set Lower than the MRV
Testing ARV’s Set Higher than the MRV (P1)
Testing ARV’s Set Higher than the MRV (P2)
Relief Valve Adjustment
Measuring Spool Displacement (Manual Spools)
Bleed Procedures
3-Stage Boom Extension Ram Circuit
Tilt Ram Circuit
Sway Ram Circuit
Parallel Servo Hydraulic SYSTEM
Introduction
Related Topics
Specifications
Control Valve Block (S1)
Control Valve Block (S2)
2 Spool Valve Block
Hydraulic Pump
Cooling Fan Motor
Operation Overview
Component Location and Identification
Oil Pump
Control Valve Block
Main Relief Valve (MRV) Operation
Auxiliary Relief Valve (ARV) Operation
Hydraulic Operation and Schematics
No Services Operated
Service Operation
Main System Pressure Relief
Main Control Valve with Unloader Section (S1)
Main Control Valve with Unloader Section (S2)
2 Spool Remote Control Valve
Parallel Lift
Boom Regenerative Valve
Twin Axis Control Valve
Single Axis Control Valve
Fault Finding
Tables
Test Procedures
Checking Pump Flow
Testing Main Relief Valve (MRV)
Testing ARV’s Set Lower than the MRV
Testing ARV’s Set Higher than the MRV
Relief Valve Adjustment
Measuring Spool Displacement (Manual Spools)
Bleed Procedures
4-Stage Boom Extension Ram Circuit
Tilt Ram Circuit
Sway Ram Circuit
Hydraulic Interlock SYSTEM
Introduction
Related Topics
Component Location
Operation Overview
Joystick Isolator Switch
Boom and Fork Isolator Solenoid
Fork Isolator Solenoid
Stabiliser Pressure Switches
Stabiliser Warning Lights
Boom Lift Unloader Solenoid
Boom Angle Proximity Switches
Final Boom Extension Switch
Extension Ram Diverter Solenoid
Stabiliser Unloader Solenoid and Isolation Switch
Stabiliser Lift isolation Solenoid
Stabiliser Lift isolation Switch
Boost Isolation Solenoid
Boost Isolator Switch
Interlock Characteristics
Electrical Operation and Schematics
Stabiliser Isolation Interlock
Electrical Connectors
Parallel Control Valve – 6 Section
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Dismantle and Assemble
Tie Rods
Valve Block Sections
Servo Pilot Pressure Reducing Valve (if fitted)
Parallel Control Valve – 5 Section
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Dismantle and Assemble
Tie Rods
Valve Block Sections
Servo Pilot Pressure Reducing Valve
Parallel Control Valve – 2 Section
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Dismantle and Assemble
Tie Rods
Dismantle
Assemble
Servo Control Valves
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Servo Solenoid Diverter Valve Block
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Dismantle and Assemble
Dismantle
Assemble
Stabiliser Isolation Valve
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Sway/Fan Selector Valve
Introduction
Related Topics
Component Location and Identification
Hydraulic Operation and Schematics
Sway operation
Electrical Operation and Schematics
Electrical Connectors
Removal and Replacement (P1)
Removal
Replacement
Removal and Replacement (P2)
Removal
Replacement
Dismantle and Assemble
Dismantle
Assemble
Main Pump
Introduction
Related Topics
Operation Overview
Hydraulic Operation and Schematics
Removal and Replacement
Removal
Replacement
Dismantle, Inspection and Assemble
Dismantle
Inspection
Assemble
Steering Priority Valve
Removal and Replacement
Dismantle, Inspection and Assemble
Cooling Fan Motor
Introduction
Related Topics
Specifications
Operation Overview
Hydraulic Operation and Schematics
Removal and Replacement
Removal
Replacement
Dismantle, Inspection and Assemble
Dismantle
Inspection
Assemble
Extension Ram
Introduction
Related Topics
Removal and Replacement – 3 Stage Boom Outer Ram
Removal
Replacement
Removal and Replacement – 4 Stage Boom Outer Ram
Removal
Replacement
Removal and Replacement – Inner Ram
Removal
Replacement
Lift Rams
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Tilt Ram
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Displacement Ram
Introduction
Related Topics
Removal and Replacement
Single Displacement Ram
Twin Displacement Rams
Sway Ram
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Stabiliser Rams
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Checking Pressure Switch Operation
Ram Maintenance
Introduction
Related Topics
Single Piston Rams
Dismantle
Assemble
JCB Ram Sealing Procedure
Piston Head Retention
Existing piston head and rod
New piston head and rod
Existing piston head and new rod
New piston head and existing rod
Drilling Dimensions
Twin Piston, 4 Stage Boom Outer Ram
Introduction
Supporting The Ram
Dismantling
Inspection
Assembly
Extension Ram Make-Up Valve (if fitted)
Removal and Replacement

Section F – Transmission
Transmission
Applications
Table
CONFIGURATION
Introduction
Operation Overview
Wheels and Tyres
Introduction
Related Topics
Specifications
Removal and Replacement
Front Wheels
Rear Wheels
Wheel Studs
Front Axles
Introduction
Related Topics
Specifications
Component Identification
Renewing the Pinion Oil Seal
Removal and Replacement – SD80 Fixed Axle
Removal
Replacement
Removal and Replacement – SD80 Pivot Sway Axle
Removal
Replacement
Removal and Replacement – SD80 Trunnion Sway Axle
Removal
Replacement
Dismantle, Inspection and Assembly
Rear Axles
Introduction
Related Topics
Specifications
Component Identification – 1 Piece Axle
Component Identification – 3 Piece Axle
Renewing the Pinion Oil Seal
Removal and Replacement – SD80 Pivot Axle
Removal
Replacement
Removal and Replacement – SD80 Trunnion Axle
Removal
Replacement
Dismantle, Inspection and Assembly
PS750 Gearbox SYSTEM
Introduction
Related Topics
Specifications
Component Identification
Operation Overview
Start Up
Drive Select
‘Manual’ Gear Select
Park Brake ON
Transmission Dump
2/4 Wheel Drive Select
Hydraulic Operation and Schematics
Electrical Operation and Schematics
Introduction
Forward Gears
Reverse Gears
Neutral
Transmission Dump
Park Brake ON
Electrical Connectors
Drive Paths
Forward
Reverse
Fault Finding
Introduction
Transmission Technical Data Check List
Fault Finding Tables
Test Procedures
Torque Converter Stall Test
Pressure and Flow Tests
Flushing the Transmission Oil
PS750 Mk IV Gearbox SYSTEM
Introduction
Related Topics
Specifications
Component Identification
Operation Overview
Start Up
Drive Select
‘Manual’ Gear Select
Park Brake ON
Transmission Dump
2/4 Wheel Drive Select
Hydraulic Operation and Schematics
Electrical Operation and Schematics
Introduction
Forward Gears
Reverse Gears
Neutral
Transmission Dump
Park Brake ON
Electrical Connectors
Drive Paths
Forward
Reverse
Fault Finding
Introduction
Transmission Technical Data Check List
Fault Finding Tables
Test Procedures
Torque Converter Stall Test
Pressure and Flow Tests
Flushing the Transmission Oil
PS764 Gearbox SYSTEM
Introduction
Related Topics
Specifications
Component Identification
Operation Overview
Start Up
Drive Select
‘Manual’ Gear Select
Park Brake ON
Transmission Dump
2/4 Wheel Drive Select
Hydraulic Operation and Schematics
Electrical Operation and Schematics
Overview
Forward Gears
Reverse Gears
Neutral
Transmission Dump, Park Brake ON
Electrical Connectors
Drive Paths
Forward
Reverse
Fault Finding
Introduction
Transmission Technical Data Check List
Tables
Test Procedures
Torque Converter Stall Test
Pressure and Flow Tests
Flushing the Transmission Oil
PS750 Gearbox
Introduction
Related Topics
Specifications
Component Identification
Operation Overview
Forward and Reverser Clutch Operation
Mainshaft and Layshaft Clutch Operation
Removal and Replacement
Dismantle, Inspection and Assembly
PS750 Mk IV Gearbox
Introduction
Related Topics
Specifications
Component Identification
Operation Overview
Forward and Reverser Clutch Operation
Mainshaft and Layshaft Clutch Operation
2 and 4 Wheel Drive Clutch (4WD Spring ON) Operation
4 Wheel Drive Operation
2 Wheel Drive Operation
2 and 4 Wheel Drive Clutch (4WD Pressure ON) Operation
4 Wheel Drive Operation
2 Wheel Drive Operation
Oil Pressure Switch – Removal and Replacement
Removal
Replacement
Solenoid Control Valves – Removal and Replacement
Gearbox Clutch Control Solenoid Valves
2/4WD Clutch Control Solenoid Valve
4 Wheel Drive Yoke and Oil Seal – Removal and Replacement
Removal
Replacement
Removal and Replacement
Dismantle, Inspection and Assembly
PS760 Gearbox
Introduction
Related Topics
Specifications
Component identification
Operation Overview
Forward and Reverser Clutch Operation
Mainshaft and Layshaft Clutch Operation
2 and 4 Wheel Drive Clutch (4WD Pressure ON) Operation
2 and 4 Wheel Drive Clutch (4WD Spring ON) Operation
Solenoid Control Valve Cartridge – Solenoid Coil
Removal and Replacement
Solenoid Control Valve Cartridge – Single Fixing Type
Removal and Replacement
Solenoid Control Valve Cartridge – Twin Fixing Type
Removal
Replacement
Oil Pressure Switch
Removal and Replacement
Oil Temperature Switch
Removal and Replacement
Removal and Replacement
Dismantle, Inspection and Assembly
Bevel Gearbox
Introduction
Related Topics
Removal and Replacement
Dismantle, Inspection and Assembly
Torque Converter
Introduction
Related Topics
Specifications
Component Identification
Operation Overview
Removal and Replacement
Transmission Oil Cooler – Air Blast
Introduction
Related Topics
Removal and Replacement
Transmission Oil Cooler – Liquid to Liquid
Introduction
Related Topics
Removal, Testing and Replacement
Propshafts
Introduction
Related Topics
Removal and Replacement
Torque Settings
Speed Sensors
Introduction
Related Topics
Gearbox Speed Sensor
Testing
Removal and Replacement
Removal
Replacement
Speedometer
Introduction
Related Topics
Calibration Procedure

Section G – Brakes
Brakes
Applications
Table
Twin Axle Service Brakes SYSTEM (S1)
Introduction
Related Topics
Specifications
Operation Overview
Hydraulic Operation and Schematics
Fault Finding
Test Procedures
Brake Vacuum Test
Brake Piston Seal Leakage
Axle Breather (Braked Axles) – Inspection
Bleeding
Dismantling and Assembly
Brake Light Switch (Proximity Type)
Adjustment
Brake Light Switch (Reed Type)
Operation
Twin Axle Service Brakes SYSTEM (S2)
Introduction
Related Topics
Specifications
Operation Overview
Hydraulic Operation and Schematics
Fault Finding
Test Procedures
Brake Vacuum Test
Brake Piston Seal Leakage
Axle Breather (Braked Axles) – Inspection
Bleeding
Dismantling and Assembly
Front Axle Brakes
Rear Hub Brakes
Brake Light Switch (Proximity Type)
Adjustment
Brake Light Switch (Reed Type)
Operation
External Park Brake SYSTEM
Introduction
Related Topics
Specifications
Operation Overview
Test Procedures
Adjustment
Lever Adjustment
Cable Adjustment
Switch Adjustment
Renewing the Brake Pads
Pad Removal
Pad Inspection
Pad Replacement
Renewing the Park Brake Cable
Removal
Replacement
Internal Park Brake SYSTEM
Introduction
Related Topics
Specifications
Operation Overview
Test Procedures
Adjustment
Lever Adjustment
Switch Adjustment
Renewing the Park Brake Cable
Removal
Replacement
Dismantle, Inspection and Assemble
Dismantle the Multi-Plate Brake Pack
Dismantle the Brake Actuator
Inspection
Assemble the Brake Actuator
Assemble the Multi-Plate Brake Pack
Park Brake Calliper
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Torque Figures
Dismantle, Inspection and Assemble
Dismantle
Inspection
Assemble
Park Brake Disc
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Park Brake Switch
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Servo Exhauster Unit
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Servo Unit, Twin Axle Brakes
Introduction
Related Topics
Removal and Replacement (P1)
Removal
Replacement
Removal and Replacement (P2)
Removal
Replacement
Master Cylinder
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Fluid Reservoir
Introduction
Related Topics
Removal and Replacement
Removal
Replacement

Section H – Steering
Steering
Applications
Table
Steering SYSTEM
Introduction
Related Topics
Specifications
Steering Pump
Hydraulic Steering Unit
Priority Valve
Operation Overview
Hydraulic Operation and Schematics
Machines with Steer Rams
Machines with Power Track Rods
Priority Valve Operation
Fault Finding
Fault Finding Tables
Diagnostic `Blink’ Codes
Test Procedures
Checking for Internal Hydraulic Leakage – Machines with Power Track Rods
Hydraulic Pressure Tests
Steer Priority Valve – Cleaning
Auto Steer Mode Valve – Checking Solenoid Operation
Re-phasing the Road Wheels
Machines with Solenoid Operated Auto Steer Mode Valve
Machines with Manual Steer Mode Valve
Bleeding the System
Machines with Solenoid Operated Auto Steer Mode Valve
Machines with Manual Steer Mode Valve
Proximity Switch – Setting
Manual Steer Mode SYSTEM
Introduction
Related Topics
Operation Overview
Hydraulic Operation and Schematics
Auto Steer Mode SYSTEM
Introduction
Related Topics
Component Location
Operation Overview
Hydraulic Operation and Schematics (S1)
Operation – 2-Wheel Steer Selected
Operation – 4-Wheel Steer Selected
Operation – Crab Steer Selected
Schematics
Hydraulic Operation and Schematics (S2)
Operation – 2-Wheel Steer Selected
Operation – 4-Wheel Steer Selected
Operation – Crab Steer Selected
Schematics
Electrical Operation and Schematics
2 Wheel Steer Selected
4 Wheel Steer Selected
Crab Steer Selected
Electrical Connectors
Hydraulic Steering Unit
Introduction
Related Topics
Hydraulic Operation and Schematics
Removal and Replacement
Removal
Replacement
Priority Valve
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Power Track Rod
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Link Arms
Dismantle and Assemble
Rams
Steer Rams
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Dismantle and Assemble
Steering Column
Introduction
Related Topics
Removal and Replacement
Steering Wheel
Steering Column Switches
Steering Column
Manual Steer Mode Valve
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Dismantle and Assemble
Dismantle
Assemble
Auto Steer Mode Valve
Introduction
Related Topics
Removal and Replacement
Machines with Power Track Rods
Machines with Steer Rams
Dismantle and Assemble
Dismantle
Assemble

Section K – Engine
Engine
Applications
Table
Start and Stop SYSTEM (Mechanical F.I. Engines)
Introduction
Related Topics
Operation Overview
Electrical Operation and Schematics
Electrical Connectors
Stop and Start SYSTEM (Electronic F.I. Engines)
Introduction
Related Topics
Electrical Operation and Schematics
Machine Electrical Interface
Engine ECU Power-Up
Cold Start Heater
Fuel Lift Pump
Throttle Position Sensor
Electrical Connectors
Fault Finding
Electronic Fault Codes
Cold Start Heater SYSTEM
Introduction
Related Topics
Operation Overview
Electrical Operation and Schematics
Electrical Connectors
Fault Finding
Diagnostic `Blink’ Codes
Starter Motor
Introduction
Related Topics
Removal, Inspection and Replacement
Removal
Inspection
Replacement
Renewing the Brush Gear
Renewing the Starter Solenoid
Cooling Pack (Non Intercooled)
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Dismantle and Assemble
Cooling Pack (Intercooled Mechanical F.I. Engines)
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Dismantle and Assemble
Cooling Pack (Electronic F.I. Engines)
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Dismantle and Assemble
Coolant Expansion Tank
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Coolant Level Sensor
Air Filter Vacuum Switch
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Throttle Pedal and Cable
Introduction
Related Topics
Removal and Replacement
Throttle Pedal Assembly
Throttle Cable
Throttle Pedal Switch
Throttle Position Sensor (TPS)
Introduction
Related Topics
Operation Overview
Removal and Replacement
Throttle Pedal Assembly
Throttle Position Sensor (TPS)
Throttle Pedal Stop Adjustment
Exhaust Silencer
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
JCB Dieselmax (Mechanical F.I. Engines)
Introduction
Related Topics
Specifications
Removal and Replacement
Removal
Replacement
Separating the Engine and Bevel Box
Dismantling
Assembly
JCB Dieselmax (Electronic F.I. Engines)
Introduction
Related Topics
Specifications
Removal and Replacement
Introduction
Removal
Replacement
Separating the Engine and Bevel Box
Dismantling
Assembly

Section M – Electronic Data Systems
Electronic Data Systems
Applications
Table
CANbus SYSTEM
Introduction
Related Topics
Operation Overview
CANbus Communications System
Electrical Operation and Schematics
Loadall Monitoring SYSTEM
Introduction
Related Topics
Operation Overview
Machines with Electronic F.I. Engines
Fault Code Display
Electrical Operation and Schematics
Electrical Schematics
Electrical Connectors
Service Hours Reset
Introduction
Using the Machine LCD Display
Using JCB Servicemaster 2
Fault Code SYSTEM
Introduction
Related Topics
Operation Overview
CAN Enabled Display
Malfunction Indicator Light (MIL)
Blink Codes
CANbus Connected Computer
Fault Code Log
Loadall Monitoring System ECU Fault Codes
General “D” Codes
Electronic F.I. Engine ECU Fault Codes
Servicemaster SYSTEM
Introduction
Related Topics
Why Use Servicemaster?
Introduction
Fault Finding
Identify Poor Maintenance
Access Machine Set Up Data
Re-Programming ECUs
Summary
What is Servicemaster?
Introduction
CANbus Communications System
Servicemaster Structure
How to Set Up Servicemaster
Install Servicemaster
Start Servicemaster
Load the DLA Laptop Driver Software
Configure the DLA Type and Communications Port
Check the DLA Firmware File
Connect Servicemaster to the Machine CANbus
Servicemaster Tools
Introduction
Related Topics
Summary
JCB 4.4L Tier 3 SE Diagnostics Tool – User Guide
Introduction
Care and Safety
Connecting 4.4L Tier 3 Diagnostics
Starting 4.4L Tier 3 Diagnostics
4.4L Tier 3 Diagnostics Overview
Navigating within Diagnostics
Menu Bar – File Menu
Menu Bar – Options Menu
Menu Bar – Window Menu
Menu Bar – Help Menu
Start and Stop Buttons
Page List
Status bar
LED Status Key
Engine Connector Page
Machine Connector Page
Actuator Tests Page
Fault Codes Page
Loadall LMS Setup – User Guide
Introduction
Care and Safety
Installing
Connection
Starting Loadall LMS Setup
Navigating within Loadall LMS Setup
Menu Bar – File Menu
Menu Bar – Utilities Menu
Menu Bar – Help Menu
Build Options
Powertrain Options
Write
Read
Connection Problems
Electronic Control Unit Theory
Introduction
Related Topics
Operation Overview
ECU Inputs
ECU Outputs
Pulse Width Modulation Theory
Introduction
Related Topics
Operation Overview

 

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JCB 535, 540, 550 Side Engine Loadalls Service Manual – 9803/3750-05.pdf

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