JCB Side Engine Loadalls 535, 540 Series Service Manual PDF

This guide describes everything you need to know about start-up, use, maintenance, and repair JCB Side Engine Loadalls of the specified models. Your JCB Side Engine Loadalls have been designed and built to give maximum performance, economy, and ease of use under a wide variety of operating conditions. This manual is intended for serve, repair, overhauls and maintains JCB Side Engine Loadalls 535-125, 535-140, 540-170, 540-140, 540-200.

Publication No. 9813/0950-5

Models covered:
540-170 from 1522578 to TBA
540-140 TBA
535-125 Hi-Viz from 1522579 to TBA
535-140 Hi-Viz from 1522591 to TBA
540-200 TBA
Note: This manual is applicable to EN15000 compliant machines only.

Contents:

• Section 1 - General Information
  • Applications
  • Use
  • Machine Identification
  • Torque Settings
  • Service Tools
  • Service Consumables
  • Fuel
  • Stall Speed Combinations
• Section 2 - Care and Safety
  • Safety Notices
  • General Procedures
• Section 3 - Routine Maintenance
  • Applications
  • Routine Maintenance (P1)
• Section B - Body and Framework
  • Applications
  • Fork Carriage
  • Cab Heating and Ventilation SYSTEM
  • Cab Air Conditioning SYSTEM
  • Longitudinal Load Moment SYSTEM (B-19-10)
  • Longitudinal Load Moment SYSTEM (B-19-11)
  • Longitudinal Load Moment SYSTEM (B-19-15)
  • 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
  • Engine Cover
  • Valve Block Covers
  • Mudguards
  • Chaff Guards
  • Deckplate
  • Boom
  • Boom - 5 Stage
  • LLMI Axle Transducer (B-18-05)
  • LLMI Axle Transducer (B-18-06)
  • Stabilisers
  • Longitudinal Load Moment Indicator Unit
  • Longitudinal Load Moment Control Sensors
  • Cab Side Cover
• Section C - Electrics
  • Applications
  • Fuses and Relays
  • Schematics
  • Electrical Harness SYSTEM
  • Battery Charging SYSTEM
  • Alternator (C-04-01)
  • Alternator (C-04-02)
  • Battery
• Section E - Hydraulics
  • Applications
  • Systems and Schematics
  • Parallel Hydraulic SYSTEM
  • Parallel Servo Hydraulic SYSTEM
  • LSP Electro Servo Hydraulic SYSTEM
  • Hydraulic Interlock SYSTEM
  • Auxiliary Relief Valve (ARV) Operation
  • Main Relief Valve (MRV)/Load Sense Relief Valve (LSRV) Operation
  • Pressure Compensator Operation
  • Parallel Lift Operation (E-60-05)
  • Parallel Circuit Operation (E-60-01)
  • Parallel Servo Circuit Operation (E-60-10)
  • LSP Circuit Operation
  • Boom Pressure Balance SYSTEM
  • Universal Hydraulic Circuit Faults
  • Parallel Circuit Faults
  • Parallel Servo Circuit Faults
  • LSP Electro Servo Circuit Faults
  • Parallel SYSTEM Pressure Tests (E-61-05)
  • Pump Flow Tests - Gearpump (E-61-03)
  • Parallel Servo SYSTEM Pressure Tests (E-61-06)
  • LSP SYSTEM Pressure Tests
  • Parallel Control Valve - 6 Section
  • Parallel Control Valve - 5 Section
  • Parallel Control Valve - 2 Section
  • Electro Servo Control Valve
  • Servo Solenoid Diverter Valve Block
  • Gear pump Operation
  • Gear pump Removal and Replacement
  • Hydraulic Cooling Fan Motor - Fixed Speed
  • Servo Control Valves
  • Electro Servo Control Lever
  • Electrical Stabiliser Control Levers
  • Stabiliser Isolation Valve
  • Stabiliser Ram
  • Sway Ram
  • Displacement Ram
  • Tilt Ram
  • Lift Rams
  • Extension Ram
  • Ram Maintenance
  • Sway/Fan Selector Valve
  • Hydraulic Oil Cooler By-Pass SYSTEM
  • Hydraulic Oil Cooler By-Pass Valve
  • Sway Circuit - Bleed Procedure
  • Tilt Circuit - Bleed Procedure
  • 3 Stage Boom - Extend Circuit - Bleed Procedure
  • 4 Stage Boom - Extend Circuit - Bleed Procedure
• Section F - Transmission
  • Applications
  • CONFIGURATION
  • Introduction 
  • Wheels and Tyres
  • Front Axles
  • Rear Axles
  • PS750 Mk IV Gearbox SYSTEM
  • PS764 Gearbox SYSTEM
  • PS750 Mk IV Hydraulic Operation
  • PS760 Gearbox Hydraulic Operation
  • PS750 Mk IV Gearbox - Hydraulic Testing
  • PS760 Gearbox - Hydraulic Testing
  • Torque Converter Stall Tests
  • Flushing the Transmission Oil
  • PS750 Mk IV Gearbox
  • PS760 Gearbox
  • Torque Converter Operation
  • Torque Converter
  • Bevel Gearbox
  • Transmission Oil Cooler - Air Blast
  • Transmission Oil Cooler - Liquid to Liquid
  • Propshafts (F-10-06)
  • Transmission Speed Sensor (S1)
  • Speed Sensors (S2)
  • Engine Speed Sensor
• Section G - Brakes
  • Applications
  • Twin Axle Service Brakes SYSTEM
  • External Park Brake SYSTEM
  • Introduction 
  • Internal Park Brake SYSTEM
  • Park Brake Calliper
  • Park Brake Disc
  • Park Brake Switch
  • Servo Exhauster Unit
  • Servo Unit, Twin Axle Brakes
  • Master Cylinder
  • Fluid Reservoir
• Section H - Steering
  • Applications
  • Steering SYSTEM
  • Manual Steer Mode SYSTEM
  • Auto Steer Mode SYSTEM
  • Hydraulic Steering Unit H-02-07
  • Priority Valve
  • Power Track Rod (H-07-06)
  • Steer Rams
  • Steering Column
  • Manual Steer Mode Valve
  • Auto Steer Mode Valve
  • Steer Proximity Switches
• Section K - Engine
  • Applications
  • Start and Stop SYSTEM (Mechanical F.I. Engines)
  • Start and Stop SYSTEM (Electronic F.I. Engines)
  • Cold Start Heater SYSTEM
  • Starter Motor (K-04-04)
  • Cooling Pack (Non-Intercooled)
  • Cooling Pack (Intercooled Mechanical F.I. Engines)
  • Cooling Pack (Electronic F. I. Engines)
  • Coolant Expansion Tank (K-05-05)
  • Air Filter Vacuum Switch
  • Throttle Pedal and Cable
  • Throttle Position Sensor (TPS) (K-07-10)
  • Throttle Position Sensor (TPS) (K-07-11)
  • Exhaust Silencer (K-06-07)
  • JCB Dieselmax (Mechanical F. I. Engines)
  • JCB Dieselmax (Electronic F. I. Engines)
• Section M - Electronic Data Systems
  • Applications
  • CANbus SYSTEM
  • Loadall Monitoring SYSTEM
  • Fault Code SYSTEM
  • Servicemaster SYSTEM
  • Servicemaster Tool Set (M-04-06)
  • JCB DieselMax (4.4L Tier 3 SE) Diagnostic Tool - User Guide
  • JCB DieselMax (4.4L Tier 3 SE) Engine Setup Tool - User Guide
  • Cluster (LMS) Setup Tool - User Guide
  • Loadall Datalogger Tool - User Guide (M-05-12)
  • Boom Angle Sensor Calibration Tool - User Guide (M-05-14)
  • Immobiliser Diagnostics Tool (M-05-17)
  • Immobiliser Setup Tool (M-05-15)
  • Pulse Width Modulation Theory
  • Electronic Control Unit Theory
  • Livelink ECU
  • Immobiliser ECU
  • Hydraulic Control ECU

To maintain this condition and ensure trouble-free operation it is important that the routine services, as specified in this PDF Service Manual. This comprehensive manual is suitable for professional technicians and novice mechanics alike.

Features of the Manual
Format: PDF
Language: English
Pages: 2187
Compatible with all versions of Windows, Mac, Linux, iPhone, iPad, and Android

This service repair manual is divided into sections and subsections.
The sections contain the general service information, current repair information, care and safety instructions, specific components, technical data, schematic descriptions, descriptions of maintenance, illustrations, electrical diagrams and hydraulic harnesses.

FAQs
How do I download the manual?
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It will help you to read, save, copy, print this manual and use it as a handbook.

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