JCB Side Engine Loadalls 540-170, 550-140, 540-140, 550-170, 535-125 Hi Viz, 535-140 Hi Viz PDF

This service manual is intended for service, current repair, routine maintenance and overhauls JCB Side Engine Loadalls 540-170, 550-140, 540-140, 550-170, 535-125 Hi-Viz, 535-140 Hi-Viz.

The service repair manual is compiled into sections and subsections. These sections are numbered and contain general service information, maintenance instruction, torque settings, and service tools. Also, these sections cover care and safety instructions, technical data, cautions and general procedures related to aspects of workshop procedures contained in the manual. 

The remaining sections are alphabetically coded and deal with dismantling, overhaul, etc. of specific components.

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 pdf service manual is an electronic PDF handbook that does not require any installation (INSTANT DOWNLOAD). For your convenience, you can print this manual and use it as a book. Before purchasing the PDF manual you can also preview it. To do this, you need to click on the link under the pdf instruction title 'JCB pdf manual instant preview'.

Publication No. 9803/3750-07

Models covered:
540-140,
540-170,
550-140,
550-170,
535-125 Hi Viz,
535-140 Hi Viz.

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
  • Introduction
  • Service Schedules - Machines with SD and SF Engines
  • Service Schedules - Machines with SE Engines
  • Fluids, Lubricants and Capacities
  • Cleaning the Machine
  • 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 (if fitted)
• Section B - Body and Framework
  • Applications
  • Fork Carriage
  • Cab Heating and Ventilation SYSTEM
  • Cab Air Conditioning SYSTEM
  • Load Moment Indicator (LMI) SYSTEM
  • Cab
  • Air Conditioning Condenser - Cooling Pack Mounted
  • Air Conditioning Condenser - Roof-Mounted
  • Cab HV and HVAC Unit
  • Air Conditioning Binary Switch
  • Heater Valve
  • Fuel Tank
  • Chassis Panels
  • Boom
  • LMI Axle Transducer
  • Stabilisers
  • Longitudinal Load Moment Indicator Unit
• Section C - Electrics
  • Applications
  • Fuses and Relays
  • Schematics
  • Electrical Harness SYSTEM
  • Battery Charging SYSTEM
  • Alternator
  • Battery
• Section E - Hydraulics
  • Applications
  • Systems and Schematics
  • Parallel Hydraulic SYSTEM
  • Parallel Servo Hydraulic SYSTEM
  • Hydraulic Interlock SYSTEM
  • Parallel Control Valve - 6 Section
  • Parallel Control Valve - 5 Section
  • Parallel Control Valve - 2 Section
  • Servo Control Valves
  • Servo Solenoid Diverter Valve Block
  • Stabiliser Isolation Valve
  • Sway/Fan Selector Valve
  • Main Pump
  • Cooling Fan Motor
  • Extension Ram
  • Lift Rams
  • Tilt Ram
  • Displacement Ram
  • Sway Ram
  • Stabiliser Rams
  • Ram Maintenance
• Section F - Transmission
  • Applications
  • CONFIGURATION
  • Wheels and Tyres
  • Front Axles
  • Rear Axles
  • PS750 Gearbox SYSTEM
  • PS750 Mk IV Gearbox SYSTEM
  • PS764 Gearbox SYSTEM
  • PS750 Gearbox
  • PS750 Mk IV Gearbox
  • PS760 Gearbox
  • Bevel Gearbox
  • Torque Converter
  • Transmission Oil Cooler - Air Blast
  • Transmission Oil Cooler - Liquid to Liquid
  • Propshafts
  • Transmission Speed Sensor
  • Engine Speed Sensor
  • Speedometer
• Section H - Steering
  • Applications
  • Steering SYSTEM
  • Manual Steer Mode SYSTEM
  • Auto Steer Mode SYSTEM
  • Hydraulic Steering Unit
  • Priority Valve
  • Power Track Rod
  • Steer Rams
  • Steering Column
  • Manual Steer Mode Valve
  • Auto Steer Mode Valve
• Section K - Engine
  • Applications
  • Start and Stop SYSTEM (Mechanical F.I. Engines)
  • Stop and Start SYSTEM (Electronic F.I. Engines)
  • Cold Start Heater SYSTEM
  • Starter Motor
  • Cooling Pack (Non Intercooled)
  • Cooling Pack (Intercooled Mechanical F.I. Engines)
  • Cooling Pack (Electronic F.I. Engines)
  • Coolant Expansion Tank
  • Air Filter Vacuum Switch
  • Throttle Pedal and Cable
  • Throttle Position Sensor (TPS)
  • Exhaust Silencer
  • JCB Dieselmax (Mechanical F.I. Engines)
  • JCB Dieselmax (Electronic F.I. Engines)
• Section M - Electronic Network
  • Applications
  • CANbus SYSTEM
  • Loadall Monitoring SYSTEM
  • Fault Code SYSTEM
  • Servicemaster SYSTEM
  • Servicemaster Tools
  • Electronic Control Unit Theory
  • Pulse Width Modulation Theory