Your machine has been designed and built to give maximum performance, economy, and ease of use under a wide variety of operating conditions. To maintain this condition and ensure trouble-free operation it is important that the routine services, as specified in this PDF Service Manual.
This service manual gives full details of the service requirements necessary to maintain your JCB machine at peak efficiency.
The service manual contains detailed technical service information on how to repair, dismantle and assemble your machine correctly.
The manual is compiled in sections, that are numbered and contain general repair information, torque settings and service tools, care and safety instructions, cautions and general procedures related to aspects of workshop procedures contained in the manual.
Also, this service repair manual includes a detailed description of routine maintenance procedures, service schedules and recommended lubricants for all the machines.
This service workshop manual comes in PDF format and works with Adobe PDF Reader (or other analogs).
For convenience, you can print the service repair manual and use it as a handbook right in the workshop, or work with it on your computer/laptop.
Publication No. 9813/0900-3
Models covered:
Model Serial Number range
531-70 1522574 to TBA
535-95 1522588 to TBA
536-60 1522577 to TBA
541-70 1522566 to TBA
533-105 1522615 to TBA
536-70 1522577 to TBA
526-56 1448231 to TBA
550-80 1186000 to TBA
531-T70 1522570 to TBA
541-T70 1522566 to TBA
536-T60 1522577 to TBA
535-T95 1522569 to TBA
536-T70 1522577 to TBA
550-T80 1186000 to 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)
- Routine Maintenance (P2)
- Section B - Body and Framework
- Applications
- Fork Carriage
- Cab Heating and Ventilation SYSTEM
- Cab Air Conditioning SYSTEM
- Longitudinal Load Moment SYSTEM (B-19-09)
- Longitudinal Load Moment SYSTEM (B-19-10)
- 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
- Boom
- Hydraulic Tank
- LLMI Axle Transducer (B-18-05)
- Stabilisers
- Longitudinal Load Moment Indicator Unit
- Longitudinal Load Moment Control Sensors
- Clean Air Kit SYSTEM
- 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
- LSP Electro Servo Hydraulic SYSTEM (S1)
- LSP Electro Servo Hydraulic SYSTEM (S2)
- LSP Electro Servo Hydraulic SYSTEM (S3)
- LSP Electro Servo Hydraulic SYSTEM (S4)
- Auxiliary Relief Valve (ARV) Operation
- Main Relief Valve (MRV)/Load Sense Relief Valve (LSRV) Operation
- Pressure Compensator Operation
- Parallel Lift Operation (E-60-05)
- Boom Pressure Balance SYSTEM
- Universal Hydraulic Circuit Faults
- Parallel Circuit Faults
- LSP Electro Servo Circuit Faults
- Parallel SYSTEM Pressure Tests (E-61-05)
- Variflow LSP SYSTEM Pressure Tests (E-61-04)
- LSP SYSTEM Pressure Tests (E-61-07)
- Pump Flow Tests - Gearpump (E-61-03)
- Smooth Ride SYSTEM (SRS) - Parallel/Electro Servo (E-05-12)
- Smooth Ride SYSTEM (SRS) (E-05-09) - Electro Servo
- Variable Hydraulic Cooling Fan Control SYSTEM
- Parallel Control Valve - 4 Section
- Parallel Control Valve - 6 Section
- Electro Servo Control Valve (E-06-34)
- Electro Servo Control Valve (E-06-33)
- Electro Servo Control Valve (E-06-35)
- Pilot Pressure Supply Valve (E-10-17)
- Pilot Pressure Supply Valve (E-10-16)
- Pilot Pressure Supply Valve (E-10-18)
- Gearpump Operation
- Variable Pump Operation
- Gearpump Removal and Replacement
- Variflow Pump Removal and Replacement
- Hydraulic Cooling Fan Motor - Fixed Speed
- Hydraulic Cooling Fan Motor - Variable Speed
- Electro Servo Control Lever
- Parallel Single Lever Control Lever
- Stabiliser Ram
- Sway Ram
- Displacement Ram
- Tilt Ram
- Lift Rams
- Extension Ram
- Ram Maintenance
- Sway/Fan Changeover Valve
- Hydraulic Oil Cooler By-Pass SYSTEM
- Hydraulic Oil Cooler By-Pass Valve
- Internal Hydraulic Tank Filter
- SRS Accumulators
- Ambient Air Temperature Sender
- Sway Circuit - Bleed Procedure
- Tilt Circuit - Bleed Procedure
- 3 Stage Boom - Extend Circuit - Bleed Procedure
- Section F - Transmission
- Applications
- CONFIGURATION
- Wheels and Tyres
- Front Axles (F-03-08)
- Front Axles (F-03-09)
- Rear Axles (F-04-08)
- Rear Axles (F-04-09)
- PS750 Mk IV Gearbox SYSTEM
- PS764 Gearbox SYSTEM (S1)
- PS764 Gearbox SYSTEM (ECU Drive Control)
- PS766 Gearbox SYSTEM (ECU 2.3)
- SS700 Gearbox SYSTEM
- Torque Converter Lock Up SYSTEM
- PS750 Mk IV Hydraulic Operation
- SS700 Gearbox Hydraulic Operation
- PS750 Mk IV Gearbox - Hydraulic Testing
- PS760 Gearbox - Hydraulic Testing
- SS700 Gearbox - Hydraulic Testing
- Torque Converter Stall Tests
- Flushing the Transmission Oil
- Dual Control SYSTEM (S1)
- Dual Control SYSTEM (S2)
- Dual Control SYSTEM (S3)
- ShiftMaster ECU
- PS750 Mk IV Gearbox
- PS760 Gearbox
- SS700 Gearbox
- Bevel Gearbox
- Torque Converter Operation
- Torque Converter
- Transmission Oil Cooler - Liquid to Liquid
- Transmission Oil Cooler - Air Blast
- Propshafts (F-10-06)
- Propshafts (F-10-05)
- Engine Speed Sensor
- Transmission Speed Sensor
- SS700 Cableshift
- Section G - Brakes
- Applications
- Single Axle Service Brakes SYSTEM
- Power Brake SYSTEM
- External Park Brake SYSTEM
- Internal Park Brake SYSTEM
- Park Brake Calliper
- Park Brake Disc
- Park Brake Switch
- Servo Exhauster Unit
- Servo Unit, Single Axle Brakes
- Master Cylinder
- Fluid Reservoir
- Power Brake Valve
- Power Brake Accumulator
- Power Brake Charge Valve
- Section H - Steering
- Applications
- Steering SYSTEM
- Manual Steer Mode SYSTEM
- Auto Steer Mode SYSTEM
- Hydraulic Steering Unit H-02-07
- Hydraulic Steering Unit (H-02-08)
- Priority Valve
- Power Track Rod (H-07-06)
- Power Track Rod (H-07-07)
- 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
- JCB 4.4L Tier 3 SE Diagnostic Tool - User Guide
- JCB 4.4L Tier 3 SE Engine Setup Tool - User Guide
- Shiftmaster 2.3 Diagnostics Tool
- Loadall LMS Setup Tool - User Guide
- Loadall LMS Setup - User Guide
- Loadall Datalogger - User Guide
- Loadall Machine Diagnostics - User Guide
- Boom Angle Sensor Calibration - User Guide
- Immobiliser Diagnostics Tool
- Immobiliser Setup Tool
- Pulse Width Modulation Theory
- Electronic Control Unit Theory
- Machine Control ECU (S1)
- Machine Control ECU (S2)
- Livelink ECU
- Immobiliser ECU
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