jcb 540-170 User manual
Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
World Class
Customer Support
9803/3750-05
Publication No.
Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
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
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Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
World Class
Customer Support
9803/3750-05
Publication No.
Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
Section 1
General Information
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
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Page No.Contents
Section 1 - General Information
1-i 1-i
Applications
Introduction ............................................................................................. 1-1-1
Tables ..................................................................................................... 1-1-2
Use
Introduction ............................................................................................. 1-2-1
Scope ..................................................................................................... 1-2-2
Format .................................................................................................... 1-2-3
Left and Right Sides ............................................................................... 1-2-4
Hydraulic Schematic Codes ................................................................... 1-2-5
Electrical Device Codes .......................................................................... 1-2-6
Machine Identification
Introduction ............................................................................................. 1-3-1
Related Topics ........................................................................................ 1-3-2
Machine Identification Plate .................................................................... 1-3-3
Component Identification Plates ............................................................. 1-3-5
Torque Settings
Introduction ............................................................................................. 1-4-1
Zinc Plated Fasteners and Dacromet Fasteners .................................... 1-4-2
Hydraulic Connections ............................................................................ 1-4-6
`Positional Type' Hydraulic Adaptors .................................................... 1-4-10
Service Tools
Introduction ............................................................................................. 1-5-1
Numerical List ......................................................................................... 1-5-2
Tool Detail Reference ............................................................................. 1-5-5
Rivet Nuts ............................................................................................. 1-5-23
Slide Hammer Kit .................................................................................. 1-5-25
Service Consumables
Introduction ............................................................................................. 1-6-1
Sealing and Retaining Compounds ........................................................ 1-6-2
Fuel
Introduction ............................................................................................. 1-7-1
Related Topics ........................................................................................ 1-7-2
Acceptable and Unacceptable Fuels ...................................................... 1-7-3
Stall Speed Combinations
Introduction ............................................................................................. 1-8-1
Related Topics ........................................................................................ 1-8-2
Specifications ......................................................................................... 1-8-3
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Section 1-1 - General Information
1-1-1 1-1-1
9803/3750-05 (1-14-01)
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 Group Model Code Model Name
5A F 540-170
5A G 550-140
5A L 540-140
5A M 550-170
5A N 535-125 Hi Viz
5A P 535-140 Hi Viz
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.
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 1-1-6)
K Section E - Hydraulics ( T 1-1-7)
K Section F - Transmission ( T 1-1-8)
K Section G - Brakes ( T 1-1-9)
K Section H - Steering ( T 1-1-10)
K Section K - Engine ( T 1-1-11)
K Section M - Electronic Data Systems ( T 1-1-12)
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Section 1-1 - General Information
Applications
Tables
1-1-2 1-1-2
9803/3750-05 (1-14-01)
Tables
Section 1 - General Information
Machine models
Topic
Ref Title Variant 540-170
5AF 550-140
5AG 540-140
5AL 550-170
5AM 535-125
HiViz
5AN
535-140
HiViz
5AP
1-2 Use All Machines
1-3 Machine Identification All Machines
1-4 Torque Settings All Machines
1-5 Service Tools All Machines
1-6 Service Consumables All Machines
1-7 Fuel All Machines
1-8 Stall Speed Combinations All Machines
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Section 1-1 - General Information
Applications
Tables
1-1-3 1-1-3
9803/3750-05 (1-14-01)
Section 2 - Care and Safety
Machine models
Topic
Ref Title Variant 540-170
5AF 550-140
5AG 540-140
5AL 550-170
5AM 535-125
HiViz
5AN
535-140
HiViz
5AP
2-1 Safety Notices All Machines
2-2 General Procedures All Machines
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Section 1-1 - General Information
Applications
Tables
1-1-4 1-1-4
9803/3750-05 (1-14-01)
Section 3 - Routine Maintenance
Machine models
Topic
Ref Title Variant 540-170
5AF 550-140
5AG 540-140
5AL 550-170
5AM 535-125
HiViz
5AN
535-140
HiViz
5AP
3-1 Introduction All Machines
3-2 Service Schedules - Machines
with SD and SF Engines Mechanical F.I.
engines z zzzzz
3-3 Service Schedules - Machines
with SE Engines Electronic F.I.
engines z zzz
3-4 Fluids, Lubricants and
Capacities All Machines
3-5 Cleaning the Machines All Machines
3-6 Inspection All Machines
3-7 Seat Belts All Machines
3-8 ROPS/FOPS (and OECD)
Structure All Machines
3-9 Greasing All Machines
3-10 Heater and Air Conditioning All Machines
3-11 Brakes All Machines
3-12 Electrical System All Machines
3-13 Engine All Machines
3-14 Engine Air FIlter All Machines
3-15 Fuel System All Machines
3-16 Hydraulic System All Machines
3-17 Transmission All Machines
3-18 Tyres and Wheels All Machines
3-19 Wear Pads All Machines
3-20 Windscreen Washer All Machines
3-21 Access Panels All Machines
3-22 Fire Extinguisher All Machines
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Section 1-1 - General Information
Applications
Tables
1-1-5 1-1-5
9803/3750-05 (1-14-01)
Section B - Body and Framework
Machine models
Topic
Ref Title Variant 540-170
5AF 550-140
5AG 540-140
5AL 550-170
5AM 535-125
HiViz
5AN
535-140
HiViz
5AP
B1 Fork Carriage zzzzzz
B2 Cab Heating and Ventilation
SYSTEM zzzzzz
B3 Cab Air Conditioning SYSTEM zzzzzz
B4 Load Moment Indicator (LMI)
SYSTEM zzzzzz
B6 Cab zzzzzz
B7 Air Conditioning Condensor -
Cooling Pack Mounted zzzzzz
B8 Air Conditioning Condensor -
Roof Mounted zzzzzz
B9 Cab HV and HVAC Unit zzzzzz
B10 Air Conditioning Binary Switch zzzzzz
B11 Heater Valve zzzzzz
B12 Fuel Tank zzzzzz
B13 Chassis Panels zzzzzz
B14 Boom 3 Stage zz zz
4 Stage zz
B15 LMI Axle Transducer zzzzzz
B16 Stabilisers zzzzzz
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Section 1-1 - General Information
Applications
Tables
1-1-6 1-1-6
9803/3750-05 (1-14-01)
Section C - Electrics
Machine models
Topic
Ref Title Variant 540-170
5AF 550-140
5AG 540-140
5AL 550-170
5AM 535-125
HiViz
5AN
535-140
HiViz
5AP
C1 Fuses and Relays zzzzzz
C2 Schematics zzzzzz
C3 Electrical Harness SYSTEM zzzzzz
C4 Battery Charging SYSTEM zzzzzz
C5 Alternator zzzzzz
C6 Battery zzzzzz
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Section 1-1 - General Information
Applications
Tables
1-1-7 1-1-7
9803/3750-05 (1-14-01)
Section E - Hydraulics
Machine models
Topic
Ref Title Variant 540-170
5AF 550-140
5AG 540-140
5AL 550-170
5AM 535-125
HiViz
5AN
535-140
HiViz
5AP
E1 Systems and Schematics zzzzzz
E2 Parallel Hydraulic SYSTEM zz zz
E3 Parallel Servo Hydraulic
SYSTEM zz
E4 Hydraulic Interlock SYSTEM zz
E5 Parallel Control Valve - 6
Section To
January
2009
zzTo
January
2009
zz
E6 Parallel Control Valve - 5
Section From
January
2009
From
January
2009
E7 Parallel Control Valve - 2
Section zz
E8 Servo Control Valves zz
E9 Servo Solenoid Diverter Valve
Block zz
E10 Stabiliser Isolation Valve zz
E11 Sway/Fan Selector Valve zzzzzz
E12 Main Pump 110 l/min zz zz
170 l/min zz
E13 Cooling Fan Motor zzzzzz
E14 Extension Ram zzzzzz
E15 Lift Rams zzzzzz
E16 Tilt Ram zzzzzz
E17 Displacement Ram zzzzzz
E18 Sway Ram zzzzzz
E19 Stabiliser Rams zzzzzz
E20 Ram Maintenance zzzzzz
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Section 1-1 - General Information
Applications
Tables
1-1-8 1-1-8
9803/3750-05 (1-14-01)
Section F - Transmission
Machine models
Topic
Ref Title Variant 540-170
5AF 550-140
5AG 540-140
5AL 550-170
5AM 535-125
HiViz
5AN
535-140
HiViz
5AP
F1 CONFIGURATION zzzzzz
F2 Wheels and Tyres zzzzzz
F3 Front Axles SD80 Pivot
sway zzzz
SD80Trunnion
sway zz
F4 Rear Axles SD80 Pivot
sway zzzz
SD80Trunnion
sway zz
F5 PS750 Gearbox SYSTEM zzzzzz
F6 PS750 Mk IV Gearbox
SYSTEM zzzzzz
F7 PS764 Gearbox SYSTEM zzzz
F8 PS750 Gearbox zzzzzz
F9 PS750 Mk IV Gearbox zzzzzz
F10 PS760 Gearbox zzzz
F11 Bevel Gearbox zzzzzz
F12 Torque Converter zzzzzz
F13 Transmission Oil Cooler -
Air Blast Intercooled
engines zzzzzz
F14 Transmission Oil Cooler -
Liquid to Liquid Non
intercooled
engines
zzzzzz
F15 Propshafts zzzzzz
F16 Speed Sensors zzzzzz
F17 Speedometer zzzzzz
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Section 1-1 - General Information
Applications
Tables
1-1-9 1-1-9
9803/3750-05 (1-14-01)
Section G - Brakes
Machine models
Topic
Ref Title Variant 540-170
5AF 550-140
5AG 540-140
5AL 550-170
5AM 535-125
HiViz
5AN
535-140
HiViz
5AP
G1 Twin Axle Service Brakes SYSTEM
(S1) zz
G2 Twin Axle Service Brakes SYSTEM
(S2) zzzz
G3 External Park Brake SYSTEM PS750
gearbox zzzzzz
G4 Internal Park Brake SYSTEM PS760
gearbox zzzz
G5 Park Brake Calliper PS750
gearbox zzzzzz
G6 Park Brake Disc PS750
gearbox zzzzzz
G7 Park Brake Switch zzzzzz
G8 Servo Exhauster Unit zzzzzz
G9 Servo Unit - Twin Axle Brakes zzzzzz
G10 Master Cylinder zzzzzz
G11 Fluid Reservoir zzzzzz
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Section 1-1 - General Information
Applications
Tables
1-1-10 1-1-10
9803/3750-05 (1-14-01)
Section H - Steering
Machine models
Topic
Ref Title Variant 540-170
5AF 550-140
5AG 540-140
5AL 550-170
5AM 535-125
HiViz
5AN
535-140
HiViz
5AP
H1 Steering SYSTEM zzzzzz
H2 Manual Steer Mode SYSTEM zzzzzz
H3 Auto Steer Mode SYSTEM zzzzzz
H4 Hydraulic Steering Unit zzzzzz
H5 Priority Valve zzzzzz
H6 Power Track Rods zz
H7 Steer Rams zzzz
H8 Steering Column zzzzzz
H9 Manual Steer Mode Valve zzzzzz
H10 Auto Steer Mode Valve zzzzzz
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Section 1-1 - General Information
Applications
Tables
1-1-11 1-1-11
9803/3750-05 (1-14-01)
Section K - Engine
Machine models
Topic
Ref Title Variant 540-170
5AF 550-140
5AG 540-140
5AL 550-170
5AM 535-125
HiViz
5AN
535-140
HiViz
5AP
K1 Stop and Start SYSTEM
(Mechanical F.I. Engines) zzzzzz
K2 Stop and Start SYSTEM
(Electronic F.I. Engines) zzzz
K3 Cold Start Heater SYSTEM Mechani
cal F.I.
Engines
zzzzzz
K4 Starter Motor zzzzzz
K5 Cooling Pack - (Non Intercooled) zzz
K6 Cooling Pack - (Intercooled
Mechanical F.I. Engines) zzzzzz
K7 Cooling Pack - (Electronic F.I.
Engines) zzzz
K8 Coolant Expansion Tank zzzzzz
K9 Air Filter Vacuum Switch zzzzzz
K10 Throttle Pedal and Cable zzzzzz
K11 Throttle Position Sensor (TPS) zzzz
K12 Exhaust Silencer zzzzzz
K13 JCB Dieselmax (Mechanical F.I.
Engines) zzzzzz
K14 JCB Dieselmax (Electronic F.I.
Engines) zzzz
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Section 1-1 - General Information
Applications
Tables
1-1-12 1-1-12
9803/3750-05 (1-14-01)
Section M - Electronic Data Systems
Machine models
Topic
Ref Title Variant 540-170
5AF 550-140
5AG 540-140
5AL 550-170
5AM 535-125
HiViz
5AN
535-140
HiViz
5AP
M1 CANbus SYSTEM zzzzzz
M2 Loadall Monitoring SYSTEM zzzzzz
M3 Fault Code SYSTEM zzzzzz
M4 Servicemaster SYSTEM zzzzzz
M5 Servicemaster Tools zzzzzz
M6 Electronic Control Unit Theory zzzzzz
M7 Pulse Width Modulation Theory zzzzzz
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Section 1-2 - General Information
1-2-1 1-2-1
9803/3750-05 (1-01-00)
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)
K Electrical Device Codes ( T 1-2-6)
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Section 1-2 - General Information
Use
Scope
1-2-2 1-2-2
9803/3750-05 (1-01-00)
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. K Applications ( T 1-1-1)
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.
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