JCB 541-70 TELESCOPIC HANDLER Service Repair Manual SN:1522566 to TBA

Please download to get full document.

View again

All materials on our website are shared by users. If you have any questions about copyright issues, please report us to resolve them. We are always happy to assist you.
 0
 
  Service Manual Side Engine Loadalls Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section B - Body and Framework…
Share
Transcript
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 SystemsPublication No.9813/0900-2World Class Customer Support Copyright Š 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. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400Section 1 - General Information Contents Page No. 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 ............................................................................................. 1-5-24 Slide Hammer Kit .................................................................................. 1-5-26 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 ......................................................................................... 1-8-31-i1-iSection 1-1 - General Information Applications IntroductionApplications Introduction This manual contains topics that relate to JCB Loadall machines in the 5A and 5T groups. There are several machine model codes in the family. Machine GroupModel CodeModel NameSerial Number range5AA531-701522574 to TBA5AB535-951522588 to TBA5AC536-601522577 to TBA5AD541-701522566 to TBA5AH533-1051522615 to TBA5AR536-701522577 to TBA5AS526-561448231 to TBA5AW550-801186000 to TBA5TA531-T701522570 to TBA5TB541-T701522566 to TBA5TC536-T601522577 to TBA5TD535-T951522569 to TBA5TE536-T701522577 to TBA5TW550-T801186000 to TBANote: This manual is applicable to EN15000 compliant machines only. 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. Where applicable information is given to help identify which machine variant is applicable for the given specifications and procedures. Use the applications tables to see which topics relate to which machine models and variants. Where no variant information is given the topic is applicable to all machine models indicated on the table. Important: The machine model names are NOT referred to in the topics. You must refer to the applications tables for the applicable machine model. Table entries shaded grey indicate a topic not included in this issue of the manual. K Tables ( T 1-1-2) K Section 1 - General Information ( T 1-1-2) K Section 2 - Care and Safety ( T 1-1-2) K Section 3 - Routine Maintenance ( T 1-1-3) K Section B - Body and Framework ( T 1-1-4) K Section C - Electrics ( T 1-1-6) K Section E - Hydraulics ( T 1-1-7) K Section F - Transmission ( T 1-1-10) K Section G - Brakes ( T 1-1-12) K Section H - Steering ( T 1-1-13) K Section K - Engine ( T 1-1-14) K Section M - Electronic Data Systems ( T 1-1-15)1-1-19813/0900-2 (1-14-05)1-1-11-1-2Machine IdentificationTorque SettingsService ToolsService ConsumablesFuel1-31-41-51-61-79813/0900-2 (1-14-05)TitleSafety NoticesGeneral ProceduresTopic Ref2-12-2Section 2 - Care and SafetyStall Speed CombinationsUse1-21-8TitleTopic RefSection 1 - General InformationVariantVariant531-70, 531-T70531-70, 531-T70Tables535-95, 535-T95536-60, 536-T60535-95, 536-60, 535-T95 536-T60533-105All MachinesAll Machines541-70, 541-T70Machine modelsAll MachinesAll MachinesAll MachinesAll MachinesAll MachinesAll MachinesAll Machines533-105Machine models 541-70, 541-T70526-56536-70, 526-56 536-T70536-70, 536-T70550-80550-80Section 1-1 - General Information Applications Tables1-1-21-1-3TitleRoutine Maintenance (P1)Routine Maintenance (P2)Topic Ref3-13-2Section 3 - Routine MaintenanceVariant 535-95, 535-T95z531-70, 531-T70zz536-60, 536-T60z541-70, 541-T70z533-105Machine modelsz536-70, 536-T70z526-56z550-80Section 1-1 - General Information Applications Tables9813/0900-2 (1-14-05)1-1-31-1-4Fork CarriageCab Heating and Ventilation SYSTEMCab Air Conditioning SYSTEMLongitidinal Load Moment SYSTEM (S1)Longitidinal Load Moment SYSTEM (S2)CabAir Conditioning Condenser - Cooling Pack MountedAir Conditioning Condenser - Cab Roof MountedCab HV and HVAC UnitAir Conditioning Binary SwitchHeater ValveFuel TankChassis PanelsBoomHydraulic TankLoad Moment Indicator Axle TransducerStabilisersB1B2B3B4B5B6B7B8B9B10B11B12B13B14B15B16B17Topic Ref TitleSection B - Body and Framework9813/0900-2 (1-14-05)3 Stage2 StageParallel Gearpump Hydraulic System MachinesAgri XtraAgri, Agri Plus, Agri SuperVariantzz z z z z zzzz z z z zzzzz z533-105zzzz zz z536-70, 536-T70zz z z z z zzz z z z z zz zzz z z z zzz z z z z zMachines with intercooled enginesMachines with non intercooled engineszzzzzz zzz zz zzz zz zz z541-70, 541-T70zz zz z536-60, 536-T60z535-95, 535-T95531-70, 531-T70Machine modelsz zz z z z z zzzzz z526-56zz z z z z zzzzz z550-80Section 1-1 - General Information Applications Tables1-1-41-1-5Longitidinal Load Moment Indicator UnitLongitidinal Load Moment Control SensorsB18B19Topic Ref TitleVariant535-95, 535-T95z z531-70, 531-T70z zz z536-60, 536-T60z z541-70, 541-T70z z533-105Machine modelsz z536-70, 536-T70z z526-56z z550-80Section 1-1 - General Information Applications Tables9813/0900-2 (1-14-05)1-1-51-1-6TitleFuses and RelaysSchematicsElectrical Harness SYSTEMBattery Charging SYSTEMAlternatorBatteryTopic RefC1C2C3C4C5C6Section C - ElectricsVariant 535-95, 535-T95z z z z z z531-70, 531-T70z z z z z zz z z zz z536-60, 536-T60z z z zz z541-70, 541-T70z z z zz z533-105Machine modelsz z z zz z z z z zz z536-70, 526-56 536-T70z z z zz z550-80Section 1-1 - General Information Applications Tables9813/0900-2 (1-14-05)1-1-61-1-7Parallel Control Valve 4 SectionParallel Control Valve 6 SectionLSP Electro Servo Control Valve (S1)LSP Electro Servo Control Valve (S2)LSP Electro Servo Control Valve (S3)Servo Pilot Pressure Supply Valve (S1) Agri XtraServo Pilot Pressure Supply Valve (S2) Agri, Agri Plus, Agri SuperServo Pilot Pressure Supply Valve (S3)E13E14E159813/0900-2 (1-14-05)E16E17E18E19Agri, Agri Plus, Agri SuperAgri XtraAgri, Agri Plus, Agri SuperE12Agri XtraVariable Hydraulic Cooling Fan Control SYSTEMSmooth Ride SYSTEM (SRS) - ParallelE7E11LSP Electro Servo SYSTEM (S4)E6Smooth Ride SYSTEM (SRS) Electro Servo (S3)LSP Electro Servo SYSTEM (S3)E5Agri, Agri Plus, Agri SuperE10LSP Electro Servo SYSTEM (S2)E4Agri XtraSmooth Ride SYSTEM (SRS) Electro Servo (S2)LSP Electro Servo SYSTEM (S1)E3E9Parallel Hydraulic SYSTEME2Smooth Ride SYSTEM (SRS) Electro Servo (S1)Systems and SchematicsE1VariantE8TitleTopic RefSection E - Hydraulicsz zz zzzzzzzzz zz zz zz zz zzzz zzz535-95, 536-60, 535-T95 536-T60z z531-70, 531-T70z zz zzzz zz zz z541-70, 541-T70zz z533-105Machine modelsz zz zzzz zz zz z536-70, 536-T70zzzz526-56zzzzzz550-80Section 1-1 - General Information Applications Tables1-1-71-1-89813/0900-2 (1-14-05)Displacement RamSway RamStabiliser RamsRam MaintenanceSway/Fan Changeover ValveHydraulic Oil Cooler By-Pass SYSTEM Agri, Agri Plus, Agri Super, Agri XtraHydraulic Oil Cooler By-Pass ValveInternal Hydraulic Tank FilterE29E30E31E32E33E34E35E36Agri, Agri Plus, Agri Super, Agri XtraAgri, Agri Plus, Agri Super, Agri XtraTilt RamE28Agri, Agri Plus, Agri SuperAgri XtraLift RamsControl Lever - Electro Servo - Pod MountedE24Variable Speed FanE27Cooling Fan Motor (P2)E23Extension RamCooling Fan Motor (P1)E22125 l/min110 l/min80 l/min Triple Pump80 l/min Double PumpE26Main Pump - GearpumpE21Control Lever - Electro Servo - Cab MountedMain Pump - VariflowE20VariantE25TitleTopic Refz z z z zz zz z z z zz z z z z z z zzz zz z zzzzzz z z zzzzzz535-95, 536-60, 535-T95 536-T60zzzz z z z531-70, 531-T70zzz z zz z z z zzzzz z z z541-70, 541-T70z zz z z zzz533-105Machine modelszzz z zz z z z zzzzz z z z536-70, 536-T70zz z z zzz526-56zzz z zz z z z zzzz550-80Section 1-1 - General Information Applications Tables1-1-8TitleAmbient Air Temperature SenderTopic RefE37Variant531-70, 531-T70535-95, 536-60, 535-T95 536-T60541-70, 541-T70533-105Machine models 536-70, 536-T70526-561-1-9 z550-80Section 1-1 - General Information Applications Tables9813/0900-2 (1-14-05)1-1-91-1-10SS700 Gearbox SYSTEMLock Up Torque Converter SYSTEMDual Control SYSTEM (S1)Dual Control SYSTEM (S2)Dual Control SYSTEM (S3)Shiftmaster ECUPS750 Mk IV GearboxPS760 GearboxSS700 GearboxBevel GearboxTorque ConverterF12F13F14F15F16F17F18F19F20F21PS750 Mk IV Gearbox SYSTEMF7F11Rear Axles (S2)F6PS766 Gearbox SYSTEM (ECU 2.3)Rear Axles (S1)F5F10Front Axles (S2)F4PS764 Gearbox SYSTEM (S2)Front Axles (S1)F3F9Wheels and TyresF2PS764 Gearbox SYSTEM (S1)ConfigurationF1F8TitleTopic RefSection F - Transmission9813/0900-2 (1-14-05)Agri, Agri Plus, Agri SuperPS766 SystemVariantzzz zz z zz zzz zz zz z zz zzz zzz zz zz535-95, 535-T95531-70, 531-T70z zz z zz zzz zzzz z536-60, 536-T60z zz z zz zzz zzzz z541-70, 541-T70z zzzzzz z533-105Machine modelsz zz z zz zzz zzzz z536-70, 536-T70z z zzzzzzzz z526-56z zzzzzzz z550-80Section 1-1 - General Information Applications Tables1-1-10Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITINGNOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.TitleTransmission Oil Cooler - Liquid to LiquidTransmission Oil Cooler - Air BlastPropshafts (S1)Propshafts (S2)Transmission Speed SensorEngine Speed SensorSpeedometerSS700 Cable ShiftTopic RefF22F23F24F25F26F27F28F29Variant1-1-11 z z zz531-70, 531-T70z z zz535-95, 535-T95541-70, 541-T70533-105536-70, 536-T70z z zz z z zz z z zz z z zzMachines with intercooled enginesMachine with non intercooled engines536-60, 536-T60Machine modelsz z z zz526-56z z z550-80Section 1-1 - General Information Applications Tables9813/0900-2 (1-14-05)1-1-111-1-12TitleSingle Axle Service Brakes SYSTEMPower Braking SYSTEMExternal Park Brake SYSTEMInternal Park Brake SYSTEMPark Brake CalliperPark Brake DiscPark Brake SwitchServo Exhauster UnitServo Unit - Single Axle BrakesMaster CylinderFluid ReservoirPower Brake ValvePower Brake AccumulatorPower Brake Charge ValveTopic RefG1G2G3G4G5G6G7G8G9G10G11G12G13G14Section G - BrakesPS750 and SS700 Gearbox SystemPS750 and SS700 Gearbox SystemPS760 Gearbox SystemsPS750 and SS700 Gearbox SystemVariantz z z z z z z z zz z z z z z z zzz z535-95, 535-T95531-70, 531-T70z z z z zzzzzz536-60, 536-T60z z z z zzzzzz541-70, 541-T70z z z z zzzzz533-105Machine modelsz z z z zzzzzz536-70, 536-T70z z z z zzzzz526-56z z zzzz550-80Section 1-1 - General Information Applications Tables9813/0900-2 (1-14-05)1-1-121-1-13Auto Steer Mode ValvePower Track Rod (P1)H7H11Priority ValveH6Manual Steer Mode ValveHydraulic Steering Unit (S2)H5H10Hydraulic Steering Unit (S1)H4Steering ColumnAuto Steer Mode SYSTEMH3H9Manual Steer Mode SYSTEMH2Power Track Rod (P2)Steering SYSTEMH1H8TitleTopic RefSection H - SteeringVariantz zz zz z zz z zz zz zz zz z535-95, 535-T95531-70, 531-T70z z zz zz zz z536-60, 536-T60z z zz zz zz zz z zz zz zz z541-70, 533-105 541-T70Machine modelsz z zz zz zz z536-70, 536-T70z z zz zz zz z526-56zz zz zzz550-80Section 1-1 - General Information Applications Tables9813/0900-2 (1-14-05)1-1-131-1-14TitleStop and Start SYSTEM (Mechanical F.I. Engines)Stop and Start SYSTEM (Electronic F.I. Engines) (S1)Stop and Start SYSTEM (Electronic F.I. Engines) (S2)Cold Start Heater SYSTEMStarter MotorCooling Pack - Non IntercooledCooling Pack - Intercooled (Mechanical F.I. Engines)Cooling Pack - Intercooled (Electronic F.I. Engines)Coolant Expansion TankAir Filter Vacuum SwitchThrottle Pedal and CableThrottle Position Sensor (TPS) (S1)Throttle Position Sensor (TPS) (S2)Exhaust SilencerJCB Dieselmax Engine (Mechanical F.I.)JCB Dieselmax Engine (Electronic F.I.)Topic RefK1K2K3K4K5K6K7K8K9K10K11K12K13K14K15K16Section K - Engine9813/0900-2 (1-14-05)Electronic F.I. engines from March 2011Electronic F.I. engines up to March 2011Mechanical F.I. enginesMechanical F.I. enginesVariantz z z z z z z z z z z zz z z z z z z z z z z zzzzzzz535-95, 535-T95531-70, 531-T70z z zzzz z zzzzzzz536-60, 536-T60z z zzzz z zzz zzzzz541-70, 541-T70z zz z zz zzzz533-105Machine modelsz z zzzz z zzz zzzzz536-70, 536-T70z zz z zz zzzz526-56zzz zzzz550-80Section 1-1 - General Information Applications Tables1-1-141-1-15Servicemaster SYSTEMServicemaster ToolsElectronic Control Unit TheoryPulse Width Modulation TheoryM4M5M6M7Machine Control ECU (S2)Fault Code SYSTEMM3M9Loadall Monitoring SYSTEMM2Machine Control ECU (S1)CANbus SYSTEMM1M8TitleTopic RefSection M - Electronic Data SystemsAgri, Agri Plus, Agri SuperVariant535-95, 535-T95z z z z z z z z531-70, 531-T70z z z z z z z zzz z z z z z z536-60, 536-T60zz z z z z z zz z z z z533-105Machine models 541-70, 541-T70zz z z z z z z536-70, 536-T70zz z z z z z z526-56zz z z z z550-80Section 1-1 - General Information Applications Tables9813/0900-2 (1-14-05)1-1-15
Related Search
We Need Your Support
Thank you for visiting our website and your interest in our free products and services. We are nonprofit website to share and download documents. To the running of this website, we need your help to support us.

Thanks to everyone for your continued support.

No, Thanks
SAVE OUR EARTH

We need your sign to support Project to invent "SMART AND CONTROLLABLE REFLECTIVE BALLOONS" to cover the Sun and Save Our Earth.

More details...

Sign Now!

We are very appreciated for your Prompt Action!

x