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

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  This is the Highly Detailed factory service repair manual for theJCB 541-70 TELESCOPIC HANDLER, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.JCB 541-70 TELESCOPIC HANDLER Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly. Service Repair Manual Covers: General Information Care and Safety Routine Maintenance Body and Framework Electrics Hydraulics Transmission Brakes Steering Engine Electronic Data Systems File Format: PDF Compatible: All Versions of Windows & Mac Language: English Requirements: Adobe PDF Reader NO waiting, Buy from responsible seller and get INSTANT DOWNLOAD, Without wasting your hard-owned money on uncertainty or surprise! All pages are is great to haveJCB 541-70 TELESCOPIC HANDLER Service Repair Workshop Manual. Looking for some other Service Repair Manual,please check: https://www.aservicemanualpdf.com/ Thanks for visiting! 8
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  • 1. 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 9813/0900-2 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
  • 2. Section 0 - Service Manual 0-0 0-09813/0900-2 Notes:
  • 3. 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 9813/0900-2 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
  • 4. Section 1 - General Information 1-0 1-09813/0900-2 Notes:
  • 5. 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 ............................................................................................. 1-5-24 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 ......................................................................................... 1-8-3
  • 6. Page No.Contents Section 1 - General Information 1-ii 1-ii
  • 7. Section 1-1 - General Information Applications Introduction 1-1-1 1-1-19813/0900-2 (1-14-05) Applications 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 Group Model Code Model Name Serial Number range 5A A 531-70 1522574 to TBA 5A B 535-95 1522588 to TBA 5A C 536-60 1522577 to TBA 5A D 541-70 1522566 to TBA 5A H 533-105 1522615 to TBA 5A R 536-70 1522577 to TBA 5A S 526-56 1448231 to TBA 5A W 550-80 1186000 to TBA 5T A 531-T70 1522570 to TBA 5T B 541-T70 1522566 to TBA 5T C 536-T60 1522577 to TBA 5T D 535-T95 1522569 to TBA 5T E 536-T70 1522577 to TBA 5T W 550-T80 1186000 to TBA Note: 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)
  • 8. Section 1-1 - General Information Applications Tables 1-1-2 1-1-29813/0900-2 (1-14-05) Tables Section1-GeneralInformation Section2-CareandSafety Machinemodels TopicRefTitleVariant531-70, 531-T70 535-95, 535-T95 536-60, 536-T60 541-70, 541-T70 533-105536-70, 536-T70 526-56550-80 1-2UseAllMachines 1-3MachineIdentificationAllMachines 1-4TorqueSettingsAllMachines 1-5ServiceToolsAllMachines 1-6ServiceConsumablesAllMachines 1-7FuelAllMachines 1-8StallSpeedCombinationsAllMachines Machinemodels TopicRefTitleVariant531-70, 531-T70 535-95, 535-T95 536-60, 536-T60 541-70, 541-T70 533-105536-70, 536-T70 526-56550-80 2-1SafetyNoticesAllMachines 2-2GeneralProceduresAllMachines
  • 9. Section 1-1 - General Information Applications Tables 1-1-3 1-1-39813/0900-2 (1-14-05) Section3-RoutineMaintenance Machinemodels TopicRefTitleVariant531-70, 531-T70 535-95, 535-T95 536-60, 536-T60 541-70, 541-T70 533-105536-70, 536-T70 526-56550-80 3-1RoutineMaintenance(P1) 3-2RoutineMaintenance(P2)
  • 10. Section 1-1 - General Information Applications Tables 1-1-4 1-1-49813/0900-2 (1-14-05) SectionB-BodyandFramework Machinemodels TopicRefTitleVariant531-70, 531-T70 535-95, 535-T95 536-60, 536-T60 541-70, 541-T70 533-105536-70, 536-T70 526-56550-80 B1ForkCarriage B2CabHeatingandVentilationSYSTEM B3CabAirConditioningSYSTEM B4LongitidinalLoadMomentSYSTEM(S1)Agri,AgriPlus,Agri Super AgriXtra B5LongitidinalLoadMomentSYSTEM(S2)ParallelGearpump HydraulicSystem Machines B6Cab B7AirConditioningCondenser-Cooling PackMounted Machineswithnonintercooledengines B8AirConditioningCondenser-CabRoof Mounted Machineswithintercooledengines B9CabHVandHVACUnit B10AirConditioningBinarySwitch B11HeaterValve B12FuelTank B13ChassisPanels B14Boom2Stage 3Stage B15HydraulicTank B16LoadMomentIndicatorAxleTransducer B17Stabilisers
  • 11. Section 1-1 - General Information Applications Tables 1-1-5 1-1-59813/0900-2 (1-14-05) B18LongitidinalLoadMomentIndicatorUnit B19LongitidinalLoadMomentControl Sensors Machinemodels TopicRefTitleVariant531-70, 531-T70 535-95, 535-T95 536-60, 536-T60 541-70, 541-T70 533-105536-70, 536-T70 526-56550-80
  • 12. Section 1-1 - General Information Applications Tables 1-1-6 1-1-69813/0900-2 (1-14-05) SectionC-Electrics Machinemodels TopicRefTitleVariant531-70, 531-T70 535-95, 535-T95 536-60, 536-T60 541-70, 541-T70 533-105536-70, 536-T70 526-56550-80 C1FusesandRelays C2Schematics C3ElectricalHarnessSYSTEM C4BatteryChargingSYSTEM C5Alternator C6Battery
  • 13. Section 1-1 - General Information Applications Tables 1-1-7 1-1-79813/0900-2 (1-14-05) SectionE-Hydraulics Machinemodels TopicRefTitleVariant531-70, 531-T70 535-95, 535-T95 536-60, 536-T60 541-70, 541-T70 533-105536-70, 536-T70 526-56550-80 E1SystemsandSchematics E2ParallelHydraulicSYSTEM E3LSPElectroServoSYSTEM(S1)AgriXtra E4LSPElectroServoSYSTEM(S2)Agri,AgriPlus,AgriSuper E5LSPElectroServoSYSTEM(S3) E6LSPElectroServoSYSTEM(S4) E7SmoothRideSYSTEM(SRS)-Parallel E8SmoothRideSYSTEM(SRS)Electro Servo(S1) AgriXtra E9SmoothRideSYSTEM(SRS)Electro Servo(S2) Agri,AgriPlus,AgriSuper E10SmoothRideSYSTEM(SRS)Electro Servo(S3) E11VariableHydraulicCoolingFanControl SYSTEM E12ParallelControlValve4Section E13ParallelControlValve6Section E14LSPElectroServoControlValve(S1)AgriXtra E15LSPElectroServoControlValve(S2)Agri,AgriPlus,AgriSuper E16LSPElectroServoControlValve(S3) E17ServoPilotPressureSupplyValve(S1)AgriXtra E18ServoPilotPressureSupplyValve(S2)Agri,AgriPlus,AgriSuper E19ServoPilotPressureSupplyValve(S3)
  • 14. Section 1-1 - General Information Applications Tables 1-1-8 1-1-89813/0900-2 (1-14-05) E20MainPump-Variflow E21MainPump-Gearpump80l/minDoublePump 80l/minTriplePump 110l/min 125l/min E22CoolingFanMotor(P1) E23CoolingFanMotor(P2)VariableSpeedFan E24ControlLever-ElectroServo-Pod Mounted AgriXtra E25ControlLever-ElectroServo-Cab Mounted Agri,AgriPlus,AgriSuper E26ExtensionRam E27LiftRams E28TiltRam E29DisplacementRam E30SwayRam E31StabiliserRams E32RamMaintenance E33Sway/FanChangeoverValve E34HydraulicOilCoolerBy-PassSYSTEMAgri,AgriPlus,AgriSuper, AgriXtra E35HydraulicOilCoolerBy-PassValveAgri,AgriPlus,AgriSuper, AgriXtra E36InternalHydraulicTankFilterAgri,AgriPlus,AgriSuper, AgriXtra Machinemodels TopicRefTitleVariant531-70, 531-T70 535-95, 535-T95 536-60, 536-T60 541-70, 541-T70 533-105536-70, 536-T70 526-56550-80
  • 15. Section 1-1 - General Information Applications Tables 1-1-9 1-1-99813/0900-2 (1-14-05) E37AmbientAirTemperatureSender Machinemodels TopicRefTitleVariant531-70, 531-T70 535-95, 535-T95 536-60, 536-T60 541-70, 541-T70 533-105536-70, 536-T70 526-56550-80
  • 16. Section 1-1 - General Information Applications Tables 1-1-10 1-1-109813/0900-2 (1-14-05) SectionF-Transmission Machinemodels TopicRefTitleVariant531-70, 531-T70 535-95, 535-T95 536-60, 536-T60 541-70, 541-T70 533-105536-70, 536-T70 526-56550-80 F1Configuration F2WheelsandTyres F3FrontAxles(S1) F4FrontAxles(S2) F5RearAxles(S1) F6RearAxles(S2) F7PS750MkIVGearboxSYSTEM F8PS764GearboxSYSTEM(S1) F9PS764GearboxSYSTEM(S2) F10PS766GearboxSYSTEM(ECU2.3) F11SS700GearboxSYSTEM F12LockUpTorqueConverterSYSTEMPS766System F13DualControlSYSTEM(S1)Agri,AgriPlus,AgriSuper F14DualControlSYSTEM(S2) F15DualControlSYSTEM(S3) F16ShiftmasterECU F17PS750MkIVGearbox F18PS760Gearbox F19SS700Gearbox F20BevelGearbox F21TorqueConverter
  • 17. Section 1-1 - General Information Applications Tables 1-1-11 1-1-119813/0900-2 (1-14-05) F22TransmissionOilCooler-Liquidto Liquid Machinewithnonintercooledengines F23TransmissionOilCooler-AirBlastMachineswithintercooledengines F24Propshafts(S1) F25Propshafts(S2) F26TransmissionSpeedSensor F27EngineSpeedSensor F28Speedometer F29SS700CableShift Machinemodels TopicRefTitleVariant531-70, 531-T70 535-95, 535-T95 536-60, 536-T60 541-70, 541-T70 533-105536-70, 536-T70 526-56550-80
  • 18. Section 1-1 - General Information Applications Tables 1-1-12 1-1-129813/0900-2 (1-14-05) SectionG-Brakes Machinemodels TopicRefTitleVariant531-70, 531-T70 535-95, 535-T95 536-60, 536-T60 541-70, 541-T70 533-105536-70, 536-T70 526-56550-80 G1SingleAxleServiceBrakesSYSTEM G2PowerBrakingSYSTEM G3ExternalParkBrakeSYSTEMPS750andSS700 GearboxSystem G4InternalParkBrakeSYSTEMPS760Gearbox Systems G5ParkBrakeCalliperPS750andSS700 GearboxSystem G6ParkBrakeDiscPS750andSS700 GearboxSystem G7ParkBrakeSwitch G8ServoExhausterUnit G9ServoUnit-SingleAxleBrakes G10MasterCylinder G11FluidReservoir G12PowerBrakeValve G13PowerBrakeAccumulator G14PowerBrakeChargeValve
  • 19. Section 1-1 - General Information Applications Tables 1-1-13 1-1-139813/0900-2 (1-14-05) SectionH-Steering Machinemodels TopicRefTitleVariant531-70, 531-T70 535-95, 535-T95 536-60, 536-T60 541-70, 541-T70 533-105536-70, 536-T70 526-56550-80 H1SteeringSYSTEM H2ManualSteerModeSYSTEM H3AutoSteerModeSYSTEM H4HydraulicSteeringUnit(S1) H5HydraulicSteeringUnit(S2) H6PriorityValve H7PowerTrackRod(P1) H8PowerTrackRod(P2) H9SteeringColumn H10ManualSteerModeValve H11AutoSteerModeValve
  • 20. Section 1-1 - General Information Applications Tables 1-1-14 1-1-149813/0900-2 (1-14-05) SectionK-Engine Machinemodels TopicRefTitleVariant531-70, 531-T70 535-95, 535-T95 536-60, 536-T60 541-70, 541-T70 533-105536-70, 536-T70 526-56550-80 K1StopandStartSYSTEM(MechanicalF.I. Engines) K2StopandStartSYSTEM(ElectronicF.I. Engines)(S1) K3StopandStartSYSTEM(ElectronicF.I. Engines)(S2) K4ColdStartHeaterSYSTEMMechanicalF.I. engines K5StarterMotor K6CoolingPack-NonIntercooled K7CoolingPack-Intercooled(MechanicalF.I. Engines) K8CoolingPack-Intercooled(ElectronicF.I. Engines) K9CoolantExpansionTank K10AirFilterVacuumSwitch K11ThrottlePedalandCableMechanicalF.I. engines K12ThrottlePositionSensor(TPS)(S1)ElectronicF.I. enginesuptoMarch 2011 K13ThrottlePositionSensor(TPS)(S2)ElectronicF.I. enginesfromMarch 2011 K14ExhaustSilencer K15JCBDieselmaxEngine(MechanicalF.I.) K16JCBDieselmaxEngine(ElectronicF.I.)
  • 21. Section 1-1 - General Information Applications Tables 1-1-15 1-1-159813/0900-2 (1-14-05) SectionM-ElectronicDataSystems Machinemodels TopicRefTitleVariant531-70, 531-T70 535-95, 535-T95 536-60, 536-T60 541-70, 541-T70 533-105536-70, 536-T70 526-56550-80 M1CANbusSYSTEM M2LoadallMonitoringSYSTEM M3FaultCodeSYSTEM M4ServicemasterSYSTEM M5ServicemasterTools M6ElectronicControlUnitTheory M7PulseWidthModulationTheory M8MachineControlECU(S1)Agri,AgriPlus,Agri Super M9MachineControlECU(S2)
  • 22. Section 1-1 - General Information Applications Tables 1-1-16 1-1-169813/0900-2 (1-14-05) Page left intentionally blank
  • 23. Section 1-2 - General Information 1-2-1 1-2-19813/0900-2 (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)
  • 24. Section 1-2 - General Information Use Scope 1-2-2 1-2-29813/0900-2 (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.
  • 25. Section 1-2 - General Information Use Format 1-2-3 1-2-39813/0900-2 (1-01-00) Format The manual is compiled in sections, the first three are numbered and contain information as follows: 1 General Information - Use the Applications Tables at the front of the section to see which topic in the manual is applicable to which machine model. The section also includes general information such as torque settings and service tools. 2 Care & Safety - includes warnings, cautions and general procedures related to aspects of workshop procedures contained in the manual. 3 Routine Maintenance - includes service schedules and recommended lubricants for all the machine. The remaining sections are alphabetically coded and deal with dismantling, overhaul etc. of specific components, for example: 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 happens because of market requirements, or when the machine specification changes after a period of time. Where applicable, a table in the introduction of each topic contains information to help you identify the correct specifications or procedures. Each topic also contains a Related Topics table. This table lists all the topics that contain related data. For example a hydraulic SYSTEM contains devices such as valves and pumps. These devices have their own topics and they are listed in the SYSTEM related topics table. A Attachments B Body and Framework...etc.
  • 26. Section 1-2 - General Information Use Left and Right Sides 1-2-4 1-2-49813/0900-2 (1-01-00) Left and Right Sides 'Left Hand' and 'Right Hand' are as viewed from the rear of the machine facing forwards.
  • 27. Section 1-2 - General Information Use Hydraulic Schematic Codes 1-2-5 1-2-59813/0900-2 (1-01-00) Hydraulic Schematic Codes Colour Codes The following colour coding, used on illustrations to denote various conditions of oil pressure and flow, is standardised throughout JCB Service Publications. Red Full Pressure: Pressure generated from operation of a service. Depending on application this may be anything between neutral circuit pressure and LSRV operating pressure. Pink Pressure: Pressure that is above neutral circuit pressure but lower than that denoted by Red. Orange Pilot: Oil pressure used in controlling a device (Pilot). Blue Neural: Neutral circuit pressure. Green Exhaust: Light Green Cavitation: Oil subjected to a par
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