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jcb 540-170 Service Manual

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Service Manual
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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
Publication No.
9803/3750-05
World Class
Customer Support
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.
Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400

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  • Page 1 Customer Support 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.
  • Page 2 Section 0 - Service Manual Notes: 9803/3750-05...
  • Page 3 Customer Support 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.
  • Page 4 Section 1 - General Information Notes: 9803/3750-05...

  • Page 5: Table Of Contents

    Section 1 - General Information Contents Page No. Applications Introduction ..................... 1-1-1 Tables ..................... 1-1-2 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 .....................
  • Page 6 Section 1 - General Information Contents Page No. 1-ii 1-ii...

  • Page 7: Introduction

    Section 1-1 - General Information Applications Introduction This manual contains topics that relate to some or all JCB Machine Group Model Code Model Name Loadall machines in the 5A group. There are several machine model codes in the family. 540-170...

  • Page 8: Tables

    Section 1-1 - General Information Applications Tables Tables Section 1 - General Information Machine models Topic Title Variant 540-170 550-140 540-140 550-170 535-125 535-140 HiViz HiViz All Machines Machine Identification All Machines Torque Settings All Machines Service Tools All Machines...
  • Page 9 Section 1-1 - General Information Applications Tables Section 2 - Care and Safety Machine models Topic Title Variant 540-170 550-140 540-140 550-170 535-125 535-140 HiViz HiViz Safety Notices All Machines General Procedures All Machines 1-1-3 1-1-3 9803/3750-05 (1-14-01)

  • Page 10: Ref 5Af 5Ag

    Section 1-1 - General Information Applications Tables Section 3 - Routine Maintenance Machine models Topic Title Variant 540-170 550-140 540-140 550-170 535-125 535-140 HiViz HiViz Introduction All Machines Service Schedules - Machines Mechanical F.I. with SD and SF Engines engines Service Schedules - Machines Electronic F.I.
  • Page 11 Section 1-1 - General Information Applications Tables Section B - Body and Framework Machine models Topic Title Variant 540-170 550-140 540-140 550-170 535-125 535-140 HiViz HiViz Fork Carriage Cab Heating and Ventilation SYSTEM Cab Air Conditioning SYSTEM Load Moment Indicator (LMI)
  • Page 12 Section 1-1 - General Information Applications Tables Section C - Electrics Machine models Topic Title Variant 540-170 550-140 540-140 550-170 535-125 535-140 HiViz HiViz Fuses and Relays Schematics Electrical Harness SYSTEM Battery Charging SYSTEM Alternator Battery 1-1-6 1-1-6 9803/3750-05 (1-14-01)
  • Page 13 Section 1-1 - General Information Applications Tables Section E - Hydraulics Machine models Topic Title Variant 540-170 550-140 540-140 550-170 535-125 535-140 HiViz HiViz Systems and Schematics Parallel Hydraulic SYSTEM Parallel Servo Hydraulic SYSTEM Hydraulic Interlock SYSTEM Parallel Control Valve - 6...
  • Page 14 Section 1-1 - General Information Applications Tables Section F - Transmission Machine models Topic Title Variant 540-170 550-140 540-140 550-170 535-125 535-140 HiViz HiViz CONFIGURATION Wheels and Tyres Front Axles SD80 Pivot sway SD80 Trunnion sway Rear Axles SD80 Pivot...
  • Page 15 Section 1-1 - General Information Applications Tables Section G - Brakes Machine models Topic Title Variant 540-170 550-140 540-140 550-170 535-125 535-140 HiViz HiViz Twin Axle Service Brakes SYSTEM (S1) Twin Axle Service Brakes SYSTEM (S2) External Park Brake SYSTEM...
  • Page 16 Section 1-1 - General Information Applications Tables Section H - Steering Machine models Topic Title Variant 540-170 550-140 540-140 550-170 535-125 535-140 HiViz HiViz Steering SYSTEM Manual Steer Mode SYSTEM Auto Steer Mode SYSTEM Hydraulic Steering Unit Priority Valve Power Track Rods...
  • Page 17 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) 1-1-11 1-1-11 9803/3750-05 (1-14-01)
  • Page 18 Section 1-1 - General Information Applications Tables Section M - Electronic Data Systems Machine models Topic Title Variant 540-170 550-140 540-140 550-170 535-125 535-140 HiViz HiViz CANbus SYSTEM Loadall Monitoring SYSTEM Fault Code SYSTEM Servicemaster SYSTEM Servicemaster Tools Electronic Control Unit Theory...

  • Page 19: Use

    Section 1-2 - General Information 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)

  • Page 20: Scope

    Section 1-2 - General Information Scope 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...

  • Page 21: Format

    Section 1-2 - General Information Format Format The manual is compiled in sections, the first three are numbered and contain information as follows: 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.

  • Page 22: Left And Right Sides

    Section 1-2 - General Information Left and Right Sides Left and Right Sides 'Left Hand' and 'Right Hand' are as viewed from the rear of the machine facing forwards. 1-2-4 1-2-4 9803/3750-05 (1-01-00)

  • Page 23: Hydraulic Schematic Codes

    The following colour coding, used on illustrations to denote various conditions of oil pressure and flow, is standardised throughout JCB Service Publications. Full Pressure: Pressure generated from operation of a service. Depending on application this may be anything between neutral circuit pressure and LSRV operating pressure.

  • Page 24: Electrical Device Codes

    Section 1-2 - General Information Electrical Device Codes Electrical Device Codes This manual uses a code system to help you identify the electrical devices on the machine. When the electrical system is designed at the factory codes are given to the electrical connectors on the electrical harnesses.

  • Page 25: Machine Identification

    Section 1-3 - General Information Machine Identification Introduction This topic contains information about a machine identification. On the machine and on the machine devices there are identification data plates. K Related Topics ( T 1-3-2) K Machine Identification Plate ( T 1-3-3) K Typical Product Identification Number (PIN) ( T 1-3-3) K Component Identification Plates ( T 1-3-5) K Typical Engine Identification Number ( T 1-3-5)

  • Page 26: Related Topics

    Section 1-3 - General Information Machine Identification Related Topics Related Topics Table 1. Related Topics in This Publication The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correct information.

  • Page 27: Machine Identification Plate

    Machine Model (3 Digits) The machine and engine serial numbers can help identify Standard Builds: exactly the type of equipment you have. 5AF = 540-170 5AM = 550-170 5AG = 550-140 5AN = 535-125 HiViz 5AL = 540-140...
  • Page 28 Machine Identification Plate Machines Built After January 2010 T011100-C1 World Manufacturer Identification (3 Digits) Machine Model (3 Digits) Standard Builds: 5AF = 540-170 5AM = 550-170 5AG = 550-140 5AN = 535-125 HiViz 5AL = 540-140 5AP = 535-140 HiViz...

  • Page 29: Component Identification Plates

    Section 1-3 - General Information Machine Identification Component Identification Plates Component Identification Plates Typical Engine Identification Number Engine data labels 2A are located on the cylinder block at position 2C and rocker cover 2D (if fitted). The data label contains important engine information and includes the engine identification number 2E.
  • Page 30 Section 1-3 - General Information Machine Identification Component Identification Plates Transmission Identification Numbers The transmission components have a serial number stamped on a data plate A as shown. 263370-C1 Fig 5. PS750 Powershift Transmission A710840-C1 Fig 3. Front Axle A401030-C2 Fig 6.
  • Page 31 Section 1-3 - General Information Machine Identification Component Identification Plates ROPS/FOPS and OECD Certification Plates 445911-5 Fig 7. Machines built to ROPS/FOPS standards have an identification label A fitted to the inside of the cab. Definition of terms: Machines built to ROPS/FOPS and OECD standards have ROPS Roll Over Protection Structure identification label B fitted to the inside of the cab.
  • Page 32 Section 1-3 - General Information Machine Identification Component Identification Plates Page left intentionally blank 1-3-8 1-3-8 9803/3750-05 (1-02-01)

  • Page 33: Torque Settings

    Section 1-4 - General Information Torque Settings Introduction This topic contains information about torques. Torque values are given for types and sizes of bolts and hydraulic connectors and adapters. Where a torque is given as a single figure it may be varied by plus or minus 3%. Torque figures are given for fasteners with different surface treatments.

  • Page 34: Zinc Plated Fasteners And Dacromet Fasteners

    For the same reason, a Dacromet nut should not be used with a Zinc or Yellow plated bolt. Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification.
  • Page 35 Section 1-4 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 2. Torque Settings - UNF Grade 'S' Fasteners Bolt Size Hexagon (A/F) Condition 1 Condition 2 kgf m lbf ft kgf m lbf ft 7/16 11.2 10.0 5/16 22.3...
  • Page 36 Section 1-4 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 4. Metric Grade 10.9 Fasteners Bolt Size Hexagon (A/F) Condition 1 Condition 2 ISO Metric Thread kgf m lbf ft kgf m lbf ft 13.9 10.2 12.5 34.0 25.0...
  • Page 37 Section 1-4 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 6. Torque Settings - Rivet Nut Bolts/Screws Bolt Size ISO Metric Thread kgf m lbf ft 10.0 24.0 18.0 48.0 35.5 82.0 60.5 Table 7. Torque Settings - Internal Hexagon Headed Cap Screws (Zinc) Bolt Size ISO Metric Thread...

  • Page 38: Hydraulic Connections

    Section 1-4 - General Information Torque Settings Hydraulic Connections Hydraulic Connections T11-003 'O' Ring Face Seal System Adaptors Screwed into Valve Blocks Adaptor screwed into valve blocks, seal onto an 'O' ring which is compressed into a 45° seat machined into the face of the tapped port.
  • Page 39 Section 1-4 - General Information Torque Settings Hydraulic Connections Hoses Screwed into Adaptors Fig 2. Hoses 2-B screwed into adaptors 2-A seal onto an `O' ring Note: Dimension 2-D will vary depending upon the torque 2-C which is compressed into a 45° seat machined into the applied.
  • Page 40 Section 1-4 - General Information Torque Settings Hydraulic Connections Adaptors into Component Connections with Bonded Washers Table 11. BSP Adaptors with Bonded Washers - Torque Settings BSP Size kgf m lbf ft 20.0 15.0 34.0 25.0 75.0 55.0 102.0 10.3 75.0 122.0 12.4...
  • Page 41 Section 1-4 - General Information Torque Settings Hydraulic Connections 'Torque Stop' Hose System Fig 3. `Torque Stop' Hoses 3-B screwed into adaptors 3-A seal Stop' Hoses have an additional shoulder 3-D, which acts onto an 'O' ring 3-C which is compressed into a 45° seat as a physical stop.

  • Page 42: Positional Type' Hydraulic Adaptors

    Note: The dimensions and shore hardness of the `O' ring is critical. Should it become necessary to replace the `O' ring, ensure that only JCB Genuine Parts are used. Screw the adaptor into the port of the hydraulic component as far as possible, so that ALL the threads engage and the `O' ring is correctly seated against the sealing face.

  • Page 43: Service Tools

    The tools listed in the table are special tools required for carrying out the procedures described in this manual. These tools are available from JCB Service or, in some instances, can be manufactured locally from the specifications given in this section.

  • Page 44: Numerical List

    Section 1-5 - General Information Service Tools Numerical List Numerical List Some tools are supplied as kits or sets. Cross references are given to tables showing the kit contents. Part Description: Tool Detail Reference: Number: K Fig 39. ( T 1-5-15) Bonded Washers - see tool detail reference for content K Fig 23.
  • Page 45 Section 1-5 - General Information Service Tools Numerical List Part Description: Tool Detail Reference: Number: K Fig 58. ( T 1-5-21) 892/00822 Splined Bolt Socket K Fig 3. ( T 1-5-6) 892/00842 Glass Lifter K Fig 4. ( T 1-5-6) 892/00843 Folding Stand for Holding Glass K Fig 17.
  • Page 46 Section 1-5 - General Information Service Tools Numerical List Part Description: Tool Detail Reference: Number: K Fig 55. ( T 1-5-20) 992/09400 Hexagon Spanner 65 mm A/F K Fig 55. ( T 1-5-20) 992/09500 Hexagon Spanner 75 mm A/F K Fig 55. ( T 1-5-20) 992/09600 Hexagon Spanner 85 mm A/F K Fig 55.

  • Page 47: Tool Detail Reference

    Section 1-5 - General Information Service Tools Tool Detail Reference Tool Detail Reference 826/01099 M6 x 16 mm Rivet Nut 826/01101 M6 x 19 mm Rivet Nut 826/01102 M8 x 18 mm Rivet Nut 826/01103 M8 x 21 mm Rivet Nut 826/01104 M10 x 23 mm Rivet Nut 826/01105A M10 x 26 mm Rivet Nut...
  • Page 48 Section 1-5 - General Information Service Tools Tool Detail Reference Fig 3. 892/00842 Glass Lifter Minimum 2 off - Essential for glass installation, 2 required to handle large panes of glass. Ensure suction cups are protected from damage during storage. Fig 6.
  • Page 49 K Fig 6. ( T supplied. extraction tool. 1-5-6). Approx 25 m length. Note: 110V models available upon request - contact JCB Technical Service. Fig 10. 926/15500 Rubber Spacer Blocks Used to provide the correct set clearance between glass edge and cab frame. Unit quantity = 500 off.
  • Page 50 Section 1-5 - General Information Service Tools Tool Detail Reference Fig 15. 4104/1310 Hand Cleaner Special blend for the removal of polyurethane adhesives (454g; 1 lb tub). Fig 18. 892/00298 Fluke Meter Fig 19. 892/00285 Hydraulic Temperature Probe Fig 16. 992/01100 Glazing Tool, used to insert aperture seal expansion strip.
  • Page 51 Section 1-5 - General Information Service Tools Tool Detail Reference Fig 21. 892/00905 LMI Test Box For testing load moment indicator system Fig 22. 993/85700 Battery Tester 1-5-9 1-5-9 9803/3750-05 (1-06-00)
  • Page 52 Section 1-5 - General Information Service Tools Tool Detail Reference K Electrical Repair Kit ( T 1-5-10) Electrical Repair Kit 7212/0002 2 Way Pin Housing 7212/0004 2 Way Pin Retainer 7212/0003 2 Way Socket Retainer 7212/0001 2 Way Socket Connector 7213/0002 3 Way Pin Housing 7213/0004...
  • Page 53 Section 1-5 - General Information Service Tools Tool Detail Reference Fig 25. 892/00349 Crimp Tool Fig 26. Splice 892/00351 Splice 0.5-1.5 mm (Red) 892/00352 Splice 1.5-2.5 mm (Blue) 892/00353 Splice 3.0-6.0 mm (Yellow) 1-5-11 1-5-11 9803/3750-05 (1-06-00)
  • Page 54 Section 1-5 - General Information Service Tools Tool Detail Reference Note: No longer available, refer to 998/11046 JCB 892/00268 Flow Monitoring Unit K Fig 28. ( T ServiceMaster Flow Test Kit. 1-5-12). 892/00269 Sensor Head 0 - 100 l/min (0 - 22 UK gal/min) 892/00273 Sensor Head 0 - 380 l/min (0 - 85.5 UK gal/min)
  • Page 55 Section 1-5 - General Information Service Tools Tool Detail Reference Note: No longer available, refer to 998/11051 JCB 892/00201 Replacement Gauge 0-20 bar (0-300 lbf/in ServiceMaster Digital Hydraulic Datalogger Pressure K Fig 30. ( T Test Kit. 1-5-13). 892/00202 Replacement Gauge 0-40 bar (0-600 lbf/in...
  • Page 56 Section 1-5 - General Information Service Tools Tool Detail Reference Male Adapters - BSP x BSP 1606/2052 3/8 in. x 1/4 in. 1604/0003A 3/8 in. x 3/8 in. 892/00071 3/8 in. x 3/8 in. taper 1606/0004 1/2 in. x 1/4 in. 1606/0007A 1/2 in.
  • Page 57 Section 1-5 - General Information Service Tools Tool Detail Reference 892/00047 3/8 in. BSP (A) x 1/4 in. BSP (B) 892/00048 1/2 in. BSP (A) x 1/4 in. BSP (B) 892/00049 5/8 in. BSP (A) x 1/4 in. BSP (B) 816/50043 3/4 in.
  • Page 58 Section 1-5 - General Information Service Tools Tool Detail Reference Fig 40. 892/00964 Test Point 1/8 BSP Fig 41. 892/00965 Test Point 3/8 BSP 892/00223 Hand Pump 892/00137 Micro-bore Hose 1/4 in BSP x 3 metres 892/00274 Adapter 1/4 in M BSP x 3/8 in M BSP Taper 892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point 892/00706...
  • Page 59 Section 1-5 - General Information Service Tools Tool Detail Reference Fig 47. 892/00301 Flow Test Adaptor Note: Components listed as follows also required: Item Description 892/00920 Adaptor 892/00302 Adaptor A313250-C1 Fig 46. 460/15708 Flow Test Adaptor Note: Components listed below also required: Item Description 460/15707 Banjo bolt...
  • Page 60 Section 1-5 - General Information Service Tools Tool Detail Reference Fig 49. Spool Clamps Fig 50. 892/00180 - Seal Fitting Tool 992/09100 Spool Clamp Seal Fitting Tool for fitting 'O' ring and back-up ring to 892/00011 Spool Clamp Danfoss Orbitrol Unit. 892/00181 - Replacement Plastic Boss 993/99512 Spanner 55 mm A/F...
  • Page 61 Section 1-5 - General Information Service Tools Tool Detail Reference 993/99525 Rig Assembly (not including spanners and ram) 993/99522 Anchor Side Plate (supplied loose unwelded) 993/99523 Anchor Cross Member (supplied loose unwelded) 993/99524 Ram Eye End Modification Plate Assembly 556/43400 Lift Ram 545/18000 Lynch Pin...
  • Page 62 Section 1-5 - General Information Service Tools Tool Detail Reference 892/01016 For 25 mm Rod Diameter 892/01017 For 30 mm Rod Diameter 892/01018 For 40 mm Rod Diameter 892/01019 For 50 mm Rod Diameter 892/01020 For 50 mm Rod Diameter (slew ram) 892/01021 For 60 mm Rod Diameter 892/01022...
  • Page 63 Section 1-5 - General Information Service Tools Tool Detail Reference Fig 60. 892/00893 Torque Converter Alignment Tool For use with 11” torque converters Fig 57. 992/04000 Torque Multiplier Fig 58. 892/00822 Splined Bolt Socket Fig 61. 332/E7911 Exhaust Fitting Clamp Fig 59.
  • Page 64 Section 1-5 - General Information Service Tools Tool Detail Reference Fig 63. 320/20050 Lifting Bracket Kit Fig 64. 892/01174 Data Link Adaptor Kit USB PC Cable 718/20235 Serial PC Cable 718/20236 USB DLA 728/26500 Machine Cable 718/20237 Kit 892/01174 (includes items A,B,C and D) 1-5-22 1-5-22 9803/3750-05 (1-06-00)

  • Page 65: Rivet Nuts

    Section 1-5 - General Information Service Tools Rivet Nuts Rivet Nuts TB-001_2 A 'Rivet Nut' is a one piece fastener installed 'blind' from Table 1. Specifications one side of the machine body/framework. The rivet nut 65- Rivet Nut Rivet Nut Material Rivet Drill...
  • Page 66 Section 1-5 - General Information Service Tools Rivet Nuts Fitting Procedure (smooth bulge) seating itself against the body/ framework 68-E. Drill a hole in the machine body/framework where the Note: The thread of the rivet nut must not be stripped, take rivet nut is to be fitted.

  • Page 67: Slide Hammer Kit

    Section 1-5 - General Information Service Tools Slide Hammer Kit Slide Hammer Kit TB-003 Fig 69. Typical M/c. Installation The slide hammer kit is used to remove pivot pins that Fit an end stop 69-B onto the other end of the adaptor must be extracted, i.e.
  • Page 68 Section 1-5 - General Information Service Tools Slide Hammer Kit Page left intentionally blank 1-5-26 1-5-26 9803/3750-05 (1-06-00)

  • Page 69: Service Consumables

    Section 1-6 - General Information Service Consumables Introduction Consumables such as sealing and retaining compounds are necessary to complete some procedures. Before you start work make sure that the consumables show in the tables are available. K Sealing and Retaining Compounds ( T 1-6-2) 1-6-1 1-6-1 9803/3750-05 (1-07-00)

  • Page 70: Sealing And Retaining Compounds

    A medium strength sealant suitable for all sizes of 4102/1212 50 ml gasket flanges, and for hydraulic fittings of 25-65 mm diameter. JCB High Strength Threadlocker A high strength locking fluid for use with threaded 4102/0551 50 ml components. Gasketing for all sizes of flange where the strength of the joint is important.

  • Page 71: Fuel

    Section 1-7 - General Information Fuel Introduction This topic contains information fuel types and use with JCB Dieselmax engines. When investigating engine related faults find out what types and sources of fuel are used by the operator. K Related Topics ( T 1-7-2)

  • Page 72: Related Topics

    Section 1-7 - General Information Fuel Related Topics Related Topics Table 1. Related Topics in This Publication The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correct information.

  • Page 73: Acceptable And Unacceptable Fuels

    CAUTION accepted for failure of fuel injection equipment where the failure is attributed to the quality and grade of the fuel used. Consult your fuel supplier or JCB distributor about the suitability of any fuel you are unsure of. GEN-9-2...
  • Page 74 Note: If performance related issues are to be reported to – Lubrizol 539N. Dosage (on Swedish low sulphur fuel) JCB Service, and the engine has been run on biodiesel, 250 ppm. then the fuel system must be filled with standard diesel (at least 2 x tank fills) to EN590 specification and relevant stall –...
  • Page 75 Unacceptable Fuels ( T 1-7-3). Any fuel purchased for operation of the JCB Dieselmax engine must be purchased from reputable oil producers/ outlets and stored in accordance with the manufacturers K Effects recommendations.
  • Page 76 Section 1-7 - General Information Fuel Acceptable and Unacceptable Fuels Usage and Effects of Fuels stability, viscosity and cetane number than those produced from unmodified vegetable oils, but it is recognised that there are potential problems Note: The information that follows does not indicate types associated with the finished fuel characteristics.
  • Page 77 Section 1-7 - General Information Fuel Acceptable and Unacceptable Fuels in filter clogging. To prevent this happening pre- Sulphur Content heating will be required. High sulphur content can cause engine wear. (High Using B20 biodiesel can result in unburnt fuels sulphur fuel is not normally found in North America, accumulating in the engine oil, ultimately this can Europe or Australia.) If you have to use high sulphur fuel...
  • Page 78 Section 1-7 - General Information Fuel Acceptable and Unacceptable Fuels Effects of Fuel Contaminates The effect of dirt, water and other contaminants in diesel can be disastrous for injection equipment: – Dirt - A severely damaging contaminant. Finely machined and mated surfaces such as delivery valves and distributor rotors are susceptible to the abrasive nature of dirt particles - increased wear will almost inevitably lead to greater leakage, uneven...

  • Page 79: Stall Speed Combinations

    Section 1-8 - General Information Stall Speed Combinations Introduction If the operator reports poor machine performance the stall speed test is a very useful way to quickly and easily determining if the engine, transmission or hydraulic system is faulty. Do the stall speed tests to help diagnose which system is at fault. Refer to the applicable section (Hydraulics, Transmission or Engine) for details of the test procedures.

  • Page 80: Related Topics

    Section 1-8 - General Information Stall Speed Combinations Related Topics Related Topics Table 1. Related Topics in This Publication The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures.

  • Page 81: Specifications

    Section 1-8 - General Information Stall Speed Combinations Specifications Specifications Tests carried out at the factory record the correct engine Note: The figures apply to `bedded-in' engines, i.e. r.p.m. (stall speed) when under maximum load from the engines that have done a minimum of 250 working hours, transmission and hydraulic systems.
  • Page 82 Section 1-8 - General Information Stall Speed Combinations Specifications Page left intentionally blank 1-8-4 1-8-4 9803/3750-05 (1-15-01)
  • Page 83 Customer Support 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.
  • Page 84 Section 2 - Care and Safety Notes: 9803/3750-05...
  • Page 85 Section 2 - Care and Safety Contents Page No. Safety Notices Introduction ....................2-1 - 1 Important Information ................2-1 - 2 Safety Check List ...................2-1 - 3 Safety Labels ..................2-1 - 16 General Procedures Introduction ....................2-2 - 1 Related Topics ..................2-2 - 2 Parking the Machine and Making it Safe ..........2-2 - 3 Boom Safety Strut .................2-2 - 4 Venting Hydraulic Pressure ..............2-2 - 7...

  • Page 86: Safety Notices

    Section 2-1 - Care and Safety Safety Notices Introduction In this publication and on the machine, there are safety notices. Each notice starts with a signal word. The signal word meanings are given below. DANGER Denotes extreme hazard exists. proper precautions are not taken, it is highly probable that the operator (or others) could be killed or seriously injured.

  • Page 87: Important Information

    Operator Manual. If other operators. you do not understand anything, ask your employer or JCB dealer to explain it. In this publication and on the machine, there are safety INT-1-4-2 notices. Each notice starts with a signal word. The signal word meanings are given below.

  • Page 88: Safety Check List

    Failure to follow these instruction will lead to dirt understand the warning messages, ask your employer or entering the fuel system. Dirt in the fuel system will JCB distributor to explain them. seriously damage the fuel injection equipment and could be expensive to repair.
  • Page 89 JCB. Refer to Section 1 - Acceptable and Unacceptable Fuels. It is critical that the machine is thoroughly cleaned prior to –...
  • Page 90 Section 2-1 - Care and Safety Safety Notices Safety Check List General Safety WARNING T1-043 Feeling Unwell WARNING Do not attempt to operate the machine if you are feeling unwell. By doing so you could be a danger to To operate the machine safely you must know the yourself and those you work with.
  • Page 91 WARNING Machine Modifications This machine is manufactured in compliance with legislative and other requirements. It should not be altered in any way which could affect or invalidate any of these requirements. For advice consult your JCB Distributor. INT-1-3-10_2 2-1-6 2-1-6...
  • Page 92 Section 2-1 - Care and Safety Safety Notices Safety Check List Operating Safety WARNING You could be killed or seriously injured if you operate WARNING a machine with a damaged or missing ROPS/FOPS. If the Roll Over Protection Structure (ROPS)/Falling Machine Condition Objects Protection Structure (FOPS) has been in an A defective machine can injure you or others.

  • Page 93: Use

    If that machine potentially explosive happens you could lose control of the machine. atmosphere, i.e. combustible vapours, gas or dust, 2-2-3-6 without first consulting your JCB Distributor. INT-2-1-14 WARNING Visibility CAUTION Accidents can be caused by working in poor visibility. Regulations Use your lights to improve visibility.
  • Page 94 Make sure the 5-5-1-1_2 forks are completely under the load before lifting. WARNING 5-1-4-2 Use only the JCB approved attachments that are CAUTION specified for your machine. Operating with non- specified attachments can overload the machine, One-Fork Lifting causing possible damage and machine instability A load lifted on one fork can slip off.
  • Page 95 Section 2-1 - Care and Safety Safety Notices Safety Check List WARNING WARNING Scaffolding Controls Overloaded scaffolding can collapse. Never load You or others can be killed or seriously injured if you scaffolding beyond the regulation capacity. operate the control levers from outside the machine. Operate the control levers only when you are correctly 5-1-4-6 seated in the machine.
  • Page 96 Section 2-1 - Care and Safety Safety Notices Safety Check List Maintenance Safety WARNING Fluid Under Pressure WARNING Fine jets of fluid at high pressure can penetrate the skin. Keep face and hands well clear of fluid under Communications pressure and wear protective glasses and gloves. Bad communications can cause accidents.
  • Page 97 Section 2-1 - Care and Safety Safety Notices Safety Check List CAUTION CAUTION It is illegal to pollute drains, sewers or the ground. 'O' rings, Seals and Gaskets Clean up all spilt fluids and/or lubricants. Badly fitted, damaged or rotted 'O' rings, seals and gaskets can cause leakages and possible accidents.
  • Page 98 Safety Notices Safety Check List WARNING WARNING Certain seals and gaskets (e.g. crankshaft oil seal) on To avoid burning, wear protective gloves when JCB machines contain fluoroelastomeric materials handling hot components. To protect your eyes, wear such Viton, Fluorel Technoflon.
  • Page 99 Prior to any work being carried out on systems incorporating accumulators, the system INT-3-1-14 pressure must be exhausted by a JCB distributor, as the sudden release of the hydraulic fluid or gas may WARNING cause injury. If you try to charge a frozen battery, or jump start and INT-3-1-17 run the engine, the battery could explode.
  • Page 100 Section 2-1 - Care and Safety Safety Notices Safety Check List WARNING Wheels and tyres are heavy. Take care when lifting or moving them. Store with care to ensure that they cannot fall and cause injury. 13-3-1-7_1 CAUTION Never use water or steam to clean inside the cab. The use of water or steam could damage the on-board computer and render the machine inoperable.

  • Page 101: Safety Labels

    Keep all safety labels clean and readable. Replace lost or damaged safety labels. Make sure replacement parts include safety labels where necessary. Each safety label has a part number printed on it, use this number to order a new decal from your JCB distributor. 2-1-16 2-1-16 9803/3750-05 (2-01-01)

  • Page 102: General Procedures

    Section 2-2 - Care and Safety General Procedures Introduction When work is done on the machine it is important that the correct care is taken. This will help to prevent personal injury and reduce the risk of component failure. As part of the procedures in this manual you will need to do some general procedures. Two examples of these general procedures are;...

  • Page 103: Related Topics

    Section 2-2 - Care and Safety General Procedures Related Topics Related Topics Table 1. Related Topics in This Publication The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures.

  • Page 104: Parking The Machine And Making It Safe

    Section 2-2 - Care and Safety General Procedures Parking the Machine and Making it Safe Parking the Machine and Making it Safe Position the machine on firm level ground. If possible choose an area that is clean and dry. When possible park the machine in a covered area if procedures include work on the hydraulic or fuel systems.

  • Page 105: Boom Safety Strut

    535-125 HiViz, 535-140 HiViz You will have to climb onto the machine to fit or K Fig 3. ( T 2-2-5) 540-140, 540-170 remove the strut. Take care, especially if the machine is wet. Remove mud and oil before climbing onto the machine.
  • Page 106 Section 2-2 - Care and Safety General Procedures Boom Safety Strut 807540-1 Fig 2. T012120-2 Fig 3. 2-2-5 2-2-5 9803/3750-05 (2-02-01)
  • Page 107 Section 2-2 - Care and Safety General Procedures Boom Safety Strut Removing WARNING You could be killed or injured if the boom drops while you are working under it. Fit the boom maintenance strut as instructed before doing any maintenance work with the boom raised.

  • Page 108: Venting Hydraulic Pressure

    Section 2-2 - Care and Safety General Procedures Venting Hydraulic Pressure Venting Hydraulic Pressure WARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses or couplings, vent the pressure trapped in the hoses in accordance with the instructions given in this publication.

  • Page 109: Connecting/Disconnecting Hydraulic Hoses

    Section 2-2 - Care and Safety General Procedures Connecting/Disconnecting Hydraulic Hoses Connecting/Disconnecting Hydraulic Hoses Introduction a For Quick Release Couplings see the procedures K Quick this section. Release Couplings ( T 2-2-9) The following paragraphs describe how to connect and disconnect hydraulic hoses safely.

  • Page 110: Quick Release Couplings

    Section 2-2 - Care and Safety General Procedures Quick Release Couplings Quick Release Couplings T4-001_2 Connecting and Disconnecting wedge underneath the sleeve and destroy the coupling. Flat face quick release couplings allow the operator to – Don't damage the faces of the couplings - this can remove and install attachments swiftly and efficiently.
  • Page 111 Section 2-2 - Care and Safety General Procedures Quick Release Couplings Connecting Quick Release Couplings Remove any residual hydraulic pressure trapped in the service line hose. Wipe the two faces of the male and female couplings and make sure they are clean. Make sure that ball 4-C in the female coupling is located in one of its slots.

  • Page 112: Hydraulic Contamination

    Section 2-2 - Care and Safety General Procedures Hydraulic Contamination Hydraulic Contamination TE-002_2 Hydraulic Fluid Quality Procedure Connect the cleaning unit in place of the hydraulic filter. Construction machinery uses a large volume of fluid in the K Fig 5. ( T 2-2-11).
  • Page 113 Section 2-2 - Care and Safety General Procedures Hydraulic Contamination Contaminant Standards Dirt that damages your system is in many cases too small to be seen with the eye. The particle size is measured in microns. 1 micron = 0.001 mm (0.0000394 in). Listed below are a few typical comparisons: –...

  • Page 114: Battery Disconnection/Connection

    Section 2-2 - Care and Safety General Procedures Battery Disconnection/Connection Battery Disconnection/Connection WARNING Keep metal watch straps and any metal fasteners on your clothes, clear of the positive (+) battery terminal. Such items can short between the terminal and nearby metal work.

  • Page 115: Removing And Replacing Components

    Section 2-2 - Care and Safety General Procedures Removing and Replacing Components Removing and Replacing Components Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt.

  • Page 116: Battery Charging System Precautions

    Section 2-2 - Care and Safety General Procedures Battery Charging System Precautions Battery Charging System Precautions Obey the procedures below to prevent damage to the alternator and battery. Ensure that the battery negative terminal is connected to the earthing cable. Never make or break connections to the battery or alternator, or any part of the charging circuit whilst the engine is running.

  • Page 117: Hydraulic Rams

    Special seal materials are necessary so check to piston rod. see if the ram that you are using is suitable or not. Use genuine JCB parts when replacing parts. 2-2-16 2-2-16 9803/3750-05 (2-02-01)
  • Page 118 Section 2-2 - Care and Safety General Procedures Hydraulic Rams a If parts other than genuine JCB parts are used, the desired results may not be obtained. Use only genuine JCB parts. Caution during dismantling and reassembly. a Dismantling the ram while it is still installed on the machine can be dangerous as unexpected movements of the machine can occur.
  • Page 119 Section 2-2 - Care and Safety General Procedures Hydraulic Rams Page left intentionally blank 2-2-18 2-2-18 9803/3750-05 (2-02-01)
  • Page 120 Customer Support 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.
  • Page 121 Section 3 - Routine Maintenance Notes: 9803/3750-05...
  • Page 122 Section 3 - Routine Maintenance Contents Page No. Introduction Health and Safety ................... 3-1-1 Service Schedules - Machines with SD and SF Engines Related Topics ..................3-2-1 Introduction ..................... 3-2-2 Pre-start Cold Checks, Service Points and Fluid Levels ......3-2-3 Functional Test and Final Inspection ............
  • Page 123 Section 3 - Routine Maintenance Contents Page No. Changing the Oil and Filter ..............3-13-3 Checking the Coolant Level ..............3-13-5 Front End Accessory Drive Belt ............3-13-9 Engine Air Filter Related Topics ..................3-14-1 Cleaning the Air Filter Dust Valve ............3-14-2 Changing the Elements ................

  • Page 124: Health And Safety

    Handling too. Hygiene WARNING JCB lubricants are not a health risk when used properly for Oil is toxic. If you swallow any oil, do not induce their intended purposes. vomiting, seek medical advice. Used engine oil contains harmful contaminants which can cause skin However, excessive or prolonged skin contact can remove cancer.
  • Page 125 Section 3-1 - Routine Maintenance Introduction Health and Safety c Use special hand cleansers to help clean dirty hands. d Never use petrol, diesel fuel, or paraffin for washing. Avoid skin contact with oil soaked clothing. Don't keep oily rags in pockets. Wash dirty clothing before re-use.
  • Page 126 Section 3-1 - Routine Maintenance Introduction Health and Safety Battery CAUTION T3-061 Damaged or spent batteries and any residue from fires WARNING or spillage should be put in a closed acid proof receptacle and must be disposed of in accordance Batteries give off an explosive gas.
  • Page 127 Section 3-1 - Routine Maintenance Introduction Health and Safety Warning Symbols First Aid - Electrolyte The following warning symbols may be found on the Do the following if electrolyte: battery. Gets into your eyes Symbol Meaning Immediately flush with water for 15 minutes, always get Keep away from children.

  • Page 128: Service Schedules - Machines With Sd And Sf Engines

    Section 3-2 - Routine Maintenance Service Schedules - Machines with SD and SF Engines Related Topics Table 1. Related Topics in This Publication The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures.

  • Page 129: Introduction

    Section 3-2 - Routine Maintenance Service Schedules - Machines with SD and SF Engines Introduction Introduction A badly maintained machine is a danger to the operator Important: Services should be carried out at either the and the people working around him. Make sure that the hourly interval or calendar interval, whichever occurs first.

  • Page 130: Pre-Start Cold Checks, Service Points And Fluid Levels

    Section 3-2 - Routine Maintenance Service Schedules - Machines with SD and SF Engines Pre-start Cold Checks, Service Points and Fluid Levels Pre-start Cold Checks, Service Points and Fluid Levels Operation 1000 2000 6000 ENGINE Coolant Quality and Level - Check Cooling System - Drain and Refill Oil level...
  • Page 131 Section 3-2 - Routine Maintenance Service Schedules - Machines with SD and SF Engines Pre-start Cold Checks, Service Points and Fluid Levels Operation 1000 2000 6000 Axle Mount Security - Check Axle(s) Oil Level - Check Axle(s) Oil - Change Hub Oil Level (Without Oil Immersed Brakes) - Check Hub Oil (Without Oil Immersed Brakes)
  • Page 132 SWL Stickers (UK) and Flip Chart - Renew as Required (1) First 100 Hours Service only, to be completed by your JCB Distributor. (2) If operating under arduous conditions, do an engine oil flush (use the normal recommended engine oil) every 250 hours.
  • Page 133 (10) The axles and driveshafts are factory greased with a high performance grease, if during service a standard grease is used, then the interval must be reduced to every 50 hours, contact your JCB Distributor for advice. (11) An additional canister filter is fitted to machines with the variable flow pump option. You must change both filters at the intervals shown in the Service Schedule.

  • Page 134: Functional Test And Final Inspection

    Section 3-2 - Routine Maintenance Service Schedules - Machines with SD and SF Engines Functional Test and Final Inspection Functional Test and Final Inspection Operation 1000 2000 6000 ENGINE Idle Speed - Check and Adjust - Check Torque Converter Stall Speed - Check and Adjust Max.
  • Page 135 - Fit and Check Security Generally for damage, leaks and wear - Check (1) First 100 Hours Service only, to be completed by your JCB Distributor. (2) Jobs which should only be done by a specialist. 3-2-8 3-2-8 9803/3750-05 (3-20-00)

  • Page 136: Service Schedules - Machines With Se Engines

    Section 3-3 - Routine Maintenance Service Schedules - Machines with SE Engines Related Topics Table 1. Related Topics in This Publication The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures.

  • Page 137: Introduction

    Section 3-3 - Routine Maintenance Service Schedules - Machines with SE Engines Introduction Introduction A badly maintained machine is a danger to the operator Important: Services should be carried out at either the and the people working around him. Make sure that the hourly interval or calendar interval, whichever occurs first.
  • Page 138 Section 3-3 - Routine Maintenance Service Schedules - Machines with SE Engines Introduction Pre-start Cold Checks, Service Points and Fluid Levels Operation 1000 2000 8000 ENGINE Coolant Quality and Level - Check Cooling System - Drain and Refill Oil level - Check - Change Oil and Filter...
  • Page 139 Section 3-3 - Routine Maintenance Service Schedules - Machines with SE Engines Introduction Operation 1000 2000 8000 Axle(s) Oil Level - Check Axle(s) Oil - Change Hub Oil Level (Without Oil Immersed - Check Brakes) Hub Oil (Without Oil Immersed Brakes) - Change - Change Hub Oil (With Oil Immersed Brakes)
  • Page 140 (10) The axles and driveshafts are factory greased with a high performance grease, if during service a standard grease is used, then the interval must be reduced to every 50 hours, contact your JCB Distributor for advice. (11) An additional canister filter is fitted to machines with the variable flow pump option. You must change both filters at the intervals shown in the Service Schedule.
  • Page 141 Section 3-3 - Routine Maintenance Service Schedules - Machines with SE Engines Introduction Functional Test and Final Inspection Operation 1000 2000 8000 ENGINE Idle Speed - Check and Adjust - Check Torque Converter Stall Speed Max. No-Load Speed - Check and Adjust - Check Exhaust System Security Air Inlet System Security...
  • Page 142 Forks - Fit and Check Security Generally for damage, leaks and wear - Check (1) First 100 Hours Service only, to be completed by your JCB Distributor. (2) Jobs which should only be done by a specialist. 3-3-7 3-3-7 9803/3750-05 (3-21-00)
  • Page 143 Section 3-3 - Routine Maintenance Service Schedules - Machines with SE Engines Introduction Page left intentionally blank 3-3-8 3-3-8 9803/3750-05 (3-21-00)

  • Page 144: Fluids, Lubricants And Capacities

    Section 3-4 - Routine Maintenance Fluids, Lubricants and Capacities Related Topics Table 1. Related Topics in This Publication The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correct information.
  • Page 145 Machines up to August 2010 535-125 HiViz, 535-140 125 (27.5) HiViz, 540-140, 540-170 Machines from August 2010 145 (31.9) Engine (Oil) JCB Engine Oil EP -10°C to SAE15W/40, ACEA E5/B3/ 4001/1800 (1)(2) A3, API CH-4/SJ 50°C (14°F to 122°F) JCB Cold Climate Engine Oil -...
  • Page 146 (7) Includes extreme performance additives. (8) JCB HP Grease is the recommended specification grease. If JCB MPL Grease is used, all 50 hour greasing operations must be carried out at ten (10) hour intervals; all 500 hour greasing operations must be carried out at 50 hour intervals.
  • Page 147 The correct concentration of antifreeze protects the engine against frost damage in winter and provides year round protection against corrosion. The protection provided by JCB High Performance Antifreeze and Inhibitor is shown below. 50% Concentration (Standard) Protects against damage down to -40 °C (-39 °F) 60% Concentration (Extreme Conditions Only) Protects against damage down to -56 °C (-68 °F)
  • Page 148 Section 3-5 - Routine Maintenance Cleaning the Machine Related Topics Table 1. Related Topics in This Publication The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correct information.
  • Page 149 Section 3-5 - Routine Maintenance Cleaning the Machine Introduction Introduction T3-024 Clean the machine using water and or steam. Do not allow Important: Do not aim the water jet directly at bearings, oil mud, debris etc. to build upon the machine. seals or electrical and electronic components such as the engine electronic control unit (ECU), alternator or fuel Before carrying out any service procedures that require...

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