jcb 533-105 Service Manual
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SERVICE MANUAL
LOADALL (ROUGH TERRAIN
VARIABLE REACH TRUCK)
533-105, 535-v125, 540-140,
540-170, 540-200, 540-v140,
540-v180, 550-140, 550-170
EN - 9813/7650 - ISSUE 2 - 04/2018
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
Copyright 2018 © 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.
www.jcb.com
Foreword
The Operator's Manual
You and others can be killed or seriously injured
if you operate or maintain the machine without
first studying the Operator's Manual. You must
understand and follow the instructions in the
Operator's Manual. If you do not understand
anything, ask your employer or JCB dealer to
explain it.
Do not operate the machine without an Operator's
Manual, or if there is anything on the machine you
do not understand.
Treat the Operator's Manual as part of the machine.
Keep it clean and in good condition. Replace the
Operator's Manual immediately if it is lost, damaged
or becomes unreadable.
Contents
01 - Machine
03 - Attachments, Couplings and Load
Handling
06 - Body and Framework
09 - Operator Station
12
-
Heating,
Conditioning (HVAC)
15 - Engine
18 - Fuel and Exhaust System
21 - Cooling System
24 - Brake System
25 - Steering System
27 - Driveline
30 - Hydraulic System
33 - Electrical System
72 - Fasteners and Fixings
75 - Consumable Products
78 - After Sales
Ventilating
and
Air-

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Summary of Contents for jcb 533-105

  • Page 1 Operator's Manual. You must understand and follow the instructions in the Operator's Manual. If you do not understand anything, ask your employer or JCB dealer to explain it. SERVICE MANUAL Do not operate the machine without an Operator's Manual, or if there is anything on the machine you do not understand.
  • Page 2 Notes: 9813/7650-2...
  • Page 3 Spine Cards SERVICE MANUAL SERVICE MANUAL Volume 1 Volume 2 533-105, 535-v125, 540-140, 533-105, 535-v125, 540-140, 540-170, 540-200, 540-v140, 540-170, 540-200, 540-v140, 540-v180, 550-140, 550-170 540-v180, 550-140, 550-170 EN 9813/7650 EN 9813/7650 SERVICE MANUAL SERVICE MANUAL Volume 3 Volume 4...
  • Page 4 Notes: 9813/7650-2...
  • Page 5: Table Of Contents

    01 - Machine Contents Page No. Acronyms Glossary ............................ 01-2 01-03 Safety 01-03-03 Safety - Yours and Others ....................01-3 01-03-06 Safety Warnings ....................... 01-4 01-03-09 General Safety ......................... 01-5 01-03-12 Maintenance Safety ......................01-6 01-03-18 Operating Safety ......................01-8 01-03-21 Worksite Safety ......................
  • Page 6: Acronyms Glossary

    Acronyms Glossary FOPS Falling Object Protective Structure Parts Identification List ROPS Roll-Over Protective Structure 9813/7650-2 2018-02-05...
  • Page 7 01 - Machine 03 - Safety 03 - Safety Contents Page No. 01-03-03 Safety - Yours and Others ....................01-3 01-03-06 Safety Warnings ....................... 01-4 01-03-09 General Safety ......................... 01-5 01-03-12 Maintenance Safety ......................01-6 01-03-18 Operating Safety ......................01-8 01-03-21 Worksite Safety ......................
  • Page 8 Notes: 01 - 2 9813/7650-2 01 - 2...
  • Page 9: Safety

    They inform you of potential hazards and how to avoid them. If you do not fully understand the warning messages, ask your employer or JCB dealer to explain them. Safety is not just a matter of responding to the warnings.
  • Page 10: Safety Warnings

    01 - Machine 03 - Safety 06 - Safety Warnings 06 - Safety Warnings Introduction In this manual there are safety notices. Each notice starts with a signal word. The signal word meanings are given below. The signal word 'DANGER' indicates a hazardous situation which, if not avoided, will result in death or serious injury.
  • Page 11: General Safety

    Keep long hair restrained. Remove altered in any way which could affect or invalidate its rings, watches and personal jewellery. compliance. For advice consult your JCB dealer. Alcohol and Drugs It is extremely dangerous to operate machinery when under the influence of alcohol or drugs.
  • Page 12: Maintenance Safety

    Repairs pressure must be discharged by a JCB dealer, as the sudden release of the hydraulic fluid or gas may If your machine does not function correctly in cause serious injury or death.
  • Page 13 Chemicals Certain seals and gaskets (e.g. crankshaft oil seal) on JCB machines contain fluoroelastomeric materials such Viton®, FluorelTM Technoflon®.
  • Page 14: Operating Safety

    Before doing any job not covered in this manual, find Parking out the correct procedure. Your local JCB distributor will be glad to advise you. An incorrectly parked machine can move without an operator. Follow the instructions in the Operator's Fuel Manual to park the machine correctly.
  • Page 15 01 - Machine 03 - Safety 18 - Operating Safety Electrical Power Cables Hands and Feet You could be electrocuted or badly burned if you get Keep your hands and feet inside the machine. the machine or its attachments too close to electrical When using the machine, keep your hands and feet power cables.
  • Page 16: Worksite Safety

    01 - Machine 03 - Safety 21 - Worksite Safety 21 - Worksite Safety An applicable worksite organisation is required in order to minimise hazards that are caused by restricted visibility. The worksite organisation is a Introduction collection of rules and procedures that coordinates the machines and people that work together in WARNING You or others can be killed or seriously the same area.
  • Page 17: Risk Assessment

    If you are unsure of the suitability of the machine for • Are any other machines or persons likely to be a specific task, contact your JCB dealer who will be in or to enter the area while operations are in pleased to advise you.
  • Page 18: Maintenance Positions

    01 - Machine 03 - Safety 27 - Maintenance Positions 27 - Maintenance Positions Introduction For: 533-105 [T4F], 540-170 [T4F], 540-200 Introduction ............ 01-12 [T4F], 550-140 [T4F], 550-170 [T4F] Health and Safety .......... 01-13 ........... Page 01-12 For: 535-v125 [T4F], 540-v140 [T4F], 540- v180 [T4F] .........
  • Page 19 01 - Machine 03 - Safety 27 - Maintenance Positions Health and Safety Lift Arm Raised 1. Install the maintenance strut. WARNING Maintenance must be done only by suitably qualified and competent persons. Refer to: PIL 06-69. Before doing any maintenance make sure the machine is safe, it must be correctly parked on (For: 535-v125 [T4F], 540-v140 [T4F], 540- solid, level ground.
  • Page 20: About This Manual

    01 - Machine 06 - About this Manual 06 - About this Manual Contents Page No. 01-06-03 Model and Serial Number ....................01-15 01-06-06 Using the Manual ......................01-16 01 - 14 9813/7650-2 01 - 14...
  • Page 21: Model And Serial Number

    01 - Machine 06 - About this Manual 03 - Model and Serial Number 03 - Model and Serial Number Introduction This manual provides information for the following model(s) in the JCB machine range: Model From: 540-140 2460601 2902000 533-105...
  • Page 22: Using The Manual

    06 - Using the Manual Introduction Information in this manual conforms to a standard List). These headings are assigned numerical JCB service manual format. The format uses section identification references. headings taken from a PIL (Parts Identification Table 1. Example...
  • Page 23 01 - Machine 09 - Description 09 - Description Contents Page No. 01-09-00 General ........................... 01-19 01-09-03 Log Moving/Object Handling ..................01-21 01-09-06 Optional Equipment and Attachments ................01-22 01-09-12 Main Component Locations ................... 01-23 01-09-15 Service Point Locations ....................01-24 01 - 17 9813/7650-2...
  • Page 24 Notes: 01 - 18 9813/7650-2 01 - 18...
  • Page 25 00 - General 00 - General Introduction Introduction ............ 01-19 The JCB Loadall is a self propelled, seated operator, Operation ............01-20 wheeled machine for operation on unimproved natural terrain and disturbed terrain. A main structural support is designed to carry an...

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