jcb 533-105 Service Manual

Loadall (rough terrain variable reach truck)
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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 - 9813/9100 - ISSUE 1 - 11/2017
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
Copyright 2017 © 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 15 - Engine 30 - Valve 00 - General 00 - General Introduction Introduction ..........15-115 The valve train system opens and closes the Technical Data ..........15-116 valves with correct timing in relation to the piston movements. Component Identification ......
  • Page 3: Technical Data

    15 - Engine 30 - Valve 00 - General Technical Data Table 106. Inlet and Exhaust Valve Data Max lift Inlet 7.56mm @ 101°ATDC (After Top Dead Centre) Max lift Exhaust 7.32mm @ 109 BTDC (Before Top Dead Cen- tre) Inlet opens (top of ramp) 4.4°BTDC Inlet closes 50.6°ABDC (After Bot-...
  • Page 4: Component Identification

    15 - Engine 30 - Valve 00 - General Component Identification Figure 312. A Camshaft gear B Crankshaft gear C Camshaft D HLA (Hydraulic Lash Adjuster) (x8) E Push rods (x8) F Rocker - exhaust (x4) G Rocker - inlet (x4) H Rocker shaft J Valve - inlet (x8) K Valve - exhaust (x8)
  • Page 5: Remove And Install

    15 - Engine 30 - Valve 00 - General Remove and Install Special Tools 4. Remove the cylinder head assembly. Description Part No. Qty. Refer to: PIL 15-06-00. Valve Stem Seal 320/03890 5. Measure the valve recession with a suitable DTI Installation Tool (430 (Dial Test Indicator).
  • Page 6: Before Installation

    15 - Engine 30 - Valve 00 - General Figure 316. If there is evidence of wear or damage to the valves, guides or seats, it is advisable to obtain a new or reconditioned cylinder head assembly. Before Installation 1. Position the cylinder head upside down in a suitable jig or fixture.
  • Page 7: Check (Condition)

    15 - Engine 33 - Connecting Rod 06 - Big-End Bearing Check (Condition) Remove and Install Special Tools 1. Check the bearing shell surfaces for signs of Description Part No. Qty. damage and excessive wear. Torque Wrench 993/70111 Refer to: PIL 15-33-00. (10-100Nm) 2.
  • Page 8 15 - Engine 33 - Connecting Rod 06 - Big-End Bearing Figure 318. Figure 319. 1 Big-end bearing caps 2 Big-end bearing cap bolts X Cast notch 2.1. Make sure that the tool is kept in inline 1 Big-end bearing cap with the bolt to avoid damaging the screw 2 Bolts thread.
  • Page 9 15 - Engine 33 - Connecting Rod 06 - Big-End Bearing 4. Install the lower bearing shell to the big-end bearing cap. Lubricate the bearing shell with clean engine oil. Install the big-end bearing cap to the connecting rod. Make sure that the cast notch on the bearing cap faces to the front of the engine.
  • Page 10 15 - Engine 36 - Piston 00 - General Technical Data Table 109. Piston Data Gudgeon pin bore diam- eter - min. 36.01mm - max. 36.015mm Piston ring clearance - Top ring 0.155–0.12mm - Middle ring 0.13–0.09mm - Bottom (oil) ring 0.08–0.02mm Piston ring gap - Top ring...
  • Page 11 15 - Engine 36 - Piston 00 - General Component Identification Figure 322. Piston B Piston ring - compression No.1 Piston ring - compression No.2 D Piston ring - oil control ring Da Spiral wire - oil control ring E Connecting rod G Retaining circlip (x2) Piston pin Piston orientation cut out...
  • Page 12: Operation

    15 - Engine 36 - Piston 00 - General Operation The groove around the diameter of the upper main The jets spray oil directly to the under side of the bearing shells allows oil transfer to an oil jet located pistons effectively transferring heat away from the in the crankcase bearing saddle.
  • Page 13 15 - Engine 36 - Piston 00 - General Check (Condition) Calibrate 1. Check the piston for signs of damage and Piston Height Measurement Above excessive wear. Measure the piston skirt Cylinder Block- DTI Method diameter, piston pin bore and the clearance in the piston ring grooves to confirm they are within In the event of sufficient liquid entering the engine, a service limits.
  • Page 14 15 - Engine 36 - Piston 00 - General Figure 324. DTI Measurement 5. Calculate the average of the 2 readings to give a figure of the piston height above the cylinder block. 5.1. If the reading obtained is lower than zero, the connecting rod may be bent.
  • Page 15 15 - Engine 36 - Piston 00 - General Remove and Install Before Removal 3. Remove the ECM (Engine Control Module). Refer to: PIL 33-45-06. This procedure requires service parts. Make sure you have obtained the correct service parts before 4.
  • Page 16 15 - Engine 36 - Piston 00 - General Figure 326. A Piston B Piston rings C Connecting rod D Big end bearing cap E Piston cut out - intake side of crankcase F Big end bearing cap orientation marks G Shortest side of connecting rod - intake side of H Longest side of connecting rod - exhaust side of crankcase...
  • Page 17 15 - Engine 36 - Piston 00 - General Remove Table 110. Torque Table Item Torque Value Angle (de- The piston and connecting rod assemblies are (Nm) grees) removed through the top of the crankcase. J (1st Stage) J (2nd Stage) 1.
  • Page 18: Disassemble And Assemble

    15 - Engine 36 - Piston 00 - General Disassemble and Assemble side of the connecting rod is on the same side as the cut out in the piston. 4. Install new circlips. Make sure that they are Dismantle installed correctly in the groove in the piston. 1.
  • Page 19 15 - Engine 36 - Piston 00 - General Figure 328. 15 - 143 9813/9100-1 15 - 143...
  • Page 20: Piston Ring

    15 - Engine 36 - Piston 03 - Piston Ring 03 - Piston Ring Introduction Gas sealing inside the piston is achieved by the use of piston rings. The rings are loosely installed into grooves in the piston. The rings are split at a point in the rim, to allow them to press against the cylinder with a light spring pressure.
  • Page 21 Download the full PDF manual instantly. Our customer service e-mail: aservicemanualpdf@yahoo.com...

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