jcb 535-95 Service Manual
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SERVICE MANUAL
LOADALL (ROUGH TERRAIN
VARIABLE REACH TRUCK)
526-56, 531-70, 535-95, 536-60, 536-70,
536-70LP, 541-70, 550-80, 560-80
EN - 9813/7600 - ISSUE 3 - 03/2018
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 535-95

  • 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: 9813/7600-3 Find manuals at https://best-manuals.com...
  • Page 3 Spine Cards SERVICE MANUAL SERVICE MANUAL Volume 1 Volume 2 526-56, 531-70, 535-95, 526-56, 531-70, 535-95, 536-60, 536-70, 536-70LP, 536-60, 536-70, 536-70LP, 541-70, 550-80, 560-80 541-70, 550-80, 560-80 EN 9813/7600 EN 9813/7600 SERVICE MANUAL SERVICE MANUAL Volume 3 Volume 4...
  • Page 4 Notes: 9813/7600-3 Find manuals at https://best-manuals.com...
  • 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 9813/7600-3 2018-02-05 Find manuals at https://best-manuals.com...
  • 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 9813/7600-3 01 - 2 Find manuals at https://best-manuals.com...
  • 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

    (For: 526-56 [T4F], 531-70 [5AA], 531-70 Health and Safety .......... 01-13 [5TA], 535-95 [5AB], 535-95 [5TB], 536-60 [5AC], 536-60 [5TC], 536-70 [5AE], 536-70 [5TE], 536-70LP [5A1], 536-70LP [5T1]) You can complete most of the maintenance procedures with the lift arm lowered. Unless a maintenance procedure instructs you differently, you must lower the lift arm.
  • Page 19: Health And Safety

    01 - Machine 03 - Safety 27 - Maintenance Positions Health and Safety WARNING Maintenance must be done only by suitably qualified and competent persons. Before doing any maintenance make sure the machine is safe, it must be correctly parked on 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 9813/7600-3 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: 536-70LP 2460601 2902000 2460601...
  • 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: Description

    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 9813/7600-3...
  • Page 24 Notes: 01 - 18 9813/7600-3 01 - 18...
  • Page 25: General

    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...
  • Page 26: Operation

    01 - Machine 09 - Description 00 - General Operation The machine is intended to be used in normal conditions for the applications described in this manual. If the machine is used for other applications or in dangerous environments, for example in a flammable atmosphere or in areas with dust containing asbestos, special safety regulations must be obeyed and the machine must be equipped for...
  • Page 27: Log Moving/Object Handling

    Introduction Do not use the machine to move or handle logs unless sufficient log protection is installed. You could cause serious injury to yourself and damage to the machine. For more information, contact your JCB dealer. 01 - 21 9813/7600-3...
  • Page 28: Optional Equipment And Attachments

    A wide range of optional attachments are available to increase the versatility of your machine. Only the JCB approved attachments are recommended for use with your machine. Contact your JCB dealer for the full list of approved attachments available. 01 - 22...
  • Page 29: Main Component Locations

    01 - Machine 09 - Description 12 - Main Component Locations 12 - Main Component Locations Component Identification Figure 3. A Lift arm B Carriage C Battery D ROPS (Roll-Over Protective Structure)/FOPS (Falling Object Protective Structure) cab E Hydraulic tow hitch (Agricultural machines only) F Mechanical tow hitch 01 - 23 9813/7600-3...
  • Page 30: Service Point Locations

    15 - Service Point Locations Component Identification (For: 526-56 [T4F], 531-70 [5AA], 531-70 [5TA], 535-95 [5AB], 535-95 [5TB], 536-60 [5AC], 536-60 [5TC], 536-70 [5AE], 536-70 [5TE], 536-70LP [5A1], 536-70LP [5T1], 541-70 [5AD], 541-70 [5TD], 550-80 [5AW], 550-80 [5UW], 560-80 [5AY], 560-80 [5UY], JCB T4F 4.4 over 55kw Electronic Dieselmax Turbocharged Aftercooled Engine)
  • Page 31: Battery Isolator

    01 - Machine 09 - Description 15 - Service Point Locations Battery Isolator Figure 5. A Battery isolator 01 - 25 9813/7600-3 01 - 25...
  • Page 32: Hydraulic Oil Level Indicator

    01 - Machine 09 - Description 15 - Service Point Locations Hydraulic Oil Level Indicator Machines with External Sight Gauge Figure 6. A Hydraulic oil level indicator Figure 7. A Label - hydraulic oil filling point B Hydraulic oil level indicator C Hydraulic tank filler cap 01 - 26 9813/7600-3...
  • Page 33 01 - Machine 09 - Description 15 - Service Point Locations Machines without External Sight Gauge Figure 8. A Hydraulic oil level indicator Figure 9. A Hydraulic oil level indicator B Label - hydraulic oil filling point C Hydraulic tank filler cap 01 - 27 9813/7600-3 01 - 27...
  • Page 34 01 - Machine 09 - Description 15 - Service Point Locations Axles For: 550-80 Figure 10. A Axle fill/level plug 01 - 28 9813/7600-3 01 - 28...
  • Page 35 01 - Machine 09 - Description 15 - Service Point Locations For: Other Models Figure 11. Machines with Double Acting Cylinders A Axle fill/level plug Filling the Tank Figure 12. A Diesel exhaust fluid tank cap (blue) B Diesel fuel tank cap (green - USA only, black - all other territories) 01 - 29 9813/7600-3...
  • Page 36 01 - Machine 09 - Description 15 - Service Point Locations Figure 13. A Diesel exhaust fluid tank cap (blue) B Diesel fuel tank cap (green - USA only, black - all other territories) 01 - 30 9813/7600-3 01 - 30...
  • Page 37 01 - Machine 33 - Cleaning 33 - Cleaning Contents Page No. 01-33-00 General ........................... 01-33 01 - 31 9813/7600-3 01 - 31...
  • Page 38 Notes: 01 - 32 9813/7600-3 01 - 32...
  • Page 39 01 - Machine 33 - Cleaning 00 - General 00 - General Introduction WARNING When using cleaning agents, solvents Introduction ............ 01-33 or other chemicals, you must adhere to Preparation ............ 01-34 the manufacturer's instructions and safety precautions. CAUTION To avoid burning, wear personal protective equipment when...
  • Page 40 01 - Machine 33 - Cleaning 00 - General Preparation Notice: The engine and other components could be damaged by high pressure washing systems. Special precautions must be taken if the machine 1. Make the machine safe. Stop the machine and is to be washed using a high pressure system.
  • Page 41 03 - Attachments, Couplings and Load Handling Contents Page No. 03-00 Attachments 03-00-00 General ..........................03-3 03-33 Fork 03-33-00 General ..........................03-7 03-33-03 Carriage .......................... 03-10 03-82 Jib 03-82-00 General ........................... 03-15 03-82-06 Shackle ........................... 03-17 03-84 Hook 03-84-06 Snatch Block ........................
  • Page 42 Notes: 9813/7600-3 2018-01-17...
  • Page 43 03 - Attachments, Couplings and Load Handling 00 - Attachments 00 - Attachments Contents Page No. 03-00-00 General ..........................03-3 03 - 1 9813/7600-3 03 - 1...
  • Page 44 Notes: 03 - 2 9813/7600-3 03 - 2...
  • Page 45 A wide range of optional attachments are available Health and Safety ........... 03-4 to increase the versatility of your machine. Only JCB approved attachments are recommended for use with your machine. Consult your JCB Distributor for the full list of approved attachments available.
  • Page 46: Health And Safety

    00 - Attachments 00 - General Health and Safety Attachments Use only the JCB approved attachments that are specified for your machine. Operating with non- specified attachments can overload the machine, causing possible damage and machine instability which could result in injury to yourself or others.
  • Page 47 03 - Attachments, Couplings and Load Handling 33 - Fork 33 - Fork Contents Page No. 03-33-00 General ..........................03-7 03-33-03 Carriage .......................... 03-10 03 - 5 9813/7600-3 03 - 5...
  • Page 48 Notes: 03 - 6 9813/7600-3 03 - 6...
  • Page 49 03 - Attachments, Couplings and Load Handling 33 - Fork 00 - General 00 - General Introduction Introduction ............03-7 Forks can be installed on many different types of Health and Safety ........... 03-8 agricultural or construction machines. Forks can be directly mounted on to a lift arm or carriage or Adjust ..............
  • Page 50 03 - Attachments, Couplings and Load Handling 33 - Fork 00 - General Health and Safety Adjust DANGER Using the forks alone as a working WARNING Loads can fall off incorrectly spaced platform is hazardous; you can fall off and be forks.
  • Page 51 03 - Attachments, Couplings and Load Handling 33 - Fork 00 - General Figure 14. A Locking pins B Lower removal notch C 'No fork' zone 5. Re-engage the locking pins. Make sure the pins and forks are correctly located. 6.
  • Page 52 03 - Attachments, Couplings and Load Handling 33 - Fork 03 - Carriage 03 - Carriage Remove and Install Figure 15. For: 531-70 [5AA], 531-70 [5TA], 536-60 [5AC], 536-60 [5TC], 536-70 [5AE], 536-70 [5TE], 541-70 [5AD], 541-70 [5TD] ........... Page 03-10 For: 550-80 [5AW], 550-80 [5UW], 560-80 [5AY], 560-80 [5UY] ....
  • Page 53 03 - Attachments, Couplings and Load Handling 33 - Fork 03 - Carriage 6. Remove the securing bolt and remove the pivot 7. Remove the fork carriage. pin 2. Figure 16. A Fork carriage B Pivot pin 1 C Tipping link D Bolt E Pivot pin 2 Install...
  • Page 54 03 - Attachments, Couplings and Load Handling 33 - Fork 03 - Carriage 5. Insert the lock pin. ensure that he keeps clear of the machine and attachment until signalled by you to proceed. 5.1. Make sure that the transmission is set to neutral and that the park brake is on.
  • Page 55 03 - Attachments, Couplings and Load Handling 33 - Fork 03 - Carriage 10. Move the thumb switch backwards to engage the 4. If the attachment is hydraulically operated, then locking pins. disconnect the hoses. 11. Move the hydraulic pin isolation valve to the 5.
  • Page 56 03 - Attachments, Couplings and Load Handling 82 - Jib 82 - Jib Contents Page No. 03-82-00 General ........................... 03-15 03-82-06 Shackle ........................... 03-17 03 - 14 9813/7600-3 03 - 14...
  • Page 57 03 - Attachments, Couplings and Load Handling 82 - Jib 00 - General 00 - General Introduction Introduction ............ 03-15 Safety Health and Safety .......... 03-16 Read and understand all the warning messages. Follow all the safety instructions given in this Operator Manual.
  • Page 58 03 - Attachments, Couplings and Load Handling 82 - Jib 00 - General Health and Safety WARNING This attachment has a maximum safe working load. Do not exceed the safe working load. Do not exceed the machine stability limits shown on the load chart(s) in the cab. WARNING Load and unload on firm, level ground.
  • Page 59 03 - Attachments, Couplings and Load Handling 82 - Jib 06 - Shackle 06 - Shackle Introduction Figure 23. This a Q-fit attachment. It gives your machine greater reach and height. This attachment is supplied with test certificates for its fabrication, its hook and its shackle.
  • Page 60 03 - Attachments, Couplings and Load Handling 82 - Jib 06 - Shackle • Placing position • Travel position Figure 24. A Placing position B Travel position C Lynch pin D Stops E Bar F Stops When in the travel position, do not extend the boom and do not raise the boom more than 45°...
  • Page 61 03 - Attachments, Couplings and Load Handling 84 - Hook 84 - Hook Contents Page No. 03-84-06 Snatch Block ........................03-21 03 - 19 9813/7600-3 03 - 19...
  • Page 62 Notes: 03 - 20 9813/7600-3 03 - 20...
  • Page 63 03 - Attachments, Couplings and Load Handling 84 - Hook 06 - Snatch Block 06 - Snatch Block Introduction Introduction ............ 03-21 The fork mounted hook allows the machine to carry Remove and Install ........03-22 slung loads with safety. It incorporates a swivel hook with a spring loaded safety catch.
  • Page 64: Remove And Install

    03 - Attachments, Couplings and Load Handling 84 - Hook 06 - Snatch Block Remove and Install 3.4. Make sure that both mounting brackets are installed securely. Figure 25. A Mounting sockets B Lynch pin C Locking bar Remove 1. Make the machine safe. Refer to (PIL 01-03). 2.
  • Page 65: Body And Framework

    06 - Body and Framework Contents Page No. Acronyms Glossary ............................ 06-3 06-00 Body and Framework 06-00-00 General ..........................06-3 06-03 Chassis 06-03-00 General ..........................06-7 06-06 Moveable Panel and Cover 06-06-00 General ........................... 06-11 06-06-03 Battery Compartment ..................... 06-12 06-06-06 Engine Compartment .....................
  • Page 66 06-89 Window Guard 06-89-00 General ......................... 06-119 06-89-03 Front Window ....................... 06-120 06-89-12 Roof Window ........................ 06-121 9813/7600-3 2017-12-18...
  • Page 67 Acronyms Glossary DTVT Dual Technology Variable Transmission FOPS Falling Object Protective Structure OECD Organization for Economic Cooperation and Development Product Identification Number ROPS Roll-Over Protective Structure 9813/7600-3 2017-12-18...
  • Page 68 Notes: 9813/7600-3 2017-12-18...
  • Page 69 06 - Body and Framework 00 - Body and Framework 00 - Body and Framework Contents Page No. 06-00-00 General ..........................06-3 06 - 1 9813/7600-3 06 - 1...
  • Page 70 Notes: 06 - 2 9813/7600-3 06 - 2...
  • Page 71 06 - Body and Framework 00 - Body and Framework 00 - General 00 - General Clean Clean ............... 06-3 Keep all intakes and grilles clear from snow, ice and Check (Condition) ..........06-4 debris. Debris can collect under the boom. Remove all debris from under the boom.
  • Page 72: Check (Condition)

    06 - Body and Framework 00 - Body and Framework 00 - General Check (Condition) 1. Make sure that all of the guards and protective devices are in position, secured by their locking devices and free from damage. 2. Inspect all of the steelwork for damage. Include the following: 2.1.
  • Page 73 06 - Body and Framework 03 - Chassis 03 - Chassis Contents Page No. 06-03-00 General ..........................06-7 06 - 5 9813/7600-3 06 - 5...
  • Page 74 Notes: 06 - 6 9813/7600-3 06 - 6...
  • Page 75 06 - Body and Framework 03 - Chassis 00 - General 00 - General Introduction Introduction ............06-7 The chassis is the underpart of the vehicle or Health and Safety ........... 06-8 machine, consisting of the frame on which the body or cab is mounted.
  • Page 76 06 - Body and Framework 03 - Chassis 00 - General Health and Safety CAUTION This component is heavy. It must only be removed or handled using a suitable lifting method and device. 06 - 8 9813/7600-3 06 - 8...
  • Page 77 06 - Body and Framework 06 - Moveable Panel and Cover 06 - Moveable Panel and Cover Contents Page No. 06-06-00 General ........................... 06-11 06-06-03 Battery Compartment ..................... 06-12 06-06-06 Engine Compartment ..................... 06-13 06-06-10 Transmission Compartment ................... 06-16 06-06-12 Front Cover ........................
  • Page 78 Notes: 06 - 10 9813/7600-3 06 - 10...
  • Page 79 06 - Body and Framework 06 - Moveable Panel and Cover 00 - General 00 - General Introduction When moved to their maintenance position, the access panels give you access to parts or areas of the machine that are not required during machine operation.
  • Page 80 06 - Body and Framework 06 - Moveable Panel and Cover 03 - Battery Compartment 03 - Battery Compartment Remove and Install Close Single Step Installation 1. Close the battery compartment cover. Open 2. Make sure the battery compartment cover is closed correctly.
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