jcb_530_533_535_540_sm.pdf

General Information 1Care & Safety 2Routine Maintenance 3Attachments ABody & Framework BElectrics CControls DHydraulics ETransmission FBrakes GSteering HEngine K

R

ServiceManual

LLOOAADDAALLLLModels:

530, 533, 535, 540from Serial No. 767001

PUBLISHED BY THE TECHNICAL PUBLICATIONS DEPARTMENT

OF JCB SERVICE; WORLD PARTS CENTRE, WATERLOO

PARK, UTTOXETER, ST14 5PA, ENGLANDTel. 01889 - 590312

PRINTED IN ENGLANDPublication No. 9803/3630

www.WorkshopManuals.co.uk

Purchased from www.WorkshopManuals.co.uk

www.maskinisten.net



www.maskinisten.net

Introduction

This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, trainingby JCB International Training Centre.

These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associatedwith the maintenance and repair of hydraulic earthmoving equipment.

Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter ofcourse. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipeconnections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt. Finally, please remember above allelse SAFETY MUST COME FIRST!

How to use this manual

The manual is compiled in sections, the first three are numbered and contain information as follows:

1 = General Information - includes torque settings and service tools.2 = Care & Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc.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:

A = AttachmentsB = Body & Framework ...etc.

The page numbering in each alphabetically coded section is not continuous. This allows for the insertion of new items in laterissues of the manual.

Section contents, technical data, circuit descriptions, operation descriptions etc are inserted at the beginning of eachalphabetically coded section.

READ the section contents to locate machine types, machine type identification IS NOT listed on individual pages.

All sections are listed on the title page; tabbed divider cards align directly with individual sections on the front cover for rapidreference.

Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for drythreads, hence for lubricated threads may be reduced by one third.

'Left Hand' and 'Right Hand' are as viewed from the rear of the machine facing forwards.

This Service Manual covers the following machines:

530533535540530FS Plus540FS Plus530FS Super (530 SXL France)540FS Super (540 SXL France)

9803/3630 Issue 5*

*

**



www.maskinisten.net



www.maskinisten.net

i

Section 1 General Information

9803/3630

Section 1

i

Issue 3*

Contents Page No.

Identification 1 - 1

Torque Settings 2 - 1

Service Tools- Numerical List 3 - 1- Section B 4 - 1- Section C 5 - 1- Section E 6 - 1- Section F 7 - 1- Section H 8 - 1- Section K 8 - 1

Sealing and Retaining Compounds 9 - 1



www.maskinisten.net

1 - 1

Vehicle Identification Number (VIN)

Your machine has an identification plate V mounted asshown. The serial numbers of the machine and its majorunits are stamped on the plate.

Explanation of Vehicle Identification Number

SLP540RE0767001A B C D E

A World Manufacturer Identification SLP = JCBB Machine Model 540C Year of Manufacture: S

P = 1993 V = 1997 1 = 2001R = 1994 W = 1998 2 = 2002S = 1995 X = 1999 3 = 2003T = 1996 Y = 2000 4 = 2004

D Manufacturing Location E = EnglandE Machine Serial Number 0754001

The serial number of each major unit is also stamped on theunit itself. If a major unit is replaced by a new one, the serialnumber on the identification plate will be wrong. Eitherstamp the new number of the unit on the identification plate,or simply stamp out the old number. This will prevent thewrong unit number being quoted when replacement partsare ordered.

The machine and engine serial numbers can help identifyexactly the type of equipment you have.

General Information

9803/3630

1 - 1

Issue 3*

Section 1 Section 1

Engine Identification Number

The engine serial number is stamped on a label W which isfastened to the right side of the cylinder block, near the fuelfilter.

Typical Engine Identification Number

AA 50261 U 500405 PA B C D E

A Engine Type:AA = 4 cylinder naturally aspiratedAB = 4 cylinder turboAR = 4 cylinder naturally aspirated - Low emissionAK = 4 cylinder turbo - Low emission

B Build Number

C Country of Origin

D Engine Sequence Number

E Year of Manufacture

W

S263330

V

*

*

A335321



www.maskinisten.net

Transmission Identification Number

The Transmission serial number is stamped on label Y whichis mounted on the side face.

The rear axle serial number is stamped on plate X mountedto the front face of the axle.

The front axle serial number is stamped on plate Z mountedon the rear face of the axle.

1 - 2


9803/3630

Section 1

1 - 2

Issue 2

S263350

S263340

S263370Y

X

Z



www.maskinisten.net

2 - 1

Torque Settings

Use only where no torque setting is specified in the text. Values are for dry threads and may be within three per cent of thefigures stated. For lubricated threads the values should be REDUCED by one third.

UNF Grade 'S' Bolts

Bolt Size Hexagon (A/F) Torque Settingsin (mm) in Nm kgf m lbf ft

1/4 (6.3) 7/16 14 1.4 105/16 (7.9) 1/2 28 2.8 203/8 (9.5) 9/16 49 5.0 367/16 (11.1) 5/8 78 8.0 581/2 (12.7) 3/4 117 12.0 879/16 (14.3) 13/16 170 17.3 1255/8 (15.9) 15/16 238 24.3 1753/4 (19.0) 11/8 407 41.5 3007/8 (22.2) 15/16 650 66.3 4801 (25.4) 11/2 970 99.0 71511/4 (31.7) 17/8 1940 198.0 143011/2 (38.1) 21/4 3390 345.0 2500

Metric Grade 8.8 Bolts

Bolt Size Hexagon (A/F) Torque Settings(mm) mm Nm kgf m lbf ft

M5 (5) 8 7 0.7 5M6 (6) 10 12 1.2 9M8 (8) 13 28 3.0 21M10 (10) 17 56 5.7 42M12 (12) 19 98 10 72M16 (16) 24 244 25 180M20 (20) 30 476 48 352M24 (24) 36 822 84 607M30 (30) 46 1633 166 1205M36 (36) 55 2854 291 2105

Rivet Nut Bolts/Screws

Bolt Size Torque Settings (for steel rivet nuts)(mm) Nm kgf m lbf ft

M3 (3) 1.2 0.12 0.9M4 (4) 3.0 0.3 2.0M5 (5) 6.0 0.6 4.5M6 (6) 10.0 1.0 7.5M8 (8) 24.0 2.5 18.0M10 (10) 48.0 4.9 35.5M12 (12) 82.0 8.4 60.5

Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification.


9803/3630

Section 1

2 - 1

Issue 1



www.maskinisten.net

http://www.workshopmanuals.co.ukhttp://www.workshopmanuals.co.uk

3 - 1

Service Tools

Numerical ListPage No

449/03702 Fitting Adapter 7-3449/03705 Adapter 7-3460/15707 Banjo Bolt 7-3460/15708 Adapter 7-31406/0011 Bonded Washer 6-11406/0014 Bonded Washer 6-11406/0018 Bonded Washer 6-11406/0021 Bonded Washer 6-11406/0029 Bonded Washer 6-11604/0003 Adapter 6-31604/0004 Adapter 6-31604/0006 Adapter 6-11606/0003 Adapter 6-31606/0004 Adapter 6-31606/0007 Adapter 6-31606/0008 Adapter 6-31606/0009 Adapter 6-31606/0012 Adapter 6-31606/0014 Adapter 6-31606/0015 Adapter 6-31606/0017 Adapter 6-31612/0006 Adapter 6-14003/0211 Anti-Seize Paste 9-14101/0251 JCB Threadlocker and Sealer 9-14101/0451 JCB Threadlocker 9-14101/0552 JCB Threadlocker and Sealer (high strgth) 9-14101/0651 JCB Retainer (high strength) 9-14102/0551 JCB High Strength Threadlocker 9-14102/0901 Clear Silicone Sealant 9-14102/1212 JCB Multi-Gasket 9-14102/1951 JCB Threadseal 9-14103/0955 Plastic to Metal Bonder 9-14103/2109 Ultra Fast Adhesive - 310 ml

(for direct glazing kit) 9-14104/0251 JCB Activator (Aerosol) 9-14104/0253 JCB Activator (Bottle) 9-14104/1203 Active Wipe 205 - 250 g

(for direct glazing kit) 9-14104/1310 Hand Cleaner 4-14104/1557 JCB Cleaner and Degreaser 9-14201/4906 Black Primer 206J - 30 ml 9-1816/00189 Blanking Cap 6-2816/00190 Blanking Cap 6-2816/00193 Blanking Cap 6-2816/00196 Blanking Cap 6-2816/00197 Blanking Cap 6-2816/00294 Blanking Cap 6-2816/15118 Pressure Test Adapter 6-3816/20008 Adapter 6-1816/50043 'T' Adapter 6-2816/55038 Pressure Test Adapter 6-1816/55040 Pressure Test Adapter 6-1892/00039 Spool Clamp 6-2892/00041 De-glazing Tool 8-1892/00047 'T' Adapter 6-2892/00048 'T' Adapter 6-2892/00049 'T' Adapter 6-2892/00051 'T' Adapter 6-2892/00055 Blanking Plug 6-2892/00056 Blanking Plug 6-2892/00057 Blanking Plug 6-2

Page No892/00058 Blanking Plug 6-2892/00059 Blanking Plug 6-2892/00060 Blanking Plug 6-2892/00071 Adapter 6-3892/00074 Female Connector 6-2892/00075 Female Connector 6-2892/00076 Female Connector 6-2892/00077 Female Connector 6-2892/00137 Micro-Bore Hose 6-3892/00179 Bearing Press 7-1892/00180 Seal Fitting Tool 8-1892/00181 Plastic Boss 8-1892/00223 Hand Pump 6-3892/00254 Hose 6-1892/00255 1/4'' BSP Test Point 6-3892/00256 3/8'' BSP Test Point 6-3892/00257 1/2'' BSP Test Point 6-3892/00258 5/8'' BSP Test Point 6-3892/00259 1'' BSP Test Point 6-3892/00260 11/4'' BSP Test Point 6-3892/00261 5/8'' UNF Test Point 6-3892/00262 1/4'' M BSP 1/4'' F BSP 6-1892/00263 5/8'' M BSP 5/8'' F BSP 6-1892/00264 3/4'' M BSP 3/4'' F BSP 6-1892/00265 1'' M BSP 1'' F BSP 6-1892/00268 Flow Monitoring Unit 6-1892/00269 Sensor Head 6-1892/00270 Load Valve 6-1892/00271 Adapter 6-1892/00272 Adapter 6-1892/00274 Adapter 6-3892/00275 Adapter 6-1892/00276 Adapter 6-1892/00277 Adapter 6-1892/00279 Pressure Gauge 0-400 bar (0-6000 lbf/in2) 6-1892/00280 Pressure Gauge 0-600 bar (0-9000 lbf/in2) 6-1892/00281 AVO Meter 5-1892/00282 Shunt 5-1892/00283 Tool Kit Case 5-1892/00284 Digital Tachometer 5-1892/00285 Hyd. Oil Temperature Probe 5-1892/00286 Surface Temperature Probe 5-1892/00295 End Float Setting Tool 7-1892/00301 Flow Test Adapter 7-3892/00302 Flow Test Adapter 7-3892/00333 Heavy Duty Socket 7-2892/00334 Ram Seal Fitting Tool 6-4892/00346 Pressure Gauge 0-70 bar (0-1000 lbf/in2) 6-1892/00347 Connector 6-1892/00706 Test Probe 6-3892/00801 Clutch Spanner for air conditioning

compressor 4-3892/00802 Rotor Puller Set for air conditioning

compressor 4-3892/00803 Rotor Installer Set for air conditioning

compressor 4-3892/00807 Front Plate Puller for air conditioning

compressor 4-3892/00808 Shaft Protector for air conditioning

compressor 4-3


9803/3630

Section 1

3 - 1

Issue 5*

*

**

*



www.maskinisten.net


3 - 2

Service Tools (contd)

Numerical ListPage No

892/00812 Drive Coupling Spanner 7-3892/00817 Heavy Duty Socket 7-2892/00818 Heavy Duty Socket 7-2892/00819 Heavy Duty Socket 7-2892/00842 Glass Lifter 4-1892/00843 Folding Stand 4-1892/00844 Long Knife 4-2892/00845 Cartridge Gun 4-1892/00846 Glass Extractor 4-2892/00847 Nylon Spatula 4-3892/00848 Wire Starter 4-2892/00849 Braided Cutting Wire 4-2892/00905 Test Box - SLI and LMI 5-1892/00912 Bevel Box Socket 7-1892/00914 Bevel Box Socket 7-1892/00915 Bevel Box Reaction Block 7-3892/00916 Spring Compressor 7-2892/00920 Flow Test Adapter 7-3892/00943 Hand held test unit MK II (ECU) 5-3892/00952 Communications Lead 5-3892/00956 Engine Timing Pin 8-2892/01027 Piston Seal Assembly Tool 6-4926/15500 Rubber Spacer Blocks 4-3992/02800 ARV Extractor 6-2992/04000 Torque Multiplier 7-2992/04800 Drive Coupling Spanner 7-1992/07603 Replacer- Bearing Cup 7-1992/07608 Bearing Adapter 7-1992/07609 Bearing Adapter 7-1992/07610 Bearing Adapter 7-1992/07611 Bearing Adapter 7-1992/07612 Bearing Adapter 7-1992/07613 Bearing Adapter 7-1992/09500 Spanner 6-2992/09700 Spanner 6-2992/10100 Spool Clamp 6-2992/12300 Mobile Oven 4-1992/12400 240V Static Oven 4-1992/12600 240V Static Oven 4-1992/12800 Cut-out Knife 4-2992/12801 L Blades 4-2993/59300 2/4 Wheel Pressure Tester & Clamp 7-2993/70100 Powershift Endfloat Checking Kit 7-4993/85700 Battery Tester 5-1

The following parts are replacement items for kits and wouldnormally be included in the kit numbers above.

Replacement item for kit no. 892/00180892/00181 Replacement Boss 8-1

Numerical List Page No

Solid Spacer Setting Tools

1 892/00918 Setting Tool Kit. Contains the following: 7-5A Sleeve for M24 Pinion

B Adapter for M30 Pinion

C fork (suitable for all axles)

The following setting tools must be purchased separately:892/00945 A Sleeve for M30 Pinion

997/11100 B Adapter for M24 Pinion

2 997/11000 Drive Head Setting Bracket

3 993/70111 Breack-back Torque Wrench- Solid spacer (see parts CD or

microfiche for part numbers)

Ram Seal Protection Sleeves 6-4

892/01016 For 25 mm Rod Diameter892/01017 For 30 mm Rod Diameter892/01018 For 40 mm Rod Diameter892/01019 For 50 mm Rod Diameter892/01020 For 50 mm Rod Diameter (slew ram)892/01021 For 60 mm Rod Diameter892/01022 For 60 mm Rod Diameter (slew ram)892/01023 For 65 mm Rod Diameter892/01024 For 70 mm Rod Diameter892/01025 For 75 mm Rod Diameter892/01026 For 80 mm Rod Diameter892/01027 Piston Seal Assembly Tool

Powershift Endfloat Checking Kit (5 speed) 7-5

993/70104 Pillar, Input Shaft (5 speed)892/01057 Pillar, 5th Speed Shaft892/01056 Setting Body (5 speed)


9803/3630

Section 1

3 - 2

Issue 6*

*



www.maskinisten.net


4 - 1


9803/3660

Section 1

4- 1

Issue 1

Service Tools

Section B - Body and Framework

S186240

4104/1310 (454g; 1lb tub)Hand Cleaner - special blend for the removal ofpolyurethane adhesives.

S186250

992/12300 - 12V Mobile Oven - 1 cartridge capacity -required to pre-heat adhesive prior to use. It is fittedwith a male plug (703/23201) which fits into a femalesocket (715/04300).

S186260

992/12400 - 2 cartridge x 240V 992/12600 - 6 cartridge x 240V - 240V Static Oven -available with 2 or 6 cartridge capacity - required topre-heat adhesive prior to use. No plug supplied. Note:110V models available upon request - contact JCBTechnical Service

S186270

892/00845Cartridge Gun - hand operated - essential for theapplication of sealants, polyurethane materials etc.

'

S186280

892/00843- Folding Stand for Holding Glass - essentialfor preparing new glass prior to installation.

S186300

892/00842 - Glass Lifter - minimum 2 off - essential forglass installation, 2 required to handle large panes ofglass. Ensure suction cups are protected from damageduring storage.



www.maskinisten.net


4 - 2


9803/3660

Section 1

4- 2

Issue 1


Section B - Body and Framework (contd)

S186310

892/00848 - Wire Starter - used to access braidedcutting wire (below) through original polyurethane seal.

S186320

892/00846 - Glass Extractor (Handles) - used withbraided cutting wire (below) to cut out broken glass.

S186330

892/00849 (approx 25m length) - Braided Cutting Wire - consumable heavy duty cut-out wire used with the glass extraction tool(above).

S186340

992/12800 - Cut-out Knife - used to remove brokenglass.

'

S186350

992/12801 (unit quantity = 5 off)'L' Blades - 25mm (1in.) cut - replacement blades forcut-out knife (above).

S186360

892/00844 - Long Knife - used to give extended reach for normally inaccessible areas.



www.maskinisten.net


4 - 3


9803/3660

Section 1

4- 3

Issue 1


Section B - Body and Framework (contd)

S186470

892/00847 - Nylon Spatula - general tool used forsmoothing sealants - also used to re-install glass inrubber glazing because metal tools will chip the glassedge.

892/00801 Clutch spanner S200940for air conditioning compressor

892/00802 Rotor puller set S200950for air conditioning compressor

892/00803 Rotor installer set S200960for air conditioning compressor

S186550

926/15500 (unit quantity = 500 off)Rubber Spacer Blocks - used to provide the correctset clearance between glass edge and cab frame.

892/00807 Front plate puller S200970for air conditioning compressor

892/00808 Shaft protector S200980for air conditioning compressor



www.maskinisten.net



9803/3630

Section 1

Issue 3

5 - 1 5 - 1

Service Tools

Section C - Electrics

AVO Test Kit

1 892/00283 Tool Kit Case

2 892/00281 AVO Meter

3 892/00286 Surface Temperature Probe

4 892/00284 Venture Microtach Digital Tachometer

5 892/00282 100 amp Shunt - open type

6 892/00285 Hydraulic Temperature Probe

993/85700 Battery Tester

892/00905 Test Box for Safe Load Indicatorand Load Moment Indicator

S188230

S244961

S239510



www.maskinisten.net


5 - 2


9803/3630

Section 1

5 - 2

Issue 2



Electrical Repair Kit2A 7212/0002 2 Way Pin Housing2B 7212/0004 2 Way Pin Retainer2C 7212/0003 2 Way Socket Retainer2D 7212/0001 2 Way Socket Connector3A 7213/0002 3 Way Pin Housing3B 7213/0004 3 Way Pin Retainer3C 7213/0003 3 Way Socket Retainer3D 7213/0001 3 Way Socket Connector4A 7213/0006 3 Way Pin Housing (DT)4B 7213/0008 3 Way Pin Retainer (DT)4C 7213/0007 3 Way Socket Retainer (DT)4D 7213/0005 3 Way Socket Connector (DT)5A 7214/0002 4 Way Pin Housing5B 7214/0004 4 Way Pin Retainer5C 7214/0003 4 Way Socket Retainer5D 7214/0001 4 Way Socket Connector

6A 7216/0002 6 Way Pin Housing6B 7216/0004 6 Way Pin Retainer6C 7216/0003 6 Way Socket Retainer6D 7216/0001 6 Way Socket Connector7A 7218/0002 8 Way Pin Housing7B 7218/0004 8 Way Pin Retainer7C 7218/0003 8 Way Socket Retainer7D 7218/0001 8 Way Socket Connector8A 7219/0002 10 Way Pin Housing8B 7219/0004 10 Way Pin Retainer8C 7219/0003 10 Way Socket Retainer8D 7219/0001 10 Way Socket Connector9A 7219/0006 14 Way Pin Housing9B 7219/0008 14 Way Pin Retainer9C 7219/0007 14 Way Socket Retainer9D 72190005 14 Way Socket Connector10 7210/0001 Dummy Plug11 7210/0002 Wire Seal (1.4 - 2.2 mm dia.)12 7210/0003 Wire Seal (2.2 - 2.9 mm dia.)

S188380



www.maskinisten.net


5 - 3


9803/3630

Section 1

5 - 3

Issue 3



892/00943 Hand Held Test Unit MK II (ECU)

299920

A314020

892/00952 Communications Lead



www.maskinisten.net


Service Tools (cont'd)

Section E - Hydraulics

Hydraulic Circuit Test Gauges and Connections

1 892/00279 Pressure Gauge 0-400 bar (0-6000 lbf/in2)2 892/00346 Pressure Gauge 0-70 bar (0-1000 lbf/in2)3 892/00347 Connector4 892/00254 Hose5 892/00280 Pressure Gauge 0-600 bar (0-9000 lbf/in2)

PressureTest 'T' Adaptors Bonded Washers

892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point 1406/0011 1/4 in. BSP816/55038 3/8 in M BSP x 3/8 in F BSP x Test Point 1406/0018 1/2 in. BSP816/55040 1/2 in M BSP x 1/2 in F BSP x Test Point 1406/0014 5/8 in. BSP892/00263 5/8 in M BSP x 5/8 in F BSP x Test Point 1406/0021 3/4 in. BSP892/00264 3/4 in M BSP x 3/4 in F BSP x Test Point 1406/0029 11/4 in. BSP892/00265 1 in M BSP x 1 in F BSP x Test Point

Flow Test Equipment

892/00268 Flow Monitoring Unit892/00269 Sensor Head 0 to 100 l/min (0 to 22 UK gal/min)892/00270 Load Valve1406/0021 Bonded Washer1604/0006 Adapter 3/4 in M x 3/4 M BSP1612/0006 Adapter 3/4 in F x 3/4 M BSP892/00271 Adapter 3/4 in F x 5/8 M BSP892/00272 Adapter 5/8 in F x 3/4 M BSP816/20008 Adapter 3/4 in F x 1/2 M BSP892/00275 Adapter 1/2 in F x 3/4 M BSP892/00276 Adapter 3/4 in F x 3/8 M BSP892/00277 Adapter 3/4 in F x 3/4 M BSP

6 - 1


9803/3630

Section 1

6 - 1

Issue 3*

S188130

S188140

S188150

1,2,5

34

*



www.maskinisten.net




Female Cone Blanking Cap Male Cone Blanking Cap

892/00055 1/4 in. BSP 816/00294 1/4 in. BSP892/00056 3/8 in. BSP 816/00189 3/8 in. BSP892/00057 1/2 in. BSP 816/00190 1/2 in. BSP892/00058 5/8 in. BSP 816/00197 5/8 in. BSP892/00059 3/4 in. BSP 816/00196 3/4 in. BSP892/00060 1 in. BSP 816/00193 1 in. BSP

T' Adapters Female Connectors

892/00047 3/8 in. BSP (A) x 1/4 in. BSP (B) 892/00074 3/8 in. BSP x 3/8 in. BSP892/00048 1/2 in. BSP (A) x 1/4 in. BSP (B) 892/00075 1/2 in. BSP x 1/2 in. BSP892/00049 5/8 in. BSP (A) x 1/4 in. BSP (B) 892/00076 5/8 in. BSP x 5/8 in. BSP816/50043 3/4 in. BSP (A) x 1/4 in. BSP (B) 892/00077 3/4 in. BSP x 3/4 in. BSP892/00051 1 in. BSP (A) x 1/4 in. BSP (B)

Hexagon Spanners for Ram Pistons and End Caps Spool Clamps

992/09500 75mm A/F 892/00039 Spool Clamp992/09700 95mm A/F 992/10100 Spool Clamp

992/02800 ARV Extractor

6 - 2


9803/3630

Section 1

6 - 2

Issue 2

S188150

S193870 S193880

S193890 S193900

S193930 S192410



www.maskinisten.net




Male Adapters - BSP x BSP

1606/0003 3/8 in. x 1/4 in.1604/0003 3/8 in. x 3/8 in.892/00071 3/8 in. x 3/8 in. taper1606/0004 1/2 in. x 1/4 in.1606/0007 1/2 in. x 3/8 in.1604/0004 1/2 in. x 1/2 in.1606/0017 5/8 in. x 1/2 in.1606/0008 3/4 in. x 3/8 in.1606/0009 3/4 in. x 1/2 in.1604/0006 3/4 in. x 3/4 in.1606/0012 3/4 in. x 1 in.1606/0014 3/4 in. x 11/4 in.1606/0015 1 in. x 11/4 in.

Pressure Test Adaptors

892/00255 1/4 in. BSP x Test Point Hand Pump Equipment892/00256 3/8 in. BSP x Test Point892/00257 1/2 in. BSP x Test Point 892/00223 Hand Pump892/00258 5/8 in. BSP x Test Point 892/00137 Micro-bore Hose 1/4 in BSP x 5 metres816/15118 3/4 in. BSP x Test Point 892/00274 Adapter 1/4 in M BSP x 3/8 in M BSP Taper892/00259 1 in. BSP x Test Point 892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point892/00260 1.1/4 in. BSP x Test Point 892/00706 Test Probe892/00261 5/8 in. UNF x Test Point 892/00279 Gauge 0 - 400 bar (0-6000 lbf/in2)

6 - 3


9803/3630

Section 1

6 - 3

Issue 3*

S193860

320380

S193850

S200141

*

*

* *

*

Pressure Test Adapters

892/00964 1/8 in BSP x Test Point892/00965 3/8 in BSP x Test Point



www.maskinisten.net


6 - 4


9803/3630

Section 1

6 - 4

Issue 2*

110mm

175mm

R 1.4mm

3o

R 3mm

7mm

11o

10mm 20mm

5mm

892/01027 Piston Seal Assembly Tool

338410

892/00334 Seal Fitting Tool

892/00948 Charging Kit (without gauge)892/00949 Gauge

308271

Ram Seal Protection Sleeves

892/01016 For 25 mm Rod Diameter892/01017 For 30 mm Rod Diameter892/01018 For 40 mm Rod Diameter892/01019 For 50 mm Rod Diameter892/01020 For 50 mm Rod Diameter (slew ram)892/01021 For 60 mm Rod Diameter892/01022 For 60 mm Rod Diameter (slew ram)892/01023 For 65 mm Rod Diameter892/01024 For 70 mm Rod Diameter892/01025 For 75 mm Rod Diameter892/01026 For 80 mm Rod Diameter

338500

161750X

161750Z



www.maskinisten.net



Section F - Transmission

992/07608 Bearing Adapter992/07609 Bearing Adapter992/07610 Bearing Adapter992/07611 Bearing Adapter992/07612 Bearing Adapter992/07613 Bearing Adapter 992/07603 Replacer- Bearing Cup

892/00295 End Float Setting Tool 892/00179 Bearing Press

Bevel Box Heavy Duty Sockets

892/00912 46mm892/00914 55mm

992/04800 Flange SpannerFor locking pinion flange while nut isslackened or torque set

7 - 1


9803/3630

Section 1

7 - 1

Issue 2*

S188160 S188170

S188190 S188200

S188220

*

* *

* *

* *

S197250



www.maskinisten.net


992/04000 Torque Multiplier

Use in conjunction with a torque wrenchto give a 5:1 multiplication when tighteningpinion nuts etc.

Fixture for Syncro Shuttle & Powershift Gearbox removal &replacement.

For details see MI 373/H, 358/E.

Note: When removing/replacing a Syncro Shuttle Gearbox,use items 1, 2 and 3.

When removing/replacing a Powershift Gearbox, use items1 and 4.

7 - 2


9803/3630

Section 1

7 - 2

Issue 2*



Heavy Duty Sockets

892/00817 17mm A/F x 3/4in square drive




993/593002/4 Wheel Drive Clutch Pressure Test Adaptor & Clamp

892/00916Clutch pack spring compressor

S197030

S197250

S196750S162580

*

*

*

*

*

*

S259320



www.maskinisten.net




7 - 3


9803/3630

Section 1

7 - 3

Issue 1

S259340

A314190

313260

892/00237 Flow Test Adaptor type A (Complete)1 892/00920 Flow Test Adapter2 892/00301 Flow Test Adapter3 892/00302 Flow Test Adapter

Flow Test Adaptor type C1 449/03705 Adapter (side/central ports)2 449/03702 Fitting Adapter3 1604/0004 Adapter4 1406/0018 Bonded Washer5 2401/0222 O-ring

Flow Test Adaptor type B1 460/15708 Adapter (side ports)2 460/15707 Banjo bolt3 2401/0222 O-ring4 2403/0110 O-ring5 2403/0108 O-ring6 1604/0004 Adapter7 1406/0018 Bonded Washer

Tighten adapters to 56 Nm (41 lbf ft). 892/00915 Bevel box gear reaction block

3

21

Alternative Pump Flow Test Adapters

313250

313260

5

2

1

63

7

4

2

1

43

892/00812 Drive Coupling Spanner for front and rear axle yoke couplingsand for 4WD outputcoupling.

S196720

5



www.maskinisten.net


7 - 4


9803/3630

Section 1

7 - 4

Issue 2*


Section F - Transmission (contd)

1

113

6

5

12 6

4

2

9

10

7

13

8

A191642

1736

96.35

81.75

15

1020

8.5

12

9

1 993/70100 Powershift Endfloat Checking Kit(includes items 2 to 13)

2 892/01055 Base Plate

3 993/70160 Yoke Assy

4 993/70130 Mainshaft Adapter Assy

5 993/70104 Mainshaft Pillar

6 993/70106 Layshaft/Reverser Pillar

7 993/70120 Layshaft Setting Assy

8 993/70140 Reverser Setting Assy

9 1391/3305 Capscrew (M8 x 20)

10 826/01417 Setscrew (M10 x 30) Flanged

11 993/70111 Setting Wrench (this is not part of the kit)

12 993/70112 Input Shaft Pillar

13 993/70150 Input Setting Assy

If these items are not in your kit they can be ordered separately but the base plate 2 will have to be drilled to secure item12, see A and B. Measurements are in mm. Apply JCB Threadlocker and Sealer and tighten item 9 to 25 - 30 Nm (18 - 22lbf ft).

A

B

A191642

*



www.maskinisten.net


7 - 5


9803/3630

Section 1

7 - 5

Issue 2*


Section F - Transmission (contd)

Solid Spacer Setting Tools

1 892/00918 Setting Tool Kit. Contains the following:A Sleeve for M24 PinionB Adapter for M30 PinionC fork (suitable for all axles)

The following setting tools must be purchased separately:892/00945 A Sleeve for M30 Pinion997/11100 B Adapter for M24 Pinion

2 997/11000 Drive Head Setting Bracket3 993/70111 Breack-back Torque Wrench

- Solid spacer (see parts CD or microfiche for part numbers)

Powershift Endfloat Checking Kit - 5 Speed Transmission

Base plate 993/70101 used for the 4-speed transmission can beadapted for use with 5 speed transmission. Cut out the cornersection A, drill and counterbore the two holes B as shownbelow. Measurements are in mm. The later base plate892/01055 is suitable for both 4- and 5-speed transmissions.

The following setting tools must be purchased to use the kit with5-speed transmissions:

14 993/70104 Pillar, Input Shaft 15 892/01057 Pillar, 5th Speed Shaft16 892/01056 Setting Body

A270851

15

1020

8.5

A362630

215

19.2461.28

14.34

31

13.60

16

15

14

B

A



www.maskinisten.net


8 - 1


9803/3630

Section 1

8 - 1

Issue 4*


Section H - Steering

Section K - Engine

For details of all engine service tools refer to engine service manual.

892/00180 Seal Fitting Tool for fitting O ring andback-up ring to Orbitrol Unit

892/00181 Replacement Plastic Boss

S191750

892/00041 De-glazing Tool for Cylinder Bores(to assist bedding-in of new piston rings)

S192390



www.maskinisten.net



Section K - Engine

8 - 2


9803/3630

Section 1

8 - 2

Issue 2*

A296430

Details for the manufacture of a lifting beam have beenmade available. This lifting beam enables the completeengine, bevel box and transmission unit to be removedfrom the machine as a complete assembly.

Refer to Technical Information Bulletin 5/160 for thematerial and dimensional details required tomanufacture the beam safely.

Limitations on UseThis tool is designed specifically to lift the side mountedengine, bevel box and powershift transmission as acomplete assembly.

The tool is not to be used to lift the engine on its own,any other part of the machine or for any other lifting dutyor use.

A314530

892/00956 Timing pin for fuel injection pumps on JCB Diesel Engines type AR and AK builds only.



www.maskinisten.net


9 - 1


9803/3630

Section 1

9 - 1

Issue 2*

Sealing and Retaining Compounds

JCB Multi-Gasket A medium strength sealant suitable for all sizes of gasket 4102/1212 50 mlflanges, and for hydraulic fittings of 25-65 mm diameter.

JCB Threadlocker For threads of 50 mm diameter upwards, 4101/0451 50 ml

e.g. suction strainer.

JCB Threadlocker A high strength locking fluid for use with threaded 4102/0551 50 ml

(High Strength) components. Gasketing for all sizes of flange where

the strength of the joint is important.

JCB Retainer (High Strength) For all retaining parts which are unlikely to be dismantled. 4101/065150 ml

JCB Threadlocker and Sealer A medium strength locking fluid for sealing and retaining 4101/0250 10 mlnuts, bolts, and screws up to 50 mm diameter, and 4101/0251 50 mlfor hydraulic fittings up to 25 mm diameter.

JCB Threadlocker and Sealer A high strength locking fluid for sealing and retaining 4101/0550 10 ml

(High Strength) nuts, bolts, and screws up to 50 mm diameter, and for 4101/0552 200 mlhydraulic fittings up to 25 mm diameter.

JCB Threadseal A medium strength thread sealing compound. 4102/1951 50 ml

JCB Activator A cleaning primer which speeds the curing rate of 4104/0251 Aerosol (1 ltr)anaerobic products. 4104/0253 Bottle (200 ml)

JCB Cleaner/Degreaser For degreasing components prior to use of anaerobic 4104/1557 Aerosol (400 ml)adhesives and sealants.

Anti-Seize Paste A compound used for assembly and prevention of 4003/0211parts seizure.

Direct Glazing Kit For one pane of glass; comprises items marked below

plus applicator nozzle etc.

Ultra Fast Adhesive For direct glazing 4103/2109 310 ml

Active Wipe 205 For direct glazing 4104/1203 250 g

Black Primer 206J For direct glazing 4201/4906 30 ml

Clear Silicone Sealant To seal butt jointed glass. 4102/0901

Plastic to Metal Bonder To seal plastic to metal joints 4103/0955

*



www.maskinisten.net


Contents Page No.

Safety Notices 1 - 1

General safety 2 - 1

Operating safety 2 - 2

Maintenance safety 2 - 4

Lubricants - Health and Safety 3 - 1

i

Care & Safety

9803/3630

i

Issue 1

Section 2 Section 2www.WorkshopManuals.co.uk


www.maskinisten.net


1 - 1

Safety Notices

In this handbook and on the machine there are safety notices. Each notice starts with asignal word. The signal word meanings are given below.

!! DANGERDenotes an extreme hazard exists. If proper precautions are not taken it is highlyprobable that the operator (or others) could be killed or seriously injured.INT-1-2-1

!! WARNINGDenotes a hazard exists. If proper precautions are not taken, the operator (or others)could be killed or seriously injured.INT-1-2-2

! CAUTIONDenotes a reminder of safety practices. Failure to follow these safety practices couldresult in injury to the operator (or others) and possible damage to the machine. INT-1-2-3

Care & Safety

9803/3630

1 - 1

Issue 1



www.maskinisten.net


2 - 1

All construction and agricultural equipment can behazardous. When a JCB machine is correctly operated andproperly maintained, it is a safe machine to work with. Butwhen it is carelessly operated or poorly maintained it canbecome a danger to you (the operator) and others.

Do not work with the machine until you are sure that youcan control it.

Do not start any job until you are sure that you and thosearound you will be safe.

If you are unsure of anything, about the machine or the job,ask someone who knows. Do not assume anything.

Remember

BE CAREFULBE ALERTBE SAFE

GEN-1-6

General Safety

! WARNINGDecals

You can be injured if you do not obey the decal safetyinstructions. Keep decals clean. Replace unreadable ormissing decals with new ones before operating themachine. Make sure replacement parts include warningdecals where necessary.INT-1-3-4

! CAUTIONHazardous Atmospheres

This machine is designed for use in normal out dooratmospheric conditions. It should not be used in anenclosed area without adequate ventilation. Do not use themachine in a potential ly explosive atmosphere, ie.combustible vapours, gas or dust, without first consultingyour JCB Distributor.INT-2-1-14

As well as the warnings in this chapter, specific warningsare given throughout the book. This section is designed togive a safety code for use of the machine generally and formaintenance practices.

! WARNINGClothing

You can be injured if you do not wear proper clothing.Loose clothing can get caught in the machinery. Wearprotective clothing to suit the job. Examples of protectiveclothing are: a hard hat, safety shoes, safety glasses, awell-fitting overall, ear-protectors and industrial gloves.Keep cuffs fastened. Do not wear a necktie or scarf. Keeplong hair restrained.INT-1-3-6

! WARNINGCare and Alertness

All the time you are working with or on the machine, takecare and stay alert. Always be careful. Always be alert forhazards.INT-1-3-5

! DANGERLightning

Lightning can kill you. Do not use the machine if there islightning in your area. 5-1-1-2

! WARNINGRaised Boom

A raised boom can fall or be lowered accidentally. Do notwalk under a raised boom which is not fitted with a safetystrut, or you could be injured. 5-1-1-1

! WARNINGLifting Equipment

You can be injured if you use faulty lifting equipment. Makesure that lifting equipment is in good condition. Make surethat lifting tackle complies with all local regulations and issuitable for the job. Make sure the lifting equipment isstrong enough for the job.INT-1-3-7

Care & Safety

9803/3630

2 - 1

Issue 1



www.maskinisten.net


2 - 2

Operating Safety

! WARNINGPractice

You and others can be killed or seriously injured if you dounfamiliar operations without first practising them. Practiseaway from the work site on a clear area. Keep other peopleaway. Do not perform new operations until you are sure youcan do them safely.INT-2-1-1

! WARNINGMachine Condition

A defective machine can injure you or others. Do not operatea machine which is defective or has missing parts. Makesure the maintenance procedures in this handbook arecompleted before using the machine.INT-2-1-2

! WARNINGMachine Limits

Operating the machine beyond its design limits can damagethe machine, it can also be dangerous. Do not operate themachine outside its limits. Do not try to upgrade themachine performance with unapproved modifications.INT-2-1-4

! WARNINGEngine

The engine has rotating parts. Do not open the engine coverwhile the engine is running. Do not use the machine with thecover open.INT-2-1-6

! WARNINGEntering/Leaving

Entering or leaving the cab or canopy must only be madewhere steps and handrails are provided. Always face themachine when entering and leaving. Make sure the step(s),handrails and your boot soles are clean and dry. Do notjump from the machine. Do not use the machine controls ashandholds, use the handrails.INT-2-1-7/1

! WARNINGROPS/FOPS Structure

The machine is fitted with a Roll Over Protection Structure(ROPS) and a Falling Objects Protection Structure (FOPS).You could be killed or seriously injured if you operate themachine with a damaged or missing ROPS/FOPS. If theROPS/FOPS has been in an accident, do not use themachine until the structure has been renewed. Modificationsand repairs that are not approved by the manufacturer maybe dangerous and wil l invalidate the ROPS/FOPScertification.INT-2-1-9/3

! WARNINGEngine/Steering Failure

If the engine or steering fails, stop the machine as quickly aspossible. Do not operate the machine until the fault has beencorrected.INT-2-1-5

! WARNINGReversing

Reversing at high speeds can cause accidents. Do notreverse in a high gear with full throttle. Always drive at a safespeed to suit working conditions.INT-2-2-9/1

! WARNINGPassengers

Passengers in or on the machine can cause accidents. TheJCB Loadall is a one man machine. Do not carrypassengers.INT-2-2-2

! WARNINGExhaust Gases

Breathing the machine exhaust gases can harm andpossibly kill you. Do not operate the machine in closedspaces without making sure there is good ventilation. Ifpossible, fit an exhaust extension. If you begin to feeldrowsy, stop the machine at once. Get out of the cab intofresh air.INT-2-1-10

! WARNINGCommunications

Bad communications can cause accidents. Keep peoplearound you informed of what you will be doing. If you will beworking with other people, make sure any hand signals thatmay be used are understood by everybody. Work sites canbe noisy, do not rely on spoken commands.INT-2-2-3

Care & Safety

9803/3630

2 - 2

Issue 1



www.maskinisten.net


2 - 3

! CAUTIONWork Site

Work sites can be hazardous. Inspect the site beforeworking on it. Check for potholes, weak ground, hiddenrocks etc. Check for utilities (electric cables, gas and waterpipes etc.) Mark the positions of underground cables andpipes. Make sure you have enough clearance beneathoverhead cables and structures. See Working With theLoadall (OPERATION section) for more information aboutthe danger of electrical cables.5-1-3-1/1

! DANGERSparks

Explosions and fire can be caused by sparks from theexhaust or the electrical system. Do not use the machine inclosed areas where there is flammable material, vapour ordust.INT-2-2-10

! WARNINGSafe Working Loads

Overloading the machine can damage it and make itunstable. Study the lifting and/or digging specifications inthis handbook before using the attachmentsINT-2-2-11/1

! WARNINGBanks and Trenches

Banked material and trenches can collapse. Do not work ordrive too close to banks and trenches where there is adanger of collapse.INT-2-2-5

! WARNINGRamps and Trailers

Water, mud, ice, grease and oil on ramps or trailers cancause serious accidents. Make sure ramps and trailers areclean before driving onto them. Use extreme caution whendriving onto ramps and trailers.INT-2-2-6

! WARNINGSafety Barriers

Unguarded machines in public places can be dangerous. Inpublic places, or when your visibility is reduced, placebarriers around the work area to keep people away.INT-2-2-8

! WARNINGParking

An incorrectly parked machine can move without anoperator. Follow the instructions in this handbook to parkthe machine correctly.INT-2-2-4

! WARNINGVisibility

Accidents can be caused by working in poor visibility. Keepwindows clean and use your lights to improve visibility. Donot operate the machine if you can not see properly.INT-2-1-11

! WARNINGRollover

Should the machine start to roll over, you can be crushed ifyou try to leave the cab. If the machine starts to roll over, DONOT TRY TO JUMP FROM THE CAB. STAY IN THE CAB,WITH YOUR SEAT BELT FASTENED.INT-2-1-12

! CAUTIONFork Spacing

Loads can fall off incorrectly spaced forks. Always space theforks correctly for the load. Make sure the forks arecompletely under the load before lifting.5-1-4-2

! CAUTIONOne-Fork Lifting

A load lifted on one fork can slip off. Never lift a load withone fork.5-1-4-3

! CAUTIONUnloading

Never unload the forks by stopping the machine suddenly.Follow the procedures in this handbook for unloading.5-1-4-4

! CAUTIONUneven Ground

Loads stacked on uneven ground can topple. Never stackloads on uneven ground.5-1-4-5

Section 2 Care & Safety

9803/3630

Section 2

2 - 3

Issue 1



www.maskinisten.net


2 - 4

! WARNINGScaffolding

Overloaded scaffolding can collapse. Never load scaffoldingbeyond the regulation capacity.5-1-4-6

! CAUTIONOverhead Clearance

A raised boom can strike overhead objects. Always checkfor overhead clearance before before raising the boom.5-1-5-1

! WARNINGBoom/Travelling

Operating the boom while travelling can cause accidents.You will not have total control of the machine. Never operatethe boom while travelling.5-1-5-2

! DANGERForks/Working Platform

Using the forks alone as a working platform is hazardous;you can fall off and be killed or injured. Never use the forksas a working platform.5-1-5-3

! CAUTIONRegulations

Obey all laws, work site and local regulations which affectyou or your machine.INT-1-3-3

Maintenance Safety

! WARNINGRepairs

Do not try to do repairs or any other type of maintenancework you do not understand. Get a Service Manual fromyour JCB distributor, or get the work done by a specialistengineer.INT-3-1-1

! WARNINGModifications and Welding

Non-approved modifications can cause injury and damage.Parts of the machine are made from cast iron; welds on castiron can weaken the structure and break. Do not weld castiron. Contact your JCB distributor for advice beforemodifying the machine.INT-3-1-2/1

! WARNINGForks/Turning

The forks extend beyond the end of the boom. Make surethere is enough clearance for the forks when making turns.5-1-5-4

! DANGEROverhead Electrical Power Lines

You can be electrocuted if you get your machine too closeto live electrical power lines. Before starting work, find out ifthere are electrical power lines on the jobsite. If there are,contact the local electricity supplier and ask what safetyprecautions you must take. Also find out if there are anylocal laws and regulations concerned with work nearelectrical power lines.

When you have found out what safety precautions, lawsand regulations apply to the jobsite, make sure they areall obeyed.5-1-5-6

! WARNINGFires

If your machine is equipped with a fire extinguisher, makesure it is checked regularly. Keep it in the operator's cabuntil you need to use it.

Do not use water to put out a machine fire, you could spreadan oil fire or get a shock from an electrical fire. Use carbondioxide, dry chemical or foam extinguishers. Contact yournearest fire department as quickly as possible. Firefightersshould use self-contained breathing apparatusINT-3-2-7/1

! WARNINGBoom Safety Strut

A raised boom can drop suddenly and cause serious injury.Before working under a raised boom, fit the boom safetystrut. See Boom Safety Strut (MAINTENANCE section).5-1-5-7

! WARNINGCommunications

Bad communications can cause accidents. If two or morepeople are working on the machine, make sure each isaware of what the others are doing. Before starting theengine make sure the others are clear of danger areas;examples of danger areas are: the rotating blades and belton the engine, the attachments and linkages, and anywherebeneath or behind the machine. People can be killed orinjured if these precautions are not taken.INT-3-1-5

Care & Safety

9803/3630

2 - 4

Issue 1



www.maskinisten.net


2 - 5

! WARNINGMetal Splinters

You can be injured by flying metal splinters when drivingmetal pins in or out. Use a soft-faced hammer or drift toremove and fit metal pins. Always wear safety glasses.INT-3-1-3

! WARNINGAsbestos

Asbestos dust can damage your lungs. Some enginegaskets contain asbestos. Do not dismantle the engine orexhaust system; get these jobs done by a qualified personwho has a copy of the engine service manual.5-1-6-1

! WARNINGOil

Oil is toxic. If you swallow any oil, do not induce vomiting,seek medical advice. Used engine oil contains harmfulcontaminants which can cause skin cancer. Do not handleused engine oil more than necessary. Always use barriercream or wear gloves to prevent skin contact. Wash skincontaminated with oil thoroughly in warm soapy water. Donot use petrol, diesel fuel or paraffin to clean your skin.INT-3-2-3

! WARNINGHydraulic Fluid

Fine jets of hydraulic fluid at high pressure can penetrate theskin. Do not use your fingers to check for hydraulic fluidleaks. Do not put your face close to suspected leaks. Hold apiece of cardboard close to suspected leaks and theninspect the cardboard for signs of hydraulic fluid. If hydraulicfluid penetrates your skin, get medical help immediately.INT-3-1-10/1

! WARNINGHydraulic Pressure

Hydraulic fluid at system pressure can injure you. Beforedisconnecting or connecting hydraulic hoses, stop theengine and operate the controls to release pressure trappedin the hoses. Make sure the engine cannot be started whilethe hoses are open.INT-3-1-11/1

! DANGERElectrolyte

Battery electrolyte is toxic and corrosive. Do not breathe thegases given off by the battery. Keep the electrolyte awayfrom your clothes, skin, mouth and eyes. Wear safetyglasses.INT-3-2-1/3

! WARNINGCounterweights

Your machine may be fitted with counterweights. They areextremely heavy. Do not attempt to remove them.INT-3-2-5

! WARNINGJacking

A machine can roll off jacks and crush you unless the wheelshave been chocked. Always chock the wheels at theopposite end of the machine that is to be jacked. Do notwork underneath a machine supported only by jacks. Alwayssupport a jacked-up machine on axle stands before workingunderneath it.INT-3-2-8

! WARNINGHot Coolant

The cooling system is pressurised when the coolant is hot.Hot coolant will burn you. Make sure the engine is coolbefore checking the coolant level or draining the system.2-3-3-3

! WARNINGTyres and Rims

Over-inflated or over-heated tyres can explode. Follow theinstructions in this handbook for inflating the tyres. Do notweld or cut rims. Get a tyre/wheel specialist to do any repairwork.INT-3-2-6

! WARNINGBattery Gases

Batteries give off explosive gases. Keep flames and sparksaway from the battery. Do not smoke close to the battery.Make sure there is good ventilation in closed areas wherebatteries are being used or charged. Do not check thebattery charge by shorting the terminals with metal; use ahydrometer or voltmeter.INT-3-1-8

! WARNINGBattery

A battery with frozen electrolyte can explode if it is used orcharged. Do not use a machine with a frozen battery. Tohelp prevent the battery from freezing, keep the battery fullycharged.INT-3-1-7

! WARNINGElectrical Circuits

Understand the electrical circuit before connecting ordisconnecting an electrical component. A wrong connectioncan cause injury and/or damage.INT-3-1-4


9803/3630

Section 2

2 - 5

Issue 1



www.maskinisten.net


2 - 6

! CAUTIONCleaning

Cleaning metal parts with incorrect solvents can causecorrosion. Use only recommended cleaning agents andsolvents.INT-3-2-11

! WARNINGHydraulic Hoses

Damaged hoses can cause fatal accidents. Inspect thehoses regularly for:Damaged end fittingsChafed outer coversBallooned outer coversKinked or crushed hosesEmbedded armouring in outer coversDisplaced end fittings.INT-3-3-2

! WARNINGPetrol

Do not use petrol in this machine. Do not mix petrol with thediesel fuel; in storage tanks the petrol will rise to the top andform flammable vapours.INT-3-1-6

! CAUTION'O' rings, Seals and Gaskets

Badly fitted, damaged or rotted 'O' rings, seals and gasketscan cause leakages and possible accidents. Renewwhenever disturbed unless otherwise instructed. Do not useTriochloroethane or paint thinners near 'O' rings and seals.INT-3-2-12

! WARNINGHot Coolant

The cooling system is pressurised when the engine is hot.Hot coolant can spray out when you remove the filler cap.Let the system cool before removing the filler cap. Toremove the cap; turn it to the first notch and let the systempressure escape, then remove the cap.INT-3-2-9/1

! WARNINGBattery Terminals

The machine is negatively earthed. Always connect thenegative pole of the battery to earth.

When connecting the battery, connect the earth (-) lead last.

When disconnecting the battery, disconnect the earth (-)lead first.INT-3-1-9

! WARNINGFluoroelastomeric Materials

Certain seals and gaskets (e.g. crankshaft oil seal) on JCBmachines contain fluoroelastomeric materials such as Viton,Fluorel and Technoflon. Fluoroelastomeric materialssubjected to high temperatures can produce highly corrosivehydrofluoric acid. THIS ACID CAN SEVERELY BURN.

New fluoroelastomeric components at ambient temperaturerequire no special safety precautions.

Used fluoroelastomeric components whose temperatureshave not exceeded 300C require no special safetyprecautions. If evidence of decomposition (e.g. charring) isfound, refer to the next paragraph for safety instructions DONOT TOUCH COMPONENT OR SURROUNDING AREA.

Used fluoroelastomeric components subjected totemperatures greater than 300C (e.g. engine fire) must betreated using the following safety procedure. Make sure thatheavy duty gloves and special safety glasses are worn:

1 Ensure that components have cooled then remove andplace material into plastic bags.

2 Thoroughly wash contaminated area with 10% calciumhydroxide or other suitable alkali solution, if necessaryuse wire wool to remove burnt remains.

3 Thoroughly wash contaminated area with detergent andwater.

4 Contain all removed material, gloves etc. used in thisoperation in sealed plastic bags and dispose of inaccordance with Local Authority Regulations.

DO NOT BURN FLUOROELASTOMERIC MATERIALS.

If contamination of skin or eyes occurs, wash the affectedarea with a continuous supply of clean water or with calciumhydroxide solution for 15-60 minutes. Get medical attentionimmediately.INT-3-3-5/1


9803/3630

Section 2

2 - 6

Issue 1



www.maskinisten.net


3 - 1

Hygiene

JCB lubricants are not a health risk when used properly fortheir intended purposes.

However, excessive or prolonged skin contact can removethe natural fats from your skin, causing dryness andirritation.

Low viscosity oils are more likely to do this, so take specialcare when handling used oils, which might be diluted withfuel contamination.

Whenever you are handling oil products you should maintaingood standards of care and personal and plant hygiene. Fordetails of these precautions we advise you to read therelevant publications issued by your local health authority,plus the following.

Storage

Always keep lubricants out of the reach of children.

Never store lubricants in open or unlabelled containers.

Waste Disposal

All waste products should be disposed of in accordancewith all the relevant regulations.

The collection and disposal of used engine oil should be inaccordance with any local regulations. Never pour usedengine oil into sewers, drains or on the ground.

Handling

New Oil

There are no special precautions needed for the handling oruse of new oil, beside the normal care and hygienepractices.

Used Oil

Used engine crankcase lubricants contain harmfulcontaminants.

Here are precautions to protect your health when handlingused engine oil:

1 Avoid prolonged, excessive or repeated skin contactwith used engine oils.

2 Apply a barrier cream to the skin before handling usedengine oil.

3 Note the following when removing engine oil from skin:a Wash your skin thoroughly with soap and water.

b Using a nail brush will help.

c Use special hand cleansers to help clean dirtyhands.

d Never use petrol, diesel fuel, or paraffin forwashing.

e Avoid skin contact with oil soaked clothing.

f Don't keep oily rags in pockets.

g Wash dirty clothing before re-use.

h Throw away oil-soaked shoes.

First Aid - Oil

Eyes

In the case of eye contact, flush with water for 15 minutes. Ifirritation persists, get medical attention.

Swallowing

If oil is swallowed do not induce vomiting. Get medicaladvice.

Skin

In the case of excessive skin contact, wash with soap andwater.

Spillage

Absorb on sand or a locally approved brand of absorbentgranules. Scrape up and remove to a chemical disposalarea.

Fires

Extinguish with carbon dioxide, dry chemical or foamextinguishers. Do not use water. Fire-fighters should useself-contained breathing apparatus.

Care & Safety

9803/3630

3 - 1

Issue 1

Lubricants - Health and Safety



www.maskinisten.net




www.maskinisten.net


i

Routine Maintenance

9803/3630

i

Issue 6*

Section 3 Section 3

Contents Page No.

Lubricants and Capacities- New Engines 1 - 1- Lubrication Charts 1 - 1- Type AA and AB Engines 1 - 2- Type AR, AK and AM Engines 1 - 3

Machine Safety 2 - 1

Working With the Boom Raised 2 - 1

Service Schedules 3 - 1

Grease- 50 Hours

530, 540 Machines 4 - 1535 Machines 4 - 2

- 500 Hours 4 - 3

Oiling 5 - 1

Tyre Inflation 6 - 1

Engine Air Filter- Changing the Elements 7 - 1

Engine Oil and Filter- Checking the Oil level 8 - 1- Changing the Oil and Filter 8 - 1

Engine Cover- Opening/Closing the Cover 8 - 2

Engine Cooling System- Checking the Coolant Level 9 - 1- Coolant Mixtures 9 - 1- Changing the Coolant 9 - 2

Cab Heater Filter - Cleaning 10 - 1

Fuel System- Fuel Types 11 - 1- Filling the Tank 11 - 2- Draining the Filter 11 - 3- Changing the Filter Element 11 - 3- Draining the Sediment Bowl 11 - 4- Cleaning the Sediment Bowl 11 - 4- Priming the System 11 - 5

Transmission - Checking the Oil Level 12 - 1- Changing the Oil and Filter 12 - 2

*



www.maskinisten.net


Contents Page No.

Axles- Checking the Axle Oil Level 13 - 1- Changing the Axle Oil 13 - 1

Front and Rear Hubs- Checking/Filling the Hub Oil Levels 14 - 1- Oil Immersed Brakes 14 - 1- Changing the Hub Oil 14 - 1

Hydraulic System- Checking the Fluid Level 15 - 1- Changing the Pilot Filter Element 15 - 1- Changing the Filter Element 15 - 2- Cleaning the Suction Strainer 15 - 3

Hose Burst Protection Valves- Checking the Hose Burst Protection Valves 16 - 1

Battery- Warning Symbols 17 - 1- Safety Notices 17 - 1- First Aid 17 - 2- Checking the Electrolyte Level 17 - 2- Isolator 17 - 3

Alternator Drive Belt Tension 17 - 4

Air Conditioning Option- Adjusting the Air Conditioning Compressor

Drive Belt 18 - 1- Cleaning the Air Conditioning Filter 18 - 1

Brakes - Checking the Foot Brake Fluid Level 19 - 1

Preparation for Use- Checking for Damage 20 - 1- Checking Seat Belt Condition and Security 20 - 1- Cleaning the Machine 20 - 2

9803/3630

Section 3

Issue 4

Routine Maintenanceii ii

Section 3www.WorkshopManuals.co.uk


www.maskinisten.net


1 - 1

Section 3 Routine Maintenance

9803/3630

Section 3

1 - 1

Issue 2

New Engines

New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately;glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under nocircumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of newmachines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operationand the engine filled with the appropriate recommended grade as shown in the lubrication chart. After the first 100 hoursoperation, it is essential that the 10W/30 oil is replaced by the lubricant recommended in the lubrication charts.

Lubrication Charts

Lubrication charts are included on the following pages for all machine models. Note that there are some differences inspecifications for machines operating in North America. Be sure you identify the machine and its lubricant requirements.

Lubricants & Capacities



www.maskinisten.net


1 - 2


9803/3630

Section 3

1 - 2

Issue 6*


Type AA and AB Engines

ITEM CAPACITY FLUID/LUBRICANT INTERNATIONALLitres UK Gal US gal SPECIFICATION

Fuel Tank 125 27.5 30 Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D

Engine (Oil) 10 (2.2) JCB 15W/40 Multigrade SAE15W/40-10 C - 50 C (14 F to 122 F) API CF4/SGJCB Super Universal Agricultural SAE10W/30, -15 C to 30 C (5 F to 86 F) API CD/SE, JCB Torque Converter Fluid SAE10W, -18 C to 0 C (0 F to 32 F) API CD/SE

NORTH AMERICA2.6 JCB 15W/40 Multigrade SAE15W/40

14 F to 122 F (-10 C to 50 C) API CF4/SG10W/30 Multigrade SAE10W/30, 5 F to 86 F (-15 C to 30 C) API CD/SE, JCB 10W SAE10W, 0 F to 32 F (-18 C to 0 C) API CD/SE

Engine (Coolant) 23 5.0 JCB Four Seasons Antifreeze ASTM D3306-74and Summer Coolant

6.0 NORTH AMERICAPermanent Antifreeze ASTM D3306-74

Transmission 21 4.6 5.5 JCB Extreme Performance JCB: 4000/2501(See Note 1) 23 5.0 6.0 Transmission Oil

AxlesHousing 18 3.9 JCB High Performance Gear OIl API GL4Hubs (x4) 2.0 0.4

NORTH AMERICAHousing 4.6 JCB Special Gear Oil ESEN-M2C 86A/BHubs (x4) 0.48

Hydraulic Tank JCB High Performance ISO VG46(See Note 2) Hydraulic Oil

(Above 38 C, 100 F)530, 540 112 24.6 JCB Special Hydraulic Fluid ISO VG32535 121 26.6 (Below 38 C, 100 F)

530, 540 29.5 NORTH AMERICA535 32.0 JCB Hydraulic oil ISO VG46

Braking System 3 0.7 0.8 JCB Light Hydraulic Fluid ISO VG15DO NOT USE ORDINARY BRAKE FLUID

Grease Points JCB HP Grease Lithium based(See Note 3)

NORTH AMERICAJCB Moly EP 2 Grease Lithium based No. 2 constituency

Wear Pad Runways JCB Waxoyl

Note 1: Wet fill capacity, eg. at fluid change 21 litres, dry fill capacity eg. after rebuild 23 litres.

Note 2: This is a tank capacity. The total hydraulic system capacity depends on the equipment being used. Fill and check withall rams closed.

Note 3: If JCB Special MPL Grease is used, all 50 hour greasing operations must be carried out at TEN (10) HOUR intervals. All500 hour greasing operations must be carried out at FIFTY (50) HOUR intervals.

*

*



www.maskinisten.net


1 - 3


9803/3630

Section 3

1 - 3

Issue 6*


Type AR, AK & AM Engines

ITEM CAPACITY FLUID/LUBRICANT INTERNATIONALLitres UK Gal US gal SPECIFICATION

Fuel Tank 125 27.5 30 Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D

Engine (Oil) 10 (2.2) JCB Super Multigrade 15W/40 CF4/SG, SAE15W/40-10 C to +50 C (14 F to 122 F)JCB Super Multigrade 10W/30 CF4/SG, SAE10W/30-15 C to +40 C (5 F to 104 F)

NORTH AMERICA2.6 JCB 15W/40 Engine Oil CF4/SG, SAE15W/40

14 F to 122 F (-10 C to +50 C)JCB Engine Oil 10W CF4/SG, SAE10W-4 F to +50 F (-20 C to +10 C)

Engine (Coolant) JCB Four Seasons Antifreeze ASTM D3306-74AR & AK Engine: 23 5.0 6.0 and Summer CoolantAM Engine: 23.5 5.2 6.2

NORTH AMERICAPermanent Antifreeze ASTM D3306-74

Transmission 21 4.6 5.5 JCB Extreme Performance JCB: 4000/2501(See Note 1) 23 5.0 6.0 Transmission oil530FS Plus 17 3.7 4.5540FS Plus 19 4.2 5.0

AxlesHousing 18 3.9 JCB High Performance Gear Oil API GL4Hubs (x4) 2.0 0.4

NORTH AMERICAHousing 4.6 JCB Special Gear Oil ESEN-M2C 86A/BHubs (x4) 0.48

Hydraulic Tank JCB High Performance ISO VG46(See Note 2) Hydraulic Oil

(Above 38 C, 100 F)530, 540 112 24.6 JCB Special Hydraulic Fluid ISO VG32535 121 26.6 (Below 38 C, 100 F)

530, 540 29.5 NORTH AMERICA535 32.0 JCB Hydraulic oil ISO VG46

Braking System 3 0.7 0.8 JCB Light Hydraulic Fluid ISO VG15DO NOT USE ORDINARY BRAKE FLUID

Grease Points JCB HP Grease Lithium based(See Note 3)

NORTH AMERICAJCB Moly EP 2 Grease Lithium based No. 2 constituency

Wear Pad Runways JCB Waxoyl

Note 1: Wet fill capacity, eg. at fluid change 21 litres, dry fill capacity eg. after rebuild 23 litres.

Note 2: This is a tank capacity. The total hydraulic system capacity depends on the equipment being used. Fill and check withall rams closed.

Note 3: If JCB Special MPL Grease is used, all 50 hour greasing operations must be carried out at TEN (10) HOUR intervals. All500 hour greasing operations must be carried out at FIFTY (50) HOUR intervals.

*

only



www.maskinisten.net


2 - 1

The machine must be made safe before carrying out anyservicing.

Machine Safety

Read Section 2, Care and Safety.

Position the machine on firm level ground. Apply the parkingbrake.

Chock both sides of all four wheels.

Make sure the forward/reverse lever is in the neutralposition.

Fully retract the boom and lower to the ground.

Switch OFF the engine and remove the starter key.

Operate the controls to vent residual pressure.

Release the hydraulic tank filler cap to release residual tankpressure.

When welding electrically disconnect the alternator.

Working with Boom Raised

Fitting Safety Strut

Carry out General Safety and the following procedure:

!! WARNINGYou could be killed or injured if the boom drops whileyou are working under it. Install the safety strut asinstructed below before doing any maintenance workwith the boom raised.5-3-1-2

Fully retract the boom (unless it needs to be extended formaintenance). Raise the boom just far enough to install thestrut.

Make sure the parking brake is engaged and thetransmission is in neutral. Switch OFF the engine andremove the starter key.

!! CAUTIONYou will have to climb onto the machine to fit or removethe safety strut. Take care, especially if the machine iswet. Remove mud and oil before climbing onto themachine.5-3-1-11

! WARNINGYou could be killed or injured if the boom is loweredwhile you are under it. Keep people away from themachine while you fit the strut.5-3-1-3

Remove the strut from its stowage position A.

Place the strut around the ram piston rod as shown. Fix it inplace with strap B.

The strap fitted to the safety strut must be in a serviceablecondition, if not fit a new strap.

To prevent any chance of the boom creeping down andtrapping your fingers, the boom should be lowered onto thestrut.

Note: Lower the boom carefully, to prevent possibledamage to the strut. Stop as soon as the weight of the boomis on the strut.

Routine Maintenance

9803/3630

2 - 1

Issue 4

Section 3 Section 3

S263560

A343230

BB

A

A343230



www.maskinisten.net


2 - 2

Working with Boom Raised(continued)

Remove Safety Strut

Start the engine and raise the boom to take the weight off ofthe strut.

Stop the engine. Make sure the parking brake is engagedand the transmission is in neutral. Remove the starter key.

!! CAUTIONYou will have to climb onto the machine to install orremove the safety strut. Take care, especially if themachine is wet. Remove mud and oil before climbingonto the machine.5-3-1-11

! WARNINGYou could be killed or injured if the boom is loweredwhile you are under it. Keep people away from themachine while you remove the safety strut.5-3-1-10

Undo the strap B, then remove the strut.

Place the strut in its stowage position A.


9803/3630

Section 3

2 - 2

Issue 2*

S263560

A343230

BB

*

A

A343230



www.maskinisten.net


3 - 1

Daily Weekly Initial 6 Monthly Yearly 2 YearlyPre-start Cold Checks Operation 10 50 100 500 1000 2000Service Points and Fluid Levels Hr Hr Hr Hr Hr Hr

ENGINEEngine Air Filter Pre-cleaner CleanOil Level and Condition CheckOil and Filter (1) ChangeAir Cleaner Dust Valve CleanAir Cleaner Outer Element ChangeAir Cleaner Inner Element ChangeFuel System For Leaks and Contamination CheckFuel Filter DrainFuel Filter ChangeCoolant Level CheckCoolant Level and Antifreeze Strength CheckFuel Sedimenter Drain and CleanFan Belt Tension/Condition CheckValve Clearances (AA - AC codes) *Check and AdjustValve Clearances (AJ - AS codes) *Check and AdjustEngine Mount Security CheckRain Cap/Pre-cleaner installed (if fitted) CheckRadiator Clean

TRANSMISSION AND AXLESTransmission Oil Level CheckTransmission Oil (2) ChangeTransmission Oil Filter ChangeAxle(s) Oil Level CheckAxle(s) Oil ChangeHub Oil Level CheckHub Oil (3) ChangeDrive Shafts and Universal Joints Security/GreaseAxle Pivots and Linkages GreaseAxle Breather(s) CheckTyre Pressures/Condition CheckHub Wheel Bearings CheckTransmission Strainer CleanWheel Nut Security CheckWheel Alignment CheckTrunnion bearings *Check/AdjustSteering Stops (if fitted) SecurityTransmission Mount Security CheckAxle Mount Security Check

(1) In arduous conditions (eg. refuse re-handling, waste paper reclamation etc.) change the oil and filter every 250 Hours orthree months (whichever comes first).

(2) After a major transmission repair, the new oil should be run to operating temperature and changed again to remove anycontamination which entered during the repair. Change the oil and filter after a further 100 hours if the oil was heavilycontaminated because of, or from the failure (eg. water contamination).

(3) After a hub repair, the new oil should be run to temperature and changed again to remove any contamination whichentered during the repair. Change the oil again after a further 100 hours to remove any bedding-in wear. This isparticularly important if new brake plates have been fitted.

Note: Jobs which should be done by a specialist are shown by *. First 100 hrs service to be completed by JCB Distributor.


9803/3630

Section 3

3 - 1

Issue 4*

Service Schedules



www.maskinisten.net


3 - 2

Pre-start Cold Checks Operation 10 50 100 500 1000 2000Service Points and Fluid Levels Hr Hr Hr Hr Hr Hr

HYDRAULICSOil Level CheckOil Sample/ChangeSystem for Leaks CheckOil Filter ChangeOil Strainers CleanPilot Filter Change

BRAKESBrake system Fluid Check Level

Change

ELECTRICSBattery Terminals for Condition and Tightness CheckWiring for Chafing Check

BODY AND FRAMEWORKMachine Generally CleanAll Pivot Pins GreaseAll Hinges LubricateWear Pad Runways WaxoylInner Boom Hoses GreaseBoom Wear Pad Clearance Check/Adjust

Replace if requiredControl Lever Linkages LubricateWindscreen Washer Fluid Level CheckCab Heater Filter CleanFire Extinguisher CheckWing Mirror Condition and Security Check

Daily Weekly Initial 6 Monthly Yearly 2 YearlyFunctional Test Operation 10 50 100 500 1000 2000and Final Inspection Hr Hr Hr Hr Hr Hr

ENGINEIdle Speed Check and AdjustTorque Converter Stall Speed CheckMax No Load Speed CheckThrottle System and Control Cable Check/AdjustExhaust Smoke CheckExhaust System Security CheckAir Inlet System Security CheckEngine for Vibration and Noise Check

TRANSMISSION AND AXLESSteer Operation Phasing CheckTorque Converter Mainline Pressure CheckDump Switch Operation Check2WD/4WD Selection (if fitted) CheckForward/Reverse/Gear Selection/Operation CheckNeutral Start Operation CheckClutch Pack Pressures Check


9803/3630

Section 3

3 - 2

Issue 4*

Service Schedules

*



www.maskinisten.net


3 - 3

Daily Weekly Initial 6 Monthly Yearly 2 YearlyFunctional Test Operation 10 50 100 500 1000 2000and Final Inspection Hr Hr Hr Hr Hr Hr

HYDRAULICSOperation of All Services CheckHose Burst Check Valves CheckMRV Pressure at Max rpm Check and AdjustARV Pressure at 750 rpm Check and AdjustSteer Circuit MRV Pressure Check and AdjustFan Motor Speed Check and AdjustAttachment Operation CheckPiston Rods and Chrome CheckBoom Extension/Phasing (3 Stage Boom)

535 machines CheckParallel Lift/Lower CheckStabiliser Leg and Sway Cut-Out (if fitted) Check

BRAKESFoot Brake Operation CheckParking Brake Check and Adjust

ELECTRICSStarter Motor CheckAlternator Check OutputAll Electrical Equipment Operation (e.g. warninglights, beacons, alarms, horn, wipers etc) CheckSafe Load Indicator/Load Moment Indicator CheckSafe Load Indicator/Load Moment Indicator CalibrateStabiliser Indicators Check

BODYWORK AND CABInclinometer (if fitted) CheckGlazing for Correct Fit /Leaks CheckSeat/Seat Belts CheckAir Conditioning (if fitted) CheckForks Fit and Check SecurityMachine Generally for Damage, Leaks & Wear Check


9803/3630

Section 3

3 - 3

Issue 4*

Service Schedules

*

**



www.maskinisten.net


4 - 1

530, 540 Machines

Routine Maintenance

9803/3630

4 - 1

Issue 2*

Grease Every 50 Hours

Section 3 Section 3

S266510

44

11

$$**

33

))

55

22

66 99

7788

00!!

@@

^&&

%%

((

*



www.maskinisten.net


4 - 2

535 Machines


9803/3630

Section 3

4 - 2

Issue 3*


*

*

345770

11

22

33

@@

**

&&

%%

55

))

88

66!!

00

44

((

77

99

$$

^



www.maskinisten.net


4 - 2A

533 Machines

Grease as shown for 535 plus the following (on both sides):


9803/3630

Section 3

4 - 2A

Issue 1


21 22 416030



www.maskinisten.net




www.maskinisten.net


4 - 3

See Greasing (50 Hours) for general information on greasing.

All 500 hour greasing operations must be carried out at50 hour intervals if JCB MPL Grease is used.

All 50 hour greasing operations must be carried out at 10hour intervals if JCB MPL Grease is used.

Note: When carrying out Greasing (50 hours) on the RearAxle Trunnion Bearings (22, 23) an extra grease point maybe found.

Extend the boom fully. Spray Waxoyl evenly over thesurfaces A and B as shown. Allow 2-3 hours drying timebefore retracting the boom.

! CAUTIONWaxoyl contains turpentine substitute, which isflammable. Keep flames away when applying Waxoyl.Waxoyl can take a few weeks to dry completely. Keepflames away during the drying period.

Do not weld near the affected area during the dryingperiod. Take the same precautions as for oil to keepWaxoyl off your skin. Do not breathe the fumes. Apply ina well-ventilated area.5-3-1-9


9803/3630

Section 3

4 - 3

Issue 3*


A335720

2211

S263620

BB

AA

33 44

AA AA

A335720

530, 540 Machines

A343900

* 533, 535 Machines

A

B

A

A

A

A343900



www.maskinisten.net


5 - 1

Oiling

The following points should be lightly oiled with engine oil atthe periods stated in the Service Schedules:

1 Lightly oil all hinges.

2 Oil the clevis at the bottom of each control lever.


9803/3630

Section 3

5 - 1

Issue 1

S267971



www.maskinisten.net


6 - 1

! WARNINGOver-inflated or overheated tyres can explode. Do notcut or weld the rims. Get a tyre/wheel specialist to doany repair work.5-3-2-4

Tyre Inflation

These instructions are for adding air to a tyre which isalready inflated. If the tyre has lost all its air pressure, call ina qualified tyre mechanic. The tyre mechanic should use atyre inflation cage and the correct equipment to do the job.

1 Before you add air to the tyre, make sure it is correctlyfitted on the machine or installed in a tyre inflation cage.

2 Use only an air supply system which includes apressure regulator. Set the regulator no higher than1.38 bar (20 lbf/in2) above the recommended tyrepressure. See the chart Section F - Transmission forrecommended tyres and pressures for your machine.(The tyre pressures are also given on the flip chartmounted in the cab and in the Specifications Section ofthe Operator Handbook).

Use an air hose fitted with a self-locking air chuck andremote shut-off valve.

3 Make sure that the air hose is correctly connected tothe tyre valve. Clear other people from the area. Standbehind the tread of the tyre while adding the air.

Inflate the tyre to the recommended pressure. Do notover-inflate.

4 Add the Air

Make sure that the air hose is correctly connected tothe tyre valve. Clear other people from the area. Standbehind the tread of the tyre while adding the air.

Inflate the tyre to the recommended pressure. Do notover-inflate.

Checking Roadwheel Nut Tightness

On new machines, and whenever a wheel has beenremoved, check the wheel nut torques every two hours untilthey stay correct.

Every day, before starting work, check that the wheel nutsare tight. If wheelnut torque indicators A are fitted, checkeach day that they have not moved.

If wheelnut torque indicators are not fitted, check that thetorques are correct as shown in the table below.

Front RearNm lbf ft Nm lbf ft680 500 680 500

! WARNINGIf, for whatever reason, a wheel stud is renewed, all thestuds for that wheel must be changed as a set, since theremaining studs may have been damaged.2-3-2-8


9803/3630

Section 3

6 - 1

Issue 5*

S089570

*

416050

AA



www.maskinisten.net


Changing the Elements

! CAUTIONThe outer element must be renewed immediately if thewarning light on the instrument panel illuminates.2-3-3-1

Note: Do not attempt to wash or clean the elements - theymust only be renewed.

Note: Do not run the engine with the dust valve J removed.

Note: A new inner element must be fitted at least every thirdtime the outer element is changed. As a reminder, mark theinner element with a felt tipped pen each time the outerelement is changed.

1 Stop the engine.

2 Open the engine cover (see Engine Cover, this Section).

3 Depress clips B and lift off cover C. Remove outerelement D. Take care not to tap or knock the element. Ifthe inner element is to be changed, lift up pulls E andremove inner element F. On turbocharged engines,remove pulsation ring L.

4 Clean inside the canister H, pulsation ring L, cover Cand dust valve J.

5 Insert the new elements into the canister, pushing themfirmly in so that seals G and K are fully seated. Onturbocharged engines, assemble the pulsation ring Linto the cover, making sure that tongue M fits into slotN. Fit cover C with dust valve J at the bottom. Push thecover firmly into position and make sure it is secured byclips B.

6 Make sure that the wire is connected to the Air FilterBlocked switch.

7 - 1


9803/3630

Section 3

7 - 1

Issue 4*

Engine Air Filter

HH

GG

KK

FF DD

EE

LL NN

MM

CC

JJMM

NNBB

JJ

CC

S257910

332260

*



www.maskinisten.net


Either remove the drain plug to allow oil to flow into thecontainer or, if the drain plug kit is fitted, remove dustcap C and, with the free end of the clear plastic hose inthe oil receptacle, screw on the drain coupling D andhose E. This automatically opens the valve, allowing theoil to flow into the container. Refit dust cap C hand tightonly.

3 Change the filter:

a Unscrew the filter canister F. Remember that it willbe full of oil.

b Check that adapter G is secure.

c Clean the filter head H.

d Add clean engine lubricating oil to the new filtercanister. Allow enough time for the oil to passthrough the filter element.

e Smear the seal J on the new filter with oil. Screw inthe new filter canister - hand tight only.

4 Fill the engine, to the upper mark on the dipstick, withnew oil through the fi l ler. See Lubricants andCapacities, this section, for recommended oil. Wipe offany spilt oil. Make sure the filler cap is correctly refitted.

5 Start the engine. Check for leaks. When the engine hascooled, check the oil level.

8 - 1

Checking the Oil Level

1 Stop the engine. Make sure the parking brake isengaged and the transmission is in neutral. Remove thestarter key.

2 Open the engine cover (see Engine Cover, this Section).

3 Check that the oil level is between the two marks on thedipstick A. Add oil if necessary, through filler B. Useonly the recommended oil (see Lubricants andCapacities, this Section). Make sure that the dipstickand filler cap are fully inserted and tightened.

Changing the Oil and Filter

! WARNINGHot oil and engine components can burn you. Make surethe engine is cool before doing this job.2-3-3-2

1 Do steps 1 and 2 of Checking the Oil Level.

! WARNINGYou will have to get beneath the machine to drain the oiland change the filter. Make sure that the engine cannotbe moved or started while you do these jobs.5-3-2-3

2 Place a container of suitable size beneath the engine.


9803/3630

Section 3

8 - 1

Issue 2*

Engine Oil and Filter

S263531

*

*

*

*

*

S174300

259251E

C D

B

GHJ

F

A

F



www.maskinisten.net


jcb_530_533_535_540_sm.pdf

Documents

service manual

section contents

service schedules

safety procedures

contents page

care safety

individual sections

torque settings