JCB Loadall 530-70, 532-120, 533-105, 535-60, 535-95, 535-125, 535-140, 537-135, 540-70 and 2 more Telehandler Service Manual
1,014 pages · Publication 9803-3630-14 · Loadall 530-70, 532-120, 533-105, 535-60, 535-95, 535-125, 535-140, 537-135, 540-70, 540-140, 540-170
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- Models
- Loadall 530-70, 532-120, 533-105, 535-60, 535-95, 535-125, 535-140, 537-135, 540-70, 540-140, 540-170
- Serial coverage
- 530-70 from SN 768740, 532-120 from SN 774598, 533-105 from SN 786756, 535-60 from SN 1064599, 535-95 from SN 778295, 535-125 from SN 1064203, 535-140 from SN 1065087, 537-135 (550) from SN 774605, 540-70 from SN 771065, 540-140 from SN 1064723, 540-170 (5508) from SN 780925
- Manual type
- Service Manual
- Pages
- 1,014
- Publication
- 9803-3630-14
- Condition
- Brand new
What's inside
From the manual's own table of contents: 9 sections, 408 entries. See sample pages (PDF, 409 KB)
General88 topics
- About This Publication
- Machine Model and Serial Number
- Using the Service Manual
- Units of Measurement
- Section Numbering
- Left Side, Right Side
- Cross References
- Identifying Your Machine
- Machine Identification Plate
- Component Identification Plates
- Zinc Plated Fasteners and Dacromet Fasteners
- Introduction
- Bolts and Screws
- Hydraulic Connections
- O' Ring Face Seal System
- Torque Stop' Hose System
- Numerical List
- Tool Detail Reference
- Section B - Frame and Bodywork
- Section C - Electrics
- Section E - Hydraulics
- Section F - Transmission
- Section H - Steering
- Section K - Engine
- Sealing and Retaining Compounds
- Colour Coding
- Hydraulic Schematic Colour Codes
- Important Information
- The Operator Manual
- Safety Warnings
- Safety Check List
- Safety - Yours and Others
- General Safety
- Operating Safety
- Maintenance Safety
- Safety Decals
- Health and Safety
- Lubricants
- Battery
- First Aid - Electrolyte
- Service Schedules
- Fluids, Lubricants and Capacities
- Coolant Mixtures
- Cleaning The Machine
- Undershield Removal and Replacement
- General Machine Cleaning
- Checking For Damage
- Seat Belt
- Checking the Seat Belt Condition and Security
- ROPS/FOPS Structure
- Checking The ROPS/FOPS Structure
- Boom Safety Strut
- Installing
- Removing
- Greasing
- General Greasing
- Every 50 Hours
- Every 500 Hours
- Every 1000 Hours
- Oiling
- Engine Cover
- Opening/Closing the Cover
- Air Conditioning and Heater
- Cleaning the Air Conditioning Filter - Series l Machines
- Cleaning the Cab Heater Filter - Series l Machines
- Changing the Air Intake Filter - Series ll Machines
- Adjusting the Air Conditioning Compressor Drive Belt
- Brakes
- Checking the Foot Brake Fluid Level
- Electrical System
- Jump Starting The Engine
- Adjusting the Alternator Drive Belt
- Engine Oil and Filter
- Checking the Oil Level
- Changing the Oil and Filter
- Engine Air Filter
- Changing the Elements
- Engine Cooling System
- Checking the Coolant Level
- Changing the Coolant
- Fuel System
- Types of Fuel
- Filling the Tank
- Priming the System
- Draining The Fuel Filter
- Changing the Fuel Filter
- Draining the Sediment Bowl
- Cleaning the Sediment Bowl
Section 3 - Routine Maintenance48 topics
- Hydraulic System
- Checking the Fluid Level
- Changing the Filter Element
- Changing the Pilot Filter Element - Series l Machines
- Checking the Hose Burst Protection Valves
- Transmission
- Check Transmission Oil Level
- Axles
- Front and Rear Axle
- Tyres and Wheels
- Tyre Inflation
- Checking Roadwheel Tightness
- Windscreen Washer
- Checking the Level
- Air Conditioning
- Boom - Telescopic Operation
- Stage Boom
- R134a Refrigerant
- PAG Type Refrigerant Oil
- System Operation
- System Control
- Safety Procedures
- Load Indicators
- Safe Load Indicator (SLI)
- Load Moment Indicator (LMI)
- Rivet Nuts
- Fitting Procedure
- Slide Hammer Kit
- Service Checks
- Service Ports
- Leak Testing
- Tightening Leaking Hoses
- Checking Refrigerant Charge Level
- Refrigerant Charging and Discharging
- Cleaning the Condenser
- Testing
- Calibration
- Boom
- Wear Pad Renewal
- General Fault Indications
- System Diagnosis
- General Fault Finding
- Manual Fault Diagnosis
- Diagnostic Fault Codes
- Evaporator Unit
- Removal
- Replacement
- Thermostat
Section B - Body and Framework42 topics
- Binary Pressure Switch
- Refitting
- Removal and Replacement
- Stage Booms
- and 4 Stage Booms
- and 4 Stage Boom
- Dismantling and Assembly
- Stage Boom
- Boom Shimming
- Typical Method
- Measurements
- Transducer
- Glazing
- Direct Glazing
- Fuel Strainer
- Machines with `A' series engines
- General Electrical Data
- Relay Identification
- Series I Machines
- Series II Machines
- Fuse Identification
- Fuse Links
- Applicable Machines
- Schematics
- All Series II Machines
- Using a Multimeter
- Measuring DC Voltage
- Measuring Resistance
- Measuring Continuity
- Measuring Frequency
- Testing a Diode or a Diode Wire
- Maintenance
- Specific Gravity Testing
- Alternator
- General Description
- Service Precautions
- Charging Circuit Test
- Alternator Charging Test
- Starter Motor
- Starting Circuit Test
- Wire and Harness Number Identification
- Wire Numbers and Functions
Section C - Electrics8 topics
- Wiring Harness Repair
- Repair Procedure
- Lucas Type
- Magneti Marelli Type
- Dismantling, Inspection and Assembly
- Dismantling
- Inspection
- Assembly
Section D - Controls25 topics
- Testing and Adjustment
- Adjustment
- 530-70 Agricultural and Wastemaster Machines
- 530-70 Construction Machines
- 530-70 Flowshare (LSV/LSV+) Machines
- Machines from 1154456
- 535-60 Flowshare (LSV/LSV+) Machines
- 535-95 Agricultural Machines
- 535-95 Construction Machines
- 540-70 Agricultural and Wastemaster Machines
- 540-70 Construction Machines
- 540-70 Flowshare (LSV/LSV+) Machines
- Introduction to Hydraulic Schematic Symbols
- General (Basic and Functional Symbols)
- Control Valves
- Example of Schematic Circuit
- Key to Circuit Schematics
- Component Key
- 530-70, 540-70 Construction Machines with Single Lever Control
- Double Pump
- Triple Pump
- Manual Auxiliary Controls
- 535-95 Machines with Double Pump
- 535-95 Machines with Triple Pump
- 540-70 Construction Machines with Manual Auxiliary Controls
Section E - Hydraulics120 topics
- Description
- 530-70, 540-70 Agricultural and Wastemaster Machines
- Machines up to 1154455 (without Inloader valve)
- Machines up to 1154455 (with Inloader valve)
- Machines with Parallel Service Valve Block
- Machines with Flowshare (LSV) Valve Block
- Boom (3 Stage Booms)
- Parallel Lift
- Smooth Ride System
- Hydraulic Contamination
- Hydraulic Fluid Quality
- Effects of Contamination
- Cleaning Operation
- Contaminant Standards
- Filters
- Connecting/Disconnecting Hydraulic Hoses
- Connecting the Hoses
- Disconnecting the Hoses
- Venting Hydraulic Pressure
- Basic Operation
- Test Equipment
- Main Services Pump
- Fan Pump
- Steering Pump
- Parallel Service, 4 Double Acting Spools
- Parallel service, 6 spool with unloader section
- Tie Rods
- Valve Block Sections
- Spools and Load Hold Check Valves
- Relief Valves Location
- Main Relief Valve (MRV)
- Auxiliary Relief Valve (ARV)
- Checking Servo Pressure
- Pilot Pressure Reducing Valve
- Services Operated
- Pressure Compensator Valves Operation
- Handling
- Electric Spool
- Standard Spool
- Load Sense Relief Valve
- Auxiliary Relief Valves (ARV's)
- Flow Regulator Valve
- Pressure Compensator Valves
- Load Hold Check Valves
- Spool Displacement
- Solenoid Resistance
- Relief Valve Location
- Load Sense Relief Valve (LSRV)
- Pilot Operated Relief Valve
- Inloader Valve Operation
- Boom Extend
- Boom Retract
- Assembling
- Solenoid Functions
- Replacement of Solenoids
- Machines up to SN770663
- Machines to SN784534 only
- Precautions During Use
- Installation
- Caution During Use
- Maintenance, Inspection Points
- Lift Ram
- Displacement Ram
- Extension Ram
- Tilt Ram
- Stabiliser Ram
- Sway Ram
- Typical Ram
- 4-Stage Boom Outer Ram
- JCB Ram Sealing Procedure
- Piston Head Retention
- Extension Ram Make Up Valve
- Bleed Procedures
- 3-Stage Boom Extension Ram Circuit
- 4-Stage Boom Extension Ram Circuit
- Sway Circuit
- Tilt Circuit
- Boom Raise Cycle
- Boom Lower Cycle
- Technical Data
- Accumulator
- Hydraulic Schematic
- Electrical Schematic
- Accumulators
- Charging and Discharging
- Dismantling, Inpsection and Assembly
- Smooth Ride System Micro-Switches
- Parallel Service Valve Block
- Flowshare (LSV) Valve Block
- Tyre Pressures
- Front Axles
- Unit Identification
- Rear Axles
- Powershift Gearboxes
- Engine Stall Speed Combinations
- Front Axle - Steer Drive Type SD70, SD80
- Component Identification
- Rear Axle - Steer Drive Type SD55, SD80
- Powershift Gearbox
- Principle of Operation
- Hydraulic and Electrical Operation - 4 Speed Gearbox
- Hydraulic and Electrical Operation - 5 Speed Gearbox
- Drivepaths
- Torque Converter
- Forward and Reverser Clutch Operation
- and 4 Wheel Drive Clutch (4WD Spring ON) Operation
- and 4 Wheel Drive Clutch (4WD Pressure ON) Operation
- Rear Axles SD55 And SD80
- Renewing the Pinion Oil Seal
- Front Axles SD70 And SD80
- Testing for Brake Piston Seal Leakage
- Flushing the Transmission Oil
- Torque Converter Stall Test
- Pressure and Flow Tests
- Solenoid Identification
- Speed Sensor (if fitted)
- Electronic Control Unit
- Speedometer (if fitted)
- Powershift Gearbox, Relay Control (4 Speed)
- Quick Reference
Section F - Transmission15 topics
- Powershift Gearbox, Electronic Control (4 speed)
- Diagnostics
- Powershift Gearbox, Electronic Control (5 Speed)
- Fault Finding Tables
- Electronic Control Unit (ECU)
- SD70 Fixed Axle
- SD70 Sway Axle
- SD80 Fixed Axle
- SD80 Sway Axle
- Dismantle and Assemble
- SD55 Axle
- SD80 Axle
- Dismantle, Inspection and Assembly
- Machines up to Serial No. 784534
- Machines from Serial No. 784535
Section G - Brakes44 topics
- Machines with SD55, SD70 Axles
- Machines fitted with AM and RJ engines
- All Other Engine Builds
- Machines with SD80 Axles
- Pedal Effort versus Brake Pressure
- Brake System
- Brake Piston Seal Leakage
- Front Axle
- Rear Axle
- Parking Brake Switch
- Bleeding
- Applicability
- Early Machines
- Later Machines
- Renewing the Brake Pads
- Brake Caliper
- Axle Breather (Braked Axles)
- All Machines
- System Type
- Steering Valve
- Hydraulic Operation
- Machines Fitted With Power Track Rods
- Machines Fitted With Steer Rams
- Electrical Operation
- Electrical Component and Connector Location
- Steer Unit Operation
- Machines upto SN 1004199
- Machines From SN 1004200
- Priority Valve Operation
- Neutral
- Turn
- 2-Wheel Steering
- 4-Wheel Steering
- Crab Steering
- Mechanical and Hydraulic
- Electrical
- Re-phasing the Road Wheels
- Machines with Solenoid Operated Steer Mode Valve
- Machines with Manual Steer Mode Valve (Option)
- System Bleeding
- Checking the Steering Pressure
- Adjusting the Steering Pressure
- Anti-Cavitation Valve - Bypassing
- Proximity Switches
Section H - Steering7 topics
- Link Arms
- Power Track Rod Ram
- Standby Pressure Testing
- Routine Maintenance
- Machines Upto Serial Number 773053
- Machines From Serial Number 773054
- Checking Solenoid Operation
Section K - Engine2 topics
- Separating the Engine and Bevel Box
- Cleaning the Strainer
Inside this manual
Real pages from this service manual (1,013 pages). Open the sample pages (PDF, 408 KB)
- Troubleshooting, page 208: Section B - Body and Framework
- Diagram, page 373: Section C - Electrics
- Specifications, page 463: Technical Data
- Color page: Section F - Transmission
- Color page: Section F - Transmission
This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 1,014 pages
Quantity one is the manual described above.
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Ships in 1 business day.
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Binder not included
Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.
Other editions and similar models
Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).