JCB Loadall Side Engine 540-170, 550-140, 540-140, 550-170, 535-125 Hi Viz, 535-140 Hi Viz Telehandler Service Manual
1,753 pages · Publication 9803-3750-7
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- Models
- Loadall Side Engine 540-170, 550-140, 540-140, 550-170, 535-125 Hi Viz, 535-140 Hi Viz
- Manual type
- Service Manual
- Pages
- 1,753
- Publication
- 9803-3750-7
- Condition
- Brand new
What's inside
From the manual's own table of contents: 184 topics. See sample pages (PDF, 428 KB)
- Introduction
- Scope
- Format
- Left and Right Sides
- Hydraulic Schematic Codes
- Electrical Device Codes
- Related Topics
- Machine Identification Plate
- Component Identification Plates
- Zinc Plated Fasteners and Dacromet Fasteners
- Hydraulic Connections
- `Positional Type' Hydraulic Adaptors
- Numerical List
- Tool Detail Reference
- Rivet Nuts
- Slide Hammer Kit
- Sealing and Retaining Compounds
- Acceptable and Unacceptable Fuels
- Specifications
- Important Information
- Safety Check List
- Safety Labels
- Parking the Machine and Making it Safe
- Boom Safety Strut
Show all 184 topics
- Venting Hydraulic Pressure
- Connecting/Disconnecting Hydraulic Hoses
- Quick Release Couplings
- Hydraulic Contamination
- Battery Disconnection/Connection
- Removing and Replacing Components
- Battery Charging System Precautions
- Hydraulic Rams
- Health and Safety
- Pre-start Cold Checks, Service Points and Fluid Levels
- Functional Test and Final Inspection
- Preparing the Machine for Cleaning
- Cleaning the Machine
- Checking for Damage
- Checking the Seat Belt Condition and Security
- Checking the ROPS/FOPS (and OECD) Structure
- Greasing
- Oiling
- Changing the Air Intake Filter
- Checking the Foot Brake Fluid Level
- Battery
- Battery Isolator
- Jump Starting the Engine
- Fuses and Relays
- Checking the Oil Level
- Changing the Oil and Filter
- Checking the Coolant Level
- Front End Accessory Drive Belt
- Cleaning the Air Filter Dust Valve
- Changing the Elements
- Fuel
- Filling the Tank
- Water Separator and Engine Fuel Filter
- Bleeding the System
- Oil and Filters
- Hose Burst Protection Valves
- Gearbox
- Front and Rear Axle
- Tyre Inflation
- Checking the Wheel Nut Torques
- Wheel Nut Torque Indicators (if fitted)
- Wheel Alignment
- Wear Pads
- Checking the Level
- Battery Cover
- Engine Cover
- Undershield
- Checking the Fire Extinguisher
- Table
- Removal and Replacement
- Operation Overview
- Electrical Operation and Schematics
- Electrical Connectors
- Fault Finding
- Safety Procedures
- Service Checks
- Test Procedures
- Refrigerant
- Compressor Drive Belt - Adjustment
- Calibration
- Freeze Thermostat (HVAC Unit)
- Wear Pads and Shims
- Angle Indicator Removal and Replacement
- Pivot Shims
- Boom Rear Cover
- Boom Removal and Replacement
- Dismantling and Assembly
- Leg Removal and Replacement
- Checking Pressure Switch Operation
- Access and Location
- Fuses - SD, SE, SF Engines 3 Stage Boom (S1)
- Fuses - SD, SE, SF Engines 3 Stage Boom (S2)
- Fuses - SD, SE, SF Engines 4 Stage Boom (S3)
- Link Box Fuses - SD, SF Engines
- Link Box Fuses - SE Engines
- Relays - SD, SE, SF Engines 3 Stage Boom (S1)
- Relays - SD, SE, SF Engines 3 Stage Boom (S2)
- Relays - SD, SE, SF Engines 4 Stage Boom (S3)
- Applications
- Earth Points
- Wire Numbers and Functions
- Harness Interconnections and Drawings
- Wiring Harness Repair
- Removal, Inspection and Replacement
- Dismantle and Assemble
- Maintenance
- Systems
- Schematics - Machines with Dual Lever Controls
- Schematics - Machines with Servo Controls
- Schematics - Machines with Servo Controls (S1)
- Hydraulic Operation and Schematics
- Bleed Procedures
- Component Location
- Interlock Characteristics
- Component Location and Identification
- Removal and Replacement (P1)
- Removal and Replacement (P2)
- Dismantle, Inspection and Assemble
- Steering Priority Valve
- Removal and Replacement - 3 Stage Boom Outer Ram
- Removal and Replacement - 4 Stage Boom Outer Ram
- Removal and Replacement - Inner Ram
- Single Piston Rams
- Piston Head Retention
- Twin Piston, 4 Stage Boom Outer Ram
- Extension Ram Make-Up Valve (if fitted)
- Component Identification
- Renewing the Pinion Oil Seal
- Removal and Replacement - SD80 Fixed Axle
- Removal and Replacement - SD80 Pivot Sway Axle
- Removal and Replacement - SD80 Trunnion Sway Axle
- Dismantle, Inspection and Assembly
- Component Identification - 1 Piece Axle
- Component Identification - 3 Piece Axle
- Removal and Replacement - SD80 Pivot Axle
- Removal and Replacement - SD80 Trunnion Axle
- Drive Paths
- Flushing the Transmission Oil
- Forward and Reverser Clutch Operation
- Mainshaft and Layshaft Clutch Operation
- and 4 Wheel Drive Clutch (4WD Spring ON) Operation
- and 4 Wheel Drive Clutch (4WD Pressure ON) Operation
- Oil Pressure Switch - Removal and Replacement
- Solenoid Control Valves - Removal and Replacement
- Wheel Drive Yoke and Oil Seal - Removal and Replacement
- Solenoid Control Valve Cartridge - Solenoid Coil
- Solenoid Control Valve Cartridge - Single Fixing Type
- Solenoid Control Valve Cartridge - Twin Fixing Type
- Oil Pressure Switch
- Oil Temperature Switch
- Removal, Testing and Replacement
- Testing
- Operation
- Axle Breather (Braked Axles) - Inspection
- Bleeding
- Brake Light Switch (Proximity Type)
- Brake Light Switch (Reed Type)
- Adjustment
- Switch Adjustment
- Renewing the Brake Pads
- Renewing the Park Brake Cable
- Re-phasing the Road Wheels
- Proximity Switch - Setting
- Hydraulic Operation and Schematics (S1)
- Hydraulic Operation and Schematics (S2)
- Renewing the Brush Gear
- Renewing the Starter Solenoid
- Separating the Engine and Bevel Box
- Service Hours Reset
- Loadall Monitoring System ECU Fault Codes
- Why Use Servicemaster?
- What is Servicemaster?
- How to Set Up Servicemaster
- Summary
- JCB 4.4L Tier 3 SE Diagnostics Tool - User Guide
- JCB 4.4L Tier 3 SE Engine Setup - User Guide
- ShiftMaster Diagnostics 2.3 - User Guide
- Loadall LMS Setup - User Guide
- Loadall Datalogger - User Guide
- Loadall Machine Diagnostics - User Guide
Inside this manual
Real pages from this service manual (1,753 pages). Open the sample pages (PDF, 427 KB)
- Diagram, page 262: Section B3 - Body and Framework
- Specifications, page 1,288: Section G2 - Brakes
- Troubleshooting, page 1,639: Section M3 - Electronic Network
- Color page: Section F7 - Transmission
- Color page: Section F6 - Transmission
This is a service manual
Here's how it compares to the other manual types.
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, 1,753 pages
Quantity one is the manual described above.
Fast free USA shipping
Ships in 1 business day.
60-day returns
Free if the mistake is ours. A manual ordered in error must come back unopened in its shrink-wrap; you pay return shipping and a 20% restocking fee applies. Return policy
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).