JCB Side Engine Loadall 535-140 Telehandler Service Manual

Name: JCB Side Engine Loadall 535-140 Telehandler Service Manual
Brand: MidWestTech
SKU: 9803-3730-10
Price: 149.97 USD
Availability: InStock

1,404 pages · Publication 9803-3730-10

$149.97

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Models: Side Engine Loadall 535-140
Serial coverage: SN 1422000 to 1441999
Manual type: Service Manual
Pages: 1,404
Publication: 9803-3730-10
Condition: Brand new

JCB Side Engine Loadall 535-140 Telehandler Service Manual, publication 9803-3730-10

What's inside

From the manual's own table of contents: 8 sections, 515 entries. See sample pages (PDF, 453 KB)

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General88 topics

About this Publication
Applicable Machines
Schematic Codes
Colour Codes
Machine Identification Plate
Typical Vehicle Identification Number (VIN)
Component Identification Plates
Typical Engine Identification Number
Transmission Identification Numbers
ROPS/FOPS and OECD Certification Plates
Acceptable and Unacceptable Fuels
Additives
Service Requirements for use of B20 Biodiesel
Warranty
Fuel Types
Usage and Effects of Fuels
Sulphur Content
Effects of Fuel Contaminates
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
Sealing and Retaining Compounds
Important Information
The Operator Manual
Safety Warnings
Safety Check List
Safety - Yours and Others
Common Rail (SE Engine) Specific
General Safety
Operating Safety
Maintenance Safety
Safety Decals
Related Topics
Parking the Machine and Making it Safe
Boom Safety Strut
Installing
Removing
Venting Hydraulic Pressure
Connecting/Disconnecting Hydraulic Hoses
Connecting the Hoses
Disconnecting the Hoses
Quick Release Couplings
Connecting and Disconnecting
Hydraulic Contamination
Hydraulic Fluid Quality
Effects of Contamination
Cleaning Operation
Contaminant Standards
Filters
Battery Disconnection/Connection
Disconnection
Connection
Removing and Replacing Components
Battery Charging System Precautions
Hydraulic Rams
Installation
Caution During Use
Maintenance, Inspection Points
Health and Safety
Lubricants
Battery
Fuel System
How to Use the Service Schedules
Calendar Equivalents
Pre-start Cold Checks, Service Points and Fluid Levels
Functional Test and Final Inspection
Specifications
Coolant Mixtures
Detergents
Pressure Washing and Steam Cleaning
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
Preparing the Machine for Greasing
Every 50 Hours
Every 500 Hours
Every 1000 Hours
Oiling
Park Brake Cable
Control Levers

Section 3 - Routine Maintenance86 topics

Changing the Air Intake Filter
Checking the Foot Brake Fluid Level
Checking the Electrolyte Level
Battery Isolator
Jump Starting the Engine
Fuses and Relays
Fuses
Link Box Fuses
Relays
Cleaning the Air Filter Dust Valve
Changing the Elements
Checking the Oil Level
Changing the Oil and Filter
Cooling System
Checking the Coolant Level
Changing the Coolant
Front End Accessory Drive Belt
Inspecting the Drive Belt
Changing the Drive Belt
Fuel
Filling the Tank
Water Separator and Engine Fuel Filter
Draining the Water Separator and Engine Fuel Filter
Changing the Engine Fuel Filter Element
Cleaning Water Separator Pump (if fitted)
Bleeding the System
Oil and Filters
Checking the Hydraulic Fluid Level
Changing the Filter Element
Changing the Pilot Filter Element (If Fitted)
Hose Burst Protection Valves
Gearbox
Front and Rear Axle
Checking the Axle Oil Level
Changing the Axle Oil
Oil Immersed Brakes
Checking the Front Axle Breather
Tyre Inflation
Checking the Wheel Nut Torques
Wheel Nut Torque Indicators (if fitted)
Wheel Alignment
Manual Steer Mode Selector
Electronic Steer Mode Selector
Wear Pads
Boom Wear Pad Clearance
Checking the Level
Battery Cover
Opening and Closing
Engine Cover
Undershield
Removal and Replacement
Checking the Fire Extinguisher
Air Conditioning (Option)
Boom - Telescopic Operation
Stage Boom
Safety Procedures
R134a Refrigerant
PAG Type Refrigerant Oil
System Operation
System Control
Load Moment Indicator (LMI)
Type 1: Cooling Pack Mounted Condenser
Type 2: Cab Roof Mounted Condenser
Machines with Analog Display
Machines with Digital Display
General Fault Indications
System Diagnosis using Test Gauges
Fault Codes
General Fault Finding
Diagnostic Tests
Rivet Nuts
Fitting Procedure
Slide Hammer Kit
Service Checks
Leak Testing
Tightening Leaking Hoses
Refrigerant Charging and Discharging
Binary Pressure Switch Testing
Compressor Drive Belt - Adjustment
Condenser Matrix Cleaning
ROPS, FOPS Structure - Checks
Direct Glazing
Calibration Procedure
Calibration Charts
Boom
Wear Pad Renewal

Section B - Body and Framework64 topics

Axle Transducer
Air Conditioning Unit (HVAC)
Freeze Thermostat
Binary Pressure Switch
Roof Mounted Condenser Unit
Cooling Pack Mounted Condenser Unit
Fork Carriage Removal and Replacement
Stage Booms
and 4 Stage Booms
Inclinometer Indicator
Boom Rear Cover (HiViz Machines)
Stage Boom (531, 541 Machines)
Stage Boom (526, 536 Machines)
Dismantling and Assembly
Stage Boom
Boom Shimming
Typical Method
Measurements
Pivot Shims
Internal Components
Roller Blind
Roof Liner
Instrument Panels
External Components
Door Handle Removal and Replacement
Door Removal and Replacement
Roof Guard
Wiper Motor Front
Wiper Motor Rear
Wiper Motor Roof
Removal
Replacement
Fuel Level Sender
Mudguard Assembly
General Electrical Data
SA,SB and SC Engines - With Analog Display Panel
Machines up to 10.5m Lift Height - 4 Speed Transmission
Machines Up To 10.5m Lift Height - 6 Speed Transmission
Machines Over 10.5m Lift Height
Using a Multimeter
Measuring DC Voltage
Measuring Resistance
Measuring Continuity
Measuring Frequency
Testing a Diode or a Diode Wire
Maintenance
First Aid - Electrolyte
Testing
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
Wiring Harness Repair
Repair Procedure
Removal, Inspection and Replacement
Dismantle and Assemble
Renewing the Voltage Regulator and Brushes
Renewing the Drive Pulley

Section C - Electrics53 topics

Renewing the Brush Gear
Renewing the Starter Solenoid
Location
Drawings and Interconnection
Drawings
Engine Throttle Cable (SA, SB, SC Engines)
Parkbrake Cable
PS750 Gearbox
PS760 Gearbox
Throttle Pedal Assembly
Operation
Throttle Position Sensor (TPS)
Hydraulic System Types
Hydraulic Pump
Double Pump
Triple Pump
Control Valve Block
Parallel Service Valve Block
Parallel Service Valve Block (Servo)
Cooling Fan Motor
Machines with SA,SB and SC Engines
Smooth Ride System (SRS)
Accumulator
Component Location and Neutral Circuit Description
Introduction to Hydraulic Schematic Symbols
General (Basic and Functional Symbols)
Control Valves
Example of Schematic Circuit
Machines with Dual Lever Controls
Machines with Single Lever Controls
Machines with Servo Controls
Pump Operation
Spool Control Valve
Spool Control Valve with Unloader Section
Spool Remote Control Valve (if fitted)
Main Relief Valve (MRV) Operation
Auxiliary Relief Valve (ARV) Operation
Parallel Lift
Boom Raise Cycle
Boom Lower Cycle
Boom Regenerative Valve (if fitted)
Boom Extend Cycle
Boom Retract Cycle
Smooth Ride System (SRS), Parallel Hydraulic System
Service Spool Microswitches
Hydraulic Schematic
Electrical Schematic
Electrical Operation
Wires and Connectors
Boom and Stabiliser Interlock System 540-170 Machines
Basic Operation
Interlock Characteristics
Boom Extension Faults

Section E - Hydraulics58 topics

`Positional Type' Hydraulic Adaptors
Flow and Pressure Tests
Checking Pump Flow
Smooth Ride System (SRS) Accumulators
Charging and Discharging
Dismantle, Inspection and Assemble
Steering Priority Valve
Hydraulic Control Lever
Precautions During Use
Lift Ram
Single Displacement Ram (Excluding 526-56 Machines)
Single Displacement Ram (526-56 Machines)
Twin Displacement Rams
Extension Ram
Tilt Ram
Stabiliser Ram (if fitted)
Sway Ram (if fitted)
Typical Ram
Extension Ram Make-Up Valve (if fitted)
JCB Ram Sealing Procedure
Piston Head Retention
4 - Stage Boom Outer Ram
Assembly
Bleed Procedures
3-Stage Boom Extension Ram Circuit
4-Stage Boom Extension Ram Circuit
Tilt Ram Circuit
Sway Ram Circuit
Accumulators
Tyre Sizes and Pressures
Front Axles
Unit Identification
Rear Axles
Powershift Gearboxes
Engine Stall Speed Combinations
Transmission Assembly
PS750 Transmission
PS760 Transmission
Front Axles - Steer Drive Type SD70, SD80
Component Identification
Rear Axles - Steer Drive Type SD55, SD80
PS750 Powershift Gearbox
Principle of Operation
Hydraulic and Electrical Operation
Drivepaths
PS764 and PS766 Powershift Gearboxes
Operation Characteristics - PS766, 6 Speed Gearbox
Drivepaths - 4 Speed
Drivepaths - 6 Speed
Torque Converter
Lock-Up 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
Mainshaft, Layshaft and 6-Speed Clutch Operation
and 4 Wheel Drive Clutch Operation
Powershift Gearbox (PS 750 4 Speed)
Quick Reference

Section F - Transmission58 topics

Powershift Gearbox (PS 760 4 Speed)
Powershift Gearbox (PS766 ECU 2.2 6 Speed)
ECU Electrical Connections
Lock Up Torque Converter
Rear Axles SD55 and SD80
Renewing the Pinion Oil Seal
Wheel Removal and Replacement
Wheel Studs
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
Solenoid Control Valve Cartridge - Solenoid Coil
Solenoid Control Valve Cartridge
Oil Pressure Switch
Oil Temperature Switch - Lock Up Torque Converter Variants
PS766 Powershift Gearbox
Speed Sensors
Electronic Control Unit
ShiftMaster Diagnostics 2.3 - User Guide
Testing the Lock Up Torque Converter
Speedometer (if fitted)
Powershift Gearbox
Fault Finding Tables
SD70 Fixed Axle
SD70 Sway Axle
SD80 Fixed Axle
SD80 Pivot Sway Axle
SD80 Trunnion Sway Axle
SD55 Axle
SD80 Pivot Axle
SD80 Trunnion Axle
Dismantle, Inspection and Assembly
Removal, Testing and Replacement
Service Brakes
Machines with SD55, SD70 Axles
Machines with SD80 Axles
Park Brake
Type 1: External Calliper
Type 2: Gearbox Integral
Brake System
Brake Light Switch - Adjustment
Bleeding
Brake Piston Seal Leakage
Brake Vacuum Test (if applicable)
Axle Breather (Braked Axles) - Inspection
Park Brake (Type 1: External Calliper)
Adjustment
Switch Adjustment
Renewing the Brake Pads
Park Brake (Type 2: Gearbox Integral)
All Machines
Machines with Hub Brakes
Torque Figures
Calliper - Removal and Replacement
Calliper - Dismantle, Inspection and Assemble

Section G - Brakes29 topics

Hydraulic Steer Unit
Gearpump Machines
Priority Valve
Hydraulic Operation
Hydraulic System
Machines upto 10.5m Lift Height (power track rods)
Machines over 10.5m Lift Height (steer rams)
Electrical System
Steer Modes
Machines with Steer Rams
2-Wheel Steer Selected
4-Wheel Steer Selected
Crab Steer Selected
Machines with Power Track Rods
Priority Valve Operation
Neutral
Turning
Steer Mode Controls
Machines Up to 10.5 Metre Lift Height with Analog Display
Machines Over 10.5 Metre Lift Height with Analog Display
Steering System
Diagnostic `Blink' Codes
Re-phasing the Road Wheels
Machines with Solenoid Operated Steer Mode Valve
Machines with Manual Steer Mode Valve (Option)
Proximity Switch - Setting
Steer Mode Valve - Checking Solenoid Operation
Anti-Cavitation Valve (if fitted)
Bypassing Procedure

Section H - Steering44 topics

Checking for Internal Hydraulic Leakage
Checking Energiser Seals
LSP Gearpump Machines
Hydraulic Pressure Tests
Steer Priority Valve - Cleaning
Link Arms
Rams
Machines Upto 10.5m Lift Height
JCB Dieselmax
Engine Specifications
Cold Start Heater - SA, SB, SC Engines
Machines with Non-Intercooled Engines
Machines with Intercooled Engines
Coolant Level Sensor
Machines with SA,SB,SC Engines
Separating the Engine and Bevel Box
Dismantling
Scope
Machine Types
Gearpump
Variflow Pump
Control Valve Block (LSP Gearpump)
Control Valve Block (LSP Variflow)
LSP Gearpump
Component Location and Identification
Oil Pump
Servo Pilot Valve
Manual Control
Proportional Control
Load Sensing
Inloader Operation
Pressure Compensation (Flowshare)
Control Lever
Hydraulic Circuit Operation
LSP Variflow
Gearpump Operation
Inloader Valve
Thumbwheel Controls Basic Operation
PWM Controller Electronic Control Unit (ECU)
ECU Inputs
ECU Outputs
Pulse Width Modulation (PWM)
Hydraulic Schematics
Hydraulic Services

Section L - Flowshare27 topics

Pressure Compensator Valves Operation
No Service Selected (All Spools in Neutral)
Operating a Service
Operating an Individual Service
Operating Multiple Services
Inloader Valve Operation
Pump P2 Directed to Tank
Pump P2 in Circuit (Inloader Operation)
Inloader Operation Override
Graph of System Pressures
Pilot Valve Proportional Solenoid Operation
Boom Extend and Retract - Example
Smooth Ride System - LSP Gearpump, LSP Variflow
Variflow Pump Operation
Hydraulic Services System
Measuring Spool Displacement (Manual Spools)
LSP Gearpump - Flow and Pressure Tests
Checking the Servo Pilot Pressure
Testing Load Sense Relief Valve (LSRV)
Testing Auxiliary Relief Valve (ARV's)
Testing Pilot Operated Relief Valve
LSP Variflow - Flow and Pressure Tests
Main System Pressures
System Pressures
Variflow
LSP Gearpump, LSP Variflow
Handling

Inside this manual

Real pages from this service manual (1,404 pages). Open the sample pages (PDF, 452 KB)

Sample pages from the JCB Side Engine Loadall 535-140 Telehandler Service Manual: Specifications, Diagram, Troubleshooting, Color page, Color page

Specifications, page 500: Section C - Electrics
Diagram, page 689: Section E - Hydraulics
Troubleshooting, page 1,193: Section H - Steering
Color page, page 1,025: Section F - Transmission
Color page, page 879: 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, 1,404 pages

Quantity one is the manual described above.

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