JCB Side Engine Loadall 540-140, 540-170, 535-125 Hi Viz, 535-140 Hi Viz Telehandler Service Manual

Name: JCB Side Engine Loadall 540-140, 540-170, 535-125 Hi Viz, 535-140 Hi Viz Telehandler Service Manual
Brand: MidWestTech
SKU: 9813-1450-2
Price: 249.83 USD
Availability: InStock

2,482 pages · Publication 9813-1450-2

$249.83

Fast free USA shippingShips in 1 business daySave 10% on 2 manuals, 15% on 3 or morePay by credit or debit card or with PayPal. No PayPal account needed.

Models: Side Engine Loadall 540-140, 540-170, 535-125 Hi Viz, 535-140 Hi Viz
Manual type: Service Manual
Pages: 2,482
Publication: 9813-1450-2
Condition: Brand new

JCB Side Engine Loadall 540-140, 540-170, 535-125 Hi Viz, 535-140 Hi Viz Telehandler Service Manual, publication 9813-1450-2

What's inside

From the manual's own table of contents: 334 topics. See sample pages (PDF, 417 KB)

Search the contents

Section 1 - General Information
Introduction
Scope
Format
Left and Right Sides
Hydraulic Schematic 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
Section 2 - Care and Safety
Important Information
Safety Check List
Safety Decals
Parking the Machine and Making it Safe

Show all 334 topics

Boom Safety Strut (P1)
Boom Safety Strut (P2)
Venting the Hydraulic Pressure
Venting the Brake System Pressure
Connecting/Disconnecting Hydraulic Hoses
Quick Release Couplings
Hydraulic Contamination
Battery Disconnection/Connection
Battery Charging System Precautions
Removing and Replacing Components
Hydraulic Rams
Gas Hydraulic Bladder Accumulators
Section 3 - Routine Maintenance
Service Requirements
Health and Safety
Service Schedules
Fluids, Lubricants and Capacities
Prepare the Machine for Maintenance
Cleaning the Machine
Checking for Damage
Greasing
Access Panels
Cab Heater and Air Conditioning
Boom
Brakes
Electrical System
Engine
Fuel System
Hydraulic System
Transmission
Tyres and Wheels
Wheel Alignment
Wear Pads
Windscreen Washer
Fire Extinguisher (if fitted)
Section B - Body and Framework
Table
Removal and Replacement
Component Location
Operation Overview
Electrical and Electronic Systems
Fault Finding
Refrigerant
Component Locations
Fault Finding and Diagnostics
Test Procedures
Compressor Drive Belt - Adjustment
Hydraulic Operation and Schematics
LLMI - Calibration
Logic Sequence
Freeze Thermostat (HVAC Unit)
Removal and Replacement (P1)
Removal and Replacement (P2)
Removal and Replacement (P3)
Heater Air Intake (Snorkel)
Testing
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 (P1)
Leg Removal and Replacement (P2)
Leg Removal and Replacement (P3)
Frame Removal and Replacement
Checking Pressure Switch Operation
Section C - Electrics
Access and Location
Primary Fuses
Engine Compartment Fuse and Relay Box
Fusebox Pin Number Identification (S1)
Fusebox Pin Number Identification (S2)
Relay Base Pin Number Identification
Overview
Applications
Earth Points
Wire Numbers and Functions
Harness Interconnections and Drawings
Wiring Harness Repair
Electrical Operation and Schematics
Removal, Inspection and Replacement
Maintenance
Disconnection and Connection
Removal and Replacement (S1)
Removal and Replacement (S2)
Removal and Replacement (S3)
Section E - Hydraulics
Systems
Schematics - Machines with Dual Lever Controls
Schematics - LLMC Machines with Servo Controls
chines)
Descriptions
Parallel Lift (S1)
Parallel Lift (S2)
Interlock Characteristics
Lift Pressure Balance System (S1)
Lift Pressure Balance System (S2)
Tilt/Lift/Extension Ram Counterbalance Valves (S1)
Extension Ram Counterbalance Valves (S2)
Checking Pump Flow
Dismantle and Assemble
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 - 4 Stage Boom Inner Ram
Removal and Replacement - 5 Stage Boom Ram
Removal and Replacement - 2 Stage Boom (P1)
Removal and Replacement - 2 Stage Boom (P2)
Removal and Replacement - 2 Stage Boom (P3)
Removal and Replacement - 3, 4 and 5 Stage Boom
Removal and Replacement - Single Ram (P1)
Removal and Replacement - Single Ram (P2)
Removal and Replacement - Single Ram (P3)
Removal and Replacement - Twin Rams, 2 Stage Boom
Removal and Replacement - Twin Rams, 3 Stage Boom
Removal and Replacement - Twin Rams, 5 Stage Boom
Single Piston Rams
Piston Head Retention
Twin Piston, 4 Stage Boom Outer Ram
Extension Ram Make-Up Valve (if fitted)
Bleed Procedure
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
Clutch Operation Overview
Forward and Reverser Clutch Operation
Mainshaft and Layshaft Clutch Operation
and 4 Wheel Drive Clutch (4WD Spring ON) Operation (if fitted)
Electronic Fault Codes
Gearbox `Limp Modes' (Powershift Electronic Control)
Procedure
Transmission Technical Data Check List
Pressure and Flow Tests
Oil Pressure Switch - Removal and Replacement
Solenoid Control Valves - Removal and Replacement
Wheel Drive Yoke and Oil Seal - Removal and Replacement
Gearbox Removal and Replacement
Gearbox Dismantle, Inspection and Assembly
Solenoid Control Valve Cartridge - Solenoid Coil
Solenoid Control Valve Cartridge - Twin Fixing Type
Oil Pressure Switch
Oil Temperature Switch (P1)
Oil Temperature Switch (P2)
Removal, Testing and Replacement
Section G - Brakes
Specifications (S1)
Specifications (S2)
Axle Breather (Braked Axles) - Inspection
Bleeding
Brake Light Switch (Proximity Type)
Brake Light Switch (Reed Type)
Lever Adjustment
Switch Adjustment
Renewing the Brake Pads
Renewing the Parkbrake Cable
Adjustment
Section H - Steering
Re-phasing the Road Wheels
Bleeding the System
Proximity Switch - Setting
Electrical Operation and Schematics - Indicated System (if fitted)
Removal and Replacement (S4)
Link Arms
Removal and Replacement (P4)
Section K - Engine
Separating the Engine and Bevel Box
Intentionally Blank
General ‘D’ Codes
Transmission ‘T’ Codes
Powertrain ‘P’ Codes
Constant Auxiliary ECU ‘A’ Codes
HVCS ‘H’ Codes
Machine Control ECU ‘L’ Codes
Cab Area ‘B’ Codes
Chassis ‘C’ Codes
CANbus ‘U’ Codes
RAS “S” Codes
Electronic Engine SE Engine ECU Codes
Electronic Engine SH/SL/DH Engine ECU Codes
Why Use ServiceMaster?
What is Servicemaster?
How to Set-up Servicemaster
Tool Suite
Diagnostics Connector
Servicemaster Machine Selection
Loadall Machine Diagnostics - User Guide
User Guide
Boom Angle Sensor Calibration - User Guide
Loadall Datalogger - User Guide
RHC ECU
Hydraulic Control ECU 3626
Transmission ECU 0711
IFM Transmission ECU
LLMI/LLMC ECU (S1)
LLMI/LLMC ECU (S2)
Joystick Powerbase ECU
Immobiliser ECU
Livelink ECU (S1)
Livelink ECU (S2)
Steer Mode ECU
LCS ECU
Park Brake Switch
Footbrake Operated Switch
Footbrake Pressure Transducer (S1)
Footbrake Pressure Transducer (S2)
Charge Pressure Transducer
Transmission Disconnect (Footbrake Dump) Switch
Fan Proportional Solenoid
Fan Reverse Solenoid
Fan Reverse Switch
Fan Speed Sensor
Fuel Level Sender
Coolant Temperature Switch
Vacuum Switch
Fuel Lift Pump
WIF Sensor
TMAF Sensor
Inlet Manifold Heater/Cold Start Relay
Alternator
Throttle Position Sensor (TPS)
Engine Compartment Fuse/Relay Box
Power Hold Relay
Engine ECU
Start Signal Relay
Fuel Lift Pump Relay
Exhaust Gas Re circulation (EGR) Actuator
Variable Geometry Turbo (VGT) Actuator
Ignition Switch
Info Operator Switch
Neutral Start Relay
Centre Cluster Warning Panel
Operator Present Switch
Direction Indicators/Turn Signal Lamps
Trailer Turn Signal Lamp Circuit
Hazard Lamps
Joystick (Thumbwheel and Button Type)
Joystick (Button Type)
Right Hand Column Switch
HVAC Blower Fan
HVAC Blower Fan Operator Switch (526-56)
HVAC Blower Fan Operator Buttons
AC Operator Switch (526-56)
AC Operator Button
AC Compressor Clutch Solenoid Relay
Valve Spool Transducers
Control Valve Solenoids (S1)
Control Valve Solenoids (S2)
Control Valve Solenoids (S3)
Control Valve Solenoids (S4)
Hydraulic Isolation Solenoid (S1)
Hydraulic Isolation Solenoid (S2)
Hydraulic Isolation Solenoid (S3)
Hydraulic Isolation Solenoid (S4)
Hydraulic Isolation Solenoids (S5)
Hydraulic Isolation Solenoids (S6)
Hydraulic Isolation Switch
Tilt Lock Switch
Constant Auxiliary Switch
Auxiliary (1 or 2) Changeover Solenoid
Emergency Stop Switch
Variflow Pump Control Solenoid
Variflow Pump Hydraulic Temperature Sender
Boom Retract Proximity Switch (Boom Back Switch)
Boom Angle Sensor
Chassis Angle Sensor
Axle Transducer
Stabiliser Deployed Sensor
Stabiliser Isolation Solenoid (S1)
Stabiliser Isolation Solenoid (S2)
Stabiliser Isolation Switch
Stabiliser, Sway Relay
Sway/Fan Selector Solenoid (Sway Isolation Solenoid)(S1)
Sway/Fan Selector Solenoid (Sway Isolation Solenoid)(S2)
Sway Direction Solenoid (S1)
Sway Direction Solenoid (S2)
Sway Switch (S1)
Sway Switch (S2)
Mode Operator Switch
Proximity Switches
Mode Valve Solenoids
2/4 WD Operator Switch
Operator LH Column Switch
Gearbox Solenoid Valves PS750
Gearbox Solenoid Valves PS760
Gearbox Solenoid Valves SS700
LUC Solenoid Valve
Operator Joystick Drive Control Switch
Oil Pressure Switch PS750/SS700
Oil Pressure Switch PS760
Oil Temperature Sender PS750/SS700
Oil Temperature Sender PS760 (S1)
Oil Temperature Sender PS760 (S2)
Gearbox Speed Sensors
Transmission Dump (S1)
Transmission Dump (S2)
Transmission Dump (S3)
Transmission Dump (S4)
Manual / Auto Transmission Mode Operator Switch
Transmission Gear Change Buttons
Harness Interconnections
Ground Points

Inside this manual

Real pages from this service manual (2,482 pages). Open the sample pages (PDF, 416 KB)

Sample pages from the JCB Side Engine Loadall 540-140, 540-170, 535-125 Hi Viz and 1 more Telehandler Service Manual: Specifications, Diagram, Troubleshooting, Color page, Color page

Specifications, page 748: Section E2 - Hydraulics
Diagram, page 1,432: Section H3 - Steering
Troubleshooting, page 1,622: Section M3 - Electronic Control Systems
Color page, page 1,681: Section M4 - Electronic Control Systems
Color page, page 1,160: Section F8 - 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, 2,482 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).