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(1)www.WorkshopManuals.co.uk General Information Care & Safety R. Routine Maintenance Attachments Body & Framework. Service Manual. Electrics Controls Hydraulics. LOADALL. Transmission. Models: 530, 533, 535, 540 from Serial No. 767001. Brakes Steering. PUBLISHED BY THE TECHNICAL PUBLICATIONS DEPARTMENT OF JCB SERVICE; © WORLD PARTS CENTRE, WATERLOO PARK, UTTOXETER, ST14 5PA, ENGLAND Tel. 01889 - 590312 PRINTED IN ENGLAND Publication No. 9803/3630. Engine. Purchased from www.WorkshopManuals.co.uk. www.maskinisten.net. 1 2 3 A B C D E F G H K.

(2) www.WorkshopManuals.co.uk. Purchased from www.WorkshopManuals.co.uk. www.maskinisten.net.

(3) www.WorkshopManuals.co.uk. www.maskinisten.net. Introduction This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training by JCB International Training Centre. These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated with 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 of course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt. Finally, please remember above all else 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 2 3. = = =. General Information - includes torque settings and service tools. Care & Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc. 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 B. = =. Attachments Body & Framework. ...etc.. The page numbering in each alphabetically coded section is not continuous. This allows for the insertion of new items in later issues of the manual. Section contents, technical data, circuit descriptions, operation descriptions etc are inserted at the beginning of each alphabetically 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 rapid reference. Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry threads, 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: 530 * 533. 535 540 * 530FS Plus * 540FS Plus 530FS Super (530 SXL France) 540FS Super (540 SXL France). 9803/3630. Issue 5*. Purchased from www.WorkshopManuals.co.uk.


(5) Section 1. www.WorkshopManuals.co.uk General Information. i. www.maskinisten.net Section 1. i. Contents. Page No.. Identification. 1-1. Torque Settings. 2-1. Service Tools - Numerical List - Section B - Section C - Section E - Section F - Section H - Section K. 3-1 4-1 5-1 6-1 7-1 8-1 8-1. Sealing and Retaining Compounds. 9-1. 9803/3630. Issue 3*. Purchased from www.WorkshopManuals.co.uk.

(6) Section 1. www.WorkshopManuals.co.uk General Information. www.maskinisten.net Section 1. 1-1. 1-1. Vehicle Identification Number (VIN). Engine Identification Number. Your machine has an identification plate V mounted as shown. The serial numbers of the machine and its major units are stamped on the plate.. The engine serial number is stamped on a label W which is fastened to the right side of the cylinder block, near the fuel filter.. V. A335321. W. S263330. Explanation of Vehicle Identification Number. SLP540RE0767001. *. A A *B C. D E. B. C D. World Manufacturer Identification Machine Model Year of Manufacture: P = 1993 V = 1997 R = 1994 W = 1998 S = 1995 X = 1999 T = 1996 Y = 2000. Typical Engine Identification Number. E SLP = JCB 540 S 1 = 2001 2 = 2002 3 = 2003 4 = 2004. Manufacturing Location E = England Machine Serial Number 0754001. AA 50261 U 500405 P A B C D E A Engine Type: AA = 4 cylinder naturally aspirated AB = 4 cylinder turbo AR = 4 cylinder naturally aspirated - Low emission AK = 4 cylinder turbo - Low emission B Build Number C Country of Origin. The serial number of each major unit is also stamped on the unit itself. If a major unit is replaced by a new one, the serial number on the identification plate will be wrong. Either stamp the new number of the unit on the identification plate, or simply stamp out the old number. This will prevent the wrong unit number being quoted when replacement parts are ordered.. D Engine Sequence Number E Year of Manufacture. The machine and engine serial numbers can help identify exactly the type of equipment you have.. 9803/3630. Issue 3*. Purchased from www.WorkshopManuals.co.uk.

(7) Section 1. www.WorkshopManuals.co.uk General Information. 1-2. www.maskinisten.net Section 1. 1-2. Transmission Identification Number The Transmission serial number is stamped on label Y which is mounted on the side face. The rear axle serial number is stamped on plate X mounted to the front face of the axle. The front axle serial number is stamped on plate Z mounted on the rear face of the axle.. Y. S263370. X. S263350. Z. S263340. 9803/3630. Issue 2. Purchased from www.WorkshopManuals.co.uk.

(8) Section 1. www.WorkshopManuals.co.uk General Information. www.maskinisten.net Section 1. 2-1. 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 the figures stated. For lubricated threads the values should be REDUCED by one third. UNF Grade 'S' Bolts Bolt Size in 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8. 1 11/4 11/2. (mm) (6.3) (7.9) (9.5) (11.1) (12.7) (14.3) (15.9) (19.0) (22.2) (25.4) (31.7) (38.1). Hexagon (A/F) in 7/16 1/2 9/16 5/8 3/4 13/16 15/16. 11/8 15/16 11/2 17/8 21/4. Nm 14 28 49 78 117 170 238 407 650 970 1940 3390. Torque Settings kgf m. lbf ft. 1.4 2.8 5.0 8.0 12.0 17.3 24.3 41.5 66.3 99.0 198.0 345.0. 10 20 36 58 87 125 175 300 480 715 1430 2500. Torque Settings kgf m. lbf ft. Metric Grade 8.8 Bolts Bolt Size (mm) M5 M6 M8 M10 M12 M16 M20 M24 M30 M36. (5) (6) (8) (10) (12) (16) (20) (24) (30) (36). Hexagon (A/F) mm 8 10 13 17 19 24 30 36 46 55. Nm 7 12 28 56 98 244 476 822 1633 2854. 0.7 1.2 3.0 5.7 10 25 48 84 166 291. 5 9 21 42 72 180 352 607 1205 2105. Rivet Nut Bolts/Screws Bolt Size (mm) M3 M4 M5 M6 M8 M10 M12. (3) (4) (5) (6) (8) (10) (12). Torque Settings (for steel rivet nuts) Nm kgf m lbf ft 1.2 3.0 6.0 10.0 24.0 48.0 82.0. 0.12 0.3 0.6 1.0 2.5 4.9 8.4. 0.9 2.0 4.5 7.5 18.0 35.5 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. Issue 1. Purchased from www.WorkshopManuals.co.uk.

(9) Section 1. www.WorkshopManuals.co.uk General Information. 3-1. www.maskinisten.net Section 1. 3-1. Service Tools Numerical List 449/03702 449/03705 460/15707 460/15708 1406/0011 1406/0014 1406/0018 1406/0021 1406/0029 1604/0003 1604/0004 1604/0006 1606/0003 1606/0004 1606/0007 1606/0008 1606/0009 1606/0012 1606/0014 1606/0015 1606/0017 1612/0006 4003/0211 4101/0251 4101/0451 4101/0552 4101/0651 4102/0551 4102/0901 4102/1212 4102/1951 4103/0955 4103/2109 4104/0251 4104/0253 4104/1203 4104/1310 4104/1557 4201/4906 816/00189 816/00190 816/00193 816/00196 816/00197 816/00294 816/15118 816/20008 816/50043 816/55038 816/55040 892/00039 892/00041 892/00047 892/00048 892/00049 892/00051 892/00055 892/00056 892/00057. Page No Fitting Adapter 7-3 Adapter 7-3 Banjo Bolt 7-3 Adapter 7-3 Bonded Washer 6-1 Bonded Washer 6-1 Bonded Washer 6-1 Bonded Washer 6-1 Bonded Washer 6-1 Adapter 6-3 Adapter 6-3 Adapter 6-1 Adapter 6-3 Adapter 6-3 Adapter 6-3 Adapter 6-3 Adapter 6-3 Adapter 6-3 Adapter 6-3 Adapter 6-3 Adapter 6-3 Adapter 6-1 Anti-Seize Paste 9-1 JCB Threadlocker and Sealer 9-1 JCB Threadlocker 9-1 JCB Threadlocker and Sealer (high strgth) 9-1 JCB Retainer (high strength) 9-1 JCB High Strength Threadlocker 9-1 Clear Silicone Sealant 9-1 JCB Multi-Gasket 9-1 JCB Threadseal 9-1 Plastic to Metal Bonder 9-1 Ultra Fast Adhesive - 310 ml (for direct glazing kit) 9-1 JCB Activator (Aerosol) 9-1 JCB Activator (Bottle) 9-1 Active Wipe 205 - 250 g (for direct glazing kit) 9-1 Hand Cleaner 4-1 JCB Cleaner and Degreaser 9-1 Black Primer 206J - 30 ml 9-1 Blanking Cap 6-2 Blanking Cap 6-2 Blanking Cap 6-2 Blanking Cap 6-2 Blanking Cap 6-2 Blanking Cap 6-2 Pressure Test Adapter 6-3 Adapter 6-1 'T' Adapter 6-2 Pressure Test Adapter 6-1 Pressure Test Adapter 6-1 Spool Clamp 6-2 De-glazing Tool 8-1 'T' Adapter 6-2 'T' Adapter 6-2 'T' Adapter 6-2 'T' Adapter 6-2 Blanking Plug 6-2 Blanking Plug 6-2 Blanking Plug 6-2. 892/00058 892/00059 892/00060 892/00071 892/00074 892/00075 892/00076 892/00077 892/00137 892/00179 892/00180 892/00181 892/00223 * 892/00254 892/00255 892/00256 892/00257 892/00258 892/00259 892/00260 892/00261 892/00262 892/00263 892/00264 892/00265 892/00268 892/00269 892/00270 892/00271 892/00272 892/00274 892/00275 892/00276 892/00277 * 892/00279 * 892/00280 892/00281 892/00282 892/00283 892/00284 892/00285 892/00286 892/00295 892/00301 892/00302 892/00333 892/00334 * 892/00346 892/00347 892/00706 892/00801 892/00802 892/00803 892/00807 892/00808. Page No Blanking Plug 6-2 Blanking Plug 6-2 Blanking Plug 6-2 Adapter 6-3 Female Connector 6-2 Female Connector 6-2 Female Connector 6-2 Female Connector 6-2 Micro-Bore Hose 6-3 Bearing Press 7-1 Seal Fitting Tool 8-1 Plastic Boss 8-1 Hand Pump 6-3 Hose 6-1 1 6-3 /4'' BSP Test Point 3 6-3 /8'' BSP Test Point 1 /2'' BSP Test Point 6-3 5 6-3 /8'' BSP Test Point 1'' BSP Test Point 6-3 11/4'' BSP Test Point 6-3 5 6-3 /8'' UNF Test Point 1 6-1 /4'' M BSP 1/4'' F BSP 5 6-1 /8'' M BSP 5/8'' F BSP 3 /4'' M BSP 3/4'' F BSP 6-1 1'' M BSP 1'' F BSP 6-1 Flow Monitoring Unit 6-1 Sensor Head 6-1 Load Valve 6-1 Adapter 6-1 Adapter 6-1 Adapter 6-3 Adapter 6-1 Adapter 6-1 Adapter 6-1 Pressure Gauge 0-400 bar (0-6000 lbf/in2) 6-1 Pressure Gauge 0-600 bar (0-9000 lbf/in2) 6-1 AVO Meter 5-1 Shunt 5-1 Tool Kit Case 5-1 Digital Tachometer 5-1 Hyd. Oil Temperature Probe 5-1 Surface Temperature Probe 5-1 End Float Setting Tool 7-1 Flow Test Adapter 7-3 Flow Test Adapter 7-3 Heavy Duty Socket 7-2 Ram Seal Fitting Tool 6-4 Pressure Gauge 0-70 bar (0-1000 lbf/in2) 6-1 Connector 6-1 Test Probe 6-3 Clutch Spanner for air conditioning compressor 4-3 Rotor Puller Set for air conditioning compressor 4-3 Rotor Installer Set for air conditioning compressor 4-3 Front Plate Puller for air conditioning compressor 4-3 Shaft Protector for air conditioning compressor 4-3. 9803/3630. Issue 5*. Purchased from www.WorkshopManuals.co.uk.

(10) Section 1. www.WorkshopManuals.co.uk General Information. www.maskinisten.net Section 1. 3-2. 3-2 Numerical List. Service Tools (cont’d). Page No. Solid Spacer Setting Tools Numerical List * 892/00812 892/00817 892/00818 892/00819 892/00842 892/00843 892/00844 892/00845 892/00846 892/00847 892/00848 892/00849 892/00905 892/00912 892/00914 892/00915 892/00916 892/00920 892/00943 892/00952 892/00956 892/01027 926/15500 992/02800 992/04000 992/04800 992/07603 992/07608 992/07609 992/07610 992/07611 992/07612 992/07613 992/09500 992/09700 992/10100 992/12300 992/12400 992/12600 992/12800 992/12801 993/59300 993/70100 993/85700. Drive Coupling Spanner Heavy Duty Socket Heavy Duty Socket Heavy Duty Socket Glass Lifter Folding Stand Long Knife Cartridge Gun Glass Extractor Nylon Spatula Wire Starter Braided Cutting Wire Test Box - SLI and LMI Bevel Box Socket Bevel Box Socket Bevel Box Reaction Block Spring Compressor Flow Test Adapter Hand held test unit MK II (ECU) Communications Lead Engine Timing Pin Piston Seal Assembly Tool Rubber Spacer Blocks ARV Extractor Torque Multiplier Drive Coupling Spanner Replacer- Bearing Cup Bearing Adapter Bearing Adapter Bearing Adapter Bearing Adapter Bearing Adapter Bearing Adapter Spanner Spanner Spool Clamp Mobile Oven 240V Static Oven 240V Static Oven Cut-out Knife ‘L’ Blades 2/4 Wheel Pressure Tester & Clamp Powershift Endfloat Checking Kit Battery Tester. Page No 7-3 7-2 7-2 7-2 4-1 4-1 4-2 4-1 4-2 4-3 4-2 4-2 5-1 7-1 7-1 7-3 7-2 7-3 5-3 5-3 8-2 6-4 4-3 6-2 7-2 7-1 7-1 7-1 7-1 7-1 7-1 7-1 7-1 6-2 6-2 6-2 4-1 4-1 4-1 4-2 4-2 7-2 7-4 5-1. 1. 892/00918. Setting Tool Kit. Contains the following: A Sleeve for M24 Pinion B. Adapter for M30 Pinion. C. fork (suitable for all axles). 7-5. The following setting tools must be purchased separately: 892/00945 A Sleeve for M30 Pinion 997/11100 2. 997/11000. 3. 993/70111 -. B. Adapter for M24 Pinion Drive Head Setting Bracket. Breack-back Torque Wrench Solid spacer (see parts CD or microfiche for part numbers). Ram Seal Protection Sleeves 892/01016 892/01017 892/01018 892/01019 892/01020 892/01021 892/01022 892/01023 892/01024 892/01025 892/01026 892/01027. For 25 mm Rod Diameter For 30 mm Rod Diameter For 40 mm Rod Diameter For 50 mm Rod Diameter For 50 mm Rod Diameter (slew ram) For 60 mm Rod Diameter For 60 mm Rod Diameter (slew ram) For 65 mm Rod Diameter For 70 mm Rod Diameter For 75 mm Rod Diameter For 80 mm Rod Diameter Piston Seal Assembly Tool. Powershift Endfloat Checking Kit (5 speed) 993/70104 892/01057 892/01056. 6-4. 7-5. Pillar, Input Shaft (5 speed) Pillar, 5th Speed Shaft Setting Body (5 speed). The following parts are replacement items for kits and would normally be included in the kit numbers above.. Replacement item for kit no. 892/00180 892/00181 Replacement Boss. 8-1. 9803/3630. Issue 6*. Purchased from www.WorkshopManuals.co.uk.

(11) Section 1. www.WorkshopManuals.co.uk General Information. www.maskinisten.net Section 1. 4-1. 4- 1. Service Tools Section B - Body and Framework. S186240. S186270. 4104/1310 (454g; 1lb tub) Hand Cleaner - special blend for the removal of polyurethane adhesives.. 892/00845 Cartridge Gun - hand operated - essential for the application of sealants, polyurethane materials etc.. '. S186250. 992/12300 - 12V Mobile Oven - 1 cartridge capacity required to pre-heat adhesive prior to use. It is fitted with a male plug (703/23201) which fits into a female socket (715/04300).. S186280. 892/00843- Folding Stand for Holding Glass - essential for preparing new glass prior to installation.. S186260. 992/12400 - 2 cartridge x 240V 992/12600 - 6 cartridge x 240V - 240V Static Oven available with 2 or 6 cartridge capacity - required to pre-heat adhesive prior to use. No plug supplied. Note: 110V models available upon request - contact JCB Technical Service. S186300. 892/00842 - Glass Lifter - minimum 2 off - essential for glass installation, 2 required to handle large panes of glass. Ensure suction cups are protected from damage during storage.. 9803/3660. Issue 1. Purchased from www.WorkshopManuals.co.uk.

(12) Section 1. www.WorkshopManuals.co.uk General Information. 4-2. www.maskinisten.net Section 1. 4- 2. Service Tools (cont’d) Section B - Body and Framework (cont’d). S186310. S186340. 992/12800 - Cut-out Knife - used to remove broken glass.. 892/00848 - Wire Starter - used to access braided cutting wire (below) through original polyurethane seal.. '. S186320 S186350. 892/00846 - Glass Extractor (Handles) - used with braided cutting wire (below) to cut out broken glass.. 992/12801 (unit quantity = 5 off) 'L' Blades - 25mm (1in.) cut - replacement blades for cut-out knife (above).. S186330. 892/00849 (approx 25m length) Braided Cutting Wire - consumable heavy duty cut-out wire used with the glass extraction tool (above).. S186360. 892/00844 - Long Knife - used to give extended reach for normally inaccessible areas.. 9803/3660. Issue 1. Purchased from www.WorkshopManuals.co.uk.

(13) Section 1. www.WorkshopManuals.co.uk General Information. www.maskinisten.net Section 1. 4-3. 4- 3. Service Tools (cont’d) Section B - Body and Framework (cont’d). S186550 S186470. 892/00847 - Nylon Spatula - general tool used for smoothing sealants - also used to re-install glass in rubber glazing because metal tools will chip the glass edge.. 926/15500 (unit quantity = 500 off) Rubber Spacer Blocks - used to provide the correct set clearance between glass edge and cab frame.. 892/00801. Clutch spanner for air conditioning compressor. S200940. 892/00807. Front plate puller for air conditioning compressor. S200970. 892/00802. Rotor puller set for air conditioning compressor. S200950. 892/00808. Shaft protector for air conditioning compressor. S200980. 892/00803. Rotor installer set for air conditioning compressor. S200960. 9803/3660. Issue 1. Purchased from www.WorkshopManuals.co.uk.

(14) Section 1. www.WorkshopManuals.co.uk General Information. www.maskinisten.net Section 1. 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 Indicator and Load Moment Indicator. S188230. S239510. S244961. 9803/3630. Issue 3. Purchased from www.WorkshopManuals.co.uk.

(15) Section 1. www.WorkshopManuals.co.uk General Information. www.maskinisten.net Section 1. 5-2. 5-2. Service Tools (cont’d) Section C - Electrics. 2A 2B 2C 2D 3A 3B 3C 3D 4A 4B 4C 4D 5A 5B 5C 5D. 7212/0002 7212/0004 7212/0003 7212/0001 7213/0002 7213/0004 7213/0003 7213/0001 7213/0006 7213/0008 7213/0007 7213/0005 7214/0002 7214/0004 7214/0003 7214/0001. Electrical Repair Kit 2 Way Pin Housing 2 Way Pin Retainer 2 Way Socket Retainer 2 Way Socket Connector 3 Way Pin Housing 3 Way Pin Retainer 3 Way Socket Retainer 3 Way Socket Connector 3 Way Pin Housing (DT) 3 Way Pin Retainer (DT) 3 Way Socket Retainer (DT) 3 Way Socket Connector (DT) 4 Way Pin Housing 4 Way Pin Retainer 4 Way Socket Retainer 4 Way Socket Connector. 6A 6B 6C 6D 7A 7B 7C 7D 8A 8B 8C 8D 9A 9B 9C 9D 10 11 12. 7216/0002 7216/0004 7216/0003 7216/0001 7218/0002 7218/0004 7218/0003 7218/0001 7219/0002 7219/0004 7219/0003 7219/0001 7219/0006 7219/0008 7219/0007 72190005 7210/0001 7210/0002 7210/0003. 6 Way Pin Housing 6 Way Pin Retainer 6 Way Socket Retainer 6 Way Socket Connector 8 Way Pin Housing 8 Way Pin Retainer 8 Way Socket Retainer 8 Way Socket Connector 10 Way Pin Housing 10 Way Pin Retainer 10 Way Socket Retainer 10 Way Socket Connector 14 Way Pin Housing 14 Way Pin Retainer 14 Way Socket Retainer 14 Way Socket Connector Dummy Plug Wire Seal (1.4 - 2.2 mm dia.) Wire Seal (2.2 - 2.9 mm dia.). S188380. 9803/3630. Issue 2. Purchased from www.WorkshopManuals.co.uk.

(16) Section 1. www.WorkshopManuals.co.uk General Information. www.maskinisten.net Section 1. 5-3. 5-3. Service Tools (cont’d) Section C - Electrics. 892/00943. Hand Held Test Unit MK II (ECU). 299920. 892/00952. Communications Lead A314020. 9803/3630. Issue 3. Purchased from www.WorkshopManuals.co.uk.

(17) Section 1. www.WorkshopManuals.co.uk General Information. 6-1. www.maskinisten.net Section 1. 6-1. Service Tools (cont'd) Section E - Hydraulics * Hydraulic Circuit Test Gauges and Connections 1 2 3 4 5. 892/00279 892/00346 892/00347 892/00254 892/00280. Pressure Gauge 0-400 bar (0-6000 lbf/in2) Pressure Gauge 0-70 bar (0-1000 lbf/in2) Connector Hose Pressure Gauge 0-600 bar (0-9000 lbf/in2). 4. 3 1,2,5. S188130 S188140. PressureTest 'T' Adaptors. Bonded Washers. 892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point 816/55038 3/8 in M BSP x 3/8 in F BSP x Test Point 816/55040 1/2 in M BSP x 1/2 in F BSP x Test Point 892/00263 5/8 in M BSP x 5/8 in F BSP x Test Point 892/00264 3/4 in M BSP x 3/4 in F BSP x Test Point 892/00265 1 in M BSP x 1 in F BSP x Test Point. 1406/0011 1406/0018 1406/0014 1406/0021 1406/0029. 1 /4. in. BSP in. BSP 5 /8 in. BSP 3 /4 in. BSP 11/4 in. BSP 1 /2. Flow Test Equipment 892/00268 892/00269 892/00270 1406/0021 1604/0006 1612/0006 892/00271 892/00272 816/20008 892/00275 892/00276 892/00277. Flow Monitoring Unit Sensor Head 0 to 100 l/min (0 to 22 UK gal/min) Load Valve Bonded Washer Adapter 3/4 in M x 3/4 M BSP Adapter 3/4 in F x 3/4 M BSP Adapter 3/4 in F x 5/8 M BSP Adapter 5/8 in F x 3/4 M BSP Adapter 3/4 in F x 1/2 M BSP Adapter 1/2 in F x 3/4 M BSP Adapter 3/4 in F x 3/8 M BSP Adapter 3/4 in F x 3/4 M BSP. 9803/3630. S188150. Issue 3*. Purchased from www.WorkshopManuals.co.uk.

(18) Section 1. www.WorkshopManuals.co.uk General Information. www.maskinisten.net Section 1. 6-2. 6-2. Service Tools (cont'd) Section E - Hydraulics. S193880. S193870. Female Cone Blanking Cap. Male Cone Blanking Cap. 892/00055 1/4 in. BSP 892/00056 3/8 in. BSP 892/00057 1/2 in. BSP 892/00058 5/8 in. BSP 892/00059 3/4 in. BSP 892/00060 1 in. BSP. 816/00294 816/00189 816/00190 816/00197 816/00196 816/00193. 1 /4. in. BSP in. BSP 1 /2 in. BSP 5 /8 in. BSP 3 /4 in. BSP 1 in. BSP 3 /8. S193900. S193890. T' Adapters. Female Connectors. 892/00047 3/8 in. BSP (A) x 1/4 in. BSP (B) 892/00048 1/2 in. BSP (A) x 1/4 in. BSP (B) 892/00049 5/8 in. BSP (A) x 1/4 in. BSP (B) 816/50043 3/4 in. BSP (A) x 1/4 in. BSP (B) 892/00051 1 in. BSP (A) x 1/4 in. BSP (B). 892/00074 892/00075 892/00076 892/00077. 3 /8. in. BSP x 3/8 in. BSP in. BSP x 1/2 in. BSP 5 5 /8 in. BSP x /8 in. BSP 3 3 /4 in. BSP x /4 in. BSP 1 /2. S192410. S193930. Hexagon Spanners for Ram Pistons and End Caps. Spool Clamps. 992/09500 75mm A/F 992/09700 95mm A/F. 892/00039 992/10100 992/02800. 9803/3630. Spool Clamp Spool Clamp ARV Extractor. S188150. Issue 2. Purchased from www.WorkshopManuals.co.uk.

(19) Section 1. www.WorkshopManuals.co.uk General Information. 6-3. www.maskinisten.net Section 1. 6-3. Service Tools (cont'd) * Section E - Hydraulics * 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. taper 1606/0004 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.. S193860. *. * S193850. Pressure Test Adaptors 892/00255 1/4 in. BSP x Test Point 892/00256 3/8 in. BSP x Test Point 892/00257 1/2 in. BSP x Test Point 892/00258 5/8 in. BSP x Test Point 816/15118 3/4 in. BSP x Test Point 892/00259 1 in. BSP x Test Point 892/00260 1.1/4 in. BSP x Test Point 892/00261 5/8 in. UNF x Test Point. Hand Pump Equipment 892/00223 892/00137 892/00274 892/00262 892/00706 892/00279. Hand Pump Micro-bore Hose 1/4 in BSP x 5 metres Adapter 1/4 in M BSP x 3/8 in M BSP Taper 1 1 /4 in M BSP x /4 in F BSP x Test Point Test Probe Gauge 0 - 400 bar (0-6000 lbf/in2). S200141. *. Pressure Test Adapters 892/00964 892/00965. 1/8 in BSP x Test Point 3/8 in BSP x Test Point 320380. 9803/3630. Issue 3*. Purchased from www.WorkshopManuals.co.uk.

(20) Section 1. www.WorkshopManuals.co.uk General Information. www.maskinisten.net Section 1. 6-4. 6-4. 7mm 11o 20mm. 10mm. 5mm R. m 3m. 338410. Ram Seal Protection Sleeves 110mm 175mm 3o R 338500. 892/01027. 1.4. mm. Piston Seal Assembly Tool. 892/01016 892/01017 892/01018 892/01019 892/01020 892/01021 892/01022 892/01023 892/01024 892/01025 892/01026. For 25 mm Rod Diameter For 30 mm Rod Diameter For 40 mm Rod Diameter For 50 mm Rod Diameter For 50 mm Rod Diameter (slew ram) For 60 mm Rod Diameter For 60 mm Rod Diameter (slew ram) For 65 mm Rod Diameter For 70 mm Rod Diameter For 75 mm Rod Diameter For 80 mm Rod Diameter. 161750X. 308271. 892/00948 892/00949. Charging Kit (without gauge) Gauge. 161750Z. 892/00334. Seal Fitting Tool. 9803/3630. Issue 2*. Purchased from www.WorkshopManuals.co.uk.

(21) Section 1. www.WorkshopManuals.co.uk General Information. www.maskinisten.net Section 1. 7-1. 7-1. Service Tools (cont'd) * Section F - Transmission *. *. S188170. S188160. 992/07608 992/07609 992/07610 992/07611 992/07612 992/07613. Bearing Adapter Bearing Adapter Bearing Adapter Bearing Adapter Bearing Adapter Bearing Adapter. 992/07603. *. Replacer- Bearing Cup. * S188200. S188190. 892/00295 End Float Setting Tool. 892/00179. *. Bearing Press. *. S197250. S188220. Bevel Box Heavy Duty Sockets 892/00912 46mm 892/00914 55mm 992/04800 Flange Spanner For locking pinion flange while nut is slackened or torque set. 9803/3630. Issue 2*. Purchased from www.WorkshopManuals.co.uk.

(22) Section 1. www.WorkshopManuals.co.uk General Information. 7-2. www.maskinisten.net Section 1. 7-2. Service Tools (cont'd) * Section F - Transmission *. *. S197250. Heavy Duty Sockets 892/00817 17mm A/F x 3/4in square drive 892/00818 22mm A/F x 3/4in square drive. 992/04000 Torque Multiplier. 892/00819 15mm A/F x 1/2in square drive 892/00333 19mm A/F x 3/4in square drive. Use in conjunction with a torque wrench to give a 5:1 multiplication when tightening pinion nuts etc.. S197030. *. *. 993/59300 2/4 Wheel Drive Clutch Pressure Test Adaptor & Clamp S196750 S162580. * 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 items 1 and 4. 892/00916 Clutch pack spring compressor S259320. 9803/3630. Issue 2*. Purchased from www.WorkshopManuals.co.uk.

(23) Section 1. www.WorkshopManuals.co.uk General Information. www.maskinisten.net Section 1. 7-3. 7-3. Service Tools (cont'd) Section F - Transmission Alternative Pump Flow Test Adapters Flow Test Adaptor type C 1 449/03705 Adapter (side/central ports) 2 449/03702 Fitting Adapter 3 1604/0004 Adapter 4 1406/0018 Bonded Washer 5 2401/0222 O-ring. 3 2. 1. A314190. 2. 892/00237 Flow Test Adaptor type A (Complete) 1 892/00920 Flow Test Adapter 2 892/00301 Flow Test Adapter 3 892/00302 Flow Test Adapter. 1 4 3. 2. 5. 892/00812. 4 5. 1. 313260 313260. Drive Coupling Spanner for front and rear axle yoke couplings and for 4WD output coupling.. 7 S196720. 3 6. 313250. Flow Test Adaptor type B 1 460/15708 Adapter (side ports) 2 460/15707 Banjo bolt 3 2401/0222 O-ring 4 2403/0110 O-ring 5 2403/0108 O-ring 6 1604/0004 Adapter 7 1406/0018 Bonded Washer Tighten adapters to 56 Nm (41 lbf ft).. 892/00915. Bevel box gear reaction block. 9803/3630. S259340. Issue 1. Purchased from www.WorkshopManuals.co.uk.

(24) Section 1. www.WorkshopManuals.co.uk General Information. www.maskinisten.net Section 1. 7-4. 7-4. Service Tools (cont'd) Section F - Transmission (cont’d) 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. 10 8. 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). Input Setting Assy. 6. 5. Reverser Setting Assy. 13† 993/70150. 11 3. 12. 993/70140. Input Shaft Pillar. 7. 4. 8. 12† 993/70112. 1. 6 13 2. 9. A191642 A191642. † 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 item 12, see A and B. Measurements are in mm. Apply JCB Threadlocker and Sealer and tighten item 9 to 25 - 30 Nm (18 - 22 lbf ft).. 8.5. 10. 20. 15 12. A B. 36 17 81.75 96.35. 9. 9803/3630. Issue 2*. Purchased from www.WorkshopManuals.co.uk.

(25) Section 1. www.WorkshopManuals.co.uk General Information. www.maskinisten.net Section 1. 7-5. 7-5. Service Tools (cont'd) Section F - Transmission (cont’d) Powershift Endfloat Checking Kit - 5 Speed Transmission Base plate 993/70101 used for the 4-speed transmission can be adapted for use with 5 speed transmission. Cut out the corner section A, drill and counterbore the two holes B as shown below. Measurements are in mm. The later base plate 892/01055 is suitable for both 4- and 5-speed transmissions. The following setting tools must be purchased to use the kit with 5-speed transmissions: 14 15 16. 993/70104 892/01057 892/01056. Pillar, Input Shaft Pillar, 5th Speed Shaft Setting Body. 215 31 14.34. 15. 19.24 61.28. A 14 13.60. 16 B. 8.5. 10. 20. 15. A362630. Solid Spacer Setting Tools 1. 2 3. 892/00918. Setting Tool Kit. Contains the following: A 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 997/11000 Drive Head Setting Bracket 993/70111 Breack-back Torque Wrench Solid spacer (see parts CD or microfiche for part numbers). 9803/3630. A270851. Issue 2*. Purchased from www.WorkshopManuals.co.uk.

(26) Section 1. www.WorkshopManuals.co.uk General Information. 8-1. www.maskinisten.net Section 1. 8-1. Service Tools (cont'd) Section H - Steering. 892/00180. Seal Fitting Tool for fitting ‘O’ ring and back-up ring to Orbitrol Unit. 892/00181. Replacement Plastic Boss. S191750. Section K - Engine. 892/00041. De-glazing Tool for Cylinder Bores (to assist bedding-in of new piston rings). S192390. For details of all engine service tools refer to engine service manual.. 9803/3630. Issue 4*. Purchased from www.WorkshopManuals.co.uk.

(27) Section 1. www.WorkshopManuals.co.uk General Information. www.maskinisten.net Section 1. 8-2. 8-2. Service Tools (cont'd) Section K - Engine. Details for the manufacture of a lifting beam have been made available. This lifting beam enables the complete engine, bevel box and transmission unit to be removed from the machine as a complete assembly. Refer to Technical Information Bulletin 5/160 for the material and dimensional details required to manufacture the beam safely. Limitations on Use This tool is designed specifically to lift the side mounted engine, bevel box and powershift transmission as a complete 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 duty or use.. A296430. 892/00956. Timing pin for fuel injection pumps on JCB Diesel Engines type AR and AK builds only.. A314530. 9803/3630. Issue 2*. Purchased from www.WorkshopManuals.co.uk.

(28) Section 1. www.WorkshopManuals.co.uk General Information. www.maskinisten.net Section 1. 9-1 *. 9-1. Sealing and Retaining Compounds JCB Multi-Gasket. A medium strength sealant suitable for all sizes of gasket 4102/1212 flanges, and for hydraulic fittings of 25-65 mm diameter.. 50 ml. JCB Threadlocker. For threads of 50 mm diameter upwards,. 4101/0451. 50 ml. 4102/0551. 50 ml. e.g. suction strainer. JCB Threadlocker. A high strength locking fluid for use with threaded. (High Strength). components. Gasketing for all sizes of flange where the strength of the joint is important.. JCB Retainer (High Strength) 50 ml. For all retaining parts which are unlikely to be dismantled.. 4101/0651. JCB Threadlocker and Sealer. A medium strength locking fluid for sealing and retaining 4101/0250 nuts, bolts, and screws up to 50 mm diameter, and 4101/0251 for hydraulic fittings up to 25 mm diameter.. 10 ml 50 ml. 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 hydraulic fittings up to 25 mm diameter.. 4101/0552. 200 ml. JCB Threadseal. A medium strength thread sealing compound.. 4102/1951. 50 ml. JCB Activator. A cleaning primer which speeds the curing rate of anaerobic products.. 4104/0251 4104/0253. Aerosol (1 ltr) Bottle (200 ml). JCB Cleaner/Degreaser. For degreasing components prior to use of anaerobic adhesives and sealants.. 4104/1557. Aerosol (400 ml). Anti-Seize Paste. A compound used for assembly and prevention of parts seizure.. 4003/0211. 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. 9803/3630. Issue 2*. Purchased from www.WorkshopManuals.co.uk.

(29) Section 2. www.WorkshopManuals.co.uk Care & Safety. i. www.maskinisten.net Section 2. i. 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. 9803/3630. Issue 1. Purchased from www.WorkshopManuals.co.uk.

(30) Section 2. www.WorkshopManuals.co.uk Care & Safety. 1-1. www.maskinisten.net Section 2. 1-1. Safety Notices In this handbook and on the machine there are safety notices. Each notice starts with a signal word. The signal word meanings are given below.. ! DANGER Denotes an extreme hazard exists. If proper precautions are not taken it is highly probable that the operator (or others) could be killed or seriously injured. INT-1-2-1. ! WARNING Denotes a hazard exists. If proper precautions are not taken, the operator (or others) could be killed or seriously injured. INT-1-2-2. ! CAUTION Denotes a reminder of safety practices. Failure to follow these safety practices could result in injury to the operator (or others) and possible damage to the machine. INT-1-2-3. 9803/3630. Issue 1. Purchased from www.WorkshopManuals.co.uk.

(31) Section 2. www.WorkshopManuals.co.uk Care & Safety. 2-1. www.maskinisten.net Section 2. 2-1. All construction and agricultural equipment can be hazardous. When a JCB machine is correctly operated and properly maintained, it is a safe machine to work with. But when it is carelessly operated or poorly maintained it can become a danger to you (the operator) and others.. As well as the warnings in this chapter, specific warnings are given throughout the book. This section is designed to give a safety code for use of the machine generally and for maintenance practices.. Do not work with the machine until you are sure that you can control it. Do not start any job until you are sure that you and those around 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 CAREFUL BE ALERT BE SAFE GEN-1-6. General Safety. ! WARNING. Decals You can be injured if you do not obey the decal safety instructions. Keep decals clean. Replace unreadable or missing decals with new ones before operating the machine. Make sure replacement parts include warning decals where necessary.. Clothing You can be injured if you do not wear proper clothing. Loose clothing can get caught in the machinery. Wear protective clothing to suit the job. Examples of protective clothing are: a hard hat, safety shoes, safety glasses, a well-fitting overall, ear-protectors and industrial gloves. Keep cuffs fastened. Do not wear a necktie or scarf. Keep long hair restrained.. INT-1-3-4. INT-1-3-6. ! WARNING. ! CAUTION. ! WARNING. Hazardous Atmospheres This machine is designed for use in normal out door atmospheric conditions. It should not be used in an enclosed area without adequate ventilation. Do not use the machine in a potentially explosive atmosphere, ie. combustible vapours, gas or dust, without first consulting your JCB Distributor.. Care and Alertness All the time you are working with or on the machine, take care and stay alert. Always be careful. Always be alert for hazards.. INT-2-1-14. Lightning Lightning can kill you. Do not use the machine if there is lightning in your area.. INT-1-3-5. ! DANGER. 5-1-1-2. ! WARNING Raised Boom A raised boom can fall or be lowered accidentally. Do not walk under a raised boom which is not fitted with a safety strut, or you could be injured. 5-1-1-1. ! WARNING Lifting Equipment You can be injured if you use faulty lifting equipment. Make sure that lifting equipment is in good condition. Make sure that lifting tackle complies with all local regulations and is suitable for the job. Make sure the lifting equipment is strong enough for the job. INT-1-3-7. 9803/3630. Issue 1. Purchased from www.WorkshopManuals.co.uk.

(32) Section 2. www.WorkshopManuals.co.uk Care & Safety. 2-2. www.maskinisten.net Section 2. 2-2. Operating Safety ! WARNING Practice You and others can be killed or seriously injured if you do unfamiliar operations without first practising them. Practise away from the work site on a clear area. Keep other people away. Do not perform new operations until you are sure you can do them safely. INT-2-1-1. ! WARNING Machine Condition A defective machine can injure you or others. Do not operate a machine which is defective or has missing parts. Make sure the maintenance procedures in this handbook are completed before using the machine. INT-2-1-2. ! WARNING Machine Limits Operating the machine beyond its design limits can damage the machine, it can also be dangerous. Do not operate the machine outside its limits. Do not try to upgrade the machine performance with unapproved modifications. INT-2-1-4. ! WARNING ROPS/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 the machine with a damaged or missing ROPS/FOPS. If the ROPS/FOPS has been in an accident, do not use the machine until the structure has been renewed. Modifications and repairs that are not approved by the manufacturer may be dangerous and will invalidate the ROPS/FOPS certification. INT-2-1-9/3. ! WARNING Engine/Steering Failure If the engine or steering fails, stop the machine as quickly as possible. Do not operate the machine until the fault has been corrected. INT-2-1-5. ! WARNING Reversing Reversing at high speeds can cause accidents. Do not reverse in a high gear with full throttle. Always drive at a safe speed to suit working conditions. INT-2-2-9/1. ! WARNING Engine The engine has rotating parts. Do not open the engine cover while the engine is running. Do not use the machine with the cover open. INT-2-1-6. ! WARNING Passengers Passengers in or on the machine can cause accidents. The JCB Loadall is a one man machine. Do not carry passengers. INT-2-2-2. ! WARNING Entering/Leaving Entering or leaving the cab or canopy must only be made where steps and handrails are provided. Always face the machine when entering and leaving. Make sure the step(s), handrails and your boot soles are clean and dry. Do not jump from the machine. Do not use the machine controls as handholds, use the handrails. INT-2-1-7/1. ! WARNING Exhaust Gases Breathing the machine exhaust gases can harm and possibly kill you. Do not operate the machine in closed spaces without making sure there is good ventilation. If possible, fit an exhaust extension. If you begin to feel drowsy, stop the machine at once. Get out of the cab into fresh air. INT-2-1-10. ! WARNING Communications Bad communications can cause accidents. Keep people around you informed of what you will be doing. If you will be working with other people, make sure any hand signals that may be used are understood by everybody. Work sites can be noisy, do not rely on spoken commands. INT-2-2-3. 9803/3630. Issue 1. Purchased from www.WorkshopManuals.co.uk.

(33) Section 2. www.WorkshopManuals.co.uk Care & Safety. 2-3. www.maskinisten.net Section 2. 2-3. ! CAUTION. ! WARNING. Work Site Work sites can be hazardous. Inspect the site before working on it. Check for potholes, weak ground, hidden rocks etc. Check for utilities (electric cables, gas and water pipes etc.) Mark the positions of underground cables and pipes. Make sure you have enough clearance beneath overhead cables and structures. See Working With the Loadall (OPERATION section) for more information about the danger of electrical cables.. Parking An incorrectly parked machine can move without an operator. Follow the instructions in this handbook to park the machine correctly.. 5-1-3-1/1. ! DANGER Sparks Explosions and fire can be caused by sparks from the exhaust or the electrical system. Do not use the machine in closed areas where there is flammable material, vapour or dust. INT-2-2-10. ! WARNING Safe Working Loads Overloading the machine can damage it and make it unstable. Study the lifting and/or digging specifications in this handbook before using the attachments INT-2-2-11/1. ! WARNING Banks and Trenches Banked material and trenches can collapse. Do not work or drive too close to banks and trenches where there is a danger of collapse. INT-2-2-5. ! WARNING Ramps and Trailers Water, mud, ice, grease and oil on ramps or trailers can cause serious accidents. Make sure ramps and trailers are clean before driving onto them. Use extreme caution when driving onto ramps and trailers.. INT-2-2-4. ! WARNING Visibility Accidents can be caused by working in poor visibility. Keep windows clean and use your lights to improve visibility. Do not operate the machine if you can not see properly. INT-2-1-11. ! WARNING Rollover Should the machine start to roll over, you can be crushed if you try to leave the cab. If the machine starts to roll over, DO NOT TRY TO JUMP FROM THE CAB. STAY IN THE CAB, WITH YOUR SEAT BELT FASTENED. INT-2-1-12. ! CAUTION Fork Spacing Loads can fall off incorrectly spaced forks. Always space the forks correctly for the load. Make sure the forks are completely under the load before lifting. 5-1-4-2. ! CAUTION One-Fork Lifting A load lifted on one fork can slip off. Never lift a load with one fork. 5-1-4-3. ! CAUTION Unloading Never unload the forks by stopping the machine suddenly. Follow the procedures in this handbook for unloading. 5-1-4-4. INT-2-2-6. ! WARNING Safety Barriers Unguarded machines in public places can be dangerous. In public places, or when your visibility is reduced, place barriers around the work area to keep people away.. ! CAUTION Uneven Ground Loads stacked on uneven ground can topple. Never stack loads on uneven ground. 5-1-4-5. INT-2-2-8. 9803/3630. Issue 1. Purchased from www.WorkshopManuals.co.uk.

(34) Section 2. www.WorkshopManuals.co.uk Care & Safety. 2-4. www.maskinisten.net Section 2. 2-4. ! WARNING. ! WARNING. Scaffolding Overloaded scaffolding can collapse. Never load scaffolding beyond the regulation capacity.. Forks/Turning The forks extend beyond the end of the boom. Make sure there is enough clearance for the forks when making turns.. 5-1-4-6. 5-1-5-4. ! CAUTION. ! DANGER. Overhead Clearance A raised boom can strike overhead objects. Always check for overhead clearance before before raising the boom.. Overhead Electrical Power Lines You can be electrocuted if you get your machine too close to live electrical power lines. Before starting work, find out if there are electrical power lines on the jobsite. If there are, contact the local electricity supplier and ask what safety precautions you must take. Also find out if there are any local laws and regulations concerned with work near electrical power lines.. 5-1-5-1. ! WARNING Boom/Travelling Operating the boom while travelling can cause accidents. You will not have total control of the machine. Never operate the boom while travelling. 5-1-5-2. ! DANGER Forks/Working Platform Using the forks alone as a working platform is hazardous; you can fall off and be killed or injured. Never use the forks as a working platform. 5-1-5-3. ! CAUTION Regulations Obey all laws, work site and local regulations which affect you or your machine. INT-1-3-3. When you have found out what safety precautions, laws and regulations apply to the jobsite, make sure they are all obeyed. 5-1-5-6. ! WARNING Fires If your machine is equipped with a fire extinguisher, make sure it is checked regularly. Keep it in the operator's cab until you need to use it. Do not use water to put out a machine fire, you could spread an oil fire or get a shock from an electrical fire. Use carbon dioxide, dry chemical or foam extinguishers. Contact your nearest fire department as quickly as possible. Firefighters should use self-contained breathing apparatus INT-3-2-7/1. Maintenance Safety ! WARNING. ! WARNING. Repairs Do not try to do repairs or any other type of maintenance work you do not understand. Get a Service Manual from your JCB distributor, or get the work done by a specialist engineer.. Boom Safety Strut A raised boom can drop suddenly and cause serious injury. Before working under a raised boom, fit the boom safety strut. See Boom Safety Strut (MAINTENANCE section). 5-1-5-7. INT-3-1-1. ! WARNING Modifications and Welding Non-approved modifications can cause injury and damage. Parts of the machine are made from cast iron; welds on cast iron can weaken the structure and break. Do not weld cast iron. Contact your JCB distributor for advice before modifying the machine. INT-3-1-2/1. ! WARNING Communications Bad communications can cause accidents. If two or more people are working on the machine, make sure each is aware of what the others are doing. Before starting the engine make sure the others are clear of danger areas; examples of danger areas are: the rotating blades and belt on the engine, the attachments and linkages, and anywhere beneath or behind the machine. People can be killed or injured if these precautions are not taken. INT-3-1-5. 9803/3630. Issue 1. Purchased from www.WorkshopManuals.co.uk.

(35) Section 2. www.WorkshopManuals.co.uk Care & Safety. 2-5. www.maskinisten.net Section 2. 2-5. ! WARNING. ! WARNING. Metal Splinters You can be injured by flying metal splinters when driving metal pins in or out. Use a soft-faced hammer or drift to remove and fit metal pins. Always wear safety glasses.. Counterweights Your machine may be fitted with counterweights. They are extremely heavy. Do not attempt to remove them. INT-3-2-5. INT-3-1-3. ! WARNING Asbestos Asbestos dust can damage your lungs. Some engine gaskets contain asbestos. Do not dismantle the engine or exhaust system; get these jobs done by a qualified person who has a copy of the engine service manual. 5-1-6-1. ! WARNING Jacking A machine can roll off jacks and crush you unless the wheels have been chocked. Always chock the wheels at the opposite end of the machine that is to be jacked. Do not work underneath a machine supported only by jacks. Always support a jacked-up machine on axle stands before working underneath it. INT-3-2-8. ! WARNING Oil Oil is toxic. If you swallow any oil, do not induce vomiting, seek medical advice. Used engine oil contains harmful contaminants which can cause skin cancer. Do not handle used engine oil more than necessary. Always use barrier cream or wear gloves to prevent skin contact. Wash skin contaminated with oil thoroughly in warm soapy water. Do not use petrol, diesel fuel or paraffin to clean your skin. INT-3-2-3. ! WARNING Hydraulic Fluid Fine jets of hydraulic fluid at high pressure can penetrate the skin. Do not use your fingers to check for hydraulic fluid leaks. Do not put your face close to suspected leaks. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of hydraulic fluid. If hydraulic fluid penetrates your skin, get medical help immediately. INT-3-1-10/1. ! WARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses, stop the engine and operate the controls to release pressure trapped in the hoses. Make sure the engine cannot be started while the hoses are open. INT-3-1-11/1. ! DANGER Electrolyte Battery electrolyte is toxic and corrosive. Do not breathe the gases given off by the battery. Keep the electrolyte away from your clothes, skin, mouth and eyes. Wear safety glasses. INT-3-2-1/3. ! WARNING Hot Coolant The cooling system is pressurised when the coolant is hot. Hot coolant will burn you. Make sure the engine is cool before checking the coolant level or draining the system. 2-3-3-3. ! WARNING Tyres and Rims Over-inflated or over-heated tyres can explode. Follow the instructions in this handbook for inflating the tyres. Do not weld or cut rims. Get a tyre/wheel specialist to do any repair work. INT-3-2-6. ! WARNING Battery Gases Batteries give off explosive gases. Keep flames and sparks away from the battery. Do not smoke close to the battery. Make sure there is good ventilation in closed areas where batteries are being used or charged. Do not check the battery charge by shorting the terminals with metal; use a hydrometer or voltmeter. INT-3-1-8. ! WARNING Battery A battery with frozen electrolyte can explode if it is used or charged. Do not use a machine with a frozen battery. To help prevent the battery from freezing, keep the battery fully charged. INT-3-1-7. ! WARNING Electrical Circuits Understand the electrical circuit before connecting or disconnecting an electrical component. A wrong connection can cause injury and/or damage. INT-3-1-4. 9803/3630. Issue 1. Purchased from www.WorkshopManuals.co.uk.

(36) Section 2. www.WorkshopManuals.co.uk Care & Safety. www.maskinisten.net Section 2. 2-6. 2-6. ! CAUTION. ! WARNING. Cleaning Cleaning metal parts with incorrect solvents can cause corrosion. Use only recommended cleaning agents and solvents.. Battery Terminals The machine is negatively earthed. Always connect the negative pole of the battery to earth.. INT-3-2-11. When connecting the battery, connect the earth (-) lead last.. ! WARNING Hydraulic Hoses Damaged hoses can cause fatal accidents. Inspect the hoses regularly for: Damaged end fittings Chafed outer covers Ballooned outer covers Kinked or crushed hoses Embedded armouring in outer covers Displaced end fittings. INT-3-3-2. ! WARNING Petrol Do not use petrol in this machine. Do not mix petrol with the diesel fuel; in storage tanks the petrol will rise to the top and form flammable vapours. INT-3-1-6. ! CAUTION 'O' rings, Seals and Gaskets Badly fitted, damaged or rotted 'O' rings, seals and gaskets can cause leakages and possible accidents. Renew whenever disturbed unless otherwise instructed. Do not use Triochloroethane or paint thinners near 'O' rings and seals. INT-3-2-12. When disconnecting the battery, disconnect the earth (-) lead first. INT-3-1-9. ! WARNING Fluoroelastomeric Materials Certain seals and gaskets (e.g. crankshaft oil seal) on JCB machines contain fluoroelastomeric materials such as Viton, Fluorel and Technoflon. Fluoroelastomeric materials subjected to high temperatures can produce highly corrosive hydrofluoric acid. THIS ACID CAN SEVERELY BURN. New fluoroelastomeric components at ambient temperature require no special safety precautions. Used fluoroelastomeric components whose temperatures have not exceeded 300°C require no special safety precautions. If evidence of decomposition (e.g. charring) is found, refer to the next paragraph for safety instructions DO NOT TOUCH COMPONENT OR SURROUNDING AREA. Used fluoroelastomeric components subjected to temperatures greater than 300°C (e.g. engine fire) must be treated using the following safety procedure. Make sure that heavy duty gloves and special safety glasses are worn: 1. Ensure that components have cooled then remove and place material into plastic bags.. 2. Thoroughly wash contaminated area with 10% calcium hydroxide or other suitable alkali solution, if necessary use wire wool to remove burnt remains.. 3. Thoroughly wash contaminated area with detergent and water.. 4. Contain all removed material, gloves etc. used in this operation in sealed plastic bags and dispose of in accordance with Local Authority Regulations.. ! WARNING Hot 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. To remove the cap; turn it to the first notch and let the system pressure escape, then remove the cap. INT-3-2-9/1. DO NOT BURN FLUOROELASTOMERIC MATERIALS. If contamination of skin or eyes occurs, wash the affected area with a continuous supply of clean water or with calcium hydroxide solution for 15-60 minutes. Get medical attention immediately. INT-3-3-5/1. 9803/3630. Issue 1. Purchased from www.WorkshopManuals.co.uk.

(37) Section 2 3-1. www.WorkshopManuals.co.uk Care & Safety. www.maskinisten.net Section 2. Lubricants - Health and Safety. 3-1. Hygiene JCB lubricants are not a health risk when used properly for their intended purposes.. 2. Apply a barrier cream to the skin before handling used engine oil.. However, excessive or prolonged skin contact can remove the natural fats from your skin, causing dryness and irritation.. 3. Note the following when removing engine oil from skin: a Wash your skin thoroughly with soap and water. b. Low viscosity oils are more likely to do this, so take special care when handling used oils, which might be diluted with fuel contamination.. Using a nail brush will help.. c Use special hand cleansers to help clean dirty hands. d Never use petrol, diesel fuel, or paraffin for washing.. Whenever you are handling oil products you should maintain good standards of care and personal and plant hygiene. For details of these precautions we advise you to read the relevant publications issued by your local health authority, plus the following.. 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.. Storage Always keep lubricants out of the reach of children. Never store lubricants in open or unlabelled containers.. First Aid - Oil. Waste Disposal Eyes All waste products should be disposed of in accordance with all the relevant regulations. The collection and disposal of used engine oil should be in accordance with any local regulations. Never pour used engine oil into sewers, drains or on the ground.. In the case of eye contact, flush with water for 15 minutes. If irritation persists, get medical attention. Swallowing. Handling. If oil is swallowed do not induce vomiting. Get medical advice.. New Oil. Skin. There are no special precautions needed for the handling or use of new oil, beside the normal care and hygiene practices.. In the case of excessive skin contact, wash with soap and water.. Used Oil Used engine crankcase lubricants contain harmful contaminants. Here are precautions to protect your health when handling used engine oil: 1. Avoid prolonged, excessive or repeated skin contact with used engine oils.. Spillage Absorb on sand or a locally approved brand of absorbent granules. Scrape up and remove to a chemical disposal area. Fires Extinguish with carbon dioxide, dry chemical or foam extinguishers. Do not use water. Fire-fighters should use self-contained breathing apparatus.. 9803/3630. Issue 1. Purchased from www.WorkshopManuals.co.uk.


(39) Section 3. www.WorkshopManuals.co.uk Routine Maintenance. i. www.maskinisten.net Section 3. i. Contents. Lubricants and Capacities - New Engines - Lubrication Charts - Type AA and AB Engines - Type AR, AK and AM Engines *. Page No.. 1-1 1-1 1-2 1-3. Machine Safety. 2-1. Working With the Boom Raised. 2-1. Service Schedules. 3-1. Grease - 50 Hours 530, 540 Machines 535 Machines - 500 Hours. 4-1 4-2 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 - Changing the Oil and Filter. 8-1 8-1. Engine Cover - Opening/Closing the Cover. 8-2. Engine Cooling System - Checking the Coolant Level - Coolant Mixtures - Changing the Coolant. 9-1 9-1 9-2. Cab Heater Filter - Cleaning. 10 - 1. Fuel System - Fuel Types - Filling the Tank - Draining the Filter - Changing the Filter Element - Draining the Sediment Bowl - Cleaning the Sediment Bowl - Priming the System. 11 - 1 11 - 2 11 - 3 11 - 3 11 - 4 11 - 4 11 - 5. Transmission - Checking the Oil Level - Changing the Oil and Filter. 12 - 1 12 - 2. 9803/3630. Issue 6*. Purchased from www.WorkshopManuals.co.uk.

(40) Section 3. www.WorkshopManuals.co.uk Routine Maintenance. ii. www.maskinisten.net Section 3. ii. Contents. Page No.. Axles - Checking the Axle Oil Level - Changing the Axle Oil. 13 - 1 13 - 1. Front and Rear Hubs - Checking/Filling the Hub Oil Levels - Oil Immersed Brakes - Changing the Hub Oil. 14 - 1 14 - 1 14 - 1. Hydraulic System - Checking the Fluid Level - Changing the Pilot Filter Element - Changing the Filter Element - Cleaning the Suction Strainer. 15 - 1 15 - 1 15 - 2 15 - 3. Hose Burst Protection Valves - Checking the Hose Burst Protection Valves. 16 - 1. Battery - Warning Symbols - Safety Notices - First Aid - Checking the Electrolyte Level - Isolator. 17 - 1 17 - 1 17 - 2 17 - 2 17 - 3. Alternator Drive Belt Tension. 17 - 4. Air Conditioning Option - Adjusting the Air Conditioning Compressor Drive Belt - Cleaning the Air Conditioning Filter. 18 - 1 18 - 1. Brakes - Checking the Foot Brake Fluid Level. 19 - 1. Preparation for Use - Checking for Damage - Checking Seat Belt Condition and Security - Cleaning the Machine. 20 - 1 20 - 1 20 - 2. 9803/3630. Issue 4. Purchased from www.WorkshopManuals.co.uk.

(41) Section 3. www.WorkshopManuals.co.uk Routine Maintenance. 1-1. Lubricants & Capacities. www.maskinisten.net Section 3. 1-1. 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 no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. After the first 100 hours operation, 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 in specifications for machines operating in North America. Be sure you identify the machine and its lubricant requirements.. 9803/3630. Issue 2. Purchased from www.WorkshopManuals.co.uk.

(42) Section 3. www.WorkshopManuals.co.uk Routine Maintenance. www.maskinisten.net Section 3. Lubricants & Capacities. 1-2. 1-2. * Type AA and AB Engines ITEM Litres. CAPACITY UK Gal US gal. Fuel Tank. 125. 27.5. Engine (Oil). 10. (2.2). 30. 2.6. Engine (Coolant). 23. 5.0. Axles Housing Hubs (x4). 21 23. 4.6 5.0. 18 2.0. 3.9 0.4. Housing Hubs (x4). 5.5 6.0. 4.6 0.48. 112 121. Braking System. Grease Points (See Note 3). Wear Pad Runways. 3. 0.7. ASTM D975-66T Nos. 1D, 2D. JCB 15W/40 Multigrade -10 °C - 50 °C (14 °F to 122 °F) JCB Super Universal Agricultural -15 °C to 30 °C (5 °F to 86 °F) JCB Torque Converter Fluid -18 °C to 0 °C (0 °F to 32 °F). SAE15W/40 API CF4/SG. NORTH AMERICA JCB 15W/40 Multigrade 14 °F to 122 °F (-10 °C to 50 °C) 10W/30 Multigrade 5 °F to 86 °F (-15 °C to 30 °C) JCB 10W 0 °F to 32 °F (-18 °C to 0 °C). NORTH AMERICA Permanent Antifreeze JCB Extreme Performance Transmission Oil. NORTH AMERICA JCB Special Gear Oil JCB High Performance Hydraulic Oil (Above 38 °C, 100 °F) JCB Special Hydraulic Fluid (Below 38 °C, 100 °F). 24.6 26.6. 530, 540 535. Diesel Oil (See Types of Fuel). SAE10W/30, API CD/SE, SAE10W, API CD/SE SAE15W/40 API CF4/SG SAE10W/30, API CD/SE, SAE10W, API CD/SE ASTM D3306-74. ASTM D3306-74 JCB: 4000/2501. JCB High Performance Gear OIl API GL4. Hydraulic Tank (See Note 2) 530, 540 535. INTERNATIONAL SPECIFICATION. JCB Four Seasons Antifreeze and Summer Coolant 6.0. * Transmission (See Note 1). FLUID/LUBRICANT. ESEN-M2C 86A/B ISO VG46. ISO VG32. 29.5 32.0. NORTH AMERICA JCB Hydraulic oil. 0.8. JCB Light Hydraulic Fluid DO NOT USE ORDINARY BRAKE FLUID. ISO VG15. JCB HP Grease. Lithium based. NORTH AMERICA JCB Moly EP 2 Grease. Lithium based No. 2 constituency. ISO VG46. 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 with all 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. All 500 hour greasing operations must be carried out at FIFTY (50) HOUR intervals.. 9803/3630. Issue 6*. Purchased from www.WorkshopManuals.co.uk.

(43) Section 3. www.WorkshopManuals.co.uk Routine Maintenance. www.maskinisten.net Section 3. Lubricants & Capacities. 1-3. 1-3. Type AR, AK & AM Engines ITEM Litres. CAPACITY UK Gal US gal. Fuel Tank. 125. 27.5. Engine (Oil). 10. (2.2). 30. 23 23.5. 5.0 5.2. INTERNATIONAL SPECIFICATION. Diesel Oil (See Types of Fuel). ASTM D975-66T Nos. 1D, 2D. 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). 2.6. Engine (Coolant) AR & AK Engine: AM Engine:. FLUID/LUBRICANT. 6.0 6.2. NORTH AMERICA 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) JCB Four Seasons Antifreeze and Summer Coolant NORTH AMERICA Permanent Antifreeze. * Transmission (See Note 1) 530FS Plus only 540FS Plus Axles Housing Hubs (x4). 21 23 17 19. 4.6 5.0 3.7 4.2. 18 2.0. 3.9 0.4. Housing Hubs (x4). 5.5 6.0 4.5 5.0. 4.6 0.48. 112 121. Braking System. Grease Points (See Note 3). Wear Pad Runways. 3. 0.7. NORTH AMERICA JCB Special Gear Oil. JCB High Performance Hydraulic Oil (Above 38 °C, 100 °F) JCB Special Hydraulic Fluid (Below 38 °C, 100 °F). 24.6 26.6. 530, 540 535. ASTM D3306-74. JCB: 4000/2501. JCB High Performance Gear Oil API GL4. Hydraulic Tank (See Note 2) 530, 540 535. JCB Extreme Performance Transmission oil. ASTM D3306-74. ESEN-M2C 86A/B. ISO VG46. ISO VG32. 29.5 32.0. NORTH AMERICA JCB Hydraulic oil. 0.8. JCB Light Hydraulic Fluid DO NOT USE ORDINARY BRAKE FLUID. ISO VG15. JCB HP Grease. Lithium based. NORTH AMERICA JCB Moly EP 2 Grease. Lithium based No. 2 constituency. ISO VG46. 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 with all 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. All 500 hour greasing operations must be carried out at FIFTY (50) HOUR intervals.. 9803/3630. Issue 6*. Purchased from www.WorkshopManuals.co.uk.

(44) Section 3. www.WorkshopManuals.co.uk Routine Maintenance. www.maskinisten.net Section 3. 2-1. 2-1. The machine must be made safe before carrying out any servicing.. Working with Boom Raised Fitting Safety Strut. Machine Safety. Carry out General Safety and the following procedure: Read Section 2, Care and Safety. Position the machine on firm level ground. Apply the parking brake. Chock both sides of all four wheels.. ! WARNING You could be killed or injured if the boom drops while you are working under it. Install the safety strut as instructed below before doing any maintenance work with the boom raised. 5-3-1-2. Make sure the forward/reverse lever is in the neutral position. 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 tank pressure. When welding electrically disconnect the alternator.. Fully retract the boom (unless it needs to be extended for maintenance). Raise the boom just far enough to install the strut. Make sure the parking brake is engaged and the transmission is in neutral. Switch OFF the engine and remove the starter key.. ! CAUTION You will have to climb onto the machine to fit or remove the safety strut. Take care, especially if the machine is wet. Remove mud and oil before climbing onto the machine. 5-3-1-11. ! WARNING You could be killed or injured if the boom is lowered while you are under it. Keep people away from the machine while you fit the strut. 5-3-1-3. A. Remove the strut from its stowage position A. Place the strut around the ram piston rod as shown. Fix it in place with strap B. The strap fitted to the safety strut must be in a serviceable condition, if not fit a new strap. A343230 A343230. To prevent any chance of the boom creeping down and trapping your fingers, the boom should be lowered onto the strut. Note: Lower the boom carefully, to prevent possible damage to the strut. Stop as soon as the weight of the boom is on the strut.. B. S263560. 9803/3630. Issue 4. Purchased from www.WorkshopManuals.co.uk.

(45) Section 3. www.WorkshopManuals.co.uk Routine Maintenance. www.maskinisten.net Section 3. 2-2. 2-2. Working with Boom Raised (continued) Remove Safety Strut Start the engine and raise the boom to take the weight off of the strut.. B. Stop the engine. Make sure the parking brake is engaged and the transmission is in neutral. Remove the starter key.. ! CAUTION You will have to climb onto the machine to install or remove the safety strut. Take care, especially if the machine is wet. Remove mud and oil before climbing onto the machine. 5-3-1-11. S263560. ! WARNING You could be killed or injured if the boom is lowered while you are under it. Keep people away from the machine 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.. A. A343230 A343230. 9803/3630. Issue 2*. Purchased from www.WorkshopManuals.co.uk.

(46) Section 3. www.WorkshopManuals.co.uk Routine Maintenance. www.maskinisten.net Section 3. Service Schedules. 3-1. 3-1. Pre-start Cold Checks Service Points and Fluid Levels. Operation. ENGINE Engine Air Filter Pre-cleaner Clean Oil Level and Condition Check Oil and Filter (1) Change Air Cleaner Dust Valve Clean Air Cleaner Outer Element Change Air Cleaner Inner Element Change Fuel System For Leaks and Contamination Check Fuel Filter Drain Fuel Filter Change Coolant Level Check Coolant Level and Antifreeze Strength Check Fuel Sedimenter Drain and Clean Fan Belt Tension/Condition Check Valve Clearances (AA - AC codes) *Check and Adjust Valve Clearances (AJ - AS codes) *Check and Adjust Engine Mount Security Check Rain Cap/Pre-cleaner installed (if fitted) Check Radiator Clean TRANSMISSION AND AXLES Transmission Oil Level Transmission Oil Transmission Oil Filter Axle(s) Oil Level Axle(s) Oil Hub Oil Level Hub Oil Drive Shafts and Universal Joints Axle Pivots and Linkages Axle Breather(s) Tyre Pressures/Condition Hub Wheel Bearings Transmission Strainer Wheel Nut Security Wheel Alignment Trunnion bearings Steering Stops (if fitted) Transmission Mount Security Axle Mount Security. Check (2) Change Change Check Change Check (3) Change Security/Grease Grease Check Check Check Clean Check Check *Check/Adjust Security Check Check. Daily 10 Hr. Weekly 50 Hr. Initial 100 Hr. z. z. z. z. z. 6 Monthly Yearly 2 Yearly 500 1000 2000 Hr Hr Hr. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z z. z z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z z. (1). In arduous conditions (eg. refuse re-handling, waste paper reclamation etc.) change the oil and filter every 250 Hours or three months (whichever comes first).. (2). After a major transmission repair, the new oil should be run to operating temperature and changed again to remove any contamination which entered during the repair. Change the oil and filter after a further 100 hours if the oil was heavily contaminated 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 which entered during the repair. Change the oil again after a further 100 hours to remove any bedding-in wear. This is particularly 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. Issue 4*. Purchased from www.WorkshopManuals.co.uk.

(47) Section 3. www.WorkshopManuals.co.uk Routine Maintenance. www.maskinisten.net Section 3. Service Schedules. 3-2. 3-2 Pre-start Cold Checks Service Points and Fluid Levels. Operation. HYDRAULICS Oil Level Oil System for Leaks Oil Filter Oil Strainers Pilot Filter. Check Sample/Change Check Change Clean Change. BRAKES Brake system Fluid. Check Level Change. ELECTRICS Battery Terminals for Condition and Tightness Wiring for Chafing. 10 Hr. 50 Hr. 100 Hr. 500 Hr. 1000 Hr. 2000 Hr. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z z. z. z. z. z. z. Check Check. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. * BODY AND FRAMEWORK Machine Generally All Pivot Pins All Hinges Wear Pad Runways Inner Boom Hoses Boom Wear Pad Clearance Control Lever Linkages Windscreen Washer Fluid Level Cab Heater Filter Fire Extinguisher Wing Mirror Condition and Security. Clean Grease Lubricate Waxoyl Grease Check/Adjust Replace if required Lubricate Check Clean Check Check. Functional Test and Final Inspection. Operation. ENGINE Idle Speed Torque Converter Stall Speed Max No Load Speed Throttle System and Control Cable Exhaust Smoke Exhaust System Security Air Inlet System Security Engine for Vibration and Noise. Check and Adjust Check Check Check/Adjust Check Check Check Check. TRANSMISSION AND AXLES Steer Operation Phasing Torque Converter Mainline Pressure Dump Switch Operation 2WD/4WD Selection (if fitted) Forward/Reverse/Gear Selection/Operation Neutral Start Operation Clutch Pack Pressures. Check Check Check Check Check Check Check. z. z z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. Daily 10 Hr. Weekly 50 Hr. Initial 100 Hr. z. z. 6 Monthly Yearly 2 Yearly 500 1000 2000 Hr Hr Hr. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. 9803/3630. Issue 4*. Purchased from www.WorkshopManuals.co.uk.

(48) Section 3. www.WorkshopManuals.co.uk Routine Maintenance. www.maskinisten.net Section 3. Service Schedules. 3-3. 3-3. Functional Test and Final Inspection. Operation. HYDRAULICS Operation of All Services Check Hose Burst Check Valves Check MRV Pressure at Max rpm Check and Adjust ARV Pressure at 750 rpm Check and Adjust Steer Circuit MRV Pressure Check and Adjust Fan Motor Speed Check and Adjust Attachment Operation Check Piston Rods and Chrome Check * Boom Extension/Phasing (3 Stage Boom) 535 machines Check Parallel Lift/Lower Check Stabiliser Leg and Sway Cut-Out (if fitted) Check BRAKES Foot Brake Operation Parking Brake. Check Check and Adjust. ELECTRICS Starter Motor Check Alternator Check Output All Electrical Equipment Operation (e.g. warning lights, beacons, alarms, horn, wipers etc) Check * Safe Load Indicator/Load Moment Indicator Check * Safe Load Indicator/Load Moment Indicator Calibrate Stabiliser Indicators Check BODYWORK AND CAB Inclinometer (if fitted) Check Glazing for Correct Fit /Leaks Check Seat/Seat Belts Check Air Conditioning (if fitted) Check Forks Fit and Check Security Machine Generally for Damage, Leaks & Wear Check. Daily 10 Hr. Weekly 50 Hr. Initial 100 Hr. 6 Monthly Yearly 2 Yearly 500 1000 2000 Hr Hr Hr. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. z. 9803/3630. Issue 4*. Purchased from www.WorkshopManuals.co.uk.

(49) Section 3. www.WorkshopManuals.co.uk Routine Maintenance Grease Every 50 Hours. 4-1 * 530,. www.maskinisten.net Section 3. 4-1. 540 Machines. 56. 3. 1. 2. 9. 4. 78. °. 0!. ‡. ¾. @ ›. ½. £. ‹. . ). ¼. *. $%. ^& (. 9803/3630. S266510. Issue 2*. Purchased from www.WorkshopManuals.co.uk.

(50) Section 3. www.WorkshopManuals.co.uk Routine Maintenance Grease Every 50 Hours. 4-2 * 535. www.maskinisten.net Section 3. 4-2. Machines. *. 1. * & ^. ( %. 2. ). $. 3 @. £. 9. 8. 4. !. 0 9803/3630. 5 6 7 345770. Issue 3*. Purchased from www.WorkshopManuals.co.uk.

(51) Section 3. www.WorkshopManuals.co.uk Routine Maintenance. 4 - 2A. www.maskinisten.net Section 3. Grease Every 50 Hours. 4 - 2A. 533 Machines Grease as shown for 535 plus the following (on both sides):. 21 22. 9803/3630. 416030. Issue 1. Purchased from www.WorkshopManuals.co.uk.


(53) Section 3. www.WorkshopManuals.co.uk Routine Maintenance Grease Every 500 Hours. 4-3. See Greasing (50 Hours) for general information on greasing. All 500 hour greasing operations must be carried out at 50 hour intervals if JCB MPL Grease is used. All 50 hour greasing operations must be carried out at 10 hour intervals if JCB MPL Grease is used. Note: When carrying out Greasing (50 hours) on the Rear Axle Trunnion Bearings (22, 23) an extra grease point may be found.. www.maskinisten.net Section 3. 4-3. Extend the boom fully. Spray Waxoyl evenly over the surfaces A and B as shown. Allow 2-3 hours drying time before retracting the boom.. ! CAUTION Waxoyl contains turpentine substitute, which is flammable. Keep flames away when applying Waxoyl. Waxoyl can take a few weeks to dry completely. Keep flames away during the drying period. Do not weld near the affected area during the drying period. Take the same precautions as for oil to keep Waxoyl off your skin. Do not breathe the fumes. Apply in a well-ventilated area. 5-3-1-9. A. A A. 1. 2. B. 4. 3. A335720 A335720. S263620. 530, 540 Machines. A A. A A B. A343900 A343900. 533, 535 Machines. * 9803/3630. Issue 3*. Purchased from www.WorkshopManuals.co.uk.

(54) Section 3. www.WorkshopManuals.co.uk Routine Maintenance. 5-1. www.maskinisten.net Section 3. 5-1. Oiling The following points should be lightly oiled with engine oil at the periods stated in the Service Schedules: 1. Lightly oil all hinges.. 2. Oil the clevis at the bottom of each control lever.. S267971. 9803/3630. Issue 1. Purchased from www.WorkshopManuals.co.uk.

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