JCB 530, 532, 533, 535, 537, 540 Side Engine Loadalls Service Manual – 9803/3630-14

This workshop repair service manual PDF download for the 530, 532, 533, 535, 537, 540 JCB Side Engine Loadalls has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

This publication provides information for the following models in the JCB product range:

– JCB 530-70 from S/N: 768740
– JCB 532-120 from S/N: 774598
– JCB 533-105 from S/N: 786756
– JCB 535-60 from S/N: 1064599
– JCB 535-95 from S/N: 778295
– JCB 535-125 from S/N: 1064203
– JCB 535-140 from S/N: 1065087
– JCB 537-135 (550) from S/N: 774605
– JCB 540-70 from S/N: 771065
– JCB 540-140 from S/N: 1064723
– JCB 540-170 (5508) from S/N: 780925

TABLE OF CONTENTS :

Section 1 – General Information
Section 2 – Care and Safety
Section 3 – Maintenance
Section A – Attachments
Section B – Body and Framework
Section C – Electrics
Section D – Controls
Section E – Hydraulics
Section F – Transmission
Section G – Brakes
Section H – Steering
Section K – Engine

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9803/3630-14
Total Pages : 1014

This complete JCB Telescopic Handler | Loadall | Telescopic Loader service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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9803-3630
Service Manual

Section 1 – General Information
Section 1
Introduction
About This Publication
Machine Model and Serial Number
Using the Service Manual
Units of Measurement
Section Numbering
Left Side, Right Side
Cross References
Identifying Your Machine
Machine Identification Plate
Typical Vehicle Identification Number (VIN)
Component Identification Plates
Typical Engine Identification Number
Transmission Identification Number
Standard Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
Introduction
Bolts and Screws
Condition 1
Condition 2
Verbus Ripp Bolts
Hydraulic Connections
‘O’ Ring Face Seal System
Adaptors Screwed into Valve Blocks
Hoses Screwed into Adaptors
Adaptors into Component Connections with Bonded Washers
‘Torque Stop’ Hose System
Service Tools
Numerical List
Tool Detail Reference
Section B – Frame and Bodywork
Section C – Electrics
Section E – Hydraulics
Section F – Transmission
Section H – Steering
Section K – Engine
Service Consumables
Sealing and Retaining Compounds
Terms and Definitions
Colour Coding
Hydraulic Schematic Colour Codes

Section 2 – Care and Safety
Section 2
Safety Notices
Important Information
The Operator Manual
Safety Warnings
Safety Check List
Safety – Yours and Others
General Safety
Operating Safety
Maintenance Safety
Safety Decals
Introduction

Section 3 – Maintenance
Maintenance
Routine Maintenance
Health and Safety
Lubricants
Battery
First Aid – Electrolyte
Service Schedules
Fluids, Lubricants and Capacities
Coolant Mixtures
Cleaning The Machine
Undershield Removal and Replacement
General Machine Cleaning
Checking For Damage
Seat Belt
Checking the Seat Belt Condition and Security
ROPS/FOPS Structure
Checking The ROPS/FOPS Structure
Boom Safety Strut
Installing
Removing
Greasing
General Greasing
Every 50 Hours
Every 500 Hours
Every 1000 Hours
Oiling
Engine Cover
Opening/Closing the Cover
Air Conditioning and Heater
Cleaning the Air Conditioning Filter – Series l Machines
Cleaning the Cab Heater Filter – Series l Machines
Changing the Air Intake Filter – Series ll Machines
Adjusting the Air Conditioning Compressor Drive Belt
Brakes
Checking the Foot Brake Fluid Level
Electrical System
Battery
Jump Starting The Engine
Adjusting the Alternator Drive Belt
Engine Oil and Filter
Checking the Oil Level
Changing the Oil and Filter
Engine Air Filter
Changing the Elements
Engine Cooling System
Checking the Coolant Level
Changing the Coolant
Fuel System
Types of Fuel
Filling the Tank
Priming the System
Draining The Fuel Filter
Changing the Fuel Filter
Draining the Sediment Bowl
Cleaning the Sediment Bowl
Hydraulic System
Checking the Fluid Level
Changing the Filter Element
Changing the Pilot Filter Element – Series l Machines
Checking the Hose Burst Protection Valves
Transmission
Check Transmission Oil Level
Changing the Oil and Filter
Axles
Front and Rear Axle
Tyres and Wheels
Tyre Inflation
Checking Roadwheel Tightness
Windscreen Washer
Checking the Level

Section A – Attachments
Attachments
Service Procedures
Quick Release Couplings
Connecting and Disconnecting

Section B – Body and Framework
Section B
Technical Data
Air Conditioning
Basic Operation
Boom – Telescopic Operation
3 Stage Boom
Air Conditioning
R134a Refrigerant
PAG Type Refrigerant Oil
System Operation
System Control
Safety Procedures
Load Indicators
Introduction
Safe Load Indicator (SLI)
Load Moment Indicator (LMI)
Service Procedures
Rivet Nuts
Fitting Procedure
Slide Hammer Kit
Fitting Procedure
Air Conditioning
Service Checks
Off-Season Operation
Service Ports
Leak Testing
Tightening Leaking Hoses
Checking Refrigerant Charge Level
Refrigerant Charging and Discharging
Refrigerant Recovery
Evacuating (Vacuuming)
Electronic Vacuum Gauge
Relubricating
Charging
Cleaning the Condenser
Series I Machines
Machines to 784534
Machines from 784535
Series II Machines
Load Indicators
Testing
Introduction
SLI/LMI Test Box
Connecting the Test Box
Testing with the SLI/LMI Test Box
Test 1: 12V Supply and Fuse Test (V1)
Test 2: Transducer 12V Supply Test (V2)
Test 3: Display Box Functional Test (SLI System Only)
Test 3: Display Unit Functional Test (LMI System Only)
Test 4: Transducer Output Test (V3)
Test 5: Harness Wiring Continuity and Short Circuit Test
Test 6: Transducer Output Test (V4)
Voltage Readings
Testing without the SLI/LMI Test Box
Test 1: 12V Supply and Fuse Test (V1)
Test 2: Transducer 12V Supply Test (V2)
Test 3: Display Box Functional Test (SLI System Only)
Test 3: Display Box Functional Test (LMI System Only)
Test 4: Transducer Output Test
Test 5: Harness Wiring Continuity And Short Circuit Test
Test 6: Transducer Output Test
Meter Readings
Calibration
SLI System
Adjustment of Balance Settings
Adjustment of Full Scale Setting
LMI System
Adjustment of Full Scale Setting
Calibration Charts
Boom
Wear Pad Renewal
Fault Finding
Air Conditioning
General Fault Indications
Sight Glass Indications
System Diagnosis
Normally Functioning Air Conditioning System
Other Indications
Low R-134a Charge
Other Symptoms
Diagnosis
Correction
Poor Refrigerant Circulation
Other Symptoms
Diagnosis
Correction
No Refrigerant Circulation
Other Symptoms
Diagnosis
Correction
Insufficient Cooling of Condenser or Refrigerant Overcharge
Other Symptoms
Diagnosis
Correction
Air in System
Other Symptoms
Diagnosis
Correction
Expansion Valve Improperly Mounted
Other Symptoms
Diagnosis
Correction
Compressor Malfunction
Diagnosis
Correction
Some Moisture in the System
Diagnosis
Correction
Further Diagnosis
Load Indicators
General Fault Finding
Manual Fault Diagnosis
Diagnostic Fault Codes
Fault Codes
Air Conditioning Option
Evaporator Unit
Removal
Replacement
Thermostat
Removal
Replacement
Binary Pressure Switch
Testing
Removal
Refitting
Fork Carriage
Removal and Replacement
2 Stage Booms
Removal
Replacement
3 and 4 Stage Booms
Removal
Replacement
Boom
Removal and Replacement
2 Stage Boom (530-70, 540-70 Only)
Removal
Replacement
2 Stage Boom (535-60 Only)
Removal
Replacement
3 and 4 Stage Boom
Removal
Replacement
Dismantling and Assembly
2 Stage Boom
Dismantling
Assembly
3 Stage Boom
Dismantling
Assembly
4 Stage Boom
Dismantling
Remove the Primary External Components
Dismantle the Main Boom Assembly
Assembly
Boom Shimming
Typical Method
Lower Wear Pads
Front Lower Wear Pads
Rear Lower Wear Pads
Top Wear Pads
Side Wear Pads
Measurements
2 Stage Boom
3 Stage Boom
4 Stage Boom
Load Indicators
Removal and Replacement
Transducer
Removal
Replacement
Cab
Glazing
Direct Glazing
Removing the Broken Glass and Old Sealant
Preparing the Cab Frame Aperture
Preparing the New Glass
Installing the New Glass
Removal and Replacement
Removal
Replacement
Fuel Tank
Removal and Replacement
Removal
Replacement
Fuel Strainer
Machines with `A’ series engines
Instrument Panels (Series II Cab)
Removal and Replacement

Section C – Electrics
Section C
Technical Data
General Electrical Data
Relay Identification
Series I Machines
Quick Reference Chart
ECU Deletion Cut-In Numbers
530-70
530-70
530-70
530-70, 533-105, 535-95, 540-70
530-70, 540-70 fitted with Smooth Ride System (SRS)
530FS Super, 540FS Super Machines
532-120, 537-135
532-120, 537-135
532-120, 537-135
532-120, 537-135, 550
532-120, 537-135, 550
540-170, 5508
540-170, 5508
Series II Machines
Quick Reference Chart
Series II Relay Configuration 1
Series II Relay Configuration 2
Series II Relay Configuration 3
Fuse Identification
Introduction
Series I Machines
Series II Machines
Fuse Links
Series I Machines
Series II Machines
Machines fitted with “R” Series Engines
Schematic Circuits
Applicable Machines
Series I Machines
530-70 Machines (and Variants)
532-120 Machines
533-105 Machines
535-95 Machines
537-135 Machines
540-70 Machines (and Variants)
540-170 Machines
550 Machines
5508 Machines
Series II Machines
Schematics
530-70
Applicability
Component Key
530-70
Applicability
Component Key
530-70
Applicability
Component Key
530-70, 540-70
Applicability
Component Key
530-70, 540-70
Applicability
Component Key
530-70, 535-95, 540-70
Applicability
Component Key
530-70, 535-95, 540-70
Applicability
Component Key
530 FS Super, 530 SXL, 540 FS Super, 540 SXL
Applicability
Component Key
532-120, 533-105, 537-135, 540-170, 550, 5508
Applicability
Component Key
532-120, 537-135
Applicability
Component Key
532-120, 537-135
Applicability
Component Key
532-120, 537-135
Applicability
Component Key
532-120, 537-135, 550
Applicability
Component Key
540-170, 5508
Applicability
Component Key
All Series II Machines
Applicability
Diagram Key
Basic Circuit
Component Key (Items 1 to 37)
Component Key (Items 38 to 56)
Component Key (Items 59 to 98)
Manual and Single Lever Hydraulic Controls
Component Key
Sway Hydraulic Controls
Component Key
Stabiliser and Sway Hydraulic Controls
Component Key
Air Conditioning and Two-speed Wiper
Component Key
Seat Options, Heated Glass, Mobile Phone, Cigar Lighter
Component Key
Smooth Ride System (SRS), Reversing Fan
Component Key
Powershift (4-Speed)
Component Key
Powershift (5-Speed)
Component Key
Servo Controls (540-170, 5508)
Component Key
Service Procedures
Using a Multimeter
Measuring DC Voltage
Measuring Resistance
Measuring Continuity
Measuring Frequency
Testing a Diode or a Diode Wire
Battery
Maintenance
First Aid – Electrolyte
GETS INTO YOUR EYES
IS SWALLOWED
GETS ONTO YOUR SKIN
Testing
Specific Gravity Testing
Alternator
General Description
Service Precautions
Charging Circuit Test
Check 1
Check 2
Alternator Charging Test
Starter Motor
Starting Circuit Test
Wire and Harness Number Identification
Introduction
Wire Numbers and Functions
Wires 000-199
Wires 200-399
Wires 400-599
Wires 600-799
Wires 800-999
Wires In Splices
General Points
Wiring Harness Repair
Introduction
Repair Procedure
Alternator
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Lucas Type
When Dismantling
When Assembling
Magneti Marelli Type
When Dismantling
When Assembling
Starter Motor
Removal and Replacement
Removal
Replacement
Dismantling, Inspection and Assembly
Dismantling
Inspection
Assembly

Section D – Controls
Controls
Accelerator Cable
Removal and Replacement
Removal
Replacement
Testing and Adjustment
Adjustment

Section E – Hydraulics
Section E
Technical Data
530-70 Agricultural and Wastemaster Machines
530-70 Construction Machines
530-70 Flowshare (LSV/LSV+) Machines
Machines up to 1154455
Machines from 1154456
532-120, 535-125, 535-140 Machines
533-105 Machines
535-60 Flowshare (LSV/LSV+) Machines
Machines up to 1154455
Machines from 1154456
535-95 Agricultural Machines
535-95 Construction Machines
537-135, 540-140, 550 Machines
540-70 Agricultural and Wastemaster Machines
540-70 Construction Machines
540-70 Flowshare (LSV/LSV+) Machines
Machines up to 1154455
Machines from 1154456
540-170, 550-170, 5508 Machines
Basic System Operation
Introduction to Hydraulic Schematic Symbols
General (Basic and Functional Symbols)
Control Valves
Example of Schematic Circuit
Example Circuit Key
Schematic Circuits
Key to Circuit Schematics
530-70 Construction Machines
Component Key
530-70, 540-70 Construction Machines with Single Lever Control
Component Key
530-70 Construction Machines with Manual Auxiliary Controls and Double Pump
Component Key
530-70 Construction Machines with Manual Auxiliary Controls and Triple Pump
Component Key
532-120, 537-135, 550 Machines
Component Key
532-120, 537-135, 550 Machines
Component Key
532-120, 535-125, 535-140, 537-135, 540-140, 550 Machines with Manual Auxiliary Controls
Component Key
533-105 Machines
Component Key
535-95 Machines with Double Pump
Component Key
535-95 Machines with Triple Pump
Component Key
540-70 Construction Machines with Manual Auxiliary Controls
Component Key
540-170, 550-170, 5508 Machines without Speed-up Kit
Description
Component Key
540-170, 550-170, 5508 Machines with Speed-up Kit
Description
Component Key
530-70, 540-70 Agricultural and Wastemaster Machines
Component Key
530-70, 540-70 Flowshare (LSV/LSV+) Machines
Machines up to 1154455 (without Inloader valve)
Machines with Type RJ Engines
Machines with Type RG Engines
Component Key
Machines up to 1154455 (with Inloader valve)
Component Key
Machines from 1154456
Component Key
535-60 Flowshare (LSV/LSV+) Machines
Machines up to 1154455 (without Inloader valve)
Machines with Type RJ Engines
Machines with Type RG Engines
Component Key
Machines up to 1154455 (with Inloader valve)
Component Key
Machines from 1154456
Component Key
Fault Finding
Machines with Parallel Service Valve Block
Machines with Flowshare (LSV) Valve Block
Boom (3 Stage Booms)
Boom and Stabiliser (540-170, 550-170, 5508 Machines)
Parallel Lift
Smooth Ride System
Service Procedures
Hydraulic Contamination
Hydraulic Fluid Quality
Effects of Contamination
Cleaning Operation
Procedure
Contaminant Standards
Filters
Connecting/Disconnecting Hydraulic Hoses
Introduction
Connecting the Hoses
Disconnecting the Hoses
Venting Hydraulic Pressure
Double Pump
Basic Operation
Testing
Test Equipment
Main Services Pump
Fan Pump
Removal and Replacement
Removal
Replacement
Dismantling, Inspection and Assembly
Introduction
Dismantling
Inspection
Assembly
Triple Pump
Basic Operation
Testing
Test Equipment
Main Services Pump
Steering Pump
Fan Pump
Removal and Replacement
Removal
Replacement
Dismantling, Inspection and Assembly
Dismantling
Inspection
Assembly
Parallel Service Valve Block
Basic Operation
Parallel Service, 4 Double Acting Spools
Parallel service, 6 spool with unloader section
Tilt Isolator Section
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Tie Rods
Introduction
Assembly
Valve Block Sections
4 Spool Valve Block
Dismantling
Assembling
6 Spool Valve Block
Dismantling
Assembling
Spools and Load Hold Check Valves
Dismantling
Assembling
Testing and Adjustment
Relief Valves Location
Component Key
4 Spool Valve Block
6 Spool Valve Block
Main Relief Valve (MRV)
Testing
Adjusting
Auxiliary Relief Valve (ARV)
Testing
Testing ARV’s Set Higher than the MRV
Tilt Ram (530-70, 540-70 Machines)
Tilt Ram (533-105, 535-95 Machines)
Tilt Ram (532-120, 535-125, 535-140, 540-140, 540-170, 550, 550-170, 5508 Machines)
Checking Servo Pressure
Pilot Pressure Reducing Valve
Inspection
Component Key
Flowshare (LSV) Valve Block
Basic Operation
Introduction
No service selected (all spools in neutral)
Spool Actuation
When a Service is Selected
Services Operated
Pressure Compensator Valves Operation
No Service Selected (All Spools in Neutral)
Operating a Service
Operating an Individual Service
Operating Multiple Services
Normal Condition
With Insufficient Flow from Pump
Removal and Replacement
Handling
Removal
Replacement
Dismantling and Assembly
Introduction
Component Key
Valve Block Sections
Dismantling
Assembly
Electric Spool
Dismantling
Inspection
Assembly
Spools Orientation
Standard Spool
Dismantling
Tongue Removal (if necessary)
Inspection
Assembly
Renewing the Valve Spool Seals
Load Sense Relief Valve
Removal
Dismantling
Inspection
Replacement
Auxiliary Relief Valves (ARV’s)
Removal
Dismantling
Inspection
Replacement
Flow Regulator Valve
Removal
Dismantling
Inspection
Assembly
Pressure Compensator Valves
Removal
Inspection
Replacement
Load Hold Check Valves
Removal
Inspection
Replacement
Testing and Adjustment
Spool Displacement
Testing
Adjusting
Solenoid Resistance
Testing
Relief Valve Location
Component Key
Load Sense Relief Valve (LSRV)
Testing
Adjusting
Auxiliary Relief Valve (ARV)
Testing
Testing ARV’s Set Higher than the MRV
Tilt Ram (530-70, 540-70 Flowshare machines)
Tilt Ram (535-60 machines)
Pilot Operated Relief Valve
Introduction
Testing
Adjusting
Inloader Valve Block
Basic Operation
Introduction
Inloader Valve Operation
Pump P2 Directed to Tank
Component Key
Pump P2 in Circuit (Inloader Operation)
Inloader Operation Override
Removal and Replacement
Removal
Replacement
Regenerative Valve Block
Basic Operation
Introduction
Component Key
Boom Extend
Light Load (Regenerative Cycle)
Heavy Load
Boom Retract
Remote Control (Two Spool) Valve Block
Basic Operation
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Dismantling
Assembling
Servo Diverter Valve Block
Basic Operation
Component Key
Solenoid Functions
Boom and Fork Isolator Solenoid
Boom Lift Unloader Solenoid
Boost Isolation Solenoid
Fork Isolator Solenoid
Removal and Replacement
Removal
Replacement
Replacement of Solenoids
Testing
Checking Servo Pressure
Servo Joystick
Removal and Replacement
Removal
Single Axis Joystick
Two Axis Joystick
Replacement
Fan Motor
Removal and Replacement
Machines up to SN770663
Removal
Replacement
Machines from SN770664 to SN784534
Removal
Replacement
Machines from SN784261 (including Reversible Fan from SN784535)
Removal
Replacement
Adjustment
Machines to SN784534 only
Dismantling and Assembly
Machines up to SN784260 and Reversible Fans up to SN784534
Introduction
Dismantling
Inspection
Assembly
Machines from SN784261 (including Reversible Fans from SN784535)
Introduction
Dismantling
Inspection
Assembly
Hydraulic Rams
Precautions During Use
Installation
Caution During Use
Maintenance, Inspection Points
Removal and Replacement
Lift Ram
Removal
Replacement
Displacement Ram
Single Displacement Ram
Removal
Replacement
Twin Displacement Rams (2 Stage Boom)
Removal
Replacement
Twin Displacement Rams (3 and 4 Stage Boom)
Removal
Replacement
Extension Ram
2 Stage Boom
Removal
Replacement
3 Stage Boom – Outer
Removal
Replacement
4 Stage Boom – Outer
Removal
Replacement
3 and 4 Stage Boom – Inner
Removal
Replacement
Tilt Ram
2 Stage Boom
Removal
Replacement
3 and 4 Stage Boom
Removal
Replacement
Stabiliser Ram
Removal
Replacement
Checking Pressure Switch Operation
Sway Ram
Removal
Replacement
Dismantling and Assembly
Typical Ram
Dismantling
When Assembling
4-Stage Boom Outer Ram
Dismantling and Assembly
Introduction
Supporting The Ram
Dismantling
Removing the Centre Cylinder from the Outer Cylinder
Removing the Piston Head Locking Screws
Removing the Centre Cylinder Piston
Removing the Inner Cylinder Seal Housing
Removing the Inner Cylinder from the Outer Cylinder
Removing the Inner Cylinder Piston
Removing the Seal Housings from the Cylinders
Inspection
Assembly
Reseal the Pistons and Seal Housings
Ram Assembly
Before Operating the Ram
JCB Ram Sealing Procedure
Piston Head Retention
Existing piston head and rod
New piston head and rod
Existing piston head and new rod
New piston head and existing rod
Drilling Dimensions
Extension Ram Make Up Valve
Removal and Replacement
Bleed Procedures
3-Stage Boom Extension Ram Circuit
4-Stage Boom Extension Ram Circuit
Sway Circuit
Tilt Circuit
Parallel Lift
Basic Operation
Boom Raise Cycle
530-70, 540-70 Machines
535-60 Machines
Boom Lower Cycle
530-70, 540-70 Machines
535-60 Machines
Smooth Ride System (SRS)
Technical Data
Accumulator
Charge Pressures
Description
Hydraulic Schematic
Component Key
Electrical Schematic
Component Key
Solenoid Logic Table
Accumulators
Removal and Replacement
Removal
Replacement
Charging and Discharging
Charging
Discharging
Dismantling, Inpsection and Assembly
Smooth Ride System Micro-Switches
Parallel Service Valve Block
Operation
Crowd/Dump Micro-switch
Lift/Lower Micro-switch
Flowshare (LSV) Valve Block
Operation
Crowd/Dump Micro-switch
Lift/Lower Micro-switch

Section F – Transmission
Section F
Transmission
Technical Data
Tyre Pressures
Front Axles
Unit Identification
Designations
Specifications
Rear Axles
Unit Identification
Designations
Specifications
Powershift Gearboxes
Unit Identification
Designations
Specifications
Engine Stall Speed Combinations
Basic Operation
General Description
Front Axle – Steer Drive Type SD70, SD80
Component Identification
Rear Axle – Steer Drive Type SD55, SD80
Component Identification
Powershift Gearbox
Component Identification
Principle of Operation
Hydraulic and Electrical Operation – 4 Speed Gearbox
Key
Hydraulic And Electrical Operation
Hydraulic and Electrical Operation – 5 Speed Gearbox
Drivepaths
Forward
Reverse
5-Speed
Torque Converter
Component Identification
Principle Of Operation
Systems Description
Powershift Gearbox
Forward and Reverser Clutch Operation
2 and 4 Wheel Drive Clutch (4WD Spring ON) Operation
4 Wheel Drive Operation
2 Wheel Drive Operation
2 and 4 Wheel Drive Clutch (4WD Pressure ON) Operation
4 Wheel Drive Operation
2 Wheel Drive Operation
Service Procedures
Rear Axles SD55 And SD80
Renewing the Pinion Oil Seal
Front Axles SD70 And SD80
Renewing the Pinion Oil Seal
Testing for Brake Piston Seal Leakage
Powershift Gearbox
Flushing the Transmission Oil
Torque Converter Stall Test
Interpreting the Test Results
Pressure and Flow Tests
Mainline Pressure
Pump Flow (Machines with direct mount oil filter)
Pump Flow (Machines fitted with remote oil filter)
Converter In Pressure
Converter Relief (Safety Valve) Pressure
Bypassing the Converter Relief Valve
Converter Out Pressure and Oil Cooler Flow Rate
Lubrication Pressure
Isolating a Suspect Clutch
Individual Clutch Leakage Test
Solenoid Identification
Speed Sensor (if fitted)
Basic Operation
Testing
Sensor Connections
Electronic Control Unit
Speedometer (if fitted)
Calibration
Electrical Connections
Powershift Gearbox, Relay Control (4 Speed)
Introduction
Component Key
Quick Reference
Component Key
Powershift Gearbox, Electronic Control (4 speed)
General Description
ECU Replacement
Basic Operation
Simplified ECU Installation
Diagnostics
Introduction
General Fault Finding
Diagnostic Tips and Warning Information
Intermittent Faults
Machine Harnesses
Testing
Solenoid Identification
Checking for (+VE) Supply to the Solenoids
Checking Solenoid Operation
Checking the Mainframe Harness
Checking the Park Brake Switch
Checking the Transmission Dump Switch
Handheld Mark II Test Unit
Operating Instructions
Basic Operation
Examples
ECU Factory Default Settings
Electronic Control Unit
ECU Mounting
When installing an ECU
Powershift Gearbox, Electronic Control (5 Speed)
General Description
Basic Operation
Automatic Operation
Manual Operation
Simplified ECU Installation
Component Key
Diagnostics
Introduction
General Fault Finding
Diagnostic Tips and Warning Information
Intermittent Faults
Machine Harnesses
Testing
Solenoid Identification
Checking for (+VE) Supply to the Solenoids
Checking Solenoid Operation
Checking the Mainframe Harness
Mainframe Harness Connector Plug Voltage Readings
Checking the Park Brake Switch
Checking the Transmission Dump Switch
Using the PC Diagnostic Tool
Operation
ECU Settings and Information Screen
System Status Screen
Solenoid Identification Screen
Solenoid Testing Screen
Electronic Control Unit
Fault Finding
Powershift Gearbox
Introduction
Fault Finding Tables
Electronic Control Unit (ECU)
Introduction
Fault Finding Tables
Propshafts
Removal And Replacement
Front Axles SD70 and SD80
Removal and Replacement
SD70 Fixed Axle
SD70 Sway Axle
SD80 Fixed Axle
SD80 Sway Axle
Dismantle and Assemble
Rear Axles SD55 and SD80
Removal and Replacement
SD55 Axle
SD80 Axle
Dismantle and Assemble
Powershift Gearbox
Removal and Replacement
Dismantle, Inspection and Assembly
Torque Converter
Removal and Replacement
Bevel Gearbox
Removal and Replacement
Dismantle, Inspection and Assembly
Oil Cooler
Removal and Replacement
Machines up to Serial No. 784534
Removal
Testing
Replacing
Machines from Serial No. 784535
Removal
Testing
Replacing

Section G – Brakes
Brakes
Technical Data
Machines with SD55, SD70 Axles
Machines fitted with AM and RJ engines
All Other Engine Builds
Machines with SD80 Axles
Pedal Effort versus Brake Pressure
Basic Operation
General Description
Fault Finding
Brake System
Service Procedures
Brake Piston Seal Leakage
Front Axle
Rear Axle
Parking Brake Switch
Adjustment
Master Cylinder
Removal and Replacement
Removal
Replacement
Servo Unit
Removal and Replacement
Machines with SD55, SD70 Axles
Machines with SD80 Axles
Service Brakes
Dismantling and Assembly
Bleeding
Machines with SD55, SD70 Axles
Machines with SD80 Axles
Parking Brake
Applicability
Introduction
Early Machines
Later Machines
Early Machines
Renewing the Brake Pads
Dismantling and Assembly
Testing and Adjustment
Later Machines
Brake Caliper
Testing and Adjustment
Axles
Axle Breather (Braked Axles)

Section H – Steering
Section H
Technical Data
All Machines
System Type
Steering Valve
Basic System Operation
Hydraulic Operation
Machines Fitted With Power Track Rods
Hydraulic Component Location
Hydraulic Pump
Priority Valve
Steering Unit
Steering Mode Valve
Power Track Rod (Front)
Power Track Rod (Rear)
Machines Fitted With Steer Rams
Hydraulic Component Location
Hydraulic Pump
Priority Valve
Steering Unit
Steering Mode Valve
Steering Ram (Front Left)
Steering Ram (Front Right)
Steering Ram (Rear Left)
Steering Ram (Rear Right)
Electrical Operation
Electrical Component and Connector Location
Steering Mode Valve
Steering Sensor (Front)
Steering Sensor (Rear)
Steer Mode Switch
Steer Mode Control Unit and Fuse Blocks
Bulkhead Connectors
Instrument Panel
Electrical Connections
Series I Machines
Component Key
Series II Machines
Component Key
Circuit Description
Steer Unit Operation
Machines upto SN 1004199
Introduction
Neutral
Turning
Machines From SN 1004200
Introduction
Neutral
Turning
Priority Valve Operation
Neutral
Turn
System Operation
2-Wheel Steering
Electrical Circuit
Hydraulic Circuit
4-Wheel Steering
Electrical Circuit
Hydraulic Circuit
Crab Steering
Electrical Circuits
Hydraulic Circuit
Fault Finding
Introduction
Contents
Mechanical and Hydraulic
Electrical
Servicing Procedures
Re-phasing the Road Wheels
Machines with Solenoid Operated Steer Mode Valve
Machines with Manual Steer Mode Valve (Option)
System Bleeding
Machines with Solenoid Operated Steer Mode Valve
Machines with Manual Steer Mode Valve (Option)
Checking the Steering Pressure
Adjusting the Steering Pressure
Anti-Cavitation Valve – Bypassing
540-170, 550-170, 5508 only
Bypass Procedure
All machines except 540-170, 550-170, 5508
Machines with Trailer Brakes or Sway Service
Proximity Switches
Machines with SD55, SD70 Axles
Sensor Mounting
Component Key
Adjustment
Sensor Connections
Machines with SD80 Axles
Sensor Mounting
Component Key
Adjustment
Sensor Connections
Power Track Rod
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Link Arms
Dismantling
Assembly
Power Track Rod Ram
When Dismantling
When Assembling
Steer Rams
Removal and Replacement
Removal
Dismantling and Assembly
Replacement
Priority Valve
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Testing and Adjustment
Standby Pressure Testing
Routine Maintenance
Steer Mode Valve
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Machines Upto Serial Number 773053
Before Dismantling
When Assembling
Machines from S/N: 773054
Dismantling
Assembly
Testing and Adjustment
Checking Solenoid Operation
Hydraulic Steering Unit
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Applicability
Early Machines
Later Machines
Early Machines
Dismantling
Assembling
Pressure Relief Valve Cartridge
Shock Valves
Later Machines
Dismantling
Inspecting
Assembling

Section K – Engine
Engine
Technical Data
All Machines
Basic System Operation
General Description
Cooling Package
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Series I Machines
Series II Machines
Engine
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Separating the Engine and Bevel Box
Fuel Lift Pump
Cleaning the Strainer

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