JCB Loadall 530, 532, 535, 537, 540 Series Telescopic Handler Service Repair Workshop Manual

Service Manual (Supplement) 532H, 537H PUBLISHED BY THE TECHNICAL PUBLICATIONS DEPARTMENT OF JCB SERVICE; © WATERLOO PARK, UTTOXETER, ST14 5PA, ENGLAND Tel. 01889 - 590312 PRINTED IN ENGLAND Publication No. 9803/3641 R General Information 1 Care & Safety 2 3 Electrics C Hydraulics E Transmission F Brakes G Steering H Engine K Routine Maintenance

i Overall Contents 9803/3641 i Issue 2* Section 1 General Information Introduction Care and Safety 1 - 1 Service Tools 1 - 2 Section 2 Care and Safety Operating Safety 1 - 1 Maintenance Safety 1 - 1 Section 3 Routine Maintenance Introduction Fluids, Lubricants, Capacities and Specifications 1 - 1 Service Schedules 2 - 1 Towing a Machine 4 - 1 Checking the Drop Box Oil Level 5 - 1 Changing the Transmission Charge Filter 6 - 1 Testing the Parking Brake 7 - 1 Section C Electrics Introduction 1 - 1 Fuses and relays Fuse Identification 1 - 2 Relay Identification 1 - 3 Transmission Controller Diagnostic LED’s 2 - 1 Schematic Diagrams 4 - 1 to 4 - 8 * *

ii Overall Contents 9803/3641 ii Issue 2* Section E Hydraulics Technical Data 1 - 1 Hydraulic Contamination 2 - 1 Fault Finding 3 - 1 Schematic Diagrams and Circuit Descriptions Schematic Diagrams 4 - 1 Circuit Descriptions Drive Pump 4 - 5 Drive Motor 4 - 6 Engine/Drive Pump Coupling 5 - 1 Drive Pump Removal and Replacement 6 - 1 Minor Repairs Location of Components 6 - 3 Shaft Seal 6 - 4 Multi-Function Valves 6 - 5 Charge Pressure Relief Valve 6 - 5 Coupling Removal and Replacement 6 - 6 Servo Piston Cover Seals Renewal 6 - 7 Control Valve 6 - 8 Speed Sensor Removal and Replacement 6 - 9 Pump Cover 6 - 10 Servo Control Valve 6 - 10 Drive Motor/Drop Box Assembly Removal and Replacement 7 - 1 Minor Repairs Location of Components 7 - 3 Shaft Seal 7 - 4 Loop Flushing Valve 7 - 5 Charge Pressure Relief Valve 7 - 5 Multi-Function Block/Pressure Compensator Valve 7 - 6 Fan Pump Removal and Replacement 8 - 1 Dismantling and Assembly 8 - 2 Fan Motor Removal and Replacement 9 - 1 Dismantling and Assembly 9 - 2 Main Service Pump Removal and Replacement 11 - 1 Dismantling and Assembly 11 - 2

iii Overall Contents 9803/3641 iii Issue 2* Section E Hydraulics (continued) Priority Valve Description and Operation 12 - 1 Removal and Replacement To Machine Serial Number 775548 12 - 2 Dismantling and Assembly To Machine Serial Number 775548 12 - 3 Removal and Replacement From Machine Serial Number 775549 12 - 4 Dismantling and Assembly From Machine Serial Number 775549 12 - 5 Transmission Oil Cooler Bypass Valve Removal and Replacement 13 - 1 Start-up procedure 15 - 1 Section F Transmission Introduction 1 - 1 Technical Data 1 - 1 Description and Operation Introduction 2 - 1 Drive Circuit 2 - 2 Fan (Charge) Pump and Fan Motor Circuit 2 - 3 Brake Pressure Defeat Valve 2 - 3 Case Drain Circuit 2 - 4 Oil Cooling Circuit 2 - 5 Test Points 2 - 6 Sensors 2 - 7 Drop Box Removal and Replacement 4 - 1 Dismantling and Assembly 5 - 1 Propshafts Removal and Replacement 6 - 1 Section G Brakes Introduction 1 - 1 Technical Data 1 - 1 Parking Brake Adjustment 2 - 1 Section H Steering Introduction 1 - 1 Technical Data 1 - 1

iv Overall Contents 9803/3641 iv Issue 1 Section K Engine Introduction 1 - 1 Technical Data 1 - 1 Engine Removal and Replacement 2 - 1 Renewing the Coupling 2 - 5 Drive Flange Replacement 2 - 6 Engine Mounting Bracket And Bushes 2 - 6 Machine Start-up Procedure 2 - 7

JCB Loadall 530, 532, 535, 537, 540 Series Telescopic Handler Service Repair Workshop Manual

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