Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
World Class
Customer Support
9813/0900-2
Publication No.
Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
Service Manual
Side Engine Loadalls
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Routine Maintenance
Section B - Body and Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section H - Steering
Section K - Engine
Section M - Electronic Data Systems
Section 0 - Service Manual
0-0 0-0
9813/0900-2
Notes:
Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
World Class
Customer Support
9813/0900-2
Publication No.
Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
Section 1
General Information
Service Manual - Side Engine Loadalls
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Routine Maintenance
Section B - Body and Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section H - Steering
Section K - Engine
Section M - Electronic Data Systems
Section 1 - General Information
1-0 1-0
9813/0900-2
Notes:
Page No. Contents
Section 1 - General Information
1-i 1-i
Applications
Introduction ............................................................................................. 1-1-1
Tables ..................................................................................................... 1-1-2
Use
Introduction ............................................................................................. 1-2-1
Scope ..................................................................................................... 1-2-2
Format .................................................................................................... 1-2-3
Left and Right Sides ............................................................................... 1-2-4
Hydraulic Schematic Codes ................................................................... 1-2-5
Electrical Device Codes .......................................................................... 1-2-6
Machine Identification
Introduction ............................................................................................. 1-3-1
Related Topics ........................................................................................ 1-3-2
Machine Identification Plate .................................................................... 1-3-3
Component Identification Plates ............................................................. 1-3-5
Torque Settings
Introduction ............................................................................................. 1-4-1
Zinc Plated Fasteners and Dacromet Fasteners .................................... 1-4-2
Hydraulic Connections ............................................................................ 1-4-6
`Positional Type' Hydraulic Adaptors .................................................... 1-4-10
Service Tools
Introduction ............................................................................................. 1-5-1
Numerical List ......................................................................................... 1-5-2
Tool Detail Reference ............................................................................. 1-5-5
Rivet Nuts ............................................................................................. 1-5-24
Slide Hammer Kit .................................................................................. 1-5-26
Service Consumables
Introduction ............................................................................................. 1-6-1
Sealing and Retaining Compounds ........................................................ 1-6-2
Fuel
Introduction ............................................................................................. 1-7-1
Related Topics ........................................................................................ 1-7-2
Acceptable and Unacceptable Fuels ...................................................... 1-7-3
Stall Speed Combinations
Introduction ............................................................................................. 1-8-1
Related Topics ........................................................................................ 1-8-2
Specifications ......................................................................................... 1-8-3
Page No. Contents
Section 1 - General Information
1-ii 1-ii
Section 1-1 - General Information
Applications
Introduction
1-1-1 1-1-1
9813/0900-2 (1-14-05)
Applications
Introduction
This manual contains topics that relate to JCB Loadall machines in the 5A and 5T groups. There are several machine
model codes in the family.
Machine Group Model Code Model Name Serial Number range
5A A 531-70 1522574 to TBA
5A B 535-95 1522588 to TBA
5A C 536-60 1522577 to TBA
5A D 541-70 1522566 to TBA
5A H 533-105 1522615 to TBA
5A R 536-70 1522577 to TBA
5A S 526-56 1448231 to TBA
5A W 550-80 1186000 to TBA
5T A 531-T70 1522570 to TBA
5T B 541-T70 1522566 to TBA
5T C 536-T60 1522577 to TBA
5T D 535-T95 1522569 to TBA
5T E 536-T70 1522577 to TBA
5T W 550-T80 1186000 to TBA
Note: This manual is applicable to EN15000 compliant machines only.
Machine variants: There are different machine variants within the same model name. This happens because of market
requirements, or when the machine specification changes after a period of time. Where applicable information is given to
help identify which machine variant is applicable for the given specifications and procedures.
Use the applications tables to see which topics relate to which machine models and variants. Where no variant information
is given the topic is applicable to all machine models indicated on the table.
Important: The machine model names are NOT referred to in the topics. You must refer to the applications tables for the
applicable machine model. Table entries shaded grey indicate a topic not included in this issue of the manual.
K Tables ( T 1-1-2)
K Section 1 - General Information ( T 1-1-2)
K Section 2 - Care and Safety ( T 1-1-2)
K Section 3 - Routine Maintenance ( T 1-1-3)
K Section B - Body and Framework ( T 1-1-4)
K Section C - Electrics ( T 1-1-6)
K Section E - Hydraulics ( T 1-1-7)
K Section F - Transmission ( T 1-1-10)
K Section G - Brakes ( T 1-1-12)
K Section H - Steering ( T 1-1-13)
K Section K - Engine ( T 1-1-14)
K Section M - Electronic Data Systems ( T 1-1-15)
Section 1-1 - General Information
Applications
Tables
1-1-2 1-1-2
9813/0900-2 (1-14-05)
Tables
Section 1 - General Information
Section 2 - Care and Safety
Machine models
Topic Ref Title Variant 531-70,
531-T70
535-95,
535-T95
536-60,
536-T60
541-70,
541-T70
533-105 536-70,
536-T70
526-56 550-80
1-2 Use All Machines
1-3 Machine Identification All Machines
1-4 Torque Settings All Machines
1-5 Service Tools All Machines
1-6 Service Consumables All Machines
1-7 Fuel All Machines
1-8 Stall Speed Combinations All Machines
Machine models
Topic Ref Title Variant 531-70,
531-T70
535-95,
535-T95
536-60,
536-T60
541-70,
541-T70
533-105 536-70,
536-T70
526-56 550-80
2-1 Safety Notices All Machines
2-2 General Procedures All Machines
Section 1-1 - General Information
Applications
Tables
1-1-3 1-1-3
9813/0900-2 (1-14-05)
Section 3 - Routine Maintenance
Machine models
Topic Ref Title Variant 531-70,
531-T70
535-95,
535-T95
536-60,
536-T60
541-70,
541-T70
533-105 536-70,
536-T70
526-56 550-80
3-1 Routine Maintenance (P1)
3-2 Routine Maintenance (P2)
Section 1-1 - General Information
Applications
Tables
1-1-4 1-1-4
9813/0900-2 (1-14-05)
Section B - Body and Framework
Machine models
Topic Ref Title Variant 531-70,
531-T70
535-95,
535-T95
536-60,
536-T60
541-70,
541-T70
533-105 536-70,
536-T70
526-56 550-80
B1 Fork Carriage
B2 Cab Heating and Ventilation SYSTEM
B3 Cab Air Conditioning SYSTEM
B4 Longitidinal Load Moment SYSTEM (S1) Agri, Agri Plus, Agri
Super
Agri Xtra
B5 Longitidinal Load Moment SYSTEM (S2) Parallel Gearpump
Hydraulic System
Machines
B6 Cab
B7 Air Conditioning Condenser - Cooling
Pack Mounted
Machines with non intercooled engines
B8 Air Conditioning Condenser - Cab Roof
Mounted
Machines with intercooled engines
B9 Cab HV and HVAC Unit
B10 Air Conditioning Binary Switch
B11 Heater Valve
B12 Fuel Tank
B13 Chassis Panels
B14 Boom 2 Stage
3 Stage
B15 Hydraulic Tank
B16 Load Moment Indicator Axle Transducer
B17 Stabilisers
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JCB LOADALL 550 Service and Repair Manual
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Description
JCB LOADALL 550 SERVICE AND REPAIR MANUAL is a comprehensive factory manual designed to assist in the maintenance and repair of your vehicle. Whether you are a professional mechanic or a DIY enthusiast, this manual provides detailed instructions and procedures for addressing vehicle issues. It includes engine illustrations, technical descriptions, torque specifications, valve adjustments, cylinder head gaskets, piston and connecting rod details, crankshaft and bearing information, lube oil circuit, coolant circuit, fuel system, engine exhaust, hydraulic pump auxiliary drive, air compressor, starter, air conditioner compressor, turbocharger, gear drive, maintenance and inspections, service fluids, troubleshooting, and special tools.
The manual is completely bookmarked and searchable, allowing for easy navigation. It is available in PDF format and is compatible with all versions of Windows and Mac. The information contained in this manual is the same as that used by the company's engineers. Additionally, it includes step-by-step instructions, diagrams, illustrations, wiring schematics, and specifications to facilitate vehicle repairs. The manual is printable, allowing you to have the necessary information on hand in the home, office, or repair shop. For any manual-specific questions or needs, customer support is available via email.
With this repair manual, you can save money and enjoy the satisfaction of completing do-it-yourself projects. It provides comprehensive details on technical data, diagrams, a complete list of vehicle parts, and pictures, making it accessible even to novice mechanics. The manual also lists accessories that can enhance engine performance. The included sample screenshots offer a glimpse of the manual's quality, and all pages are printable for convenience.
For ease of use, the manual is designed to eliminate the need for flipping through books to find the required information. It is compatible with Windows Vista 32 and 64, XP, ME, 98, NT, 2000, and Mac. Accepted payment methods include all major credit/debit cards and PayPal.
