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JCB Loadall Rough Terrain Variable Reach Truck Manual **Copyright Information** This manual is the property of JCB Service and is copyrighted. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means without prior permission from JCB Service. **World Class Customer Support**
Contact information: Tel +44 1889 591300, Fax +44 1889 591400 **Publication Information** Publication No., Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. **Table of Contents** Section 1: General Information - Applications - Introduction - Tables - Use - Scope - Format - Left
and Right Sides - Hydraulic Schematic Codes - Electrical Device Codes - Machine Identification Section 2: Care and Safety ... **Note:** I followed the guidelines provided, separating the text into sections using ** 1-14-01 Service Consumables Introduction Service consumables for the JCB Loadall machines include sealing and retaining compounds,
fuel, torque settings, service tools, and stall speed combinations. 1-7-3 Stall Speed Combinations Introduction Stall speed combinations are an important aspect of maintaining stability while operating the machine, particularly in high-speed applications. 1-8-2 Specifications Specifications for each machine model can be found in the relevant sections of
this manual, including topics related to care and safety, routine maintenance, and performance characteristics. **Machine Maintenance Manual** The manual covers general procedures and maintenance schedules for various machine models, including those with SD and SF engines, mechanical fuel-injected (F.I.) engines, electronic F.I. engines, and
others. **Machine Models Covered** The manual includes information on the following machine models: * 540-170 (5AF) * 550-140 (5AG) * 540-140 (5AL) * 550-170 (5AM) * 535-125 HiViz (5AN) * 535-140 HiViz (5AP) **Manual Sections** The manual is divided into several sections, including: 1. **General Information**: Overview of machine
applications and maintenance procedures. 2. **Routine Maintenance**: Service schedules for machines with SD and SF engines, mechanical F.I. engines, and electronic F.I. engines. 3. **Body and Framework**: Information on the body and framework of the machines, including fork carriage, cab heating and ventilation systems, air conditioning
systems, load moment indicator (LMI) systems, and more. 4. **Electrics**: Details on electrical systems, including fuses and relays, schematics, electrical harness systems, battery charging systems, alternators, and batteries. 5. **Hydraulics**: Information on hydraulic systems, including parallel hydraulic systems, servo hydraulic systems, hydraulic
interlock systems, parallel control valves, and more. **Accessing the Manual** The manual is available in digital format, and users can access it by clicking on a provided link or downloading a PDF document first and then clicking on it. The following is a general overview of the Rams E20 Ram Maintenance manual, divided into sections. The main
topics covered include transmission machine models, brakes, steering, and engine information. **Section F: Transmission Machine Models** This section discusses various transmission machine models, including PS750 Gearbox SYSTEM, PS764 Gearbox SYSTEM, and others. **Section G: Brakes** The brakes section covers twin axle service brakes,
external park brake systems, internal park brake systems, and more. **Section H: Steering** Steering system information is provided in this section, including manual steer mode, auto steer mode, hydraulic steering units, and priority valves. **Section K: Engine** This section focuses on engine machine models, discussing stop and start systems, cold
start heater systems, starter motors, cooling packs, and more. Given article text here 1. Section K - Engine 2. Section F2 - Transmission Remove wheel. Replacement Note: Ensure mating surfaces of wheel and axle hub are clean. !MWARNING If new wheel stud is installed, all studs for that wheel must be changed as set, since remaining studs may
have been damaged. 2-3-2-8 Replacement opposite of removal procedure. During replacement work also do this: – Torque tighten nuts B. – Check wheel nut torques correct after every two hours machine operation until stay correct. Table 4. Torque Settings C045590 Fig 2. Item Nm kgf m lbf ft B(1) (1) 550-80 machines 650 66 480 B(2) (2) Other
machines 680 69 500 Section F2 - Transmission Wheels and Tyres Removal and Replacement F2-6 F2-6F-02-03 Issue 01 Wheel Studs Removal and Replacement !MWARNING If new wheel stud is installed, all studs for that wheel must be changed as set, since remaining studs may have been damaged. 2-3-2-8 Removal 1 Remove wheel from hub. K
Front Wheels ( T F2-4) K Rear Wheels ( T F2-5) 2 Push out wheel stud 3-A. Important: Remove all the wheel studs 3-A and discard them. C045650 Fig 3. Replacement Important: Examine wheel stud holes 4-B in hub carrier 4-C. If holes are defective, do not use hub carrier. Replace hub carrier with new one. Refer to Applications for related axle topics.
K Related Topics ( T F2-2) 1 Put stud 4-A into hub carrier hole. 2 Use nut and washer to pull in stud 4-A into hub carrier 4-C. 3 Examine stud and make sure it is correctly installed. If stud is loose, replace hub carrier 4-C. Refer to Applications for related axle topics. C045650-C1 Fig 4. Section F3 - Transmission Front Axles Introduction F3-1 F3-1F-03-
10 Issue 01 5AF 550-140, 5AG 540-140, 5AL 550-170, 5AM 535-125 HiViz, 5AN 535-140 HiViz, 5AP 540-200 K Removal and Replacement - SD80 Pivot Sway Axle (T F3-9), K Removal and Replacement - SD80 Trunnion Sway Axle (T F3-12) Gears within hub assemblies are connected via a Yoke mechanism to the propshaft, Pinion, Crownwheel, and
Differential unit. The drive head component includes these items. Other key parts include the drive shaft, Universal coupling, Reduction gear hub, Steer swivel trunnion bearings, Inboard oil-immersed multi-plate disc brakes, Brake actuating piston, and Hydraulic brake lines. K Related Topics ( T F3-2) – Grease the axle pivot trunnions. Table 5.
Torque Settings Item Nm kgf m lbf ft A 78 8 57 B 56 5.7 41 C 680 69 500 D 969 99 715 D(1) 969 99 715 D(2) 600 60 440 E 98 10 72 12 Section F3 - Transmission Front Axles Removal and Replacement - SD80 Fixed Axle F3-8 F3-8F-03-10 Issue 01 Fig 3. SD80 Fixed Axle E B C A D 13. Section F3 - Transmission Front Axles Removal and Replacement -
SD80 Pivot Sway Axle F3-9 F3-9F-03-10 Issue 01 Removal and Replacement - SD80 Pivot Sway Axle !MWARNING Raise the machine on a firm, level surface and support it before working underneath. Ensure the machine is blocked in place to prevent movement. Disconnect the battery to avoid engine start-up while working under the machine. GEN-1-
1 If the boom is raised, fit the maintenance strut. Follow safety procedures.K Related Topics ( T F3-2) Removal K Fig 5. ( T F3-11) Removal 1 Disconnect and remove propshaft coupling bolts A. !MWARNING When disconnecting driveshaft, park brake function will cease. Securely block the machine before proceeding. TRANS-1-3 2 Disconnect and plug
hydraulic hoses to steer rams. 3 Slacken roadwheel nuts C, raise support stands or blocks under chassis, and remove front roadwheels. 4 Remove front mudguards, undo bracket retaining nuts K at steering trunnions. 5 Disconnect brake hose at axle, blank off connections. 6 Uncouple steer proximity switch electrical connector (if fitted). 7 Undo bolt
D, remove pivot pin E. 8 Undo sway ram pivot bracket mounting bolts H, lift away bracket. 9 Support axle on trolley jack. 10 Undo bolt F, remove pivot pin G. 11 Remove axle from machine. Replacement Replacing is generally reverse of removal sequence. During replacement: – Bleed brake system, see Section G - Brakes. K Related Topics ( T F3-2) –
Adjust sway sight rod M so that top of rod aligns with tube L when horizontal. To adjust, slacken locknuts N and screw up or down to correct position, then tighten locknuts.K Related Topics ( T F3-2) – Refit road wheels, carry out tightness checks in Section 3 - Routine Maintenance. K Related Topics ( T F3-2) – Bleed steering system, see Section H -
Steering. 1. Transmission Front Axles Removal and Replacement - SD80 Pivot Sway Axle Remove and replace pivot sway axle to access front trunnion bolts. 2. Warning: Raise machine on firm surface with one end secured, avoid relying solely on hydraulics or jacks. 3. Disconnect battery to prevent engine start while under machine. 4. Fit maintenance
strut if boom is raised. 5. Remove propshaft coupling and disconnect hydraulic hoses to power track rod. 6. Slacken roadwheel nuts, raise and support front end with blocks positioned under chassis, then remove wheels. 7. Remove mudguards and undo steering trunnion bracket retaining nuts. 8. Disconnect brake hose at axle, blank off connections,
and uncouple steer proximity switch electrical connector (if fitted). 9. Undo sway ram pivot bracket mounting bolts, lift away bracket to access front trunnion bolts. 10. Support axle on trolley jack and undo six trunnion bolts B and nuts C. 11. Remove axle from machine, retrieve dowels J, and record their positions if shims are fitted. 12. Use wire to tie
trunnions to axle during removal. Here's a rephrased version of the given text: To update the steering system, refer to Section H - Steering (T F3-2). Additionally, grease the axle pivot trunnions. For more information, see Table 7: Torque Settings. The following sections provide further guidance on transmission front axles removal and replacement, as
well as dismantling, inspection, and assembly procedures: * Section F3 - Transmission Front Axles Removal and Replacement (SD80 Trunnion Sway Axle) (F3-14) * Section F3 - Transmission Front Axles Dismantle, Inspection and Assembly (F3-15) Please note that the correct identification of axle sub-assemblies is crucial. For detailed procedures,
refer to the Transmissions Service Manual.