JCB 535-125 HiVIZ, 535-140 HMz., 540-140, 540-170, 550-140, 550-170 Telescopic Handler Service Repair Manual Instant Download

1
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 Publication No. 9813-1450-2 World Class Customer Support
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
Issued by JCB Technical Publications, JCB
Aftermarket Training, Woodseat, Rocester,
Staffordshire, ST14 5BW, England. Tel 44 1889
591300 Fax [phone]
2
Section F2 - Transmission Wheels and
Tyres Removal and Replacement Removal and
Replacement
Front Wheels
When the replacement procedure is complete
Check the wheel nut torques are correct after
every two hours of machine operation until they
stay correct.
Important The wheel and tyre assembly is heavy.
Get the aid of one more person to remove and
replace a wheel.
! WARNING
Table 3. Torque Settings
Item Nm kgf m lbf ft
B(1) 650 66 480
B(2) 680 69 500
A raised and badly supported machine can fall on
you. Position the machine on a firm, level
surface before raising one end. Ensure the other
end is securely chocked. Do not rely solely on
the machine hydraulics or jacks to support the
machine when working under it.

1. 550-80 machines
2. Other machines

• Disconnect the battery, to prevent the engine
  being started while you are beneath the machine.
• GEN-1-1
• Removal (one wheel)
• Park the machine and make it safe. Fit the boom
  safety strut. Obey the care and safety
  procedures. K Related Topics ( F2-2)
• Make sure that the engine cannot be started.
• Put chocks A under the rear wheels.
• Loosen the five wheel nuts B by half a turn.
• Put a jack C under the axle arm. Use the correct
  jack.
• Use the jack to lift the machine until the front
  wheel D
• is off the ground.
• Put chocks E under the axle arm.

9 Remove the wheel. Replacement
C045590
Fig 1.
Note Make sure that the mating surfaces of the
wheel and axle hub are clean. ! WARNING If, for
whatever reason, a wheel stud is renewed, all the
studs for that wheel must be changed as a set,
since the remaining studs may have been
damaged. 2-3-2-8 Replacement is the opposite of
the removal procedure. During the replacement
procedure do this work also Torque tighten the
nuts B.
F2-4
F2-4
F-02-03 Issue 01
3
Section F2 - Transmission Wheels and Tyres
Removal and Replacement Replacement is the
opposite of the removal procedure.
Rear Wheels
During the replacement procedure do this work
also
Important The wheel and tyre assembly is heavy.
Get the aid of one more person to remove and
replace a wheel.
Torque tighten the nuts B.
! WARNING
When the replacement procedure is complete
A raised and badly supported machine can fall on
you. Position the machine on a firm, level
surface before raising one end. Ensure the other
end is securely chocked. Do not rely solely on
the machine hydraulics or jacks to support the
machine when working under it.
Check the wheel nut torques are correct after
every two hours of machine operation until they
stay correct.
Table 4. Torque Settings
Item Nm kgf m lbf ft
B(1) 650 66 480
B(2) 680 69 500
Disconnect the battery, to prevent the engine
being started while you are beneath the
machine. GEN-1-1

1. 550-80 machines
2. Other machines

Removal (one wheel)

• Park the machine and make it safe. Fit the boom
  safety strut. Obey the care and safety
  procedures. K Related Topics ( F2-2)
• Make sure that the engine cannot be started.
• Put chocks A under the front wheels.
• Loosen the five wheel nuts B by half of one turn.
• Put a jack C under the centre of the rear axle.
  Use the correct jack.
• Use the jack to lift the machine until both rear
  wheels are off the ground.
• Put chocks E under each end of the rear axle.
• Hold the wheel D and remove the wheel nuts.
• Remove the wheel.
• Replacement

C045590
Fig 2.
Note Make sure that the mating surfaces of the
wheel and axle hub are clean. ! WARNING If, for
whatever reason, a wheel stud is renewed, all the
studs for that wheel must be changed as a set,
since the remaining studs may have been
damaged. 2-3-2-8
F2-5
F2-4
F-02-03 Issue 01
4
https//www.ebooklibonline.com Hello dear
friend! Thank you very much for reading. Enter
the link into your browser. The full manual is
available for immediate download. https//www.eb
ooklibonline.com
5
Section F2 - Transmission Wheels and Tyres
Removal and Replacement 1 Put the stud 4-A into
the hub carrier hole.
Wheel Studs
2 Use a nut and washer to pull in the stud 4-A
into the hub carrier 4-C.
Removal and Replacement
The procedures that follow are for one wheel
stud. The procedures are the same for all the
wheel studs.
3 Examine the stud and make sure it is correctly
installed. If the stud is loose replace the hub
carrier 4- C. Refer to Applications for related
axle topics. K Related Topics ( F2-2)
! WARNING

• If, for whatever reason, a wheel stud is renewed,
  all the studs for that wheel must be changed as
  a set, since the remaining studs may have been
  damaged.
• 2-3-2-8
• Removal
• Remove the wheel from the hub. K Front Wheels
  ( F2-4) K Rear Wheels ( F2-5)
• Push out the wheel stud 3-A.
• Important Remove all the wheel studs 3-A and
  discard them.

C045650-C1
Fig 4.
C045650
Fig 3. Replacement Important Examine the wheel
stud holes 4-B in the hub carrier 4-C. If the
holes are defective do not use the hub carrier.
Replace the hub carrier with a new one. Refer to
Applications for related axle topics. K Related
Topics ( F2-2)
6
Section F3 - Transmission Front
Axles Introduction Front Axles Introduction
This topic contains information about a machine
DEVICE. Make sure you are referring to the
correct device. Refer to the applications
table. Descriptions and procedures relate to the
device and not related systems. For information
about the systems refer to the relevant
topics. This topic is intended to help you
understand what the device does and how it works.
Where applicable it also includes procedures
such as removal and replacement and dismantle and
assemble. K Related Topics ( F3-2) K
Specifications ( F3-3) K SD80 3 Piece Steer Drive
Axle ( F3-3) K Component Identification ( F3-4) K
Renewing the Pinion Oil Seal ( F3-6) K Removal
and Replacement - SD80 Fixed Axle ( F3-7) K
Removal and Replacement - SD80 Pivot Sway Axle
( F3-9)(1) K Removal and Replacement - SD80
Trunnion Sway Axle ( F3-12)(1) K Dismantle,
Inspection and Assembly ( F3-15) (1) Procedure
variant. Make sure you refer to the correct
procedure. Table 1. Procedure and Specification
Variants
Procedures, Specifications(1) Machine Model Application Machine Model Application Machine Model Application Machine Model Application Machine Model Application Machine Model Application Machine Model Application
540-170 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 ( F3-9) ? ? ? ? ?
K Removal and Replacement - SD80 Trunnion Sway Axle ( F3-12) ? ?
(1) The table lists procedure and specification
variants and the applicable machine models. Use
the table to make sure you refer to the correct
information.
7
Section F3 - Transmission Front Axles Related
Topics Related Topics Table 2. Related Topics in
This Publication
The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correct information. Some machines have different systems and devices. Make sure you refer to the correct topic, refer to Section 1 - Applications. The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correct information. Some machines have different systems and devices. Make sure you refer to the correct topic, refer to Section 1 - Applications. The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correct information. Some machines have different systems and devices. Make sure you refer to the correct topic, refer to Section 1 - Applications.
Sections Topic Titles Sub Titles
1 Applications ALL
2 ALL (Care and Safety)(1) ALL
3 Maintenance ALL
F Applications ALL
F Rear Axles Renewing the Pinion Oil Seal
G Service Brakes SYSTEM Bleeding
H Steering SYSTEM Bleeding
H Steering SYSTEM Re-Phasing
(1) You must obey all of the relevant care and
safety procedures. Table 3. Related Topics in
Publication 9803/8610, Transmissions
The table lists topics in another manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correct information. Some machines have different systems and devices. Make sure you refer to the correct topics, refer to Designations. K Specifications ( F3-3) The table lists topics in another manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correct information. Some machines have different systems and devices. Make sure you refer to the correct topics, refer to Designations. K Specifications ( F3-3) The table lists topics in another manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correct information. Some machines have different systems and devices. Make sure you refer to the correct topics, refer to Designations. K Specifications ( F3-3)
Sections Section Titles Topic Titles
A Axle Hubs 80 Series Hub
B Axle Hub Swivels and Driveshafts 55 Series Hub Swivel and Driveshaft
C Axle Integral Brakes 70 Series Integral Brakes (3 Piece Axles)
D Axle Drive Heads 80 Series Drive Heads (3 Piece Axles)
8
Section F3 - Transmission Front
Axles Specifications Specifications
The axle serial number is stamped on the unit
identification plate A as shown.
Note It is essential that the correct ratio axle
in relationship to the gearbox ratio is fitted
to the machine. Do not fit a new axle with a
different ratio to the axle being replaced.
Fig 1. Table 4. SD80 3 Piece Steer Drive Axle
Designations Designations
Hubs 80 Series
Hub swivels and drive shafts 55 Series
Drive head 80 Series 3 piece
Brakes 70 Series Integral Brakes (3 Piece Axles)

Type JCB spiral bevel input with epicyclic hub reduction
Brakes Oil immersed multi-plate discs, located in centre section
Steering Steer rams or power track rod
9
Section F3 - Transmission Front Axles Component
Identification Component Identification The
illustration shows a typical 3 piece steer drive
front axle. K Fig 2. ( F3-5) The front axle
consists of a centre casing (drivehead) and two
axle arms and swivel wheel hubs. The drivehead
houses the differential gearing and two oil-
immersed disc brake units. The axle arms house
the driveshafts. Specially shaped spider gears
in the differential provide torque
proportioning'. This means that drive power will
be kept on one wheel if the other is
slipping. The wheel hubs are connected to the
halfshafts through universal joints which drive
sun-and-planet gears inside the hubs.
A Yoke connection to propshaft
B Pinion
C Crownwheel
D Differential unit
Note Items A, B, C and D form the drive head' part of the axle. Note Items A, B, C and D form the drive head' part of the axle.
E Drive shaft
F Universal coupling
G Reduction gear hub
H Steer swivel trunnion bearings
L Inboard oil-immersed multi-plate disc brakes
M Brake actuating piston
N Hydraulic brake lines
10
Section F3 - Transmission Front Axles Component
Identification
Fig 2. Typical Steer Drive Front Axle
11
Section F3 - Transmission Front Axles Renewing
the Pinion Oil Seal Renewing the Pinion Oil
Seal The front axle pinion oil seal is renewed
using the same procedure as described for the
rear axles. K Related Topics ( F3-2)
12
Section F3 - Transmission Front Axles Removal and
Replacement - SD80 Fixed Axle Removal and
Replacement - SD80 Fixed Axle
! WARNING
5 Disconnect the brake hose at the axle. Blank
off the exposed connections.
A raised and badly supported machine can fall on
you. Position the machine on a firm, level
surface before raising one end. Ensure the other
end is securely chocked. Do not rely solely on
the machine hydraulics or jacks to support the
machine when working under it.
6 Uncouple the steer proximity switch electrical
connector (if fitted).
7 Support the axle on a trolley jack.
8 Unscrew axle mounting nuts D and remove the
bolts and washers.
Disconnect the battery, to prevent the engine
being started while you are beneath the machine.
9 Lower the axle down from the machine.
GEN-1-1
If the boom is raised, make sure the maintenance
strut is fitted. Obey the care and safety
procedures. K Related Topics ( F3-2)
10 Remove the axle from the machine. Replacement
K Fig 3. ( F3-8)
Replacement is the opposite of the removal
procedure.
Note Some machines may have shims installed on
the axle mounts. Make sure to note the position
and quantity of these shims before removal. Make
sure to retain the shims and replace them in the
correct position when replacing the axle. There
may be an uneven number of shims between each
side of the axle as the shims are used to adjust
the machine height and make it level.
During replacement do this work also

• Bleed the brake system, see Section G - Brakes.
• K Related Topics ( F3-2)
• Refit the road wheels and carry out the tightness
  checks as detailed in Section 3 - Routine
  Maintenance. K Related Topics ( F3-2)
• Bleed the steering system, see Section H -
  Steering.
• K Related Topics ( F3-2)
• Re-phase the steering system, see Section H -
  Steering. K Related Topics ( F3-2)
• Grease the axle pivot trunnions.

Removal
1 Disconnect the propshaft coupling from the axle
by unscrewing bolts A.
! WARNING
Table 5. Torque Settings
When the driveshaft is disconnected the park
brake will no longer function. The machine must
be securely blocked to prevent any machine
movement before disconnecting the
driveshaft. TRANS-1-3 2 Disconnect and plug the
hydraulic hoses to the steer rams/ power track
rod.
Item Nm kgf m lbf ft
A 78 8 57
B 56 5.7 41
C 680 69 500
D (1) 969 99 715
D (2) 600 60 440
E 98 10 72
3 Slacken off the roadwheel retaining nuts C then
raise and support the front end of the machine
on axle stands or blocks positioned under the
chassis. Remove the front roadwheels.

1. Dry nuts.
2. Nuts with special dry lubricating film.

4 Remove the front mudguards. Undo the bracket
retaining nuts E at the steering trunnions.
13
Section F3 - Transmission Front Axles Removal and
Replacement - SD80 Fixed Axle
E
D
C
A
B
Fig 3. SD80 Fixed Axle
14
Section F3 - Transmission Front Axles Removal and
Replacement - SD80 Pivot Sway Axle Removal and
Replacement - SD80 Pivot Sway Axle
! WARNING
8 Undo the sway ram pivot bracket mounting bolts
H. Lift away the bracket.
A raised and badly supported machine can fall on
you. Position the machine on a firm, level
surface before raising one end. Ensure the other
end is securely chocked. Do not rely solely on
the machine hydraulics or jacks to support the
machine when working under it.
9 Support the axle on a trolley jack.
10 Undo bolt F and remove pivot pin G.
11 Remove the axle from the machine. Replacement
Disconnect the battery, to prevent the engine
being started while you are beneath the machine.
GEN-1-1
Replacing is generally the reverse of the removal
sequence.
If the boom is raised, make sure the maintenance
strut is fitted. Obey the care and safety
procedures.K Related Topics ( F3-2)
Replacement is the opposite of the removal
procedure.
During replacement do this work also
Removal K Fig 5. ( F3-11)

• Bleed the brake system, see Section G - Brakes.
• K Related Topics ( F3-2)
• Adjust the sway sight rod M so that the top of
  the rod is in line with the top of the tube L
  when the machine is horizontal. To adjust this
  slacken the locknuts N and screw the sight rod
  up or down to the correct position. Tighten the
  locknuts when the position is correct. K Fig 4.
  ( F3-10)
• Refit the road wheels and carry out the tightness
  checks as detailed in Section 3 - Routine
  Maintenance. K Related Topics ( F3-2)
• Bleed the steering system, see Section H -
  Steering.
• K Related Topics ( F3-2)
• Re-phase the steering system, see Section H -
  Steering. K Related Topics ( F3-2)
• Grease the axle pivot trunnions.

Removal
1 Disconnect the propshaft coupling from the axle
by unscrewing bolts A.
! WARNING
When the driveshaft is disconnected the park
brake will no longer function. The machine must
be securely blocked to prevent any machine
movement before disconnecting the driveshaft.
TRANS-1-3
2 Disconnect and plug the hydraulic hoses to the
steer rams.
3 Slacken off the roadwheel retaining nuts C then
raise and support the front end of the machine
on support stands or blocks positioned under the
chassis. Remove the front roadwheels.

1. Remove the front mudguards. Undo the bracket
   retaining nuts K at the steering trunnions.
2. Disconnect the brake hose at the axle. Blank off
   the exposed connections.
3. Uncouple the steer proximity switch electrical
   connector (if fitted).
4. Undo bolt D and remove pivot pin E.

15
Section F3 - Transmission Front Axles Removal and
Replacement - SD80 Pivot Sway Axle
L
M
N N
C127500
Fig 4. Table 6. Torque Settings
Item Nm kgf m lbf ft
A 78 8 57
B 56 5.7 41
C 680 69 500
H 969 99 715
K 98 10 72
16
Section F3 - Transmission Front Axles Removal and
Replacement - SD80 Pivot Sway Axle
K
E
D
H
J
C
G
A F
B
Fig 5. SD80 Pivot Sway Axle
17
Section F3 - Transmission Front Axles Removal and
Replacement - SD80 Trunnion Sway Axle Removal and
Replacement - SD80 Trunnion Sway Axle
! WARNING
8 Undo the sway ram pivot bracket mounting bolts
H. Lift away the bracket.
A raised and badly supported machine can fall on
you. Position the machine on a firm, level
surface before raising one end. Ensure the other
end is securely chocked. Do not rely solely on
the machine hydraulics or jacks to support the
machine when working under it.
L
Disconnect the battery, to prevent the engine
being started while you are beneath the machine.
GEN-1-1 If the boom is raised, make sure the
maintenance strut is fitted. Obey the care and
safety procedures.K Related Topics (
F3-2) Removal
1 Disconnect the propshaft coupling from the axle
by unscrewing bolts A.
M
! WARNING
When the driveshaft is disconnected the park
brake will no longer function. The machine must
be securely blocked to prevent any machine
movement before disconnecting the driveshaft.
N
C053980
Fig 6.
TRANS-1-3
9 Remove the access plate screws M and lift off
the plate N to get access to the front trunnion
bolts.
2 Disconnect and plug the hydraulic hoses G to
the power track rod.
10 Support the axle on a trolley jack.
3 Slacken off the roadwheel retaining nuts
then raise and support the front end of the
machine on support stands or blocks positioned
under the chassis. Remove the front roadwheels.
11 Undo the six trunnion bolts B and nuts C. The
top of the bolts can be accessed from underneath
the boom as shown at L and below the access
cover N.
12 Remove the axle from the machine. Be sure to
retrieve dowels J. If shims are fitted record
their positions. Use some wire to tie the
trunnions to the axle.
4 Remove the front mudguards. Undo the bracket
retaining nuts F at the steering trunnions.
5 Disconnect the brake hose at the axle. Blank
off the exposed connections.

1. Uncouple the steer proximity switch K electrical
   connector (if fitted).
2. Undo bolt D and remove pivot pin E.

18
Section F3 - Transmission Front Axles Removal and
Replacement - SD80 Trunnion Sway Axle
Replacement
X
Replacement is the opposite of the removal
procedure. During replacement do this work also

• Bleed the brake system, see Section G - Brakes.
• K Related Topics ( F3-2)
• Adjust the sway sight rod Y so that the top of
  the rod is in line with the top of the tube X
  when the machine is horizontal. To adjust this
  slacken the locknuts Z and screw the sight rod
  up or down to the correct position. Tighten the
  locknuts when the position is correct. K Fig 7.
  ( F3-13)
• Make sure you re-fit dowels J together with any
  shims in their original positions.
• Make sure that the axle oscillates freely before
  final tightening of the fixing bolts.
• Refit the road wheels and carry out the tightness
  checks as detailed in Section 3 - Routine
  Maintenance. K Related Topics ( F3-2)
• Bleed the steering system, see Section H -
  Steering.
• K Related Topics ( F3-2)
• Re-phase the steering system, see Section H -
  Steering. K Related Topics ( F3-2)
• Grease the axle pivot trunnions.

Y
Z Z
C127500-C1
Fig 7. Table 7. Torque Settings
Item Nm kgf m lbf ft
A 78 8 57
B 476 48 352
C 476 48 352
H 600 60 440
F 98 10 72
19
Section F3 - Transmission Front Axles Removal and
Replacement - SD80 Trunnion Sway Axle G
G
J
J
J
B
J
C
K
E H
D
F
A
A
A312090-C2
Fig 8. SD80 Trunnion Axle
20
Suggest If the above button click is invalid.
Please download this document first, and then
click the above link to download the complete
manual. Thank you so much for reading
21
Section F3 - Transmission Front Axles Dismantle,
Inspection and Assembly Dismantle, Inspection and
Assembly Make sure that you identify the axle
sub-assemblies designations correctly. K
Specifications ( F3-3) The procedures for
dismantling, inspection and assembly are
described in the Transmissions Service Manual. K
Related Topics ( F3-2)
F3-15
F3-15
F-03-10 Issue 01
22
https//www.ebooklibonline.com Hello dear
friend! Thank you very much for reading. Enter
the link into your browser. The full manual is
available for immediate download. https//www.eb
ooklibonline.com