JCB 540-170, 540-140, 535-125 Hi Viz, 535-140 Hi Viz, 540-200 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. 9813/0950-5 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 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 Publication No. 9813/0950-5 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]
3
Section 1 - General Information
Contents Page No. 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 Machine
Identification Introduction ......................
..................................................
..................... 1-3-1 Related Topics
..................................................
......................................
1-3-2 Machine Identification Plate
..................................................
.................. 1-3-3 Component Identification
Plates ...........................................
.................. 1-3-7 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 ...........................
..................................................
................ 1-5-27 Slide Hammer Kit
..................................................
................................ 1-5-29 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
1-i
1-i
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Section 1-1 - General Information Applications I
ntroduction
This manual contains topics that relate to some or all JCB Loadall machines in the 5A group. There are several machine model codes in the family. This manual contains topics that relate to some or all JCB Loadall machines in the 5A group. There are several machine model codes in the family. This manual contains topics that relate to some or all JCB Loadall machines in the 5A group. There are several machine model codes in the family. This manual contains topics that relate to some or all JCB Loadall machines in the 5A group. There are several machine model codes in the family.
Machine Group Model Code Model Name Serial Number range
5A F 540-170 from 1522578 to TBA
5A L 540-140 TBA
5A N 535-125 Hi Viz from 1522579 to TBA
5A P 535-140 Hi Viz from 1522591 to TBA
5A X 540-200 TBA
Note This manual is applicable to EN15000 compliant machines only. Note This manual is applicable to EN15000 compliant machines only. Note This manual is applicable to EN15000 compliant machines only. 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. Information relating specifically to different variants of the same model is given in the applications tables and in the Topics throughout the manual where applicable. 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. Information relating specifically to different variants of the same model is given in the applications tables and in the Topics throughout the manual where applicable. 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. Information relating specifically to different variants of the same model is given in the applications tables and in the Topics throughout the manual where applicable. 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. Information relating specifically to different variants of the same model is given in the applications tables and in the Topics throughout the manual where applicable.
Use the applications tables to see which topics relate to which machine models and variants. Important The machine model names are NOT referred to in the topics. You must refer to the applications tables for the applicable machine models. Note For full details of machine identification refer to Section 1 - Machine Identification. Use the applications tables to see which topics relate to which machine models and variants. Important The machine model names are NOT referred to in the topics. You must refer to the applications tables for the applicable machine models. Note For full details of machine identification refer to Section 1 - Machine Identification. Use the applications tables to see which topics relate to which machine models and variants. Important The machine model names are NOT referred to in the topics. You must refer to the applications tables for the applicable machine models. Note For full details of machine identification refer to Section 1 - Machine Identification. Use the applications tables to see which topics relate to which machine models and variants. Important The machine model names are NOT referred to in the topics. You must refer to the applications tables for the applicable machine models. Note For full details of machine identification refer to Section 1 - Machine Identification.
K Tables ( 1-1-2) K Section 1 - General
Information ( 1-1-2) K Section 2 - Care and
Safety ( 1-1-3) K Section 3 - Routine
Maintenance ( 1-1-4) K Section B - Body and
Framework ( 1-1-5) K Section C - Electrics (
1-1-7) K Section E - Hydraulics ( 1-1-8) K
Section F - Transmission ( 1-1-10) K Section G -
Brakes ( 1-1-12) K Section H - Steering
( 1-1-13) K Section K - Engine ( 1-1-14) K
Section M - Electronic Data Systems ( 1-1-15)
1-1-1
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Section 1-1 - General Information Applications Tab
les Tables Section 1 - General Information
Machine models Machine models Machine models Machine models Machine models
Topic Ref Title Variant 540-170 5AF 540-140 5AL 535-125 HiViz 5AN 535-140 HiViz 5AP 540-200 5AX
1-2 Use All Machines All Machines All Machines All Machines All Machines
1-3 Machine Identification All Machines All Machines All Machines All Machines All Machines
1-4 Torque Settings All Machines All Machines All Machines All Machines All Machines
1-5 Service Tools All Machines All Machines All Machines All Machines All Machines
1-6 Service Consumables All Machines All Machines All Machines All Machines All Machines
1-7 Fuel All Machines All Machines All Machines All Machines All Machines
1-8 Stall Speed Combinations All Machines All Machines All Machines All Machines All Machines
1-1-2
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Section 1-1 - General Information Applications Tab
les
Section 2 - Care and Safety
Machine models Machine models Machine models Machine models Machine models
Topic Ref Title Variant 540-170 5AF 540-140 5AL 535-125 HiViz 5AN 535-140 HiViz 5AP 540-200
2-1 Safety Notices All Machines All Machines All Machines All Machines All Machines
2-2 General Procedures All Machines All Machines All Machines All Machines All Machines
1-1-3
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Section 1-1 - General Information Applications Tab
les
Section 3 - Routine Maintenance
Machine models Machine models Machine models Machine models Machine models
Topic Ref Title Variant 540-170 5AF 540-140 5AL 535-125 HiViz 5AN 535-140 HiViz 5AP 540-200
3-1 Routine Maintenance ? ? ? ? ?
1-1-4
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Section 1-1 - General Information Applications Tab
les
Section B - Body and Framework
Machine models Machine models Machine models Machine models Machine models
Topic Ref Title Variant 540-170 5AF 540-140 5AL 535-125 HiViz 5AN 535-140 HiViz 5AP 540-200 5AX
B1 Fork Carriage ? ? ? ? ?
B2 Cab Heating and Ventilation SYSTEM ? ? ? ? ?
B3 Cab Air Conditioning SYSTEM ? ? ? ? ?
B4 Longitudinal Load Moment System (B-19-10) ? ? ?
B5 Longitudinal Load Moment System (B-19-11) ?
B6 Longitudinal Load Moment System (B-19-15) ?
B7 Cab ? ? ? ? ?
B8 Air Conditioning Condensor - Cooling Pack Mounted ? ? ? ? ?
B9 Air Conditioning Condensor - Roof Mounted ? ? ? ?
B10 Cab HV and HVAC Unit ? ? ? ? ?
B11 Air Conditioning Binary Switch ? ? ? ? ?
B12 Heater Valve ? ? ? ? ?
B13 Fuel Tank ? ? ? ? ?
B14 Engine Cover ? ? ? ? ?
B15 Valve Block Covers ? ?
B16 Mudguards ? ? ? ? ?
B17 Chaff Guards ? ?
B18 Deckplate ? ? ? ? ?
B19 Boom 3 Stage ? ? ?
4 Stage ?
B20 Boom 5 Stage ?
B21 LMI Axle Transducer (B-18-05) ? ? ? ?
B22 LMI Axle Transducer (B-18-06) ?
B23 Stabilisers ? ? ? ? ?
1-1-5
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Section 1-1 - General Information Applications Tab
les
Machine models Machine models Machine models Machine models Machine models
Topic Ref Title Variant 540-170 5AF 540-140 5AL 535-125 HiViz 5AN 535-140 HiViz 5AP 540-200 5AX
B24 Longitudinal Load Moment Indicator Unit ? ? ? ?
B25 Longitudinal Load Moment Control Sensors ? ? ? ?
1-1-6
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Section 1-1 - General Information Applications Tab
les
Section C - Electrics
Machine models Machine models Machine models Machine models Machine models
Topic Ref Title Variant 540-170 5AF 540-140 5AL 535-125 HiViz 5AN 535-140 HiViz 5AP 540-200 5AX
C1 Fuses and Relays ? ? ? ? ?
C2 Schematics ? ? ? ? ?
C3 Electrical Harness SYSTEM ? ? ? ? ?
C4 Battery Charging SYSTEM ? ? ? ? ?
C5 Alternator (C-04-01) Engine serial number up to U0193211 ? ? ? ?
C6 Alternator (C-04-02) Engine serial number from U0193212 ? ? ? ? ?
C7 Battery ? ? ? ? ?
1-1-7
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Section 1-1 - General Information Applications Tab
les
Section E - Hydraulics
Machine models Machine models Machine models Machine models Machine models
Topic Ref Title Variant 540-170 5AF 540-140 5AL 535-125 HiViz 5AN 535-140 HiViz 5AP 540-200 5AX
E1 Systems and Schematics ? ? ? ? ?
E2 Parallel Hydraulic SYSTEM ? ? ?
E3 Parallel Servo Hydraulic SYSTEM ?
E4 LSP Electro Servo Hydraulic SYSTEM ?
E5 Hydraulic Interlock SYSTEM ?
E6 Auxiliary Relief Valve (ARV) Operation ? ? ? ? ?
E7 Main Relief Valve (MRV)/ Load Sense Relief valve (LSRV) Operation ? ? ? ? ?
E8 Pressure Compensator Operation ?
E9 Parallel Lift Operation ? ? ? ? ?
E10 Parallel Circuit Operation ? ? ?
E11 Parallel Servo Circuit Operation ?
E12 LSP Electro Servo Circuit Operation ?
E13 Boom Pressure Balance System ? ? ? ? ?
E14 Universal Hydraulic Circuit Faults ? ? ? ?
E15 Parallel Circuit Faults ? ? ?
E16 Parallel Servo Circuit Faults ?
E17 LSP Electro Servo Circuit Faults ?
E18 Parallel System Pressure Tests ? ? ?
E19 Pump Flow Tests - Gearpump ? ? ? ? ?
E20 Parallel Servo System Pressure Tests ?
E21 LSP Electro Servo System Pressure Tests ?
E22 Parallel Control Valve - 6 Section ? ? ?
E23 Parallel Control Valve - 5 Section ?
E24 Parallel Control Valve - 2 Section ?
E25 Electro Servo Control Valve ?
1-1-8
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Section 1-1 - General Information Applications Tab
les
Machine models Machine models Machine models Machine models Machine models
Topic Ref Title Variant 540-170 5AF 540-140 5AL 535-125 HiViz 5AN 535-140 HiViz 5AP 540-200 5AX
E26 Servo Solenoid Diverter Valve Block ?
E27 Gearpump Operation ? ? ? ? ?
E28 Gearpump Removal and Replacement ? ? ? ? ?
E29 Hydraulic Cooling Fan Motor - Fixed Speed ? ? ? ? ?
E30 Servo Control Valves ?
E31 Electro Servo Control Lever ?
E32 Electrical Stabiliser Control Levers ?
E33 Stabiliser Isolation Valve ?
E34 Stabiliser Rams ? ? ? ? ?
E35 Sway Ram ? ? ? ? ?
E36 Displacement Ram ? ? ? ? ?
E37 Tilt Ram ? ? ? ? ?
E38 Lift Rams ? ? ? ? ?
E39 Extension Ram ? ? ? ? ?
E40 Ram Maintenance ? ? ? ? ?
E41 Sway/Fan Selector Valve ? ? ? ? ?
E42 Hydraulic Oil Cooler By Pass SYSTEM 74Kw ?
E43 Hydraulic Oil Cooler By Pass Valve 74Kw ?
E44 Sway Circuit - Bleed Procedure ? ? ? ? ?
E45 Tilt Circuit - Bleed Procedure ? ? ?
E46 3 Stage Boom - Extend Circuit - Bleed Procedure ? ? ?
E47 4 Stage Boom - Extend Circuit - Bleed Procedure ?
1-1-9
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Section 1-1 - General Information Applications Tab
les
Section F - Transmission
Machine models Machine models Machine models Machine models Machine models
Topic Ref Title Variant 540-170 5AF 540-140 5AL 535-125 HiViz 5AN 535-140 HiViz 5AP 540-200 5AX
F1 CONFIGURATION ? ? ? ? ?
F2 Wheels and Tyres ? ? ? ? ?
F3 Front Axles SD80 Pivot sway ? ? ?
SD80 Trunnion sway ? ?
F4 Rear Axles SD80 Pivot sway ? ? ?
SD80 Trunnion sway ? ?
F5 PS750 Mk IV Gearbox SYSTEM ? ? ? ? ?
F6 PS764 Gearbox SYSTEM ? ?
F7 PS750 Mk IV Gearbox Hydraulic Operation ? ? ? ? ?
F8 PS764 Gearbox Hydraulic Operation ? ?
F9 Gearbox Systems Fault Finding ? ? ? ? ?
F10 PS750 Mk IV Gearbox - Hydraulic Testing ? ? ? ? ?
F11 PS760 Gearbox - Hydraulic Testing ? ?
F12 Torque Converter Stall Tests ? ? ? ? ?
F13 Flushing the Transmission Oil ? ? ? ? ?
F14 PS750 Mk IV Gearbox ? ? ? ? ?
F15 PS760 Gearbox ? ?
F16 Torque Converter Operation ? ? ? ? ?
F17 Torque Converter ? ? ? ? ?
F18 Bevel Gearbox ? ? ? ? ?
F19 Transmission Oil Cooler - Air Blast Intercooled engines ? ? ? ? ?
F20 Transmission Oil Cooler - Liquid to Liquid Non intercooled engines ? ? ? ?
F21 Propshafts ? ? ? ? ?
1-1-10
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Section 1-1 - General Information Applications Tab
les
Machine models Machine models Machine models Machine models Machine models
Topic Ref Title Variant 540-170 5AF 540-140 5AL 535-125 HiViz 5AN 535-140 HiViz 5AP 540-200 5AX
F22 Transmission Speed Sensor (S1) ?
F23 Transmission Speed Sensor (S2) ? ? ? ?
F24 Engine Speed Sensor ? ? ? ?
1-1-11
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Section 1-1 - General Information Applications Tab
les
Section G - Brakes
Machine models Machine models Machine models Machine models Machine models
Topic Ref Title Variant 540-170 5AF 540-140 5AL 535-125 HiViz 5AN 535-140 HiViz 5AP 540-200 5AX
G1 Twin Axle Service Brakes SYSTEM ? ? ? ? ?
G2 External Park Brake SYSTEM PS750 gearbox ? ? ? ? ?
G3 Internal Park Brake SYSTEM PS760 gearbox ? ?
G4 Park Brake Calliper PS750 gearbox ? ? ? ? ?
G5 Park Brake Disc PS750 gearbox ? ? ? ? ?
G6 Park Brake Switch ? ? ? ? ?
G7 Servo Exhauster Unit ? ? ? ? ?
G8 Servo Unit - Twin Axle Brakes ? ? ? ? ?
G9 Master Cylinder ? ? ? ? ?
G10 Fluid Reservoir ? ? ? ? ?
1-1-12
9813/0950-5 (1-14-04)
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Section 1-1 - General Information Applications Tab
les
Section H - Steering
Machine models Machine models Machine models Machine models Machine models
Topic Ref Title Variant 540-170 5AF 540-140 5AL 535-125 HiViz 5AN 535-140 HiViz 5AP 540-200 5AX
H1 Steering SYSTEM ? ? ? ? ?
H2 Manual Steer Mode SYSTEM ? ? ? ? ?
H3 Auto Steer Mode SYSTEM ? ? ? ? ?
H4 Hydraulic Steering Unit (H-02-07) ? ? ? ? ?
H5 Priority Valve ? ? ? ? ?
H6 Power Track Rods (H-07-06) ? ?
H7 Steer Rams ? ? ?
H8 Steering Column ? ? ? ? ?
H9 Manual Steer Mode Valve ? ? ? ? ?
H10 Auto Steer Mode Valve ? ? ? ? ?
H11 Steer Proximity Switches ? ? ? ? ?
1-1-13
9813/0950-5 (1-14-04)
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Section 1-1 - General Information Applications Tab
les
Section K - Engine
Machine models Machine models Machine models Machine models Machine models
Topic Ref Title Variant 540-170 5AF 540-140 5AL 535-125 HiViz 5AN 535-140 HiViz 5AP 540-200 5AX
K1 Stop and Start SYSTEM (Mechanical F.I. Engines) ? ? ? ? ?
K2 Stop and Start SYSTEM (Electronic F.I. Engines) ? ?
K3 Cold Start Heater SYSTEM Mechanical F.I. Engines ? ? ? ? ?
K4 Starter Motor ? ? ? ? ?
K5 Cooling Pack - (Non Intercooled) ? ? ?
K6 Cooling Pack - (Intercooled Mechanical F.I. Engines) ? ? ? ? ?
K7 Cooling Pack - (Electronic F.I. Engines) ? ?
K8 Coolant Expansion Tank ? ? ? ? ?
K9 Air Filter Vacuum Switch ? ? ? ? ?
K10 Throttle Pedal and Cable ? ? ? ? ?
K11 Throttle Position Sensor (TPS) (K-07-10) Electronic F.I. engines up to March 2011 ? ?
K12 Throttle Position Sensor (TPS) (K-07-11) Electronic F.I. engines from March 2011 ? ?
K13 Exhaust Silencer ? ? ? ? ?
K14 JCB Dieselmax (Mechanical F.I. Engines) ? ? ? ? ?
K15 JCB Dieselmax (Electronic F.I. Engines) ? ?
1-1-14
9813/0950-5 (1-14-04)
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Section 1-1 - General Information Applications Tab
les Section M - Electronic Data Systems
Machine models Machine models Machine models Machine models Machine models
Topic Ref Title Variant 540-170 5AF 540-140 5AL 535-125 HiViz 5AN 535-140 HiViz 5AP 540-200 5AX
M1 CANbus SYSTEM ? ? ? ? ?
M2 Loadall Monitoring SYSTEM ? ? ? ? ?
M3 Fault Code SYSTEM ? ? ? ? ?
M4 Servicemaster SYSTEM ? ? ? ? ?
M5 Servicemaster Tool Set ? ? ? ? ?
M6 JCB DieselMax (4.4L Tier 3 SE) Diagnostic Tool - User Guide ? ?
M7 JCB DieselMax (4.4L Tier 3 SE) Engine Setup Tool - User Guide ? ?
M8 Cluster (LMS) Setup Tool - User Guide ? ? ? ? ?
M9 Loadall Datalogger Tool - User Guide ? ? ? ? ?
M10 Loadall Machine Diagnostics Tool - User Guide ? ? ? ? ?
M11 Boom Angle Sensor Calibration Tool - User Guide ? ? ? ? ?
M12 Immobiliser Diagnostics Tool - User Guide ? ? ? ? ?
M13 Immobiliser Setup Tool - User Guide ? ? ? ? ?
M14 Pulse Width Modulation Theory ? ? ? ? ?
M15 Electronic Control Unit Theory ? ? ? ? ?
M16 Livelink ECU ? ? ? ? ?
M17 Immobiliser ECU ? ? ? ? ?
M18 Hydraulic Control ECU ?
1-1-15
9813/0950-5 (1-14-04)
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Section 1-2 - General Information Use Introducti
on
This topic contains information about the
structure of the manual and how to use the
manual. K Scope ( 1-2-2) K Personnel ( 1-2-2) K
Applications ( 1-2-2) K Newest Data ( 1-2-2) K
Format ( 1-2-3) K Left and Right Sides ( 1-2-4) K
Hydraulic Schematic Codes ( 1-2-5) K Colour Codes
( 1-2-5)
1-2-1
1-01-03 Issue 01
21
Section 1-2 - General Information Use Scope Scope
Personnel This publication is designed for the
benefit of JCB Distributor Service Engineers who
are receiving, or have received, training by JCB
Technical Training Department. These personnel
should have a sound knowledge of workshop
practice, safety procedures, and general
techniques associated with the maintenance and
repair of hydraulic earthmoving equipment.
Finally, please remember above all else SAFETY
MUST COME FIRST! Applications This manual
contains data relevant to a range of machines.
Make sure you reference the data for the correct
machine. Refer to the Applications topic in this
section. Newest Data From time to time new
machines, systems or devices require the manual
to be re-issued. Make sure you have the newest
issue. Always check the on-line JCB data system
for relevant technical information.
1-2-2
1-01-03 Issue 01
22

• Section 1-2 - General Information
• Use
• Format
• Format
• The manual is compiled in sections, the first
  three are numbered and contain information as
  follows
• General Information - Use the Applications Tables
  at the front of the section to see which topic in
  the manual is applicable to which machine model.
  The section also includes general information
  such as torque settings and service tools.
• Care Safety - includes warnings, cautions and
  general procedures related to aspects of workshop
  procedures contained in the manual.
• Routine Maintenance - includes service schedules
  and recommended lubricants for all the machine.
• The remaining sections are alphabetically coded
  and deal with dismantling, overhaul etc. of
  specific components, for example
• Attachments
• Body and Framework...etc.
• The sections contain topics. Each topic is a self
  contained set of data about a machine SYSTEM or
  Device.

1-2-3
1-01-03 Issue 01
23
Section 1-2 - General Information Use Left and
Right Sides Left and Right Sides 'Left Hand' and
'Right Hand' are as viewed from the rear of the
machine facing forwards.
1-2-4
1-01-03 Issue 01
24
Section 1-2 - General Information Use Hydraulic
Schematic Codes Hydraulic Schematic Codes Colour
Codes The following colour coding, used on
illustrations to denote various conditions of oil
pressure and flow, is standardised throughout JCB
Service Publications.
Full Pressure Pressure generated from operation
of a service. Depending on application this may
be anything between neutral circuit pressure and
LSRV operating pressure.
Red
Pink
Pressure Pressure that is above neutral circuit
pressure but lower than that denoted by Red.
Orange
Pilot Oil pressure used in controlling a device
(Pilot).
Blue
Neural Neutral circuit pressure.
Green
Exhaust
Light Green
Cavitation Oil subjected to a partial vacuum due
to a drop in pressure (cavitation).
Yellow
Lock Up Oil trapped within a chamber or line,
preventing movement of components (lock up).
1-2-5
1-01-03 Issue 01
25
Section 1-3 - General Information Machine
Identification Introduction
This topic contains information about a machine
identification. On the machine and on the machine
devices there are identification data plates. K
Related Topics ( 1-3-2) K Machine Identification
Plate ( 1-3-3) K Typical Product Identification
Number (PIN) ( 1-3-3) K European Tractor Type
Approved Builds ( 1-3-5) K Component
Identification Plates ( 1-3-7) K Typical Engine
Identification Number ( 1-3-7) K Transmission
Identification Numbers ( 1-3-8) K ROPS/FOPS and
OECD Certification Plates ( 1-3-11)
1-3-1
1-02-07 Issue 02
26
Section 1-3 - General Information Machine
Identification Related Topics Related
Topics Table 1. 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
Table 2. Related Topics in Publication 9813/1400
- Personnel Platform Supplement
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. 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. 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.
Sections Section Titles Topic Titles
ALL ALL ALL
1-3-2
1-02-07 Issue 02
27
Section 1-3 - General Information Machine
Identification Machine Identification
Plate Machine Identification Plate The machine
has an identification plate mounted as shown. K
Fig 1. ( 1-3-3). The serial numbers of the
machine and its major units are stamped on the
plate. Note The machine model and build
specification is indicated by the PIN.
GET Gatersleben, Germany
PUN Pune, India
SHA Shanghai, China
JBP JCB Branded Products
2 Machine Model (3 Digits)
The serial number of each major unit is also
stamped on the unit itself. If a major unit is
replaced by a new one, the serial number on the
identification plate will be wrong. Either stamp
the new number of the unit on the identification
plate, or simply stamp out the old number. This
will prevent the wrong unit number being quoted
when replacement parts are ordered.
Standard Builds
5AA 531-70
5AB 535-95
5AC 536-60
5AD 541-70
5AF 540-170
5AG 550-140
5AH 533-105
5AL 540-140
5AM 550-170
5AN 535-125 HiViz
5AP 535-140 HiViz
5AR 536-70
5AS 526-56
5AT 527-58 Low Cab
5AV 527-58 High Cab
5AW 550-80
5AX 540-200
5CD 506-36
5CE 507-42
5CF 509-42
5CG 510-56
5CH 512-56
5CJ 514-56
5MN 535-125 MP(1)
5MP 535-140 MP(1)
The machine and engine serial numbers can help
identify exactly the type of equipment you have.
420811
Fig 1. Typical Product Identification Number
(PIN)
(1) Man Platform Variant - Refer to Service
Manual Supplement - 9813/1400
T011100-C1
European Tractor Type Approved Builds European Tractor Type Approved Builds
5TA 531-70 5TD 535-95
5TB 541-70 5TE 536-70
5TC 536-60 5TW 550-80
5UW 550U80
1 World Manufacturer Identification (3 Digits)
JCB UK
GEO Georgia, US
HAR Haryana, India
SOR Sorocaba, Brazil
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Section 1-3 - General Information Machine
Identification Machine Identification Plate
3 Engine Type (1 Digit)
JCB Dieselmax (Tier 3)
P Turbocharged and intercooled, 85kW (114Hp)
R Turbocharged and intercooled, 97kW (130Hp)
S Turbocharged, 74.2kW (100Hp)
T Turbocharged, 63kW (85Hp)
V Turbocharged and intercooled, 108 kW (145Hp)
JCB Ecomax (Tier 4)
W Turbocharged and intercooled,55kW (74Hp)
X Turbocharged and intercooled, 81kW (109Hp)
Y Turbocharged and intercooled,93kW (125Hp)
Z Turbocharged and intercooled, 108kW (145Hp)
4 Gearbox Model (1 Digit) Table 3.
Powershift/SyncroShuttle Transmission
E 3 Speed (PS750) J 6 Speed (PS760)
F 3 Speed (PS760) M 4 Speed (SS700)
G 4 Speed (PS750) N 4 Speed (PS750 - 40 KPH)
H 4 Speed (PS760)
Table 4. HydroStatic Transmission
P 20 Kph
R 25 Kph
S 34 kph
T 40 Kph

• Randomly generated check letter (1 Digit)
• Machine Serial Number (8 Digits)
• Each machine has a unique serial number.

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Section 1-3 - General Information Machine
Identification Machine Identification Plate
European Tractor Type Approved Builds
332-d6975-4
Fig 2. Table 5. Machines with SA/SB/SC/SD/SE/SF
Engines
Item 531-70 535-95 536-60 536-70 541-70 550-80
Item kg (lb) kg (lb) kg (lb) kg (lb) kg (lb) kg (lb)
A Total Permissible Mass 8200 8500 8200 8350 8400 TBA
(18073) (18734) (18073) (18403) (18513)
B Permissible Front Axle Load(1) From To 2400 (5291) 2400 (5291) 2400 (5291) 2400 (5291) 2400 (5291) TBA
B Permissible Front Axle Load(1) From To 6600 7300 6200 7000 7000 TBA
B Permissible Front Axle Load(1) From To (14550) (16093) (13668) (15432) (15432)
C Permissible Rear Axle Load(1) From To 2400 (5291) 2400 (5291) 2400 (5291) 2400 (5291) 2400 (5291) TBA
C Permissible Rear Axle Load(1) From To 6600 7300 6200 7000 7000 TBA
C Permissible Rear Axle Load(1) From To (14550) (16093) (13668) (15432) (15432)
D Unbraked Towable Mass 750 (1653) 750 (1653) 750 (1653) 750 (1653) 750 (1653) TBA
E Independently Braked 6000 6000 6000 6000 6000 TBA
Towable Mass (13227) (13227) (13227) (13227) (13227)
F Inertia Braked Towable Mass 3500 (7716) 3500 (7716) 3500 (7716) 3500 (7716) 3500 (7716) TBA
G Towable Mass Fitted with a Proportional Assisted Braking System 10 Tonne Hydraulic Hitch Rockinger/Tractor Hitch 10000 10000 10000 10000 10000 TBA
G Towable Mass Fitted with a Proportional Assisted Braking System 10 Tonne Hydraulic Hitch Rockinger/Tractor Hitch (22040) (22040) (22040) (22040) (22040)
G Towable Mass Fitted with a Proportional Assisted Braking System 10 Tonne Hydraulic Hitch Rockinger/Tractor Hitch 17800 17100 17800 17250 17200 TBA
G Towable Mass Fitted with a Proportional Assisted Braking System 10 Tonne Hydraulic Hitch Rockinger/Tractor Hitch (39231) (37699) (39231) (38019) (37909)
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Section 1-3 - General Information Machine
Identification Machine Identification Plate
(1) Dependent on tyres option. Table 6.
Machines with SH/SL/DH Engines
Item Item 5TA 5TB 5TC 5TD 5TE 5UW
Item Item 531-70 535-95 536-60 536-70 541-70 550-80
Item Item kg (lb) kg (lb) kg (lb) kg (lb) kg (lb) kg (lb)
A Total Permissible Mass 9000 (19836) 10250 (22591) 9000 (19836) 10250 (22591) 10250 (22591) 12005 (26459)
B Permissible Front Axle Load(1) From To 2400 (5291) 2400 (5291) 2400 (5291) 2400 (5291) 2400 (5291) 2400 (5291)
B Permissible Front Axle Load(1) From To 6580 7500 6400 7500 7500 9000
B Permissible Front Axle Load(1) From To (14502) (16530) (14105) (16530) (16530) (19836)
C Permissible Rear Axle Load(1) From To 2400 (5291) 2400 (5291) 2400 (5291) 2400 (5291) 2400 (5291) 2400 (5291)
C Permissible Rear Axle Load(1) From To 6580 7500 6400 7500 7500 9000
C Permissible Rear Axle Load(1) From To (14502) (16530) (14105) (16530) (16530) (19836)
D Unbraked Towable Mass 750 (1653) 750 (1653) 750 (1653) 750 (1653) 750 (1653) 750 (1653)
E Independently Braked 6000 6000 6000 6000 6000 6000
Towable Mass (13227) (13227) (13227) (13227) (13227) (13227)
F Inertia Braked Towable Mass 3500 (7716) 3500 (7716) 3500 (7716) 3500 (7716) 3500 (7716) 3500 (7716)
G Towable Mass Fitted with a Proportional Assisted Braking System 10 Tonne Hydraulic Hitch Rockinger/Tractor Hitch 10000 9800 10000 9360 9800 7660
G Towable Mass Fitted with a Proportional Assisted Braking System 10 Tonne Hydraulic Hitch Rockinger/Tractor Hitch (22040) (21819) (22040) (20629) (21819) (16882)
G Towable Mass Fitted with a Proportional Assisted Braking System 10 Tonne Hydraulic Hitch Rockinger/Tractor Hitch 17800 16700 17800 15300 16700 11200
G Towable Mass Fitted with a Proportional Assisted Braking System 10 Tonne Hydraulic Hitch Rockinger/Tractor Hitch (39231) (37027) (39231) (33721) (37027) (24684)
(1) Dependent on tyres option.
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Section 1-3 - General Information Machine
Identification Component Identification
Plates Component Identification Plates Typical
Engine Identification Number Engine data labels A
are located on the cylinder block at position C
and rocker cover D (if fitted). The data label
contains important engine information and
includes the engine identification number E. A
typical engine identification number is explained
as follows
SD 320/40001 U 00001 04
1 2 3 4 5
1 Engine Type SD turbocharged SE
electronic common rail fuel injection,
turbocharged and intercooled.
C007280-C5.jpg
SF turbocharged and intercooled.
Fig 3. Engine

• SH 4.4 litre electronic common rail fuel
  injection with Variable Geometry Turbocharger
  (81kW, 93kW)
• SL 4.4 litre electronic common rail fuel
  injection with Fixed Geometry Turbocharger (55kW)
• DH 4.8 litre electronic common rail fuel
  injection with Variable Geometry Turbocharger
  (108kW)
• Engine part number
• Country of manufacture U United Kingdom
• Engine Serial Number
• Year of Manufacture
• The last three parts of the engine identification
  number are stamped on the cylinder block at
  position B.
• U 00001 04

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33
Section 1-3 - General Information Machine
Identification
Component Identification Plates Axles (550-80
Machines)
Transmission Identification Numbers
The axles have a serial number stamped on a data
plate label A as shown.
Axles (Excluding 550-80 Machines)
The transmission components have a serial number
stamped on a data plate A as shown.
To view to the front axle data plate remove the
cover B and the plate will be visible through
hole C.
B
C
A
A710840-C1
Fig 4. Front Axle
C107510
Fig 6. Front Axle
A710830-C1
Fig 5. Rear Axle
A
C107520
Fig 7. Rear Axle
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Section 1-3 - General Information Machine
Identification Component Identification Plates
Gearbox The transmission components have a serial
number stamped on a data plate A as shown.
C007640
Fig 10. SS700 Transmission
263370-C1
Fig 8. PS750 Powershift Transmission
A401030-C2
Fig 9. PS760 Powershift Transmission
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1-02-07 Issue 02
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