JCB Loadall Service Manual – Rough Terrain Variable Reach Truck (9813/8750)

JCB 533-105, 535-V125, 535-V140, 540-140, 540-170, 540-200, 540-V140, 540-V180, 550-140, 550-170 Loadall (Rough Terrain Variable Reach Truck) Service Manual (9813/8750 - Issue 1 - 07/2017)

This comprehensive service manual provides complete technical coverage, repair data, and maintenance instructions for JCB Loadall rough terrain telescopic handlers. Designed for professional workshops, it delivers detailed servicing procedures, component-level diagnostics, and step-by-step disassembly/reassembly guidelines across mechanical, hydraulic, and electrical systems.

Model Covers:

This manual provides detailed servicing information for the following models:

JCB 533-105, 535-V125, 535-V140, 540-140, 540-170, 540-200, 540-V140, 540-V180, 550-140, 550-170.

Note: Each model is covered with full technical data, repair procedures, and system specifications. Model variants (V-series) include enhanced visibility and performance configurations; service instructions differ where applicable.

File Format: PDF

Size: 352.99 MB

No. of pages: 2868

Language: English

Delivery Method: Instant Download - Access your file immediately after purchase.

📑 Included Sections:

01 - Machine

• Machine identification and serial number location
• Technical data and performance specifications
• Component layout and system architecture
• Machine lifting points, towing data, and transport configurations

03 - Attachments, Couplings and Load Handling

• Attachment mounting procedures and quick hitch operations
• Hydraulic couplings, auxiliary circuits, and flow requirements
• Load handling systems calibration and capacity charts
• Fork carriage alignment and boom extension mechanisms

06 - Body and Framework

• Chassis structure inspection and service guidelines
• Cab removal, installation, and safety frame maintenance
• Panel replacement procedures and corrosion protection
• Structural torque tightening sequences and welding specifications

09 - Operator Station

• Cab layout, control console functions, and instrumentation
• Operator seat adjustment and restraint systems
• Display unit diagnostics and switchgear servicing
• Canopy service, door removal, and wiper mechanism maintenance

12 - Heating, Ventilating and Air-Conditioning (HVAC)

• HVAC circuit schematics and air distribution diagrams
• Refrigerant type, pressure parameters, and charging procedures
• Compressor servicing, evaporator and condenser maintenance
• Electronic control system fault tracing and temperature regulation

15 - Engine

• Engine removal and installation processes
• Complete technical specifications and torque values
• Fuel injection system calibration and timing procedures
• Emission control components and turbocharger servicing

18 - Fuel and Exhaust System

• Fuel tank, lines, and filtration servicing
• High-pressure common-rail system diagnostics
• Diesel oxidation catalyst and DPF regeneration procedures
• Exhaust manifold inspection and heat shield installation

21 - Cooling System

• Cooling circuit flow diagrams and radiator servicing
• Coolant specifications, refill, and bleeding procedures
• Water pump, thermostat, and cooling fan maintenance
• Temperature sensor diagnostics and fault code interpretation

24 - Brake System

• Hydraulic braking schematics and component layout
• Service brake testing, bleeding, and pad replacement
• Parking brake mechanism adjustment and calibration
• Pressure switch diagnostics and fault isolation

25 - Steering System

• Hydrostatic steering circuit analysis
• Steering column disassembly, steering ram servicing
• Steering angle sensors and alignment procedures
• Orbitrol valve troubleshooting and replacement

27 - Driveline

• Transmission types, operation, and oil specifications
• Axle servicing, differential lock and planetary hub repair
• Propshaft balancing and joint inspection
• Torque converter testing and gearbox control diagnostics

30 - Hydraulic System

• Hydraulic schematics and functional flow analysis
• Main pump regulation, relief valve settings, and test procedures
• Joystick and servo control diagnostics
• Boom lift, crowd, and extension cylinder servicing
• Load-sensing system calibration and pressure testing

33 - Electrical System

• Complete wiring diagrams and harness routing
• ECU functions, CAN-bus communication and sensor network
• Lighting, instrumentation, and alarm system servicing
• Battery, starter motor, and alternator testing
• Diagnostic tool connection and fault code interpretation

72 - Fasteners and Fixings

• Torque specifications for zinc-plated and Dacromet fasteners
• Thread classification, locking methods, and tightening sequences
• Recommended lubricants and anti-seize compounds

75 - Consumable Products

• Approved lubricants, coolants, and hydraulic fluids
• Sealants, adhesives, and retaining compounds
• Periodic maintenance material references

78 - After Sales

• Warranty guidelines and claim submission procedures
• Technical service bulletins and software updates
• Parts ordering information and contact details

This JCB Loadall Service Manual is an essential resource for service engineers and maintenance professionals, delivering in-depth system knowledge and factory-approved repair data for rough terrain telescopic handlers in construction, agriculture, and industrial applications.