JCB 5A Series Loadall Tier 4i Service Manual (9813/0950-3)

JCB 5A Series Loadall Tier 4i Service Manual (9813/0950-3)

This comprehensive workshop manual provides detailed technical service data, diagnostic procedures, and system analysis for JCB 5A Series Loadall Tier 4i machines. Developed for professional technicians, it includes component-level repair instructions, calibration sequences, and integrated hydraulic and electrical schematics for efficient troubleshooting and servicing.

Model Covers:

This service manual applies to the following JCB Loadall models:

540-170 Loadall

550-140 Loadall

540-140 Loadall

550-170 Loadall

535-125 Hi Viz Loadall

535-140 Hi Viz Loadall

Note: The manual includes machine-specific schematics, electronic calibration parameters, and component maintenance data for the full range of Tier 4i Loadall models. Individual system sections are structured for clear fault isolation, ensuring precise and safe service operations.

File Format: PDF

Size: 54.35 MB

No. of pages: 1662

Language: English

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

📑 Included Sections:

Section 1 – General Information

• Application data and operational scope for Tier 4i Loadall units
• Machine identification numbers and component traceability guide
• Complete torque settings, stall speed charts, and service tool specifications
• Fuel specifications, service consumables, and compatibility data

Section 2 – Care and Safety

• General safety procedures and workshop best practices
• Operator safety signage and risk control systems
• Hydraulic and electrical isolation procedures for secure maintenance

Section 3 – Routine Maintenance

• Planned maintenance intervals and inspection routines
• Lubrication charts, fluid capacities, and recommended service fluids
• Preventative maintenance workflows for high-performance operation

Section B – Body and Framework

• Cab structure, panels, and HVAC systems (heating, ventilation, and air conditioning)
• Fork carriage, boom structures (3-stage / 4-stage), and stabiliser assemblies
• Longitudinal Load Moment Indicators (LMI) – sensors, control units, and calibration
• Fuel tank service, chassis maintenance, and corrosion protection

Section C – Electrics

• Complete wiring schematics with relay and fuse box identification
• Battery charging circuits, alternator systems, and speed sensor configuration
• Electrical harness routing diagrams and ECU interconnects
• Power supply troubleshooting and diagnostic pinout references

Section E – Hydraulics

• Parallel and servo hydraulic systems – theory, schematics, and maintenance
• Control valves (2/5/6-section) and solenoid diverter valve operation
• Stabilisers, isolation circuits, and sway/fan selector valve testing
• Main pump configurations (110/170 l/min) and calibration methods
• Hydraulic rams – lift, tilt, extension, sway, and stabiliser cylinder servicing

Section F – Transmission

• Axle configurations: SD80 Pivot / Trunnion Sway systems
• Gearbox variants: PS750 Mk IV, PS760, PS764 – assembly and service data
• Bevel gearbox and torque converter calibration procedures
• Transmission oil coolers (air-blast and liquid-to-liquid) – maintenance and testing
• Propshaft installation, alignment, and speed sensor integration

Section G – Brakes

• Twin axle service brake systems (S1 & S2) layout and fluid routing
• Park brake (external/internal) caliper, disc, and switch service instructions
• Master cylinder operation, servo unit diagnostics, and fluid reservoir servicing
• Brake pressure testing and exhauster system fault resolution

Section H – Steering

• Hydraulic steering circuits and auto/manual steer mode configuration
• Priority valve, power track rods, and steering ram calibration
• Steer mode valves and steering column component service

Section K – Engine

• JCB Dieselmax engine (mechanical and electronic fuel injection)
• Stop/start control systems and cold start heater diagnostics
• Cooling system configuration – intercooled and non-intercooled packs
• Throttle sensors (TPS S1/S2), exhaust silencer, and air filtration systems
• Starter motor testing, coolant expansion tank servicing, and airflow control

Section M – Electronic Data Systems

• CANbus network design and Loadall monitoring architecture
• Electronic Control Unit (ECU) programming and data flow theory
• Servicemaster software tools and diagnostic fault code systems
• Pulse Width Modulation (PWM) control systems and calibration principles

This JCB 5A Series Loadall Tier 4i Service Manual provides complete technical reference for service engineers handling mechanical, hydraulic, and electronic systems on modern Loadall telehandlers, ensuring reliability and compliance with JCB Tier 4i performance standards.