JCB Loadall 540-170, 550-140, 535-125 Hi Viz and Related Models Service Manual (9803/3750)

JCB Loadall 540-170, 550-140, 535-125 Hi Viz and Related Models Service Manual (9803/3750-07)

This official JCB service manual offers in-depth maintenance, diagnostics, and servicing data for Loadalls in the 5A model group. Covering models like 540-170, 550-140, 535-125 Hi Viz, and others, it includes complete routines for hydraulics, brakes, engine systems, HVAC, electronic controls, and transmission units. Designed for qualified technicians, this manual is a comprehensive tool for Loadall service procedures.

Model Covers:

JCB Side Engine Loadalls Service Manual:

JCB Loadall machines in the 5A group:

- 540-170 (F)

- 550-140 (G)

- 540-140 (L)

- 550-170 (M)

- 535-125 Hi Viz (N)

- 535-140 Hi Viz (P)

(Various market-specific and updated variants included)

File Format: PDF

Size: 104.49 MB

No. of pages: 1736

Language: English

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

📑 Included Sections:

General and Safety Information

• Machine identification, torque settings, fuel and lubricant specs
• Battery safety, hydraulic contamination, boom safety procedures

Routine Maintenance

• Service schedules by engine type, filter and fluid replacements
• Cooling, brakes, tyres, electricals, greasing and inspections

Body and Cab Framework

• Cab air conditioning, heater units, LMI systems and condenser servicing
• Fuel tank, boom wear pads, pivot shims, cab structure maintenance

Electrical and ECU Systems

• Fuse/relay layout, electrical schematics and harness diagnostics
• Alternator, starter motor, battery system testing and repair

Transmission Systems

• Coverage for PS750, PS760, PS764, Mk IV gearboxes and torque converters
• Drive paths, flushing, solenoid diagnostics, sensor testing

Hydraulic and Brake Systems

• Hydraulic schematics, flow diagnostics, brake light switch adjustment
• External/internal park brake testing, axle breathers, bleeding procedures

Engine, CANbus, and Monitoring Systems

• Dieselmax engines (mechanical and electronic), cold start heaters
• Servicemaster diagnostics, Loadall Monitoring System and ECU fault codes

This JCB Side Engine Loadalls Service Manual is an advanced maintenance companion, supporting fault diagnosis, component replacement, and detailed service routines for high-performance JCB Loadall machines.

Note: 

General service manual for a wide range of 5A group machines. If your machine is newer or EN15000-compliant, consider:

• 9813/0950-3 – For EN15000-compliant versions.
• 9813/1450-2 – Advanced EN15000 version.
• 9813/0900-2 – For LLMC-equipped models.
• 9803/3760-07 – For other 5T machines.
• 9803/3730-10 – Dieselmax with analogue interface.