PDF Service Repair Manual JCB 1253 1202 1553 1554 Liftall - 3 MB
This service repair manual covers the JCB Liftall models 1253, 1202, 1553, and 1554.
It is a comprehensive resource for maintenance and repair, providing detailed instructions and diagrams.
Technicians will find this manual essential for troubleshooting problems and performing complex repairs according to manufacturer specifications.
Keep your JCB Liftall equipment in top condition with this guide.
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--- Page 1 ---
Service Manual
Liftall 1253/1202/1553/1554
Service Manual - Liftall 1253/1202/1553/1554
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Routine Maintenance
Section B - Body and Framework
Section C - Electrics
Section D - Controls
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section K - Engine
Publication No.
9813/1650
World Class
Customer Support
Copyright Β© 2007 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.
Issued by JCB India Limited, 23/7, Mathura Road, Ballabgarh - 121004, Haryana (India), Tel 0129 4299000 Fax 0129 2309051
--- Page 3 ---
Section 1 - General Information
General Information
Torque
Torque
Torque Settings Values are for dry threads and may be within three percent
of the figures stated. For lubricated thread the values
Use only where no torque setting is specified in the test. should be reduced by one third.
Table 1.
Bolt Size Hexagon (A/F) Torque Setting
In (mm) In Nm Kgfm lbf ft
1/4 (6.3) 7/16 14 1.4 10
5/18 (7.9) 1/2 28 2.8 20
3/8 (9.5) 9/16 49 5.0 36
7/16 (11.1) 5/8 78 8.0 58
1/2 (12.7) 3/4 117 12.0 87
9/10 (14.3) 13/16 170 17.3 125
5/8 (15.9) 15/16 238 24.3 175
3/4 (19.0) 11/8 407 41.5 300
7/8 (22.2) 15/16 650 66.3 480
1 (25.4) 11/2 970 99.0 715
11/4 (31.7) 17/8 1940 198.0 1430
11/2 (38.1) 21/4 3390 345.0 2500
Table 2. Metric Grade 8.8 Bolts
Bolt Size Hexagon (A/F) Torque Setting
M5 (5) 8 7 0.7 5
M6 (8) 10 12 1.2 9
M8 (8) 13 28 3.0 21
M10 (10) 17 56 5.7 42
M12 (12) 19 98 10 72
M16 (16) 24 244 25 180
M20 (20) 30 476 48 352
M24 (24) 36 822 84 607
M30 (30) 46 1633 166 1205
M36 (36) 55 2854 291 2105
Note: All bolts used on JCB machines are high tensile and
must not be replaced by bolts of a lesser tensile
specification.
1-7 9813/1650 1-7
--- Page 4 ---
Section 1 - General Information
General Information
Tool Detail Reference
Fig 33. 892/00849 Braided Cutting Wire Fig 36. 992/12400 Static Oven 240V
Consumable heavy duty cut-out wire used with the glass Required to pre-heat adhesive prior to use. No plug
extraction tool. K Fig 30. ( T 1-16). Approx 25 m length. supplied.
Note: 110V models available upon request - contact JCB
Technical Service.
Fig 34. 926/15500 Rubber Spacer Blocks
Used to provide the correct set clearance between glass
edge and cab frame. Unit quantity = 500 off.
Fig 37. 992/12800 Cut-Out Knife
Used to remove broken glass.
Fig 35. 992/12300 Mobile Oven 12V
1 cartridge capacity. Required to pre-heat adhesive prior
to use. It is fitted with a male plug (703/23201) which fits Fig 38. 992/12801 'L' Blades
into a female socket (715/04300).
25 mm (1 in.) cut. Replacement blades for cut-out knife.
K Fig 37. ( T 1-17). Unit quantity = 5 off.
1-17 9813/1650 1-17
--- Page 5 ---
Section 1 - General Information
General Information
Tool Detail Reference
A408900
Fig 66. Socket Box Wrench
Note: For disassembly and assembly of slew motor gearbox. This tool can not be ordered from JCB.
1-27 9813/1650 1-27
--- Page 6 ---
Section 2 - Care and Safety
Contents
Contents Page No.
Safety Notices
Important Information ...............................................................................1 - 2
Safety Warnings ..................................................................................1 - 2
2-i 2-i
--- Page 7 ---
Section 3 - Routine Maintenance
Contents
Contents Page No.
Hydraulic System ..................................................................................... 3-48
Introduction ..........................................................................................3-48
Checking the Fluid Level .....................................................................3-49
Hydraulic Tank Cap/Breather ..............................................................3-50
Changing the Return Line Filter Element ............................................3-50
Changing the Suction Strainer .............................................................3-51
Transmission ........................................................................................... 3-52
Gearbox ...............................................................................................3-52
Wheels and Tyres .................................................................................... 3-54
Water Ballast .......................................................................................3-54
Tyre Inflation ........................................................................................3-55
Wheel Nuts ..........................................................................................3-56
3-ii 3-ii
--- Page 8 ---
Section 3 - Routine Maintenance
Routine Maintenance
Service Schedule
(1) If working conditions are extremely dusty and quality of fuel/ lubricant is poor, please change filters earlier than
specified period.
(2) Bolts loosening to be checked and worn out lock nuts to be replaced.
(3) Front brake shoe carrier mounting nuts to be checked for loosening at regular intervals and are to be replaced only.
Discard old worn out lock nuts.
(4) Wire rope care and lubrication is required at regular intervals for trouble free operations. With time and usage of the
machine, the extension and retraction wire rope gets loose and it can affect the boom operations. Adjust the wire rope
tension properly.
3-10 9813/1650 3-10
--- Page 9 ---
Section 3 - Routine Maintenance
Routine Maintenance
Checking For Damage
Shackle Inspection
F
G
H
J
D030910
Fig 5.
Check shackle for excessive wear. K Fig 5. ( T 3-20).
K
D030900
Fig 4.
F Check for wear
G Check for wear
H Check for wear and straightness
J Check to insure the pin is seated
K Check Shackle for opening
D030920
Fig 6.
Look for improper replacement of pins. K Fig 6. ( T 3-20).
Do not replace a pin with a bolt or any other fastener.
K Fig 6. ( T 3-20).
3-20 9813/1650 3-20
--- Page 10 ---
Section 3 - Routine Maintenance
Routine Maintenance
Electrical System
A
B
A089660-11
Fig 23.
4 Refit battery.
5 Close and lock the access panels.
3-30 9813/1650 3-30
--- Page 11 ---
Section 3 - Routine Maintenance
Routine Maintenance
Engine
Changing the Filter Elements 4 Release the clamps and remove outer end cap B.
Note: Do not try to wash or clean the elements, they must 5 Remove the outer element G.
be replaced.
Pull out the element G. Take care not to tap or knock
Note: In dusty conditions, replace the outer-element more the element as you remove it.
frequently than the service schedule recommendation.
Install a new inner-element every other time the outer 6 Clean the canister
element is replaced. As a reminder, put a mark on the
inner-element with a felt tip pen when you only replace the Clean the inside of the canister C and dust valve D
outer-element. K Fig 36. ( T 3-40).
1 Stop the engine. Refer to K Prepare the Machine 7 Fit a new element.
for Maintenance ( T 3-13).
Insert the new element into the canister. Make sure it
2 Clean the pre-cleaner. K Cleaning the Pre- seats correctly. Check all hoses for condition and
Cleaner ( T 3-38). tightness.
3 Open the side cover to access the air cleaner.
E G B
C
D
D023849
Fig 36.
3-40 9813/1650 3-40
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Section 3 - Routine Maintenance
Routine Maintenance
Hydraulic System
Hydraulic Tank Cap/Breather Changing the Return Line Filter Element
The hydraulic tank cap/breather (and filter) forms an
integral part of the hydraulic tank cap B. Replace the cap
!MWARNING
(and breather filter) with a new one at the recommended Fluid Under Pressure
interval. K Fig 45. ( T 3-50). Fine jets of fluid at high pressure can penetrate the
skin. Keep face and hands well clear of fluid under
pressure and wear protective glasses. Hold a piece of
B cardboard close to suspected leaks and then inspect
the cardboard for signs of fluid. If fluid penetrates your
skin, get medical help immediately.
INT-3-1-10_2
1 Refer to K Prepare the Machine for
D Maintenance ( T 3-13)
2 Remove the hydraulic tank filler cap.
3 Remove the nuts C, cover plate D and seal E.
E 4 Remove the complete element assembly F and the
seal.
5 Remove the nut and spring K.
Fig 45.
6 Remove the filter element L from the spindle and
The cap incorporates a side mounted barrel lock that is clean magnets J.
operated by the ignition/door key. It is important to note
that the seal must be in good condition and correctly 7 Install the new element L and the new seals G and H.
installed in the cap.
8 Put the cover plate D in position and tighten the nut C.
Fit the Cap
9 Add the recommended hydraulic fluid to the correct
Insert the key and turn anticlockwise D, screw the cap on level.
until resistance is felt then turn a further quarter of a turn,
turn the key clockwise E and remove the key. With the key 10 Attach the filler cap and make sure its tight.
removed the cap will rotate and can not be undone.
Remove the Cap J
C
Insert the key and turn anticlockwise D, unscrew the cap G
K Fig 45. ( T 3-50).
H
Note: The key must be inserted in the cap when removing
D
L
and fitting. E F
K
Fig 46.
3-50 9813/1650 3-50
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Section B - Body and Framework
Contents
Contents Page No.
B-ii B-ii
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Section B - Body and Framework
Body and Framework
Boom Assembly Overview
Retracting the 4th Stage Boom inside the Boom base, it will also pull the 4th stage boom inside the
Assembly boom assembly.
Refer to following instructions carefully before trying to Note: Do not operate the winch at high speed; operate it at
retract the 4th stage boom inside the boom assembly; Use idle rpm (750-800) only.
a suitable platform/ramp to access and carry out the 4th
stage boom retraction.
1 Remove the securing pin H between inner boom G
and 4th stage boom E rear side. K Fig 13. ( T B-9)
D068540-14
Fig 16.
D068540-12
Fig 14. 4 Stop the winch lever operation when 4th stage boom
E is completely inside the inner boom G. Re-secure
2 Now lift up the boom assembly slightly by 5ΒΊ-10ΒΊ by pin H between inner boom G and 4th stage boom E
operating the lift ram lever. This is required to ensure front side.
smooth retraction of 4th stage boom later.
D068540-13
Fig 15.
D068540-15
3 Now operate the winch lever in reverse such that Fig 17.
snatch block L is fully butting the 4th stage boom E
nose. After this, keep operating the winch lever in 5 The machine with 4th stage boom in is ready for use
reverse i.e. pulling the snatch block secured at boom now.
B-10 9813/1650 B-10
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Section B - Body and Framework
Body and Framework
Boom Assembly Service Procedure (Liftall 1253)
Standard Wear Pads Assembly β maintained for the trouble free and smooth extension/
retraction operation of the boom assembly.
Liftall 1253
These wear pads are consumable items with a limited life
Different sets of wear pads are provided in boom assembly
subjected to wear and tear. Change period depends upon
to ensure running clearance among boom members in
the usage, application and routine maintenance of the
assembled condition. These clearances need to be
boom assembly.
B1
A1 B2
A3
A B3
A2
A4 B
A6
A5
B4
C B6 B5
D068540-25
Fig 27. Standard Wear Pad Assemblies in Liftall 1253
A1, A2 and A3 Between outer boom A and middle
boom B front side.
B1, B2, and B3 Between outer boom A and middle
boom B rear side.
A4, A5, and A6 Between middle boom B and inner
boom C front side.
B4, B5, and B6 Between middle boom B and inner
boom C rear side.
B-20 9813/1650 B-20
--- Page 16 ---
Section B - Body and Framework
Body and Framework
Boom Assembly Service Procedure (Liftall 1202)
A1 B1
A
A3
C
B2
B3
A2
D068540-71
Fig 34. Standard Wear Pads Assembly Arrangement β Liftall 1202
B-30 9813/1650 B-30
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Section B - Body and Framework
Body and Framework
Boom Assembly Service Procedure (Liftall 1554)
Note: Ensure that the pulleys, guards are not damaged
2 and fitted properly. Always replace if damaged, bent or
broken otherwise it can lead to winch rope jumping out
15 pulley and getting damaged.
8 14
10 14 5 11
1
9
8
12
14 8
14
15 2 5
12
7
7
7
11 2 6
5 9
4 7
11
11 8
13 5
3
6
4
13
D068540-36
2
Fig 45. Intermediate Boom Pulley Installation
Item Description Qty. 10
1 Inner boom pin 1 4
2 Guide rope 2 D068540-37
Fig 46. Intermediate Wear Pad Assembly
3 Bolt M24 x 50 2
Item Description Qty.
4 Tapped boss 4
1 Adjuster assembly
5 Clamp nut 2
2 Setscrew M19 x 20mm
6 Middle boom pulley 4
3 Wear pad spacer 12mm
7 Ball bearing deep groove 4
4 Wear pad
8 Pulley assembly 1
5 Wear pad
9 Lock nut 1
6 Wear pad 150 x 75 x 14.25mm
10 Loctite 262 1
7 Wear pad 45 x 150 x19mm
11 Grub screw M10 x 50 long 4
8 Plain washer
12 Bolt M10 x 80 1
9 Plain washer
13 Bolt 2
10 Wear pad assemble 2mm
14 Pulley spacer 4
11 Screw M12 x 35mm
15 Pulley shim 2
12 Setscrew
B-40 9813/1650 B-40
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Section B - Body and Framework
Body and Framework
Boom Assembly Service Procedure (Liftall 1554)
A1 B1 2 mm
A4
B4
2 mm
2.5 mm
3 mm
A B7
B5
A8 A3
B
C
A6
D
B8
B2 A7
2.5 mm B6
2 mm A2 3 mm
A5
B3
4 mm
2 mm
Fig 59.
To Adjust the Clearance from Top and Bottom Sides of increased, then shimming can be done by removing the
the Boom Members pad and adding the shim below wear pads A1 and A4. This
will ensure that boom assembly clearance is restored to its
Inspect the wear pads A1, A2, A4, A5, and A7. If pads original condition. Use shims properly while fixing the
have worn-out and clearance among boom members have clearance. However If pads have worn-out, and pad insert/
B-50 9813/1650 B-50
--- Page 19 ---
Section B - Body and Framework
Body and Framework