JCB 515-40 Telescopic Handler Repair Service Manual

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(S/N: 1627500 – 1628499)

This service manual PDF download for the 515-40 JCB Telescopic Handler has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

JCB Telescopic Handler 515-40 – from S/N: 1627500 – 1628499

TABLE OF CONTENTS :

Section 1 – General Information
Section 2 – Care and Safety
Section 3 – Maintenance
Section A – Attachments
Section B – Body and Framework
Section C – Electrics
Section D – Controls
Section E – Hydraulics
Section F – Transmissions
Section G – Brakes
Section H – Steering
Section K – Engine

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9803/9900-2
Total Pages : 602

This complete JCB Telescopic Handler | Loadall | Telescopic Loader service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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9803-9900

Section 1 – General Information
General Information
Introduction
About This Publication
Machine Model and Serial Number
Using the Service Manual
Section Numbering
Units of Measurement
Left Side, Right Side
Cross References
Identifying Your Machine
Machine Identification Plate
Component Identification Plates
Standard Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
Introduction
Bolts and Screws
Hydraulic Connections
‘O’ Ring Face Seal System
‘Torque Stop’ Hose System
Service Tools
Numerical List
Tool Detail Reference
Section B – Body and Framework
Section C- Electrics
Section E – Hydraulics
Section F – Transmission
Section H – Steering
Section K – Engine
Service Consumables
Sealing and Retaining Compounds
Terms and Definitions
Colour Coding
Hydraulic Schematic Colour Codes

Section 2 – Care and Safety
Care and Safety
Safety Notices
Important Information
The Operator Manual
Safety Warnings
Safety Check List
Safety – Yours and Others
General Safety
Operating Safety
Maintenance Safety
Safety Labels
Introduction
Safety Label Identification
Part Numbers and Descriptions

Section 3 – Maintenance
Maintenance
Routine Maintenance
Service Requirements
Introduction
Owner/Operator Support
Service/Maintenance Agreements
Fit for Purpose Tests for Lifting Equipment
Obtaining Replacement Parts
Health and Safety
Lubricants
Battery
Service Schedules
Introduction
How to Use the Service Schedules
Calendar Equivalents
Pre-start Cold Checks, Service Points and Fluid Levels
Functional Test and Final Inspection
Fluids, Lubricants and Capacities
Specifications
Coolant Mixtures
Prepare the Machine for Maintenance
Introduction
How to Make the Machine Safe (Boom Lowered)
How to Make the Machine Safe (Boom Lifted)
Using a Jack to Lift the Machine
Cleaning the Machine
Introduction
Preparing the Machine for Cleaning
Cleaning the Machine
Checking For Damage
Check the Machine Body and Structure
Check the Tyres
Check the Seat and Seat Belt
Check the Hydraulic Hoses and Fittings
Checking the ROPS/FOPS
Greasing
Introduction
Preparing the Machine for Greasing
Greasing Sequence
Grease Points
Oiling
Access Panels
Engine Cover
Engine Side Panel
Rear Engine Guard
Underfloor Cover
Hydraulic Tank Cover
Operators Seat Base
Rear Wheel Arch Panels
Left Instrument Panel
Right Cab Panel
Air Conditioning (if fitted)
Service Checks
Cab Heater Filter
Replacing the Cab Heater Filter
Brakes
Park Brake
Testing the Park Brake
Park Brake Adjustment
Foot Brake
Electrical System
Battery
Jump Starting the Engine
Fuses
Primary Fuses
Relays
Engine
Oil and Filter
Cooling System
Alternator Drive Belt
Compressor Drive Belt (if fitted)
Air Filter
Fuel System
Introduction
Fuel Filter
Bleeding/Priming the Fuel System
Hydraulic System
Introduction
Release the Hydraulic Pressure
Oil and Filter
Changing the Hydraulic Breather Cap
Hose Burst Protection Valves
Tyres and Wheels
Tyre Inflation
Tyre Wear
Changing A Wheel
Checking the Wheel Nut Torques
Wheel Alignment
Steer Phasing Adjustment
Wear Pads
Windscreen Washer Reservoir
Fire Extinguisher (if fitted)
Checking the Fire Extinguisher

Section A – Attachments
Attachments
Service Procedures
Connecting/Disconnecting Hydraulic Hoses
Introduction
Connecting the Hydraulic Hoses
Disconnecting the Hydraulic Hoses
Quick Release Couplings

Section B – Body and Framework
Body and Framework
Service Tools
Numerical List
Technical Data
Heating, Ventilation and Air Conditioning (HVAC)
Systems Operation
Load Moment Indicator (LMI)
Cab Heating and Ventilation
Operation Overview
Electrical Operation and Schematics
Air Conditioning
Operation Overview
Electrical Operation and Schematics
R134a Refrigerant
PAG Type Refrigerant Oil
Fault Finding
Load Moment Indicator (LMI)
Fault Codes
General Fault Finding
Diagnostic Tests
Cab Heating and Ventilation
Tables
Air Conditioning
Introduction
Tables
System Diagnosis using Test Gauges
Service Procedures
Rivet Nuts
Fitting Procedure
Slide Hammer Kit
Fitting Procedure
Air Conditioning
Safety Procedures
R134a Refrigerant
PAG Type Refrigerant Oil
Leak Testing
Tightening Leaking Hoses
Refrigerant Charging and Discharging
Service Checks
Binary Switch
Compressor Drive Belt – Adjustment
Glazing
Direct Glazing
Boom
Wear Pads
Adjusting Carriage/Attachment Alignment
Load Moment Indicator (LMI)
Calibration
Boom
Removal and Replacement
Removal
Replacement
Inner Boom
Removal and Replacement
Removal
Replacement
Quickhitch/Tool Carrier
Removal and Replacement
Removal
Replacement
Cab
Removal and Replacement
Removal
Replacement
External Components
Roof and Rear Wiper Motor
Front Wiper
External Door Handle Removal and Replacement
Internal Door Handle Removal and Replacement
Door Removal and Replacement
Internal Components
Left Instrument Panel
Right Instrument Panel
Steering Column Cover
Side Console
Operators Seat Base
Engine Cover
Removal and Replacement
Removal
Replacement
Counterweight
Removal and Replacement
Removal
Replacement
Load Moment Indicator (LMI)
Removal and Replacement
Axle Transducer
Hydraulic Tank
Removal and Replacement
Removal
Replacement
Body Panels and Guards
Cooling Pack Cover
Removal and Replacement
Fuel Sender Guard Plate
Removal and Replacement
Screen Guard
Removal and Replacement
Front Transmission Hose Guards
Removal and Replacement
Engine Side Panel
Removal and Replacement
Rear Engine Guard
Removal and Replacement
Underfloor Cover
Removal and Replacement
Hydraulic Tank Cover
Removal and Replacement
Rear Wheel Arch Panels
Removal and Replacement
Fuel Level Sender Unit
Removal and Replacement
Removal
Replacement
Testing
Heating, Ventilation and Air Conditioning (HVAC)
Heater Assembly
Removal and Replacement
Air Conditioning Unit
Removal and Replacement
Condenser Unit
Removal and Replacement
Compressor
Removal and Replacement

Section C – Electrics
Electrics
Service Tools
Numerical List
Technical Data
General Technical Data
Fuses and Relays
Schematic Circuits
Machine Electrical Schematics
Sheets
Component Keys
Service Procedures
Using a Multimeter
Measuring DC Voltage
Measuring Resistance
Measuring Continuity
Measuring Frequency
Testing a Diode or a Diode Wire
Battery
Maintenance
Testing
Specific Gravity Testing
Alternator
General Description
Service Precautions
Charging Circuit Test
Alternator Charging Test
Starter Motor
Starting Circuit Test
Wire and Harness Number Identification
Introduction
Wire Numbers and Functions
Wiring Harness Repair
Introduction
Repair Procedure
Alternator
Removal and Replacement
Removal
Replacement
Starter Motor
Removal and Replacement
Removal
Replacement
Battery
Removal and Replacement
Removal
Replacement
Battery Tray
Removal and Replacement
Battery Isolator
Removal and Replacement
Harness Data
Drawings and Interconnection
Harness Interconnection
Harness Drawings

Section D – Controls
Controls
Manual Control Levers
Component Identification
Joystick
Basic Electrical Operation
Removal and Replacement
Control Assembly
Removal and Replacement
Control Rod Assembly
Removal and Replacement

Section E – Hydraulics
Hydraulics
Service Tools
Numerical List
Technical Data
Specifications
Systems Operation
Operation Overview
Component Location
Oil Pump
Control Valve Block
Main Relief Valve (MRV) Operation
Auxiliary Relief Valve (ARV) Operation
Main Services Pump
Main Services Control Valve
Description
Main Service Spools
Priority Valve
Relief Valves
Hydraulic Operation and Schematics
No Services Operated
Service Operation
Main System Pressure Relief
Neutral Circuit
Extension Circuit
Tilt Circuit
Lift Circuit
Auxiliary Circuit
Introduction to Hydraulic Schematic Symbols
General (Basic and Functional Symbols)
Control Valves
Example of Schematic Circuit
Schematic Circuits
Hydraulic Schematics
Fault Finding
Main Hydraulic Services
Service Procedures
Hydraulic Filling/Flushing Procedure
Hydraulic Fluid Quality
Effects of Contamination
Cleaning Operation
Contaminant Standards
Filters
Connecting and Disconnecting Hydraulic Hoses
Connecting the Hoses
Disconnecting the Hoses
Venting/Releasing the Hydraulic Pressure
Checking Pump Flow
Relief Valve Testing
Testing Main Relief Valve (MRV)
Testing Fan Motor Relief Valve
Hydraulic Services Pump
Removal and Replacement
Removal
Replacement
Control Valve Block
Removal and Replacement
Removal
Replacement
Hydraulic Oil Cooler
Removal and Replacement
Cooling Fan Motor
Removal and Replacement
Removal
Replacement
Rams
Precautions During Use
Installation
Caution During Use
Maintenance, Inspection Points
Removal and Replacement
Lift Ram
Displacement Ram
Extension Ram
Tilt Ram
Dismantling and Assembly
Dismantle
Assemble
JCB Ram Sealing Procedure
Piston Head Retention

Section F – Transmissions
Transmissions
Service Tools
Numerical List
Technical Data
Tyre Sizes and Pressures
Hydrostatic Transmission
Transmission Pump
Wheel Motor (Front)
Wheel Motor (Rear)
Systems Operation
Component Location
Hydraulic Operation
General Description
Transmission Pump
Wheel Motors
Electrical Operation
Forward/Neutral and Reverse Operation
Two Speed Operation
Service Procedures
Moving a Disabled Machine
Hydraulic Contamination
Hydraulic Fluid Quality
Effects of Contamination
Cleaning Operation
Contaminant Standards
Filters
System Priming Procedure
Hydraulic Pressure Tests
General Precautions
Charge Pressure
Maximum System Pressure
Neutral Setting
Fault Finding
Transmission Pump
Introduction
Fault Tables
Wheel Motors
Transmission Pump
Removal and Replacement
Removal
Replacement
Relief Valves
Removal and Replacement
Solenoid Valve
Removal and Replacement
Pump and Engine Coupling
Replacement
Transmission Control Valve Block
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Dismantling
Assembly
Rear Axle
Removal and Replacement
Removal
Replacement
Wheel Motor Carriers
Removal and Replacement
Removal
Replacement
Wheel Motors
Front Motor – Removal and Replacement
Removal
Replacement
Rear Motor – Removal and Replacement
Removal
Replacement
Wheel Motor – Dismantling and Assembly
Component Identification
Dismantling
Assembly
Wheels and Tyres
Inflating the Tyres
Tyre Inflation
Changing a Wheel

Section G – Brakes
Brakes
Technical Data
Service Brakes
Park Brake
Systems Operation
General Description
Inching Control
Inching Valve
Fault Finding
Brake System
Fault Finding Tables
Service Procedures
Service Brakes
Checking the Brake Shoe Condition
Bleeding the System
Park Brake
Testing the Park Brake
Brake Cable Adjustment
Switch Adjustment
Brake Shoes
Removal and Replacement
Removal
Replacement
Adjustment
Brake Wheel Cylinder
Removal and Replacement
Removal
Replacement
Brake Master Cylinder
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Brake Pedal Assembly
Removal and Replacement
Removal
Replacement
Dismantling
Assembly
Brake Pedal Stop Adjustment
Park Brake Cable
Removal and Replacement
Removal
Replacement

Section H – Steering
Steering
Service Tools
Numerical List
Technical Data
Hydraulic Steer Unit
Priority Valve
Systems Operation
General Description
Steer Circuit Schematic
Priority Valve
Neutral
Turning
Hydraulic Steer Unit
Neutral
Turning
Fault Finding
Introduction
Troubleshooting
Service Procedures
Re-phasing the Wheels
Bleeding the System
Steer Ram
Removal and Replacement
Removal
Replacement
Hydraulic Steer Unit
Removal and Replacement
Removal
Replacement
Dismantle and Assemble
Steering Column
Removal and Replacement
Removal
Replacement
Steer Stops
Removal and Replacement
Front
Rear
Adjustment

Section K – Engine
ManualSubHeading – Engine
Heading – Technical Data
Heading – Typical Engine Identification Number
Heading – Specification
Heading – System Operation
Heading – Starting System
Heading – Cold Start Glow Plugs
Heading – Engine
Heading – Removal and Replacement
Heading – Removal
Heading – Replacement
Heading – Engine Sensors and Switches
Heading – Engine Oil Pressure Switch
Heading – Removal
Heading – Replacement
Heading – Engine Coolant Temperature Switch
Heading – Removal
Heading – Replacement
Heading – Engine Coolant Thermostat
Heading – Removal and Replacement
Heading – Removal
Heading – Replacement
Heading – Air Filter
Heading – Removal and Replacement
Heading – Removal
Heading – Replacement
Heading – Exhaust Assembly
Heading – Removal and Replacement
Heading – Removal
Heading – Replacement
Heading – Throttle Cable
Heading – Removal and Replacement
Heading – Removal
Heading – Replacement
Heading – Adjustment
Heading – Engine Compartment Fan
Heading – Removal and Replacement
Heading – Removal
Heading – Replacement
Heading – Cooling Pack
Heading – Removal and Replacement
Heading – Removal
Heading – Replacement
Heading – Coolant Reservoir
Heading – Removal and Replacement
Heading – Removal
Heading – Replacement
Heading – Coolant Expansion Bottle
Heading – Removal and Replacement
Heading – Removal
Heading – Replacement
Heading – Fuel Lift Pump
Heading – Removal and Replacement
Heading – Compressor
Heading – Removal and Replacement
Heading – Removal
Heading – Replacement
Heading – Bracket

 

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JCB 515-40 Telescopic Handler Repair Service Manual.pdf

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