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jcb 516-40, Service Manual

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Copyright © 2004 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.

World Class

Customer Support

9813/4600-1

Publication No.

Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400

Service Manual

516-40

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

Summary of Contents for 516-40

Page 1: ...tomer Support 9813 4600 1 Publication No Issued by JCB Technical Publications JCB Aftermarket Training Woodseat Rocester Staffordshire ST14 5BW England Tel 44 1889 591300 Fax 44 1889 591400 Service Manual 516 40 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...

Page 2: ...813 4600 1 Publication No Issued by JCB Technical Publications JCB Aftermarket Training Woodseat Rocester Staffordshire ST14 5BW England Tel 44 1889 591300 Fax 44 1889 591400 Section 1 General Information Service Manual 516 40 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 Secti...

Page 3: ...Section 1 General Information 1 0 1 0 9813 4600 1 Notes ...

Page 4: ...Disabled Machine 1 7 Transporting the Machine 1 8 Lifting the Machine 1 10 Standard Torque Settings Zinc Plated Fasteners and Dacromet Fasteners 1 13 Hydraulic Connections 1 17 Service Tools Numerical List 1 21 Tool Detail Reference 1 23 Service Consumables Sealing and Retaining Compounds 1 39 Terms and Definitions Colour Coding 1 41 ...

Page 5: ...Page No Contents Section 1 General Information 1 ii 1 ii ...

Page 6: ...e or pipe connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt Where a torque setting is given as a single figure it may be varied by plus or minus 3 Torque figures indicated are for dry threads hence for lubricated threads may be reduced by one third The manufacturer s policy is one of continuous improvement The right to change the specification of the mach...

Page 7: ... when you are seated correctly in the machine 447200 2 Fig 1 Cross References T1 004_2 In this publication page cross references are made by presenting the subject title printed in bold italic and underlined It is preceeded by the go to symbol The number of the page upon which the subject begins is indicated within the brackets For example K Cross References T 1 2 ...

Page 8: ...e will be wrong Either stamp the new number of the unit on the identification plate or simply stamp out the old number This will prevent the wrong unit number being quoted when replacement parts are ordered The machine and engine serial numbers can help identify exactly the type of equipment you have C091000 Fig 2 The plate is below the seat Typical Product Identification Number The PIN weight eng...

Page 9: ...ement 3 EPA Family ID 4 Tune up Specifications Injection Timing 5 Tune up Specifications Injection Opening Pressure 6 PM 7 Fuel Type C089970 C2 Fig 5 ROPS Data Plate MWARNING You could be killed or seriously injured if you operate a machine with a damaged or missing ROPS FOPS If the Roll Over Protection Structure ROPS Falling Objects Protection Structure FOPS has been in an accident do not use the...

Page 10: ...d has a data plate attached to the frame For an example of the ROPS data plate refer to K Fig 6 T 1 5 C090690 Fig 6 SERIALNo YEAR ROPS COMPLIESTO ENISO3471 2008 333 P2846 515 40 CABPARTNo 332 W1466 J C B CABSYSTEMS LAKESIDEWORKS ROCESTER UTTOXETER STAFFS ST145JP ENGLAND FOPS COMPLIESTO ENISO3449 2008 LEVEL1 MAXIMUMUNLADEN MASS5000kg ...

Page 11: ...dicates what level protection the structure provides There are two levels of FOPS Level I Impact Protection impact strength for protection from small falling objects e g bricks small concrete blocks hand tools encountered in operations such as highway maintenance landscaping and other construction site services Level II Impact Protection impact strength for protection from heavy falling objects e ...

Page 12: ...achine and the towing vehicle 3 Place blocks both sides of each wheel on the disabled machine Important If the machine is to be towed a short distance the transmission pump bypass valves should be opened The machine should only be towed the minimum distance required to load it onto a transporter The transporter should be positioned as close as possible to the machine 4 Open the two bypass valves a...

Page 13: ...in place and secure b Set the boom c Carefully drive the machine onto the trailer d Engage the park brake and set the drive to neutral e Lower the carriage onto the trailer f Check that the overall height of the load is within regulations Adjust if necessary g Switch off the engine h Put blocks at the front and rear of all four tyres i Secure the cab j Cover the exhaust pipe Loading a disabled mac...

Page 14: ...Section 1 General Information Introduction Transporting the Machine 1 9 1 9 9813 4600 1 T043110 C2 Fig 9 Hooks can be used on the anchor points ...

Page 15: ... ground 6 Switch off the engine and remove the starter key 7 Isolate the battery 8 Remove all loose equipment 9 Attach the D shackles Attach a D shackle A to the front sling point The front sling point is a permanent fixture which is welded to the steel fuel tank The fuel tank is part of the chassis which gives the sling point extra strength Attach a D shackle B to the two rear sling points The tw...

Page 16: ...lear and to one side until the load has been safely lowered Make sure that the area is clear of other people before lowering the load If you do not follow these precautions you or others could be killed or seriously injured 2 3 5 3 1 Make sure that the lifting eye is directly above the centre of the machine 2 Lift the machine Make sure that the lifting equipment does not catch the machine ...

Page 17: ...Section 1 General Information Introduction Lifting the Machine 1 12 1 12 9813 4600 1 Page left intentionally blank ...

Page 18: ... Zinc or Yellow plated bolt Note All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification Note Dacromet bolts due to their high corrosion resistance are used in areas where rust could occur Dacromet bolts are only used for external applications They are not used in applications such as gearbox or engine joint seams or internal applications...

Page 19: ...144 6 177 0 18 0 130 5 3 4 19 0 1 1 8 343 0 35 0 253 0 309 0 31 5 227 9 7 8 22 2 1 15 16 547 0 55 8 403 4 492 0 50 2 362 9 1 25 4 1 1 2 814 0 83 0 600 4 732 0 74 6 539 9 1 1 8 31 7 1 7 8 1181 0 120 4 871 1 1063 0 108 4 784 0 1 1 4 38 1 2 1 4 1646 0 167 8 1214 0 1481 0 151 0 1092 3 Bolt Size Hexagon A F Condition 1 Condition 2 ISO Metric Thread mm mm Nm kgf m lbf ft Nm kgf m lbf ft M5 5 8 5 8 0 6 4...

Page 20: ... 191 0 M20 20 30 562 0 57 3 414 5 506 0 51 6 373 2 M24 24 36 971 0 99 0 716 9 874 0 89 1 644 6 M30 30 46 1930 0 196 8 1423 5 1737 0 177 1 1281 1 M36 36 55 3374 0 344 0 2488 5 3036 0 309 6 2239 2 Bolt Size Hexagon A F Condition 1 Condition 2 ISO Metric Thread mm mm Nm kgf m lbf ft Nm kgf m lbf ft M5 5 8 9 8 1 0 7 2 8 8 0 9 6 5 M6 6 10 16 6 1 7 12 2 15 0 1 5 11 1 M8 8 13 40 0 4 1 29 5 36 0 3 7 26 5 ...

Page 21: ...Zinc Bolt Size Nm kgf m lbf ft ISO Metric Thread mm M3 3 1 2 0 1 0 9 M4 4 3 0 0 3 2 0 M5 5 6 0 0 6 4 5 M6 6 10 0 1 0 7 5 M8 8 24 0 2 5 18 0 M10 10 48 0 4 9 35 5 M12 12 82 0 8 4 60 5 Bolt Size Nm kgf m lbf ft ISO Metric Thread M3 2 0 0 2 1 5 M4 6 0 0 6 4 5 M5 11 0 1 1 8 0 M6 19 0 1 9 14 0 M8 46 0 4 7 34 0 M10 91 0 9 3 67 0 M12 159 0 16 2 117 0 M16 395 0 40 0 292 0 M18 550 0 56 0 406 0 M20 770 0 79 ...

Page 22: ...ptor Size Hexagon A F Nm kgf m lbf ft in mm 1 4 19 0 18 0 1 8 13 0 3 8 22 0 31 0 3 2 23 0 1 2 27 0 49 0 5 0 36 0 5 8 30 0 60 0 6 1 44 0 3 4 32 0 81 0 8 2 60 0 1 38 0 129 0 13 1 95 0 1 1 4 50 0 206 0 21 0 152 0 SAE Tube Size SAE Port Thread Size Hexagon A F Nm kgf m lbf ft mm 4 7 16 20 15 9 20 0 28 0 2 0 2 8 16 5 18 5 6 9 16 18 19 1 46 0 54 0 4 7 5 5 34 0 40 0 8 3 4 16 22 2 95 0 105 0 9 7 10 7 69 0...

Page 23: ...sion 12 D will vary depending upon the torque applied Table 10 BSP Hose Torque Settings BSP Hose Size Hexagon A F Nm kgf m lbf ft in mm 1 8 14 0 14 0 16 00 1 4 1 6 10 3 11 8 1 4 19 0 24 0 27 0 2 4 2 7 17 7 19 9 3 8 22 0 33 0 40 0 3 4 4 1 24 3 29 5 1 2 27 0 44 0 50 0 4 5 5 1 32 4 36 9 5 8 30 0 58 0 65 0 5 9 6 6 42 8 47 9 3 4 32 0 84 0 92 0 8 6 9 4 61 9 67 8 1 38 0 115 0 126 0 11 7 12 8 84 8 92 9 1 ...

Page 24: ...nto Component Connections with Bonded Washers Table 11 BSP Adaptors with Bonded Washers Torque Settings BSP Size Nm kgf m lbf ft in 1 8 20 0 2 1 15 0 1 4 34 0 3 4 25 0 3 8 75 0 7 6 55 0 1 2 102 0 10 3 75 0 5 8 122 0 12 4 90 0 3 4 183 0 18 7 135 0 1 203 0 20 7 150 0 1 1 4 305 0 31 0 225 0 1 1 2 305 0 31 0 225 0 ...

Page 25: ...e O ring being damages as a result of over tightening Torque Stop Hoses have an additional shoulder 13 D which acts as a physical stop Note Minimum dimension 13 E fixed by shoulder 13 D Table 12 BSP Torque Stop Hose Torque Settings BSP Hose Size Hexagon A F Nm kgf m lbf ft in mm 1 8 14 0 14 0 1 4 10 0 1 4 19 0 27 0 2 7 20 0 3 8 22 0 40 0 4 1 30 0 1 2 27 0 55 0 5 6 40 0 5 8 30 0 65 0 6 6 48 0 3 4 3...

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