jcb 516-40 Service Manual
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jcb 516-40 Service Manual

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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
Publication No.
9813/4600-1
World Class
Customer Support
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.
Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400

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  • Page 1 Customer Support 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.
  • Page 2 Customer Support 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.
  • Page 3 Section 1 - General Information Notes: 9813/4600-1...

  • Page 4: Table Of Contents

    Section 1 - General Information Contents Page No. Introduction About This Publication ................1-1 Identifying Your Machine ................1-3 Moving a 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 ................
  • Page 5 Section 1 - General Information Contents Page No. 1-ii 1-ii...

  • Page 6: Introduction

    Using the Service Manual General Information - includes torque settings and T11-004 This publication is designed for the benefit of JCB service tools. Distributor Service Engineers who are receiving, or have Care and Safety - includes warnings and cautions received, training by JCB Technical Training Department.
  • Page 7 Section 1 - General Information Introduction About This Publication Left Side, Right Side In this manual, 'left' A and 'right' B mean your left and right 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.

  • Page 8: Identifying Your Machine

    Section 1 - General Information Introduction Identifying Your Machine Identifying Your Machine Machine Identification Plate Typical Product Identification Number The PIN, weight, engine power and serial number of the Your machine has an identification plate mounted as machine are stamped on the identification plate. shown.
  • Page 9 Section 1 - General Information Introduction Identifying Your Machine Component Identification Plates EPA Family ID Tune-up Specifications: Injection Timing Typical Engine Identification Number Tune-up Specifications: Injection Opening Pressure The engine data label is located on the top of the engine. If the engine is replaced by a new one, the data plate serial number will be wrong.
  • Page 10 Section 1 - General Information Introduction Identifying Your Machine The machine is built to the ROPS standard and has a data plate attached to the frame. For an example of the ROPS data plate, refer to K Fig 6. ( T 1-5).
  • Page 11 If the machine is used in any application where there is a risk of falling objects then a falling-objects protective structure (FOPS) must be installed. For further information contact your JCB Dealer The falling objects protection structure (FOPS) is fitted with a dataplate. The dataplate indicates what level protection the structure provides.

  • Page 12: Moving A Disabled Machine

    Section 1 - General Information Introduction Moving a Disabled Machine Moving a Disabled Machine b On the bottom bypass valve, slacken locknut A CAUTION Screw in adjuster B until the top is level with the locknut. Tighten the locknut. The transmission will be damaged, if the machine is moved unless the transmission pump is prepared for Repeat the procedure with the top bypass valve.

  • Page 13: Transporting The Machine

    Section 1 - General Information Introduction Transporting the Machine Transporting the Machine g Switch off the engine. WARNING h Put blocks at the front and rear of all four tyres. The safe transit of the load is the responsibility of the transport contractor and driver.
  • Page 14 Section 1 - General Information Introduction Transporting the Machine T043110-C2 Fig 9. Hooks can be used on the anchor points 9813/4600-1...

  • Page 15: Lifting The Machine

    The lifting-eyes can not support the weight of the machine. To safely lift the machine, the Lifting Point Option (333/ R3798) must be installed, refer to your JCB Dealer. Preparing the Machine Stop the machine on level, solid ground.
  • Page 16 Section 1 - General Information Introduction Lifting the Machine Lifting the Machine DANGER Do not stand underneath the raised load during the lowering procedure. Stand clear 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.
  • Page 17 Section 1 - General Information Introduction Lifting the Machine Page left intentionally blank 1-12 9813/4600-1 1-12...

  • Page 18: Standard Torque Settings

    For the same reason, a Dacromet nut should not be used with a 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.
  • Page 19 Section 1 - General Information Standard Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 2. Torque Settings - UNF Grade 'S' Fasteners Bolt Size Hexagon (A/F) Condition 1 Condition 2 kgf m lbf ft kgf m lbf ft 7/16 11.2 10.0 5/16...
  • Page 20 Section 1 - General Information Standard Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 4. Metric Grade 10.9 Fasteners Bolt Size Hexagon (A/F) Condition 1 Condition 2 ISO Metric Thread kgf m lbf ft kgf m lbf ft 13.9 10.2 12.5 34.0...
  • Page 21 Section 1 - General Information Standard Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 6. Torque Settings - Rivet Nut Bolts/Screws Bolt Size ISO Metric Thread kgf m lbf ft 10.0 24.0 18.0 48.0 35.5 82.0 60.5 Table 7. Torque Settings - Internal Hexagon Headed Cap Screws (Zinc) Bolt Size ISO Metric Thread...

  • Page 22: Hydraulic Connections

    Section 1 - General Information Standard Torque Settings Hydraulic Connections Hydraulic Connections T11-003 'O' Ring Face Seal System Adaptors Screwed into Valve Blocks Adaptor screwed into valve blocks, seal onto an 'O' ring which is compressed into a 45° seat machined into the face of the tapped port.
  • Page 23 Section 1 - General Information Standard Torque Settings Hydraulic Connections Hoses Screwed into Adaptors Fig 12. Hoses 12-B screwed into adaptors 12-A seal onto an `O' Note: Dimension 12-D will vary depending upon the ring 12-C which is compressed into a 45° seat machined torque applied.
  • Page 24 Section 1 - General Information Standard Torque Settings Hydraulic Connections Adaptors into Component Connections with Bonded Washers Table 11. BSP Adaptors with Bonded Washers - Torque Settings BSP Size kgf m lbf ft 20.0 15.0 34.0 25.0 75.0 55.0 102.0 10.3 75.0 122.0...
  • Page 25 Section 1 - General Information Standard Torque Settings Hydraulic Connections 'Torque Stop' Hose System Fig 13. `Torque Stop' Hoses 13-B screwed into adaptors 13-A seal Stop' Hoses have an additional shoulder 13-D, which acts onto an 'O' ring 13-C which is compressed into a 45° seat as a physical stop.

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