jcb 516-40 User manual

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 [phone] Fax [phone]
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

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 [phone] Fax [phone]
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
Section E - Hydraulics
Section F - Transmissions
Section G - Brakes
Section H - Steering
Section K - Engine

Section 1 - General Information
1-0 1-0
9813/4600-1
Notes:

Page No.Contents
Section 1 - General Information
1-i 1-i
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 ............................................................................. 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 No.Contents
Section 1 - General Information
1-ii 1-ii

Section 1 - General Information
1-1 1-1
9813/4600-1
Introduction
About This Publication
Machine Model and Serial Number
This manual provides information for the following
model(s) in the JCB machine range:
– 516-40 from 2415604 to 2416000.
Using the Service Manual
T11-004
This publication is designed for the benefit of JCB
Distributor Service Engineers who are receiving, or have
received, training by JCB Technical Training Department.
These personnel should have a sound knowledge of
workshop practice, safety procedures, and general
techniques associated with the maintenance and repair of
hydraulic earthmoving equipment.
The illustrations in this publication are for guidance only.
Where the machines differ, the text and/or the illustration
will specify.
General warnings in Section 2 are repeated throughout the
manual, as well as specific warnings. Read all safety
statements regularly, so you do not forget them.
Renewal of oil seals, gaskets, etc., and any component
showing obvious signs of wear or damage is expected as
a matter of course. It is expected that components will be
cleaned and lubricated where appropriate, and that any
opened hose 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
machine without notice is reserved. No responsibility will
be accepted for discrepancies which may occur between
specifications of the machine and the descriptions
contained in this publication.
Finally, please remember above all else safety must come
first!
Section Numbering
T11-005
The manual is compiled in sections, the first three are
numbered and contain information as follows:
The remaining sections are alphabetically coded and deal
with Dismantling, Overhaul etc. of specific components, for
example:
Section contents, technical data, circuit descriptions,
operation descriptions etc. are inserted at the beginning of
each alphabetically coded section.
1General Information - includes torque settings and
service tools.
2Care and Safety - includes warnings and cautions
pertinent to aspects of workshop procedures etc.
3Maintenance - includes service schedules and
recommended lubricants for all the machine.
AAttachments
BBody and Framework, etc.

Section 1 - General Information
Introduction
About This Publication
1-2 1-2
9813/4600-1
Left Side, Right Side
In this manual, 'left' Aand 'right' Bmean 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. 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).

Section 1 - General Information
Introduction
Identifying Your Machine
1-3 1-3
9813/4600-1
Identifying Your Machine
Machine Identification Plate
Your machine has an identification plate mounted as
shown. The serial numbers of the machine and its major
units are stamped on the plate.
Note: The machine model and build specification is
indicated by the PIN. Refer to Typical Product
Identification Number (PIN).
The serial number of each major unit is also stamped on
the unit itself. If a major unit is replaced by a new one, the
serial number on the identification plate 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, engine power and serial number of the
machine are stamped on the identification plate.
1World Manufacturer Identification (3 Digits)
2Machine Model (5 Digits)
3Randomly Generated Check Letter (1 Digit)
4Machine Serial Number (8 Digits)
Each machine has a unique serial number.
817-18435-2
Fig 3.
0
1
2
3
POWER
OUTLET
12V
1
0
F
R
JCB5 1 54 0 L9 1 627501
321 4

Section 1 - General Information
Introduction
Identifying Your Machine
1-4 1-4
9813/4600-1
Component Identification Plates
Typical Engine Identification Number
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.
Either stamp the new number on the plate or stamp out the
old one. This will prevent the wrong number being quoted
when you order replacement parts.
aEngine Model
bEngine Serial Number
cEU Approval Code
dSpecification Number
eRPM
C089970-C10
Fig 4.
Emission Control Information
The data plate which shows the EPA regulations is on the
rocker arm cover.
1Power Category
2Engine Displacement
3EPA Family ID
4Tune-up Specifications: Injection Timing
5Tune-up Specifications: Injection Opening Pressure
6PM
7Fuel 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 machine until the structure
has been renewed. Modifications and repairs that are
not approved by the manufacturer may be dangerous
and will invalidate the ROPS/FOPS certification.
INT-2-1-9_6
!MWARNING
Seat Belts
The ROPS/FOPS is designed to give you protection in
an accident. If you do not wear your seat belt, you
could be thrown out of the machine and crushed. You
must wear a seat belt when using the machine. Fasten
the seat belt before starting the engine.
0153
c
d
b
e
a
47
62
1
3
5

Section 1 - General Information
Introduction
Identifying Your Machine
1-5 1-5
9813/4600-1
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).
C090690
Fig 6.
SERIAL No:
YEAR:
ROPS:
COMPLIES TO
EN ISO 3471:2008
333/P2846
515-40
CAB PART No:
332/W1466
J.C.B.CAB SYSTEMS
LAKESIDE WORKS
ROCESTER
UTTOXETER,STAFFS
ST14 5JP
ENGLAND
FOPS:
COMPLIES TO
EN ISO 3449:2008
LEVEL 1
MAXIMUM UNLADEN
MASS 5000kg.

Section 1 - General Information
Introduction
Identifying Your Machine
1-6 1-6
9813/4600-1
FOPS Data Plate
!MWARNING
Do not use the machine if the falling objects protection
level provided by the structure is not sufficient for the
application. Falling objects can cause serious injury.
8-2-8-17
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 fallingobjects protection structure (FOPS) is fitted with
a dataplate. The dataplate indicates 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.g. trees,
rocks) for machines involved in site clearing,
overhead demolition or forestry.
For an example of the FOPS data plate, refer to
K Fig 7. ( T 1-6).
C090690
Fig 7.
SERIAL No:
YEAR:
ROPS:
COMPLIES TO
EN ISO 3471:2008
333/P2846
515-40
CAB PART No:
332/W1466
J.C.B.CAB SYSTEMS
LAKESIDE WORKS
ROCESTER
UTTOXETER,STAFFS
ST14 5JP
ENGLAND
FOPS:
COMPLIES TO
EN ISO 3449:2008
LEVEL 1
MAXIMUM UNLADEN
MASS 5000kg.

Section 1 - General Information
Introduction
Moving a Disabled Machine
1-7 1-7
9813/4600-1
Moving a Disabled Machine
!MCAUTION
The transmission will be damaged, if the machine is
moved unless the transmission pump is prepared for
towing.
4-2-5-6
!MCAUTION
Towing a machine too far or too fast can damage the
transmission. Do not tow the machine further than one
mile. Use a trailer for greater distances. When towing
do not travel faster than 15 mph (25 km/h).
Use a rigid draw-bar. If a towing chain must be used,
then use two towing vehicles. One towing vehicle
should be coupled to the front of the disabled
machine. The other towing vehicle should be coupled
to the rear of the disabled machine, to provide braking
power.
The towing vehicle(s) must have enough pulling and
braking power to move and stop the machine.
2-2-7-3-2
1Using suitable lifting equipment, remove any payload
from the machine.
2Attach a rigid tow bar between a suitable connection
point on the machine and the towing vehicle.
3Placeblocks bothsides ofeach 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.
4Open the two bypass valves, as follows:
aRemove the seat and seat pan to gain access to
the transmission pump. Refer to Access Panels,
Section 3.
bOn the bottom bypass valve, slacken locknut A
Screw in adjuster Buntil the top is level with the
locknut. Tighten the locknut.
Repeat the procedure with the top bypass valve.
5Remove the wheel blocks from each wheel and tow
the machine to a place of repair at a maximum speed
of 2kph (1 1/4mph). Tow the machine the minimum
distance necessary (maximum 1km). When towing is
complete, place chocks both sides of each wheel.
6Close the bypass valves: Slacken the locknut and
rotate the two bypass valve adjusters until the stop is
felt. Retighten the locknut.
7Remove the tow bar and wheel chocks.
8Refit the seat and seat pan.
Fig 8.
448950-C1
AB
AB

Section 1 - General Information
Introduction
Transporting the Machine
1-8 1-8
9813/4600-1
Transporting the Machine
!MWARNING
The safe transit of the load is the responsibility of the
transport contractor and driver. Any machine,
attachments or parts that may move during transit
must be adequately secured.
5-2-5-9
Important: Use only the tie down anchor points specified.
Note: Before transporting the machine make sure you will
be obeying the rules and laws of all the areas that the
machine will be carried through.
Make sure that the transporting vehicle is suitable. See
Static Dimensions (SPECIFICATIONS section) for the
dimensions of your machine.
!MWARNING
Before moving the machine onto the trailer, make sure
that the trailer and ramp are free from oil, grease and
ice. Remove oil, grease and ice from the machine
tyres. Make sure the machine will not foul on the ramp
angle. See Static Dimensions in SPECIFICATION
section for the minimum ground clearance of your
machine.
2-2-7-5_1
1Place blocks at the front and rear of the trailer wheels.
2Move the machine onto the trailer.
Loading a serviceable machine onto the trailer:
aMake sure the ramps are correctly in place and
secure.
bSet the boom.
cCarefully drive the machine onto the trailer.
dEngage the park brake and set the drive to
neutral.
eLower the carriage onto the trailer.
fCheck that the overall height of the load is within
regulations. Adjust if necessary.
gSwitch off the engine.
hPut blocks at the front and rear of all four tyres.
iSecure the cab.
jCover the exhaust pipe.
Loading a disabled machine onto the trailer:
aAlign the trailer with the rear of the machine.
Note: The trailer must be equipped with a winch to pull the
machine aboard.
bMake sure the ramps are correctly in place and
secure.
cConnect the winch cable onto the recovery hitch
on the back of the machine.
dPrepare the machine for recovery. K Moving a
Disabled Machine ( T 1-7)
eOperate the winch and pull the machine onto the
trailer until the shovel/attachment is well inside the
back end of the trailer.
fEngage the park brake.
gPut blocks at the front and rear of all four tyres.
hLower the carriage onto the trailer.
iCheck that the overall height of the load is within
regulations. Adjust if necessary.
jSecure the cab.
kCover the exhaust pipe.
3Anchor the machine to the trailer with chains. The
anchor points are shown on the illustration.
4Measure the maximum height of the machine from
the ground. Make sure the truck driver knows the
clearance height before he drives away.

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

Section 1 - General Information
Introduction
Lifting the Machine
1-10 1-10
9813/4600-1
Lifting the Machine
Introduction
Do not use the anchor points to lift the machine. If the
anchor points are used, the machine will not lift evenly and
become unstable.
The lifting-eyes in the top surface of the counterweight are
for the removal and installation of the counterweight only.
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
1Stop the machine on level, solid ground.
2Engage the park brake and set the drive to neutral.
3Retract the boom.
4Lower the boom fully, then lift it slightly.
5Tilt the carriage back to keep the heel of the forks
300mm (12in.) above the ground.
6Switch off the engine and remove the starter key.
7Isolate the battery.
8Remove all loose equipment.
9Attach the D-shackles:
Attach a D-shackle Ato 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 Bto the two rear sling-points. The
two rear sling-points are attached to the chassis with
M16 bolts.
Note: The D-shackles each have a safe working load of
five tonnes.
333-R3798
Fig 10.
!MWARNING
Lifting Equipment
You can be injured if you use incorrect or faulty lifting
equipment. You must identify the weight of the item to
be lifted then choose lifting equipment that is strong
enough and suitable for the job. Make sure that lifting
equipment is in good condition and complies with all
local regulations.
INT-1-3-7_2
10 Attach the lifting equipment to the D-shackles.
11 Install a spreader-frame to prevent damage to the
machine.
A
B

Section 1 - General Information
Introduction
Lifting the Machine
1-11 1-11
9813/4600-1
Lifting the Machine
!MDANGER
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.
If you do not follow these precautions you or others
could be killed or seriously injured.
2-3-5-3
1Make sure that the lifting-eye is directly above the
centre of the machine.
2Lift the machine.
Make sure that the lifting equipment does not catch
the machine.

Section 1 - General Information
Introduction
Lifting the Machine
1-12 1-12
9813/4600-1
Page left intentionally blank

Section 1 - General Information
Standard Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
1-13 1-13
9813/4600-1
Standard Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
T11-002
Introduction
Some external fasteners on JCB machines are
manufactured using an improved type of corrosion
resistant finish. This type of finish is called Dacromet and
replaces the original Zinc and Yellow Plating used on
earlier machines.
The two types of fasteners can be readily identified by
colour and part number suffix. K Table 1. Fastener Types
(T 1-13).
Table 1. Fastener Types
Note: As the Dacromet fasteners have a lower torque
setting than the Zinc and Yellow fasteners, the torque
figures used must be relevant to the type of fastener.
Note: A Dacromet bolt should not be used in conjunction
with a Zinc or Yellow plated nut, as this could change the
torque characteristics of the torque setting further. 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.
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.
Bolts and Screws
Use the following torque setting tables only where no
torque setting is specified in the text.
Note: Dacromet fasteners are lubricated as part of the
plating process, do not lubricate.
Torque settings are given for the following conditions:
Condition 1
– Un-lubricated fasteners
– Zinc fasteners
– Yellow plated fasteners
Condition 2
– Zinc flake (Dacromet) fasteners
– Lubricated zinc and yellow plated fasteners
– Where there is a natural lubrication. For example,
cast iron components
Verbus Ripp Bolts
Fig 11.
Torque settings for these bolts are determined by the
application. Refer to the relevant procedure for the
required settings.
Fastener
Type Colour Part No. Suffix
Zinc and
Yellow Golden finish 'Z' (e.g. 1315/3712Z)
Dacromet Mottled silver finish 'D' (e.g. 1315/3712D)

Section 1 - General Information
Standard Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
1-14 1-14
9813/4600-1
Table 2. Torque Settings - UNF Grade 'S' Fasteners
Table 3. Torque Settings - Metric Grade 8.8 Fasteners
Bolt Size Hexagon (A/F) Condition 1 Condition 2
in. mm in. Nm kgf m lbf ft Nm kgf m lbf ft
1/4 6.3 7/16 11.2 1.1 8.3 10.0 1.0 7.4
5/16 7.9 1/2 22.3 2.3 16.4 20.0 2.0 14.7
3/8 9.5 9/16 40.0 4.1 29.5 36.0 3.7 26.5
7/16 11.1 5/8 64.0 6.5 47.2 57.0 5.8 42.0
1/2 12.7 3/4 98.00 10.0 72.3 88.0 9.0 64.9
9/16 14.3 13/16 140.0 14.3 103.2 126.0 12.8 92.9
5/8 15.9 15/16 196.0 20.0 144.6 177.0 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 4.3 5.2 0.5 3.8
M6 6 10 9.9 1.0 7.3 9.0 0.9 6.6
M8 8 13 24.0 2.4 17.7 22.0 2.2 16.2
M10 10 17 47.0 4.8 34.7 43.0 4.4 31.7
M12 12 19 83.0 8.5 61.2 74.0 7.5 54.6
M16 16 24 205.0 20.9 151.2 184.0 18.8 135.7
M20 20 30 400.0 40.8 295.0 360.0 36.7 265.5
M24 24 36 690.0 70.4 508.9 621.0 63.3 458.0
M30 30 46 1372.0 139.9 1011.9 1235.0 125.9 910.9
M36 36 55 2399.0 244.6 1769.4 2159.0 220.0 1592.4

Section 1 - General Information
Standard Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
1-15 1-15
9813/4600-1
Table 4. Metric Grade 10.9 Fasteners
Table 5. Metric Grade 12.9 Fasteners
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 8.1 0.8 6.0 7.3 0.7 5.4
M6 6 10 13.9 1.4 10.2 12.5 1.3 9.2
M8 8 13 34.0 3.5 25.0 30.0 3.0 22.1
M10 10 17 67.0 6.8 49.4 60.0 6.1 44.2
M12 12 19 116.0 11.8 85.5 104.0 10.6 76.7
M16 16 24 288.0 29.4 212.4 259.0 26.4 191.0
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
M10 10 17 80.0 8.1 59.0 72.0 7.3 53.1
M12 12 19 139.0 14.2 102.5 125.0 12.7 92.2
M16 16 24 345.0 35.2 254.4 311.0 31.7 229.4
M20 20 30 674.0 68.7 497.1 607.0 61.9 447.7
M24 24 36 1165.0 118.8 859.2 1048.0 106.9 773.0
M30 30 46 2316.0 236.2 1708.2 2084.0 212.5 1537.1
M36 36 55 4049.0 412.9 2986.4 3644.0 371.6 2687.7