JCB 515-40 Operator Manual 9821-0600

Description

• Model List:
  • 515-40

• 1. Safety Notices
• 2. Important Information ………………………………………………………………………. xv
• 3. The Operator Manual ………………………………………………………………….. xv
• 4. Safety Warnings ………………………………………………………………………….xvi
• 5. Introduction
• 6. About This Manual ……………………………………………………………………………..1
• 7. Machine Model and Serial Number ………………………………………………….1
• 8. Using this Manual ………………………………………………………………………….1
• 9. Left Side, Right Side ………………………………………………………………………2
• 10. Cab-Canopy …………………………………………………………………………………2
• 11. Cross References ………………………………………………………………………….3
• 12. Machine Description …………………………………………………………………………..4
• 13. The JCB 515-40 ……………………………………………………………………………4
• 14. Intended Use ………………………………………………………………………………..4
• 15. Component Location ……………………………………………………………………..4
• 16. Safety Check List ……………………………………………………………………………….6
• 17. Safety – Yours and Others ………………………………………………………………6
• 18. General Safety ……………………………………………………………………………..7
• 19. Operating Safety …………………………………………………………………………10
• 20. Maintenance Safety ……………………………………………………………………..20
• 21. Safety Labels …………………………………………………………………………………..32
• 22. Introduction …………………………………………………………………………………32
• 23. Safety Label Identification …………………………………………………………….33
• 24. Part Numbers and Descriptions …………………………………………………….35
• 25. Identifying Your Machine …………………………………………………………………..39
• 26. Machine Identification Plate ………………………………………………………….39
• 27. Component Identification Plates …………………………………………………….41
• 28. Machine Security ……………………………………………………………………………..45
• 29. Introduction …………………………………………………………………………………45
• 30. JCB Plantguard …………………………………………………………………………..45
• 31. Construction Equipment Security And Registration Scheme (CESAR) .45
• 32. Operation
• 33. Introduction ……………………………………………………………………………………..47
• 34. Before Entering the Cab ……………………………………………………………………48
• 35. Entering and Leaving the Cab ……………………………………………………………51
• 36. Emergency Exit …………………………………………………………………………..53
• 37. Doors and Windows …………………………………………………………………………54
• 38. Opening and Closing the Doors …………………………………………………….54
• 39. Opening and Closing the Door Upper Section …………………………………55
• 40. Seat Controls …………………………………………………………………………………..57
• 41. Introduction …………………………………………………………………………………57
• 42. Operators Seat ……………………………………………………………………………58
• 43. Seat Belt …………………………………………………………………………………………59
• 44. Inertia Reel Seat Belt …………………………………………………………………..59
• 45. Cab Layout ……………………………………………………………………………………..62
• 46. Component Key …………………………………………………………………………..63
• 47. Drive Controls, Switches and Instrument Panel ……………………………………64
• 48. Drive Controls ……………………………………………………………………………..64
• 49. Switches …………………………………………………………………………………….68
• 50. Instrument Panel …………………………………………………………………………76
• 51. Heater Controls …………………………………………………………………………..83
• 52. Operating Levers ……………………………………………………………………………..85
• 53. Introduction …………………………………………………………………………………85
• 54. Boom and Carriage Controls …………………………………………………………87
• 55. Auxiliary Controls ………………………………………………………………………..90
• 56. Safety Equipment …………………………………………………………………………….91
• 57. Load Charts ………………………………………………………………………………..91
• 58. Longitudinal Load Moment Indicator (LLMI) …………………………………….95
• 59. Longitudinal Load Moment Indicator With Longitudinal Load Motion Control
• 60. ………………………………………………………………………………………………..104
• 61. Inclinometer ……………………………………………………………………………… 113
• 62. Fire Extinguisher (if fitted) ………………………………………………………….. 114
• 63. Beacon ……………………………………………………………………………………. 115
• 64. Before Starting the Engine ………………………………………………………………. 117
• 65. Starting the Engine …………………………………………………………………………120
• 66. Preparing the Machine for Travel ……………………………………………………..123
• 67. Introduction ……………………………………………………………………………….123
• 68. Preparing for Road Travel …………………………………………………………..123
• 69. Preparing for Site Travel ……………………………………………………………..126
• 70. Getting the Machine Moving …………………………………………………………….127
• 71. Operating Practices ……………………………………………………………………127
• 72. Operating Procedure ………………………………………………………………….129
• 73. Stopping and Parking the Machine ……………………………………………………131
• 74. Working with the Machine ……………………………………………………………….134
• 75. Operating Practices and Site Safety …………………………………………….134
• 76. Clothing and Safety Equipment ……………………………………………………135
• 77. Danger Zone …………………………………………………………………………….135
• 78. Working with the Boom ………………………………………………………………136
• 79. Use of Machines on Gradients or Slopes ………………………………………157
• 80. Operating Environment ……………………………………………………………………162
• 81. Operating in Low Temperatures …………………………………………………..162
• 82. Operating in High Temperatures ………………………………………………….162
• 83. Refuelling the Machine ……………………………………………………………………164
• 84. Low Fuel Levels ………………………………………………………………………..164
• 85. Filling the Tank ………………………………………………………………………….164
• 86. Moving a Disabled Machine …………………………………………………………….167
• 87. Transporting the Machine ………………………………………………………………..170
• 88. Lifting the Machine …………………………………………………………………………174
• 89. Storage of the Machine …………………………………………………………………..175
• 90. Introduction ……………………………………………………………………………….175
• 91. Storage Area …………………………………………………………………………….175
• 92. Prepare the Machine for Storage …………………………………………………175
• 93. Put the Machine into Storage ………………………………………………………176
• 94. During Storage ………………………………………………………………………….176
• 95. Take the Machine Out of Storage …………………………………………………177
• 96. Routine Maintenance
• 97. Service Requirements …………………………………………………………………….179
• 98. Introduction ……………………………………………………………………………….179
• 99. Owner-Operator Support …………………………………………………………….180
• 100. Service-Maintenance Agreements ……………………………………………….181
• 101. Fit for Purpose Tests for Lifting Equipment …………………………………….181
• 102. Obtaining Replacement Parts ………………………………………………………181
• 103. Health and Safety …………………………………………………………………………..182
• 104. Lubricants …………………………………………………………………………………182
• 105. Battery ……………………………………………………………………………………..186
• 106. Service Schedules ………………………………………………………………………….190
• 107. Introduction ……………………………………………………………………………….190
• 108. How to Use the Service Schedules ………………………………………………191
• 109. Calendar Equivalents …………………………………………………………………192
• 110. Pre-start Cold Checks, Service Points and Fluid Levels ………………….193
• 111. Functional Test and Final Inspection …………………………………………….199
• 112. Fluids, Lubricants and Capacities ……………………………………………………..203
• 113. Specifications ……………………………………………………………………………203
• 114. Coolant Mixtures ……………………………………………………………………….207
• 115. Tools …………………………………………………………………………………………….209
• 116. Toolbox …………………………………………………………………………………….209
• 117. Carrying Tools onto the Machine ………………………………………………….209
• 118. Prepare the Machine for Maintenance ………………………………………………210
• 119. Introduction ……………………………………………………………………………….210
• 120. How to Make the Machine Safe (Boom Lowered) ………………………….. 211
• 121. How to Make the Machine Safe (Boom Lifted) ……………………………….212
• 122. Using a Jack to Lift the Machine ………………………………………………….215
• 123. Cleaning the Machine ……………………………………………………………………..218
• 124. Introduction ……………………………………………………………………………….218
• 125. Preparing the Machine for Cleaning ……………………………………………..220
• 126. Cleaning the Machine …………………………………………………………………220
• 127. Checking For Damage …………………………………………………………………….226
• 128. Check the Machine Body and Structure ………………………………………..226
• 129. Check the Tyres ………………………………………………………………………..226
• 130. Check the Seat and Seat Belt ……………………………………………………..227
• 131. Check the Hydraulic Hoses and Fittings ……………………………………….228
• 132. Checking the ROPS-FOPS …………………………………………………………229
• 133. Greasing ……………………………………………………………………………………….232
• 134. Introduction ……………………………………………………………………………….232
• 135. Preparing the Machine for Greasing …………………………………………….233
• 136. Greasing Sequence ……………………………………………………………………234
• 137. Grease Points ……………………………………………………………………………235
• 138. Oiling ……………………………………………………………………………………………242
• 139. Access Panels ……………………………………………………………………………….244
• 140. Engine Cover …………………………………………………………………………….244
• 141. Engine Side Panel ……………………………………………………………………..246
• 142. Rear Engine Guard ……………………………………………………………………248
• 143. Underfloor Cover ……………………………………………………………………….251
• 144. Hydraulic Tank Cover …………………………………………………………………252
• 145. Operators Seat Base ………………………………………………………………….255
• 146. Rear Wheel Arch Panels …………………………………………………………….256
• 147. Left Instrument Panel …………………………………………………………………257
• 148. Right Cab Panel ………………………………………………………………………..259
• 149. Air Conditioning (if fitted) …………………………………………………………………261
• 150. Service Checks …………………………………………………………………………261
• 151. Cab Heater Filter ……………………………………………………………………………263
• 152. Replacing the Cab Heater Filter …………………………………………………..263
• 153. Brakes ………………………………………………………………………………………….264
• 154. Park Brake ………………………………………………………………………………..264
• 155. Testing the Park Brake ……………………………………………………………….265
• 156. Park Brake Adjustment ……………………………………………………………….267
• 157. Foot Brake ………………………………………………………………………………..268
• 158. Electrical System ……………………………………………………………………………271
• 159. Battery ……………………………………………………………………………………..271
• 160. Jump Starting the Engine ……………………………………………………………275
• 161. Fuses ……………………………………………………………………………………….278
• 162. Primary Fuses …………………………………………………………………………..281
• 163. Relays ……………………………………………………………………………………..282
• 164. LLMC Components ……………………………………………………………………284
• 165. Engine ………………………………………………………………………………………….285
• 166. Oil and Filter ……………………………………………………………………………..285
• 167. Cooling System …………………………………………………………………………292
• 168. Alternator Drive Belt …………………………………………………………………..297
• 169. Compressor Drive Belt (if fitted) …………………………………………………..301
• 170. Air Filter ……………………………………………………………………………………304
• 171. Fuel System …………………………………………………………………………………..308
• 172. Introduction ……………………………………………………………………………….308
• 173. Fuel Filter …………………………………………………………………………………310
• 174. Bleeding-Priming the Fuel System ……………………………………………….313
• 175. Hydraulic System ……………………………………………………………………………315
• 176. Introduction ……………………………………………………………………………….315
• 177. Release the Hydraulic Pressure …………………………………………………..316
• 178. Oil and Filter ……………………………………………………………………………..317
• 179. Changing the Hydraulic Breather Cap …………………………………………..321
• 180. Hose Burst Protection Valves ………………………………………………………322
• 181. Tyres and Wheels …………………………………………………………………………..324
• 182. Tyre Inflation ……………………………………………………………………………..324
• 183. Tyre Wear …………………………………………………………………………………326
• 184. Changing A Wheel …………………………………………………………………….327
• 185. Checking the Wheel Nut Torques …………………………………………………330
• 186. Wheel Alignment ……………………………………………………………………………331
• 187. Steer Phasing Adjustment …………………………………………………………..331
• 188. Wear Pads …………………………………………………………………………………….333
• 189. Windscreen Washer Reservoir …………………………………………………………335
• 190. Fire Extinguisher (if fitted) ………………………………………………………………..336
• 191. Checking the Fire Extinguisher ……………………………………………………336
• 192. Optional Attachments
• 193. Introduction ……………………………………………………………………………………337
• 194. Attachments for your Machine ………………………………………………………….340
• 195. Connecting-Disconnecting Hydraulic Hoses ……………………………………….342
• 196. Introduction ……………………………………………………………………………….342
• 197. Connecting the Hydraulic Hoses ………………………………………………….343
• 198. Disconnecting the Hydraulic Hoses ………………………………………………345
• 199. Quick Release Couplings ……………………………………………………………347
• 200. Quickhitch ……………………………………………………………………………………..350
• 201. Introduction ……………………………………………………………………………….350
• 202. Installing Attachments ………………………………………………………………..351
• 203. Removing Attachments ………………………………………………………………353
• 204. Tool Carrier Hitch ……………………………………………………………………………355
• 205. Installing Attachments ………………………………………………………………..355
• 206. Removing Attachments ………………………………………………………………357
• 207. Pallet Forks ……………………………………………………………………………………360
• 208. Safety ………………………………………………………………………………………360
• 209. Fitting-Removing Pallet Forks ……………………………………………………..361
• 210. Road Travel ………………………………………………………………………………361
• 211. Adjust the Fork Spacing ……………………………………………………………..362
• 212. Daily Maintenance ……………………………………………………………………..363
• 213. 6-in-1 Shovel …………………………………………………………………………………364
• 214. Safety ………………………………………………………………………………………364
• 215. Preparing for Travel ……………………………………………………………………364
• 216. Control ……………………………………………………………………………………..364
• 217. Operation ………………………………………………………………………………….364
• 218. Daily Maintenance ……………………………………………………………………..367
• 219. Work Platforms ………………………………………………………………………………369
• 220. Specifications
• 221. Static Dimensions …………………………………………………………………………..371
• 222. Performance Dimensions ………………………………………………………………..373
• 223. Lift Performance ………………………………………………………………………..373
• 224. Loader Performance …………………………………………………………………..373
• 225. Maximum Wading Depth …………………………………………………………….374
• 226. Engine ……………………………………………………………………………………..374
• 227. Load Charts …………………………………………………………………………………..375
• 228. Introduction ……………………………………………………………………………….375
• 229. Load Chart ………………………………………………………………………………..376
• 230. Tyre Sizes and Pressures ………………………………………………………………..377
• 231. Introduction ……………………………………………………………………………….377
• 232. Specifications ……………………………………………………………………………378
• 233. Noise Data …………………………………………………………………………………….379
• 234. Introduction ……………………………………………………………………………….379
• 235. 515-40 ……………………………………………………………………………………..380
• 236. Vibration Data ………………………………………………………………………………..381
• 237. Introduction ……………………………………………………………………………….381
• 238. 515-40 ……………………………………………………………………………………..383
• 239. Warranty Information
• 240. Machine Service Record Sheet ………………………………………………………..385
• 241. Registration Information ………………………………………………………………….389
• 242. European Community Standards
• 243. EC Declaration of Conformity …………………………………………………………..391
• 244. Introduction ……………………………………………………………………………….391
• 245. Explanation of the EC Declaration of Conformity ……………………………394