JCB 515-40 Service Manual (9803/9900-4)

This professional-grade service manual provides detailed maintenance, diagnostics, and repair procedures for the JCB 515-40 Telehandler. Designed for technicians and operators, it includes advanced guidance for ensuring machine performance and longevity in demanding conditions.

Model Covers:

This manual provides service information for the following model in the JCB range:

JCB 515-40 from Serial Number 1627500 to 1769999

Note: The machine may have multiple configurations identified by model number suffixes. This manual includes specific service details for these variants where applicable.

File Format: PDF

Size: 65.15 MB

No. of pages: 668

Language: English

Delivery Method: Instant Download - Access your file immediately after purchase.

📑 Included Sections:

General Information

• Machine identification, serial number ranges, and transport guidelines
• Standard torque settings for zinc plated and Dacromet fasteners
• Hydraulic connections and service tooling references
• List of sealing and retaining compounds with technical details
• Terminology and color coding for component identification

Care and Safety

• Safety notices and operator warnings for all service procedures
• Comprehensive safety checklists and label identification guides
• Worksite safety protocols for both operators and technicians

Maintenance

• Routine maintenance schedules with recommended service intervals
• Procedures for greasing, oiling, and fluid changes
• Air conditioning and HVAC system maintenance
• Specific guidelines for servicing brakes, hydraulics, electrical systems, and tyres

Body and Framework

• Cab structure service, panel removal, and counterweight maintenance
• Detailed procedures for glazing, body panels, and guard replacements
• Load Moment Indicator (LMI) system operation and diagnostics

Electrical Systems

• Wiring schematics, fuse and relay diagrams for full system coverage
• Battery, starter motor, and alternator servicing procedures
• Multimeter usage and wiring harness repair techniques

Hydraulic Systems

• Comprehensive hydraulic schematics including pre-LLMI and LLMI systems
• Control valve block and main services pump servicing
• Rams, hydraulic tank, and oil cooler replacement guidelines

Transmission

• Hydrostatic transmission fault finding and repair procedures
• Wheel motor servicing, rear axle removal, and tyre pressure data
• System priming and hydraulic pressure testing

Brakes and Steering

• Service brake and park brake system maintenance
• Steering circuit schematics, troubleshooting, and component replacement

Engine

• Engine removal and replacement procedures for Deutz and Kohler variants
• Exhaust system, cooling fan, and throttle cable servicing
• Fuel system maintenance including lift pump and filters

Note: For detailed engine-specific repairs and diagnostics, refer to the Engine Service Manual Publication Number 9806/4020 (Deutz) or 9806/4060 (Kohler).

This JCB 515-40 Service Manual is a vital resource for professionals performing diagnostics, advanced repairs, and preventive maintenance across various industries.