Hydrostatic drive is the hardest system to get right on a JCB 515-40 Loadall telehandler, and this 641-page JCB 515-40 service manual PDF (publication 9803/9900-4) takes you through the transmission pump and wheel motors before widening out to the boom, load moment indicator, brakes, steering, and both the Deutz and Kohler engines. Wiring schematics trace each circuit through the alternator, starter motor and harness, and the hydraulic chapter pairs a schematic symbols key with the main services pump, control valve block and rams. Service schedules, fluids and greasing points take up a long stretch of the book. Expect 80A nominal from the alternator (82A maximum) when you test the charging circuit, and torque a 3/8 in. BSP hose to 33.0 to 40.0 Nm. A guessed hose torque is how a fitting lets go under boom load. Bookmarked and text-searchable, the download travels with you to the yard, the site cabin, or wherever your Loadall is parked.
What's Inside This Manual
| System | Pages | Key Topics |
|---|
| General Information | 1-47 | Introduction, Machine Identification, Standard Torque Settings, Service Tools, Service Consumables, Colour Coding |
| Care and Safety | 48-67 | Safety Notices, Safety Check List, Safety Labels, General Safety, Maintenance Safety |
| Maintenance | 68-167 | Service Schedules, Fluids and Lubricants, Cleaning, Checking for Damage, Greasing, Oiling |
| Attachments | 168-175 | Connecting Hydraulic Hoses, Disconnecting Hydraulic Hoses, Quick Release Couplings |
| Body and Framework | 176-275 | Load Moment Indicator, Cab Heating and Ventilation, Air Conditioning, Glazing, Boom, Counterweight |
| Electrics | 276-355 | Schematic Circuits, Multimeter Usage, Alternator, Starter Motor, Battery, Harness Data |
| Controls | 356-369 | Manual Control Levers, Joystick, Control Assembly, Control Rod Assembly |
| Hydraulics | 370-441 | Hydraulic Schematic Symbols, Main Services Pump, Control Valve Block, Rams, Hydraulic Tank |
| Transmissions | 442-509 | Hydrostatic Transmission, Transmission Pump, Wheel Motors, Wheels and Tyres |
| Brakes | 510-541 | Service Brakes, Park Brake, Brake Shoes, Brake Wheel Cylinder, Brake Master Cylinder |
| Steering | 542-573 | Hydraulic Steer Unit, Priority Valve, Steer Ram, Steer Stops, Re-Phasing Wheels |
| Engine | 574-641 | Deutz Engine, Kohler Engine, Engine Sensors, Cooling Pack, Throttle Cable, Fuel System |
Quick Reference Specifications
| Specification | Value | Page |
|---|
| BSP Hose Torque (1/8 in.) | 14.0 - 16.00 Nm | p. 23 |
| BSP Hose Torque (1/4 in.) | 24.0 - 27.0 Nm | p. 23 |
| Hydraulic filter cap torque | 20 Nm (14.7 lbf ft) | p. 165 |
| Alternator Maximum output | 82A | p. 282 |
| Alternator Nominal output | 80A | p. 282 |
| Battery voltage | 12 volts | p. 282 |
| Maximum charging voltage | 15.8 Volts | p. 300 |
| Filtration Size | 12-16 micron | p. 376 |
| Suction Strainer | 135 micron | p. 376 |
| Fan Motor Relief Valve test pressure | 0 - 100 bar (0 - 1450 lbf/in2) | p. 414 |
| Torque for piston head 40-6 | 405 Nm (41 Kgf m, 300 lbf ft) | p. 435 |
| Deutz Engine Oil Capacity | 8.0 (1.76) Litres (Gal) | p. 85 |
