JCB 500 Series Loadall Service Manual (N.America) – 9803/3600U-16

(S/N: 561001 Onwards)
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This workshop repair service manual PDF download for the 500 Series JCB Telescopic Handler has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

This Service Manual covers the following Machines:-
JCB 505-19 – Serial Number 561001 – 579365
JCB 505-22 – Serial Number 561001 – 579365
JCB 508-40 – Serial Number 562601 – 579365
JCB 506-36 – Serial Number 563359 – 579999
JCB 510-40 – Serial Number 564542 – 579365
JCB 508-40, 508-40 – PlaceAce
JCB 505-19, 505-22 – Basic Servo Options
JCB 506-36, 508-40 – Servo Options
JCB 506B – Serial Number 570000 – 579766
Information covers two stage and three stage boom machines.

JCB 505-19 (Includes Basic Servo Option) – from S/N: 561001 – 579365
JCB 505-22 (Includes Basic Servo Option) – from S/N: 561001 – 579365
JCB 506-36 (Includes Servo Options) – from S/N: 563359 – 579999
JCB 506B – from S/N: 5570000 – 579766
JCB 508-40 (Includes PlaceAce & Servo Options) – from S/N: 5562601 – 579365
JCB 510-40 – from S/N: 5564542 – 579365

TABLE OF CONTENTS :

General
Hydraulics
Body and Framework
PlaceAce Control System
Servo Control System
Engine
Transmission
Axles
Brakes
Hydraulic Steering
Electrics
Service Tools
Boom Float, Return to Dig Option

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9803/3600U Issue 16 (N.America)
Total Pages : 701

This complete JCB Telescopic Handler | Loadall | Telescopic Loader service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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Cover
Contents
Introduction
Colour Coding

1 – General
FLUIDS, LUBRICANTS, CAPACITIES AND SPECIFICATIONS(505-19, 505-22)
FLUIDS, LUBRICANTS, CAPACITIES AND SPECIFICATIONS(506-36)
FLUIDS, LUBRICANTS, CAPACITIES AND SPECIFICATIONS(508-40 and 510-40)
FLUIDS, LUBRICANTS, CAPACITIES AND SPECIFICATIONS(506B)
Torque Settings
Service Schedules
Greasing
505-19, 22
508-40 and 510-40
506-36
506B
Front Axle and Driveshaft
Rear Axle and Driveshaft
Carriage Lock Pins
Fork Pivot Pins
Boom Wear Pad Runways
Boom Extension Ram Pivots
Oiling
Boom Safety Strut

2 – Hydraulics
Technical Data
505-19/22
408-40
506-36
510-40
506B
General Description
Hydraulic Fluid Level and Filter
505-19/20, 506-36 and early 508-40
508-40 later machines, 510-40, 506B
Draining Fluid and Celaning Suction Strainers
Hydraulic Tank – Removal and Replacement
505-19.22 & 506-36
506B, 508-40, 510-40
Pump Operation
Pump – Removal and Replacement
505-19.22, 506B & 506-36
508-40, 510-40 up to serial No. 569293
508-40, 510-40 from serial No. 569294
Pump – Dismantling and Assembly
All & 508-40, 510-40 up to serial No. 577458
508-40 & 510-40 from serial No. 577459
Machine Neutral Circuit (without torsion box cooling)
Machine Neutral Circuit (with torsion box cooling)
Machine Neutral Circuit (with fitler in steer circuit)
Machine Neutral Circuit (with priority steer/fan pump)
Control Valve Block Ceutral Circuit
Boom Lift Operation (505-22)
Boom Lower Operation (505-22)
Boom Lift Operation (505-19)
Boom Lower Operation (505-19)
Hose Burst Operation
Boom Extend/Retract Operation (505-19/22, 506B)
Sway Operation
Boom Lift Operation (506-36, 508-40 & 510-40)
Boom Lower Operation (506-36, 508-40 & 510-40)
Boom Extend Regenerative (506-36, 508-40 & 510-40)
Boom Extend High Pressure (506-36, 508-40 & 510-40)
Boom Retract (506-36, 508-40 & 510-40)
Stabilizer Check Valve Operation
Stabilizer Operation
M.R.V. Operation
A.R.V. Operation
Boom Extend Regenerative (506B)
Boom Extend High Pressure (506B)
Boom Retract (506B)
Hose Burst Operation (506B)
Boom Extend Regenerative Combined Valve (506B)
Boom Extend High Pressure Combined Valve (506B)
Boom Retract Combined Valve (506B)
Hose Burst Operation Cobmined Valve (506B)
Control Valve Block – Removal and Replacement
Control Valve Block – Dismantling and Assembly
Dual Function Controls Assembly
Pressure Testing
Lift Rams – Removal and Replacement
Displacement Rams – Removal and Replacement
Extension Cylinder – Removal and Replacement (505-19)
Extension Cylinder – Removal and Repalcement (505-22)
Tilt Cylinder – Removal and Replacement
Sway Cylinder – Removal and Replacement
Tow Hitch Cylinder – Removal and Replacement
Inner Extension Cylinder – Removal and Replacement (506-36, 508-40 & 510-40)
Outer Extesion Cylinder – Removal and Replacement (506-36, 508-40 & 510-40)
Stabilizer Cylidner – Removal and Replacement
Boom Extension Circuit Bleeding Procedure (506-36, 508-40 & 510-40)
Extension Cylinder Make Up Valve (506-36, 508-40 & 510-40)
Diverter Valve – Removal and Replacement
Diverter Valve – Dismantling and Assembly
Hose Burst Protection Valve (506B) – Removal & Replacement, Dismantling & Assembly
Typical Cylinder – Dismantling and Assembly
Tow Hitch Cylinder – Dismantling and Assembly
typical Cylinder with Dowel Head – Dismantling and Assembly
Fan Motor
Removal, Replacement and Adjustment
(Sundstrand) Dismantling and Assembly
(Ultra) Dismantling and Assembly
Schematic Hydraulic Circuit
505-19/22 up to machines s/n 567217
505-19/22 from machine s/n 567218
505-19/22 from machine s/n 574296
506-36 up to machine s/n 567217
506-36 from machine s/n 567218
508-40
510-40
506B

3 – Body & Framework
Boom Shimming
Typical Method
505-19/22
506-36
508-40, 510-40
506B
Inner Extension Ram Wear Pads – 508-40, 510-40
Inner Boom – Removal and Replacement – 505-19/22
Boom – Removal and Replacement
505-19
505-22
506-36, 508-40 & 410-40
Boom Extend Chain – Removal and Replacement – 506B
Boom Retract Chain – Removal adn Replacement – 506B
Boom Chains – Adjustment – 506B
Boom Chains – Inspection – 506B
Cab – Removal and Replacement
Front Windshield – Removal and Replacement
Rear Window – Removal and Replacement
Side Window – Removal and Replacement
Rear Window Hinged
Q-fit Carriage – Removal and Replacement
Fuel Tank – Removal and Replacement (505-19/22 & 506-36)
Air Conditioning Option
Technical Data
Description of Operation
Control
Safety Procedures
Wiring Diagram
Fault Finding
Leak Testing
Condenser Coil Cleaning
Condenser Cooling Fan – Removal and Replacement
Condenser Fan Relay – Removal and Replacement
Receiver Drier – Removal and Replacement
Binary Switch – Removal and Replacement
Evaporator Unit – Removal and Replacement
Thermostat – Removal and Replacement
Blower Motor – Removal and Replacement
Expansion Valve – Removal and Replacement
Evaporator Coil – Removal and Replacement
Adjusting the Compressor Drive Belt

4 – Loadall PlaceAce Control System
Technical Data
508-40
510-40
Control System Description
Valve Block Operation
Pulsar Description and Operation
Valve Block – Removal and Replacement
Pulsar Solenoid – Removal and Replacement
Main Spool – Removal and Replacement
Boom Angle Sensor – Removal and Replacement
Boom Extension Sensor – Removal and Replacement
Attitude Sensor – Removal and Replacement
Motion Pac Control Unit – Removal and Repalcement
Driver Cards – Removal and Replacement
Display Unit – Removal and Replacement
Joystick – Removal and Replacement
Lever Control (Stabilizers) – Removal and Replacement
Control Valve – Dismantle and Assembly
Valve Stack – Dismantle and Assembly
Pressure Testing
Full System Calculation
Vehicale Attitude and Tachometer Signal Calibration
Pulsar Solenoid Calibration
Driver Card Calibration/Adjustment
Functional Checks
Fault Finding
Schematic Hydraulic Circuit 508-40, 510-40
Schematic Electical Circuit 508-40, 510-40

4A – Servo Control System
Technical Data
505-19/22
506-36, 508-40
Basic Servo Cotnrol System Description – 505-19/22
Servo Control System Description – 506-36, 508-40
Valve Block Operation
Valve Block Main Spool Operation
Joystick Control Lever Operation
Cab and Chassis Electrical Circuits Description
505-19/22
506-36, 508-40
Valve Block – Removal and Replacement
Control Valve Section – Dismantle and Assembly
Control Valve Inlet & Outlet – Dismantle and Assembly
Joystick – Removal and Replacement
Lever Control – Removal and Replacement
Pressure Testing
Bench Testing Joystick Control Levers
Bench Testing Sway/Stabilizer Control Levers
Fault Finding
505-19/22
506-36, 508-40
Schematic Hydraulic Circuit
505-19/22 up to machines s/n 567217
505-19/22 from machines s/n 567218
506-36, 508-40
Schematic Electrical Circuit
505-19
505-22
506-36, 508-40

5 – Engine
Technical Data
General Description
Engine Cover
Engine Oil Filter
Fuel Filter
Fuel Sediment Bowl
Fuel Lift Pump
Bleeding
Naturally Aspirated
Turbocharged
Self Bleeding Fuel System
Cooling System
Alternator Drive Belt
Pre-Cleaner
Air Filter
Radiator
Engine – Removal and Replacement
Exhauster – Removal and Replacement
Turbo Charger Engine Insulation
Naturally Aspirated Engine Insulation

6 – Transmission
Syncro Shuttle Technical Data
Syncro Shuttle General Description
Powershift Technical Data
Recovery Procedure
Checking & Changing Oil
Syncro Shuttle General Description & Operation
Syncro Shuttle Operation
Syncromesh Description
Four Wheel Drive Clutch Operation (4 Wheel Drive)
Four Wheel Drive Clutch Operation (2 Wheel Drive)
Powershift General Description
Powershift Operation
Powershift Drive Paths
Fault Finding
Syncro Shuttle
Powershift
Transmission – Removal and Replacement
Torque Covnerter – Removal and Replacement
Syncro Shuttle – Dismantling
Syncro Shuttle – Assembly
Solenoid Valve – Dismantling and Assmbly
Reverser Unit
Dismantling
Assembly
Later Type – Dismantling
Later Type – Assembly
Mechanical 4 Wheel Drive – Dismantling
Mechanical 4 Wheel Drive – Assembly
Hydraulic 4 Wheel Drive – Dismantling
Hydraulic 4 Wheel Drive – Assembly
Hydraulic 2/4 Wheel Drive IP 67 Machines
Pressure Testing 2/4WD Clutch
2/4 Wheel Drive Clutch – Fault Finding
Torque Converter Stall Test
Polytetrafluoroethene (PTFE) Piston Ring Seals – Fitting Procedure
Powershift
Removal and Replacement
Dismantling
Assembly
Clutch – Dismantling
Clutch – Assembly
Mainshaft – Dismantling
Mainshaft – Assembly
Layshaft – Dismantling
Layshaft – Assembly
Solenoid Identification
Torque Converter Stall Test
Clutch Leak Testing
Pressure and Flow Testing

7 – Axles
Technical Data
505-19/22
508-40
510-40
506-36, 506B
Road Wheel – Removal and Replacement
Front Axle Breather
Water Ballast Tyres
Front Axle Breather – Removal and Replacement
Axle Oil Level
Cutaway of Front Axle
Cutaway of Rear Axle
Front Axle (Fixed) – Removal and Replacement and Proximity Switch Setting
Front Axle (Sway) – Removal and Replacement and Proximity Switch Setting
Rear Axle – Removal and Replacement and Proximity Switch Setting
Hubs
Hub (Dowel) & Driveshaft Dismantling
Hub (Dowel) & Driveshaft Assembly
Front Hub (Splined) & Driveshaft Dismantling
Front Hub (Splined) & Driveshaft Assembly
Rear Hub (Splined), Brakes & Driveshaft Dismantling
Rear Hub (Splined), Brakes & Driveshaft Assembly
Brakes
Dismantling
Assembly
Front Drive Head
Dismantling
Assembly
Renewing the Axle Pinion Oil Seal
Rear Drive Head
Dismantling
Assembly
Limited Slip Differential – Dismantling & Assembly

8 – Brakes
Technical Data & General Description
505-19/22
508-40 & 510-40
506-36, 506B
Parking Brake
Adjusting and Testing
Dismantling and Assembly
Brake System
Bleeding (Front Axle)
Bleeding (Rear Axle)
Single Master Cylinder Without Servo – Removal and Replacement
Single Master Cylinder With Servo – Removal and Replacement
Tandem Master Cylinder With Servo – Removal and Replacement
Single Master Cylinder Without Servo – Dismantling and Assembly
Single Master Cylinder With Servo – Dismantling and Assembly
Tandem Master Cylinder Wtih Servo – Dismantling and Assembly

9 – Hydraulic Steering
Tehcnical Data
General Description
Flow Regulating Valve Operation
Tandem Steering/Fan Pump – Dismantling and Assembly
Steering/Fan Motor Pump – Removal and Replacement
Single Steering/Fan Pump – Dismantling and Assembly
System Operation (Machines Without IP67 Electrics)
2 Wheel Steer
4 Wheel Steer
Crab Steer
System Operation (Machines With IP67 Electrics)
2 Wheel Steer
4 Wheel Steer
Crab Steer
Steering Description
Operation 1
Operation 2
Steering Shock Valve Description
Normal Condition
Shock Condiltion
Priority Valve Description/Operation
Steering Unit
Removal and Replacement
Dismantling and Assembly
Hydraulic Steering Unit
Steering Mode Valve – Removal and Replacement
Machines Without IP67 Electrics
Machines With IP67 Electrics
Steering Mode Valve – Dismantling and Assembly
Machines With IP67 Electrics
Steering Ram – Removal and Replacement
Steering Ram – Dismantling and Assembly
505-19/22 up to machine s/n 561929
505-19/22 from machine s/n 561930
508-40 & 510-40
Typical Steer Ram with Dowel Piston Head
Bleeding
Pressure Testing

10 – Electrics
Introduction
Technical Data
Fuses
Relay Location
Test Moethods
Battery Testing
Alternator
General Description
Service Precautions
Removal and Replacement
Dismantling and Assembly
Starting Circuit Test
Starter Motor – Lucal M127
Removal and Replacement
Dismantling and Assembly
Harness Repair
Wiring Diagrams
Machines without IP67 Electrics (With Roadlights)
Machines without IP67 Electrics (Without Roadlights)
Machines with IP67 Electrics
Wire Number Identification
Machines with IP67 Electrics
All Machines from Serial No. 572168; 508-40 from Serial No. 572242
Powershift Option
506B Machines up to Serial No. 758676
506B Machines from Serial No. 578677

11 – Service Tools
Numerical List
Section 2 – Hydraulics
Section 5 – Engine
Section 6 – Transmission
Section 7 – Axles
Section 9 – Steering
Section 10 – Electrics
Sealing and Retaining Compounds

12 – Boom, Float, Return To Dig Option
Description
Schematic Hydraulic Circuit
Wiring Diagram
Relay Location
Fault Finding
Micro Switch Adjustment
Proximity Switch Adjustment
Hose Burst Solenoid – Removal and Replacement
Displacement Isolation Valve & Pressure Switch – Removal and Repalcement

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