JCB 505-19, 505-22, 506-36, 506B, 508-40, 510-40 Telescopic Handler Service Repair Manual

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

Contents 9803/3600U Issue 8* General 1 Hydraulics 2 Body and Framework 3 PlaceAce Control System 4 Servo Control System 4A Engine 5 Transmission 6 Axles 7 Brakes 8 Hydraulic Steering 9 Electrics 10 Service Tools 11 Boom Float, Return to Dig Option 12

9803/3600 Issue 2* Introduction This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training by JCB Technical Training Department. It is assumed that these personnel have a sound knowledge of workshop practice, safety procedures, and general techniques associated with the maintenance and repair of hydraulic earthmoving equipment. Therefore these basic subjects generally are omitted from this manual, the intention being to convey only more specialised information concerning particular aspects of a machine or component. For example, renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of course, and therefore information of this nature is included only in the context of specialised procedures or where a range of wear tolerances is required. Similarly, it is expected that components will be cleaned and lubricated where appropriate, also that any opened hose or pipe connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt. For convenience this manual is compiled in sections, e.g. "Hydraulics", "Electrics", etc. but, to find details of a specific component, reference should be made to the alphabetical index at the back of the book. Illustrations which show a dismantled component are numbered as a guide to the dismantling sequence, which generally can be reversed for assembly. Torque settings are given as a 'mean' figure which 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. Where no figure is quoted in the text, refer to page 1/1 - 3. 'Left Hand' and 'Right Hand' are as viewed from the rear of the machine looking forward. ! WARNING Asbestos Asbestos dust can damage your lungs. Some engine joints and gaskets may contain asbestos. Take the following precautions when working on them. 1 Wear a face mask and gloves. 2 Work in a well ventilated area and do not smoke. 3 Do not use a rotary wire brush, use a hand scraper. 4 Make sure the material to be removed is wet with oil or water to contain loose particles. 5 Place all material into plastic bags and dispose in accordance with local regulations. GEN-1-8 ! WARNING Fluoroelastomeric Materials Certain seals and gaskets (e.g. crankshaft oil seal) on JCB machines contain fluoroelastomeric materials such as Viton, Fluorel and Technoflon. Fluoroelastomeric materials subjected to high temperatures can produce highly corrosive hydrofluoric acid. THIS ACID CAN SEVERELY BURN. New fluoroelastomeric components at ambient temperature require no special safety precautions. Used fluoroelastomeric components whose temperatures have not exceeded 300°C require no special safety precautions. If evidence of decomposition (e.g. charring) is found, refer to the next paragraph for safety instructions DO NOT TOUCH COMPONENT OR SURROUNDING AREA. Used fluoroelastomeric components subjected to temperatures greater than 300°C (e.g. engine fire) must be treated using the following safety procedure. Make sure that heavy duty gloves and special safety glasses are worn: 1 Ensure that components have cooled then remove and place material into plastic bags. 2 Thoroughly wash contaminated area with 10% calcium hydroxide or other suitable alkali solution, if necessary use wire wool to remove burnt remains. 3 Thoroughly wash contaminated area with detergent and water. 4 Contain all removed material, gloves etc. used in this operation in sealed plastic bags and dispose of in accordance with Local Authority Regulations. DO NOT BURN FLUOROELASTOMERIC MATERIALS. If contamination of skin or eyes occurs, wash the affected area with a continuous supply of clean water or with calcium hydroxide solution for 15-60 minutes. Get medical attention immediately. INT-3-3-5/1

Colour Coding The following colour coding, used on illustrations to denote various conditions of oil pressure and flow, is standardised throughout JCB Service publications. 9803/3600U Issue 1 A390940 Full Pressure Pressure generated from operation of a service. Depending on application this may be anything between neutral circuit pressure and M.R.V. operating pressure. Pressure Pressure that is above neutral circuit pressure but lower than that denoted by red. Servo Oil pressure used in controlling a device (servo). Neutral Neutral circuit pressure. Exhaust Cavitation Oil subjected to a partial vacuum due to a drop in pressure (cavitation). Lock Up Oil trapped within a chamber or line, preventing movement of components (lock up). Red Pink Orange Blue Green Light Green Yellow

General Issue 1 i 1 9803/3600U 1 i Contents Page No. Fluids, Lubricants, Capacities & Specifications - 505-19/22 1 - 1 - 506-36 1 - 2 - 508-40 & 510-40 1 - 2A - 506B 1 - 2B - Torque Settings 1 - 3 Service Schedules 2 - 1 Greasing Pivot Pins - 555-19/22 3 - 1 - 508-40 & 510-40 3 - 2 - 506-36 3 - 3 - 506B 3 - 4 Front Axle 3 - 5 Rear Axle 3 - 6 Carriage Lock Pins 3 - 7 Boom Wear Pad Runways 3 - 8 Extension Ram Pivots - 505- 19/22 3 - 9 - 508-40 3 - 10 - 506-36 3 - 11 - 506B 3 - 11A Oiling 3 - 12 - 506B 3 - 13 Boom Safety Strut 4 - 1

1 - 1 1 General 9803/3600U 1 1 - 1 Issue 6* FLUIDS, LUBRICANTS, CAPACITIES AND SPECIFICATIONS (505-19, 505-22) Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run- in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below. ITEM CAPACITY FLUID/LUBRICANT INTERNATIONAL US Gal (Litres) SPECIFICATION Fuel Tank 24 (90) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D Engine (Oil) 2.6 (10) JCB 15W/40 Multigrade SAE15W/40, MIL-L-46152B, -10 °C to 50 °C (14 °F to 122 °F) API CD/SE, MIL-L-2104 JCB Super Universal Agricultural SAE10W/30, MIL-L-2105, MIL-L-46152 -15 °C to 30 °C (5 °F to 86 °F) API CD/SE, MIL-L-2104C JCB Torque Converter Fluid SAE10W, MIL-L-46152, MIL-L-2104D -18 °C to 0 °C (0 °F to 32 °F) API CD/SE Engine (Coolant) 4.4 (17) JCB Universal Antifreeze/water ASTM D3306-74 ( See Coolant Mixtures) Gearbox Syncro Shuttle 4.0 (18.25) JCB Special Transmission Fluid ESP-M2C 33G Powershift †4.8 (15.0) JCB Special Transmission Fluid ESP-M2C 33G Front Axle Housing 4.6 (18) JCB Special Gear Oil ESEN-M2C 86A/B Hubs (x2) 0.4 (2.0) JCB Special Gear Oil ESEN-M2C 86A/B Rear Axle Housing 3.3 (13) JCB Special Gear Oil ESEN-M2C 86A/B Hubs (x2) 0.4 (2.0) JCB Special Gear Oil ESEN-M2C 86A/B Brake System JCB Light Hydraulic Fluid ISO VG15 DO NOT USE ORDINARY BRAKE FLUID Hydraulic Tank *40.2 (152) JCB High Performance Hydraulic Oil ISO VG46 (Above 38 °C, 100 °F) JCB Special Hydraulic Fluid ISO VG32 (Below 38 °C, 100 °F) Grease Points JCB Special MPL Grease Lithium based, No. 2 consistency Wear Pad Runways JCB Waxoyl Boom Hoses JCB Special Slide Lubricant * Note: This is nominal machine capacity. The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level sight glass when filling. † Note: This is a system capacity. Use the 'MIN' and 'MAX' marks on the dipstick when refilling the system. Coolant Mixtures % Antifreeze Starts to Freeze 55 2.45 gal (9.35 litres) -36° C (-33 °F) * * * * *

1 - 2 1 General 9803/3600U 1 1 - 2 Issue 7* Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run- in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below. ITEM CAPACITY FLUID/LUBRICANT INTERNATIONAL US Gal (Litres) SPECIFICATION Fuel Tank 24 (90) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D Engine (Oil) 2.6 (10) JCB 15W/40 Multigrade SAE15W/40, MIL-L-46152B, -10 °C to 50 °C (14 °F to 122 °F) API CD/SE, MIL-L-2104 JCB Super Universal Agricultural SAE10W/30, MIL-L-2105, MIL-L-46152 -15 °C to 30 °C (5 °F to 86 °F) API CD/SE, MIL-L-2104C JCB Torque Converter Fluid SAE10W, MIL-L-46152, MIL-L-2104D -18 °C to 0 °C (0 °F to 32 °F) API CD/SE Engine (Coolant) 4.6 (18) JCB Universal Antifreeze/water ASTM D3306-74 ( See Coolant Mixtures) Syncro Shuttle 4.8 (18.25) JCB Special Transmission Fluid ESP-M2C 33G Front Axle Housing 4.6 (18) JCB Special Gear Oil ESEN-M2C 86A/B Hubs (x2) 0.4 (2.0) JCB Special Gear Oil ESEN-M2C 86A/B Rear Axle Housing 3.3 (13) JCB Special Gear Oil ESEN-M2C 86A/B Hubs (x2) 0.4 (2.0) JCB Special Gear Oil ESEN-M2C 86A/B Brake System JCB Light Hydraulic Fluid ISO VG15 DO NOT USE ORDINARY BRAKE FLUID Hydraulic Tank †50.2 (190) JCB High Performance Hydraulic Oil ISO VG46 (Above 38 °C, 100 °F) JCB HP32 ISO 32 (Below 38 °C, 100 °F) JCB Light Hydraulic Fluid ISO VG15 (For Iceland, Norway, Sweden and Finland ONLY) Grease Points JCB Special MPL Grease Lithium based, No. 2 consistency Wear Pad Runways JCB Waxoyl Boom Hoses JCB Special Slide Lubricant † Note: This is nominal machine capacity. The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level sight glass when filling. Coolant Mixtures % Antifreeze Starts to Freeze 55 2.2 litres (10 gal) -36° C (-33 °F) FLUIDS, LUBRICANTS, CAPACITIES AND SPECIFICATIONS (506-36) * *

1 - 2A 1 General 9803/3600U 1 1 - 2A Issue 2* Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run- in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below. ITEM CAPACITY FLUID/LUBRICANT INTERNATIONAL US Gal (Litres) SPECIFICATION Fuel Tank 24 (90) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D Engine (Oil) 2.6 (10) JCB 15W/40 Multigrade SAE15W/40, MIL-L-46152B, -10 °C to 50 °C (14 °F to 122 °F) API CD/SE, MIL-L-2104 JCB Super Universal Agricultural SAE10W/30, MIL-L-2105, MIL-L-46152 -15 °C to 30 °C (5 °F to 86 °F) API CD/SE, MIL-L-2104C JCB Torque Converter Fluid SAE10W, MIL-L-46152, MIL-L-2104D -18 °C to 0 °C (0 °F to 32 °F) API CD/SE Engine (Coolant) 6.2 (23.5) JCB Universal Antifreeze/water ASTM D3306-74 ( See Coolant Mixtures) Syncro Shuttle 4.8 (18.25) JCB Special Transmission Fluid ESP-M2C 33G Front Axle Housing 4.4 (17) JCB Special Gear Oil ESEN-M2C 86A/B Hubs (x2) 0.4 (2.0) JCB Special Gear Oil ESEN-M2C 86A/B Rear Axle Housing 4.6 (18) JCB Special Gear Oil ESEN-M2C 86A/B Hubs (x2) 0.19 (0.75) JCB Special Gear Oil ESEN-M2C 86A/B Brake System JCB Light Hydraulic Fluid ISO VG15 DO NOT USE ORDINARY BRAKE FLUID Hydraulic Tank †77.2 (292) JCB High Performance Hydraulic Oil ISO VG46 (Above 38 °C, 100 °F) JCB HP32 ISO 32 (Below 38 °C, 100 °F) Grease Points JCB Special MPL Grease Lithium based, No. 2 consistency Wear Pad Runways JCB Waxoyl Boom Hoses JCB Special Slide Lubricant † Note: This is nominal machine capacity. The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level sight glass when filling. Coolant Mixtures % Antifreeze Starts to Freeze 55 3.4 gal (12.92 litres) -36° C (-33 °F) FLUIDS, LUBRICANTS, CAPACITIES AND SPECIFICATIONS (508-40 and 510-40) * *

1 - 2B 1 General 9803/3600U 1 1 - 2B Issue 2* Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run- in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below. ITEM CAPACITY FLUID/LUBRICANT INTERNATIONAL US Gal (Litres) SPECIFICATION Fuel Tank 24 (90) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D Engine (Oil) 3.1 (10) JCB 15W/40 Multigrade SAE15W/40, MIL-L-46152B, -10 °C to 50 °C (14 °F to 122 °F) API CD/SE, MIL-L-2104 JCB Super Universal Agricultural SAE10W/30, MIL-L-2105, MIL-L-46152 -15 °C to 30 °C (5 °F to 86 °F) API CD/SE, MIL-L-2104C JCB Torque Converter Fluid SAE10W, MIL-L-46152, MIL-L-2104D -18 °C to 0 °C (0 °F to 32 °F) API CD/SE Engine (Coolant) 7.9 (23.5) JCB Universal Antifreeze/water ASTM D3306-74 ( See Coolant Mixtures) Syncro Shuttle 4.8 (18.25) JCB Special Transmission Fluid ESP-M2C 33G Front Axle Housing 4.7 (18) JCB Special Gear Oil ESEN-M2C 86A/B Hubs (x2) 0.5 (2.0) JCB Special Gear Oil ESEN-M2C 86A/B Rear Axle Housing 3.4 (13) JCB Special Gear Oil ESEN-M2C 86A/B Hubs (x2) 0.5 (2.0) JCB Special Gear Oil ESEN-M2C 86A/B Brake System JCB Light Hydraulic Fluid ISO VG15 DO NOT USE ORDINARY BRAKE FLUID Hydraulic Tank ††32.0 (121) JCB High Performance Hydraulic Oil ISO VG46 (Above 38 °C, 100 °F) JCB Special Hydraulic Fluid ISO VG32 (Below 38 °C, 100 °F) Grease Points JCB Special MPL Grease Lithium based, No. 2 consistency Wear Pad Runways JCB Waxoyl Boom Hoses JCB Special Slide Lubricant †† Note: This is nominal machine capacity. The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level sight glass when filling. † Note: This is a system capacity. Use the 'MIN' and 'MAX' marks on the dipstick when refilling the system. Coolant Mixtures % Antifreeze Starts to Freeze 55 3.4 gal (12.92 litres) -36° C (-33 °F) FLUIDS, LUBRICANTS, CAPACITIES AND SPECIFICATIONS (506B) * *

1 - 3 1 General 9803/3600 Section 1 1 - 3 Issue 2* Torque Settings Use only where no torque setting is specified in the text. Values are for dry threads and may be within three per cent of the figures stated. For lubricated threads the values should be REDUCED by one third. UNF Grade 'S' Bolts Bolt Size Hexagon (A/F) Torque Settings in (mm) in Nm kgf m lbf ft 1 /4 (6.3) 7 /16 14 1.4 10 5 /16 (7.9) 1 /2 28 2.8 20 3 /8 (9.5) 9 /16 49 5.0 36 7 /16 (11.1) 5 /8 78 8.0 58 1 /2 (12.7) 3 /4 117 12.0 87 9 /16 (14.3) 13 /16 170 17.3 125 5 /8 (15.9) 15 /16 238 24.3 175 3 /4 (19.0) 1 1 /8 407 41.5 300 7 /8 (22.2) 1 5 /16 650 66.3 480 1 (25.4) 1 1 /2 970 99.0 715 1 1 /4 (31.7) 1 7 /8 1940 198.0 1430 1 1 /2 (38.1) 2 1 /4 3390 345.0 2500 Metric Grade 8.8 Bolts Bolt Size Hexagon (A/F) Torque Settings (mm) mm Nm kgf m lbf ft M5 (5) 8 7 0.7 5 M6 (6) 10 12 1.2 9 M8 (8) 13 28 3.0 21 M10 (10) 17 56 5.7 42 M12 (12) 19 98 10 72 M16 (16) 24 244 25 180 M20 (20) 30 476 48 352 M24 (24) 36 822 84 607 M30 (30) 46 1633 166 1205 M36 (36) 55 2854 291 2105 Rivet Nut Bolts/Screws Bolt Size Torque Settings (for steel rivet nuts) (mm) Nm kgf m lbf ft M3 (3) 1.2 0.12 0.9 M4 (4) 3.0 0.3 2.0 M5 (5) 6.0 0.6 4.5 M6 (6) 10.0 1.0 7.5 M8 (8) 24.0 2.5 18.0 M10 (10) 48.0 4.9 35.5 M12 (12) 82.0 8.4 60.5 Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification. *

JCB 505-19, 505-22, 506-36, 506B, 508-40, 510-40 Telescopic Handler Service Repair Manual

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