JCB 506-36 507-42 509-42 510-56 Telescopic Handler Service Repair Workshop Manual

Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE. World Class Customer Support 9803/3740-08 Publication No. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400 Service Manual 506-36, 507-42, 509-42, 510-56, 512-56 Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine Section M - Electronic Network

Section i - Front Cover i-ii i-ii 9803/3740-08 Notes:

Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE. World Class Customer Support 9803/3740-07 Publication No. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400 Section 1 General Information Service Manual - 506-36, 507-42, 509-42, 510-56, 512-56 Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine Section M - Electronic Network

Section 1 - General Information 1-0 1-0 9803/3740-07 Notes:

Page No. Contents Section 1 - General Information 1 - i 1 - i Applications Introduction ............................................................................................1-1 - 1 Tables ....................................................................................................1-1 - 2 Section 1 - General Information .......................................................1-1 - 2 Section 2 - Care and Safety .............................................................1-1 - 2 Section 3 - Routine Maintenance .....................................................1-1 - 3 Section B - Body and Framework .....................................................1-1 - 3 Section C - Electrics .........................................................................1-1 - 4 Section E - Hydraulics ......................................................................1-1 - 5 Section F - Transmission ..................................................................1-1 - 6 Section G - Brakes ...........................................................................1-1 - 7 Section H - Steering .........................................................................1-1 - 8 Section K - Engine ............................................................................1-1 - 9 Section M - Electronic Data Systems .............................................1-1 - 10 Introduction to the Manual Introduction ............................................................................................1-2 - 1 Scope ....................................................................................................1-2 - 2 Personnel .........................................................................................1-2 - 2 Applications ......................................................................................1-2 - 2 Newest Data .....................................................................................1-2 - 2 Format ...................................................................................................1-2 - 3 Left and Right Sides ..............................................................................1-2 - 4 Hydraulic Schematic Codes ..................................................................1-2 - 5 Colour Codes ...................................................................................1-2 - 5 Electrical Device Codes .........................................................................1-2 - 6 Machine Identification Introduction ............................................................................................1-3 - 1 Related Topics .......................................................................................1-3 - 2 Machine Identification Plate ...................................................................1-3 - 3 Typical Product Identification Number (PIN) ....................................1-3 - 3 Component Identification Plates ............................................................1-3 - 5 Typical Engine Identification Number ...............................................1-3 - 5 Transmission Identification Numbers ...............................................1-3 - 6 ROPS/FOPS Certification Plates .....................................................1-3 - 7 Torque Settings Introduction ............................................................................................1-4 - 1 Zinc Plated Fasteners and Dacromet Fasteners ...................................1-4 - 2 Introduction .......................................................................................1-4 - 2 Bolts and Screws ..............................................................................1-4 - 2 Hydraulic Connections ...........................................................................1-4 - 6 'O' Ring Face Seal System ...............................................................1-4 - 6 'Torque Stop' Hose System ..............................................................1-4 - 9 `Positional Type' Hydraulic Adaptors ...................................................1-4 - 10 Fitting Procedure ............................................................................1-4 - 10 Service Tools Introduction ............................................................................................1-5 - 1 Numerical List ........................................................................................1-5 - 2 Tool Detail Reference ............................................................................1-5 - 5 Rivet Nuts ............................................................................................1-5 - 21 Fitting Procedure ............................................................................1-5 - 22

Section 1 - General Information Contents 1 - ii 1 - ii Page No. Contents Slide Hammer Kit .................................................................................1-5 - 23 Fitting Procedure ............................................................................1-5 - 23 Service Consumables Introduction ............................................................................................1-6 - 1 Sealing and Retaining Compounds .......................................................1-6 - 2 Fuel Introduction ............................................................................................1-7 - 1 Related Topics .......................................................................................1-7 - 2 Acceptable and Unacceptable Fuels .....................................................1-7 - 3 Additives ...........................................................................................1-7 - 4 Service Requirements for use of B20 Biodiesel ...............................1-7 - 4 Fuel Types ........................................................................................1-7 - 5 Usage and Effects of Fuels ..............................................................1-7 - 6 Sulphur Content ...............................................................................1-7 - 7 Effects of Fuel Contaminates ...........................................................1-7 - 8

Section 1-1 - General Information 1-1-1 1-1-1 9803/3740-07 (1-14-00) Applications Introduction This manual contains topics that relate to some or all JCB Loadall machines in the 5C group. There are several machine model codes in the family. Machine Group Model Code Model Name 5C D 506-36 5C E 507-42 5C F 509-42 5C G 510-56 5C H 512-56 Machine variants: There are different machine variants within the same model name. This happens because of market requirements, or when the machine specification changes after a period of time. Use the applications tables to see which topics relate to which machine models and variants. Important: The machine model names are NOT referred to in the topics. You must refer to the applications tables for the applicable machine models K Tables ( T 1-1-2) K Section 1 - General Information ( T 1-1-2) K Section 2 - Care and Safety ( T 1-1-2) K Section 3 - Routine Maintenance ( T 1-1-3) K Section B - Body and Framework ( T 1-1-3) K Section C - Electrics ( T 1-1-4) K Section E - Hydraulics ( T 1-1-5) K Section F - Transmission ( T 1-1-6) K Section G - Brakes ( T 1-1-7) K Section H - Steering ( T 1-1-8) K Section K - Engine ( T 1-1-9) K Section M - Electronic Data Systems ( T 1-1-10)

Section 1-1 - General Information Applications Tables 1-1-2 1-1-2 9803/3740-07 (1-14-00) Tables Section 1 - General Information Section 2 - Care and Safety Machine models Topic Ref Title Variant 506-36 5CD 507-42 5CE 509-42 5CF 510-56 5CG 512-56 5CH 1-2 Introduction to the Manual All Machines 1-3 Machine Identification All Machines 1-4 Torque Settings All Machines 1-5 Service Tools All Machines 1-6 Service Consumables All Machines 1-7 Fuel All Machines Machine models Topic Ref Title Variant 506-36 5CD 507-42 5CE 509-42 5CF 510-56 5CG 512-56 5CH 2-1 Safety Notices All Machines 2-2 General Procedures All Machines

Section 1-1 - General Information Applications Tables 1-1-3 1-1-3 9803/3740-07 (1-14-00) Section 3 - Routine Maintenance Section B - Body and Framework Machine models Topic Ref Title Variant 506-36 5CD 507-42 5CE 509-42 5CF 510-56 5CG 512-56 5CH 3-1 Maintenance All Machines Machine models Topic Ref Title VARIANT 506-36 5CD 507-42 5CE 509-42 5CF 510-56 5CG 512-56 5CH B1 Cab Heating and Ventilation SYSTEM B2 Cab Air Conditioning SYSTEM B3 Cab B4 Air Conditioning Condenser B5 Cab HV and HVAC Unit B6 Air Conditioning Binary Switch B7 Heater Valve B8 Fuel Tank B9 Engine Cover B10 Stabilisers B11 RAS SYSTEM B12 Interlock SYSTEM B13 Boom B14 RAS ECU

Section 1-1 - General Information Applications Tables 1-1-4 1-1-4 9803/3740-07 (1-14-00) Section C - Electrics Machine models Topic Ref Title VARIANT 506-36 5CD 507-42 5CE 509-42 5CF 510-56 5CG 512-56 5CH C1 Fuses and Relays C2 Schematics C3 Electrical Harness SYSTEM C4 Battery Charging SYSTEM C5 Alternator C6 Battery

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JCB 506-36 507-42 509-42 510-56 Telescopic Handler Service Repair Workshop Manual

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