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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Factory Jcb 506 36 507 42 509 42 510 56 Telescopic Handler S
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What's Included?
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Online & Offline Access
Access PDF Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
Description
The Factory Jcb 506 36 507 42 509 42 510 56 Telescopic Handler Service Repair Workshop Manual is an essential resource for professional mechanics and DIY enthusiasts alike. This comprehensive manual provides detailed technical information and instructions for servicing and repairing the JCB 506 36, 507 42, 509 42, and 510 56 telescopic handlers. Whether you're performing routine maintenance or tackling more complex repairs, this manual equips you with the knowledge needed to ensure the optimal performance of these machines.
