JCB 506C, 506CHL, 508C Loadalls Repair Service Manual (N.America)

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This service manual PDF download for the 506B, 506C, 506 (HL), 508C JCB Loadalls 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 manual provides information for the following model(s) in the JCB machine range:

– JCB Loadall 506C - from S/N: 579781
– JCB Loadall 506CHL - from S/N: 579569
– JCB Loadall 508C - from S/N: 579569


TABLE OF CONTENTS :

Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Routine Maintenance
Section A - Attachments
Section B - Body and Framework
Section C - Electrics
Section D - Controls
Section E - Hydraulics
Section F - Transmissions
Section G - Brakes
Section H - Steering
Section K - Engine


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Publication No. : 9803/3640U-8 (N.America)
Total Pages : 718


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9803-3640U

Section 1 - General Information
General Information
Introduction
About This Manual
Machine Model and Serial Number
Using the Service Manual
Units of Measurement
Section Numbering
Left Side, Right Side
Using the Machine
Cab/Canopy
Cross References
Identifying Your Machine
Machine Identification Plate
Typical Vehicle Identification Number (VIN)
Typical Product Identification Number (PIN)
Component Identification Plates
Typical Engine Identification Number
Transmission Identification Numbers
ROPS/FOPS Certification Plate
Standard Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
Introduction
Bolts and Screws
Condition 1
Condition 2
Verbus Ripp Bolts
Hydraulic Connections
'O' Ring Face Seal System
Adaptors Screwed into Valve Blocks
Hoses Screwed into Adaptors
Adaptors into Component Connections with Bonded Washers
'Torque Stop' Hose System
Service Tools
Numerical List
Tool Detail Reference
Section B - Frame and Bodywork
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section H - Steering
Section K - Engine
Service Consumables
Sealing and Retaining Compounds
Terms and Definitions
Colour Coding
Hydraulic Schematic Colour Codes

Section 2 - Care and Safety
Safety Notices
Important Information
The Operator Manual
Safety Warnings
Safety Check List
Safety - Yours and Others
General Safety
Operating Safety
Maintenance Safety
Safety Decals
Safety Decal Definitions

Section 3 - Routine Maintenance
Routine Maintenance
Service Requirements
Introduction
Owner/Operator Support
Service/Maintenance Agreements
Initial Service and Inspection (100 Hours)
Obtaining Replacement Parts
Health and Safety
Lubricants
Battery
First Aid - Electrolyte
Service Schedules
Introduction
How to Use the Service Schedules
Machines with A and R Series Engines
Machines with JCB Dieselmax Engine
Fluids, Lubricants and Capacities
Coolant Mixtures
Greasing
Every 50 Hours
Every 500 Hours
Every 1000 Hours
Oiling
Park Brake Cable
Control Levers
Boom Chains
Cleaning the Machine
Introduction
Preparing the Machine for Cleaning
Cleaning the Machine
Checking for Damage
Seat Belt
Checking the Seat Belt Condition and Security
ROPS/FOPS Structure
Checking the ROPS/FOPS Structure
Boom Safety Strut
Installing
Removing
Access Panels
Radiator Grill
Battery Cover
Engine Hood and Cover
Brakes
Park Brake Adjustment (Later Machines)
Checking the Foot Brake Fluid Level
Electrical System
Battery
Jump Starting the Engine
Adjusting the Alternator Drive Belt
Engine Air Filter
Cleaning the Pre-Cleaner (if fitted)
Changing the Elements
Engine (A and R Series)
Checking the Oil Level
Changing the Oil and Filter
Checking the Coolant Level
Changing the Coolant
Engine (JCB Dieselmax)
Checking the Oil Level
Changing the Oil and Filter
Checking the Coolant Level
Changing the Coolant
Front End Accessory Drive Belt
Fuel System
Types of Fuel
Filling the Tank
Machines with A Series Engine
Machines with R Series Engine
Machines with JCB Dieselmax Engine
Hydraulic System
Checking the Fluid Level
Hydraulic Tank Cap
Changing the Filter Element
Checking the Hose Burst Protection Valves
Transmission
Checking the Transmission Oil Level
Changing the Transmission Oil and Filter
Tires and Wheels
Tire Inflation
Checking the Wheel Nut Torques
Tire Ballast
Axles
Front and Rear Axle
Windshield Washer
Checking the Level

Section A - Attachments
Service Procedures
Quick Release Couplings
Connecting and Disconnecting
Venting Hydraulic Pressure

Section B - Body and Framework
Body and Framework
Service Procedures
Rivet Nuts
Fitting Procedure
Slide Hammer Kit
Fitting Procedure
Boom
Removal and Replacement
Removal
Replacement
Re-Shimming the Boom
Boom Shimming
Typical Method
Measurements
Boom Chains
Servicing
Adjustment
Chain Roller Inspection
Wear Limits
Removal, Inspection and Replacement
Extend Chains
Retract Chain
Combined Fuel and Hydraulic Tank
Removal and Replacement
Machines with A and R Series Engines
Machines with JCB 444 Engines
Cab
Removal and Replacement
Removal
Replacement
Glazing
Removal and Replacement

Section C - Electrics
Electrics
Technical Data
General Electrical Data
Fuses and Relays
Fuse Identification
Link Box Fuses
Relay Identification
Basic System Operation
Circuit Schematics
Syncro Shuttle Machines up to S/N 585396
Syncro Shuttle Machines S/N 585397 to 587635
Syncro Shuttle Machines S/N 587636 to 589999
Syncro Shuttle Machines from S/N 1184000
Powershift Machines up to S/N 585396
Powershift Machines S/N 585397 to 589999
Powershift Machines S/N 585397 to 589999
Service Procedures
Using a Multimeter
Measuring DC Voltage
Measuring Resistance
Measuring Continuity
Measuring Frequency
Testing a Diode or a Diode Wire
Battery
Maintenance
First Aid - Electrolyte
Testing
Specific Gravity Testing
Alternator
General Description
Service Precautions
Charging Circuit Test
Alternator Charging Test
Starter Motor
Starting Circuit Test
Wire and Harness Number Identification
Introduction
Wire Numbers and Functions
Wiring Harness Repair
Introduction
Repair Procedure
Alternator (A and R Series Engine)
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Lucas Type
Alternator (JCB 444 Engine)
Removal, Inspection and Replacement
Removal
Inspection
Replacement
Dismantle and Assembly
Starter Motor (A and R Series Engine)
Removal and Replacement
Removal
Replacement
Dismantling, Inspection and Assembly
Dismantling
Inspection
Assembly
Starter Motor (JCB 444 Engine)
Removal, Inspection and Replacement
Removal
Inspection
Replacement
Dismantle and Assembly
Switches
Proximity Switches (if fitted)
Adjustment
Harness Data
Drawings And Interconnection
Harnesses
Drawings

Section D - Controls
Controls
Dual Control Function Levers
Assembly
Adjustment

Section E - Hydraulics
Hydraulics
Technical Data
506C Machines
506C Machines (from S/N 1184000)
506CHL and 508C Machines
506CHL and 508C Machines (from S/N 1184000)
Basic System Operation
General Description
Introduction to Hydraulic Schematic Symbols
General (Basic and Functional Symbols)
Control Valves
Example of Schematic Circuit
Circuit Schematics
506C Machines
Component Key
506CHL and 508C Machines
Component Key
All Models (from S/N 1184000)
Description
Component Key
Circuit Descriptions
Hydraulic Pump
Hose Burst Check Protection
Boom Extend Regenerative
Boom Extend High Pressure
Boom Retract
Hose Burst Operation
Parallel Lift
Boom Raise Cycle
Boom Lower Cycle
Fault Finding
General Machine
Parallel Lift
Service Procedures
Hydraulic Contamination
Hydraulic Fluid Quality
Effects of Contamination
Cleaning Operation
Contaminant Standards
Filters
Connecting/Disconnecting Hydraulic Hoses
Introduction
Connecting the Hoses
Disconnecting the Hoses
Venting Hydraulic Pressure
Main Pump
Removal and Replacement
506CHL and 508C
Machines from M1184000
Preparation
Removal
Replacement
Dismantling and Assembly
506C
506C-HL, 508C
Main Hydraulic and Fan Pump - from M1184000
Fan Pump
Removal and Replacement
Removal
Replacement
Tandem Steer/Fan Pump
Removal and Replacement
Introduction
Removal
Replacement
Dismantling, Inspection and Assembly
Dismantling
Inspection
Assembly
Testing and Adjustment
Control Valve
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Tie Rods
Valve Block Sections
Spools
Testing and Adjustment
Relief Valve Locations
Pressure Testing
Fan Motor
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Dismantling
Inspection
Assembling
Testing and Adjustment
Fan Motor (from S/N 1184000)
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Dismantling
Inspection
Assembling
Testing and Adjustment
Rams
Precautions During Use
Installation
Caution During Use
Maintenance, Inspection Points
Removal and Replacement
Lift Ram
Displacement Ram
Extension Ram
Tilt Ram
Sway Ram
Dismantling and Assembly
Typical Ram
JCB Ram Sealing Procedure
Piston Head Retention
Bleed Procedures
Sway Circuit

Section F - Transmissions
Transmission
Technical Data
Syncro Shuttle
Powershift
Axles
Tyres
Recovery Procedure
General Description - Syncro Shuttle
General Description - Powershift
Powershift, Drive Paths
Transmission Oil
Fault Finding
Syncro Shuttle
Powershift
Transmission Removal and Replacement
Syncro Shuttle
Powershift
Torque Converter
Syncro Shuttle
Testing
Dismantling
Assembly
Reverser Unit
Dismantling
Assembly
Solenoid Valve - Dismantling and Assembly
PTFE Piston Ring Seals - Fitting Procedure
Collapsible Spacer - Assembly
Output Shaft Removal - Larger Diameter Gear
Powershift Transmission
Summary of Changes
PS700 Section Views and Torque Figures
PS750 Section Views and Torque Figures
Dismantling (With Reverser Shaft Cover Plate)
Assembling (With Reverser Shaft Cover
Powershift (PS700 with reverser Shaft Sealing Plug & PS750) List of Components
Dismantling (With Reverser Shaft Sealing Plug & PS750)
Assembly (With Reverser Shaft Sealing Plug & PS750)
Input and Reverser Clutch (PS700)
Location of Components
Dismantling
Assembly
Mainshaft (PS700)
Location of Components
Dismantling
Assembly
Layshaft (PS700)
Location of Components
Dismantling
Assembly
Input and Reverser Clutch (PS750)
Dismantling
Assembly
Mainshaft (PS750)
Dismantling
Assembly
Layshaft (PS750)
Dismantling
Assembly
Permanent 4 Wheel Drive Unit Dismantling and Assembly
Solenoid Identification
Torque Converter Stall Test
Clutch Leakage Testing
Pressure & Flow Testing
Propshafts - Removal and Replacement
Road Wheel - Removal and Replacement
Water Ballast Tires
Axles
Removal and Replacement
Front Axle
Rear Axle
Front and Rear Hubs Drive Shaft
Dismantling
Assembly
Front Inboard Brakes Dismantling and Assembly
Front Drive Head
Dismantling
Pinion Depth
Assembly
Rear Drive Head
Dismantling
Pinion Depth
Assembly
Renewing the Pinion Oil Seal
SD55 Splined Hub and Driveshaft
Dismantling
Assembly
Oil Cooler
Oil Contamination
Flushing System
Checking Transmission Oil
Axle Operating Temperature
Salvage/Repair
Drive Shaft Oil Seal
Oil Seal Replacement
Wear Sleeve Fitting
Axle and Gearbox Driveshaft Flange Seals
Hub and Driveshaft - Fitting Bearing Carrier Seal
Product Changes
Axles (SD55)

Section G - Brakes
Section G
Brakes
Technical Data
All Models
Basic Operation
General Description
Service Procedures
Brake Piston Seal Leakage
Introduction
Low Pressure:
High Pressure:
Testing
Test for a High Pressure Leak
Test for a Low Pressure Leak
Bleeding Procedure
Front Axle
Rear Axle
Master Cylinder
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Dismantling
Assembly
Park Brake
Machines up to SN 586873
Renewing the Brake Pads
Dismantling and Assembly
Dismantling
Assembly
Testing and Adjustment
Testing
Adjustment
Machines from SN 586874
Brake Calliper
Removal and Replacement
Removal
Inspection
Replacement
Renewing the Brake Pads
Torque Figures
Dismantle, Inspection And Assemble
Component Identification
Dismantle
Inspection
Assemble
Testing and Adjustment
Testing
Adjustment
Lever Adjustment
Cable Adjustment

Section H - Steering
Steering
Technical Data
506C
506CHL & 508C
Basic System Operation
Hydraulic Steer Circuit
Steer Mode Selection
Circuit Descriptions
Steer Unit Operation
Machines from S/N 1184000
Priority Valve Operation
Early Machines
Machines from S/N 1184000
Steer Mode Valve Operation
Crab Steer
2 Wheel Steer
4 Wheel Steer
Service Procedures
Bleeding
Re-phasing the Road Wheels
Manual Steer Mode Valve
Priority Valve
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Steer Rams
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Steer Mode Valve
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Operating Cable
Steer Unit
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Early Machines
Later Machines

Section K - Engine
Engine
Technical Data
A Series Engines
R Series Engines
JCB 444 Series Engines

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