JCB 506-36, 507-42, 509-42, 510-56 Loadalls Repair Service Manual
JCB 506-36, 507-42, 509-42, 510-56 Loadalls Repair Service Manual
(S/N: 1402000 - 1404999) - This service manual PDF download for the 506-36, 507-42, 509-42, 510-56 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 :
- JCB Loadall 506-36 - from S/N: 1402000 - 1404999 - JCB Loadall 507-42 - from S/N: 1402000 - 1404999 - JCB Loadall 509-42 - from S/N: 1402000 - 1404999 - JCB Loadall 510-56 - from S/N: 1402000 - 1404999
TABLE OF CONTENTS :
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
MANUAL SPECIFICATION :
File Format : PDF Language : English Printable : Yes Searchable : Yes Bookmarked : Yes Publication No. : 9803/3740-06 Total Pages : 1206
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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9803-3740 506-36, 507-42, 509-42, 510-56
Section 1 - General Information General Information Applications Introduction Tables 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 Data Systems Introduction to the Manual Introduction Scope Personnel Applications Newest Data Format Left and Right Sides Hydraulic Schematic Codes Colour Codes Electrical Device Codes Machine Identification Introduction Related Topics Machine Identification Plate Typical Product Identification Number (PIN) Component Identification Plates Typical Engine Identification Number Transmission Identification Numbers ROPS/FOPS Certification Plates Torque Settings Introduction Zinc Plated Fasteners and Dacromet Fasteners Introduction Bolts and Screws Hydraulic Connections 'O' Ring Face Seal System 'Torque Stop' Hose System `Positional Type' Hydraulic Adaptors Fitting Procedure Service Tools Introduction Numerical List Tool Detail Reference Rivet Nuts Fitting Procedure Slide Hammer Kit Fitting Procedure Service Consumables Introduction Sealing and Retaining Compounds Fuel Introduction Related Topics Acceptable and Unacceptable Fuels Additives Service Requirements for use of B20 Biodiesel Fuel Types Usage and Effects of Fuels Sulphur Content Effects of Fuel Contaminates
Section 2 - Care and Safety 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 - Yours and Others General Procedures Introduction Parking the Machine and Making it Safe Safety - Yours and Others Boom Maintenance Strut Installing the Maintenance Strut Removing the Maintenance Strut Venting Hydraulic Pressure Connecting/Disconnecting Hydraulic Hoses Introduction Connecting the Hoses Disconnecting the Hoses Quick Release Couplings Connecting and Disconnecting Hydraulic Contamination Hydraulic Fluid Quality Effects of Contamination Cleaning Operation Contaminant Standards Filters Battery Disconnection/Connection Disconnection Connection Removing and Replacing Components Battery Charging System Precautions Hydraulic Rams Installation Caution During Use Maintenance, Inspection Points
Section 3 - Routine Maintenance Routine Maintenance Maintenance Related Topics Health and Safety Lubricants Battery Service Schedules Introduction How to Use the Service Schedules Calendar Equivalents Pre-start Cold Checks, Service Points and Fluid Levels Functional Test and Final Inspection Fluids, Lubricants and Capacities Coolant Mixtures Prepare the Machine for Maintenance Introduction How to Make the Machine Safe (Boom Lowered) How to Make the Machine Safe (Boom Lifted) Cleaning the Machine Preparing the Machine for Cleaning Cleaning the Machine Checking for Damage Check the Machine Body and Structure Check the Tyres Check the Seat and Seat Belt Check the Hydraulic Hoses and Fittings Checking the ROPS/FOPS Structure Greasing Introduction Preparing the Machine for Greasing Every 50 Hours Every 500 Hours Every 1000 Hours Oiling Park Brake Cable Control Levers Boom Chains Access Panels Battery Cover Engine Cover Undershield Rear Boom Cover Central Access Panels Heater and Air Conditioning Changing the Air Intake Filter Boom Chains Adjustment Brakes Park Brake Adjustment Checking the Foot Brake Fluid Level Electrical System Battery Jump Starting the Engine Engine Oil and Filter Cooling System Front End Accessory Drive Belt Air Filter Fuel System Introduction Filling the Tank Water Separator and Engine Fuel Filter Bleeding the System Hydraulic System Oil and Filter Changing the Pilot Filter Element Hose Burst Protection Valves Transmission Gearbox Axles Tires and Wheels Tire Ballast Wheel Alignment Introduction Manual Steer Mode Selector Wear Pads Boom Wear Pad Clearance Windshield Washer Checking the Level Fire Extinguisher (if fitted) Checking the Fire Extinguisher
Section B - Body and Framework Body and Framework Applications Table Cab Heating and Ventilation SYSTEM Introduction Related Topics Operation Overview Electrical Operation and Schematics Electrical Connectors Fault Finding Tables Cab Air Conditioning SYSTEM Introduction Related Topics Specifications R134a Refrigerant PAG Type Refrigerant Oil Operation Overview Component Location System Operation System Control Electrical Operation and Schematics Electrical Connectors Safety Procedures Service Checks Off-Season Operation Fault Finding Introduction Tables System Diagnosis using Test Gauges Test Procedures Leak Testing Tightening Leaking Hoses Binary Switch Refrigerant Refrigerant Charging and Discharging Compressor Drive Belt - Adjustment Cab Introduction Related Topics Removal and Replacement Direct Glazing Doors Roof Guard Front Wiper Motor Rear Wiper Motor Roof Wiper Motor Roller Blind Roof Liner Instrument Panels Cab Air Conditioning Condenser Introduction Related Topics Cleaning Removal and Replacement Removal Replacement Cab HV and HVAC Unit Introduction Related Topics Freeze Thermostat (HVAC Unit) Removal Replacement Removal and Replacement Removal Replacement Air Conditioning Binary Switch Introduction Related Topics Removal and Replacement Removal Replacement Heater Valve Introduction Related Topics Removal and Replacement Removal Replacement Fuel Tank Introduction Related Topics Specifications Removal and Replacement Fuel Tank Fuel Level Sender Unit Engine Cover Introduction Related Topics Removal and Replacement Removal Replacement Stabilisers Introduction Related Topics Frame Removal and Replacement Removal Replacement Leg Removal and Replacement Removal Replacement Checking Pressure Transducer Operation RAS SYSTEM Introduction Related Topics Operation Overview Hydraulic Operation and Schematics Operation - Mode 1 - Locked Operation - Mode 2 - Cushioned Operation - Mode 3 - Unlocked Schematic Electrical Operation and Schematics Control Devices Actuated Devices Electrical Connectors Fault Finding Diagnostic `Blink' Codes Test Procedures Leak Test Procedure (With Use of Servicemaster Diagnostics) Leak Test Procedure (Without Use of Servicemaster Diagnostics) Bleed Procedure Interlock SYSTEM Introduction Related Topics Operation Overview Introduction Component Location Hydraulic Operation and Schematics Lift Pilot Pressure Supply Isolation Valve Sway/Stabiliser Isolation Valve Electrical Operation and Schematics Control Devices Actuated Devices Electrical Connectors Fault Finding Diagnostic Blink Codes Hydraulic System Faults Boom Introduction Related Topics Specifications Boom Wear Pad Clearance Operation Overview Telescopic Operation Hydraulic Operation and Schematics Boom Extend and Retract Operation Boom Raise and Lower Operation Wear Pads and Shims 3 Stage Boom 4 Stage Boom Chain Maintenance Introduction Adjustment - 3 Stage boom Adjustment - 4 Stage Boom Chain Component Inspection Wear Limits Extend Chains Removal and Replacement - 3 Stage Boom Removal Inspection Replacement Retract Chain Removal and Replacement - 3 Stage Boom Removal Inspection Replacement Extend Chains Removal and Replacement - 4 Stage Boom Removal Inspection Replacement Retract Chains Removal and Replacement - 4 Stage Boom Removal Inspection Replacement Angle Indicator Removal and Replacement Removal Replacement Pivot Shims Removal Replacement RAS ECU Introduction Related Topics Overview Introduction Removal and Replacement Removal Replacement
Section C - Electrics Electrics Applications Table Fuses and Relays Introduction Related Topics Fuses Link Box Fuses Relays Schematics Introduction 506-36, 507-42, 509-42 Sheets Component Keys 510-56 Sheets Component Keys Electrical Harness SYSTEM Introduction Related Topics Earth Points Wire Numbers and Functions Wires 000-199 Wires 200-399 Wires 400-599 Wires 600-799 Wires 800-999 Wires In Splices General Points Harness Interconnections and Drawings Interconnections Harness Identification Drawings Test Procedures How to Use a Multimeter Measuring DC Voltage Measuring Resistance Measuring Continuity Measuring Frequency Testing a Diode or a Diode Wire Wiring Harness Repair Introduction Repair Procedure Battery Charging SYSTEM Introduction Related Topics Specifications Operation Overview Electrical Operation and Schematics Electrical Connectors Test Procedures Charging Circuit Test Alternator Charging Test Alternator Introduction Related Topics Specifications Electrical Operation and Schematics Removal, Inspection and Replacement Removal Inspection Replacement Dismantle and Assemble Renewing the Voltage Regulator and Brushes Renewing the Drive Pulley Battery Introduction Related Topics Specifications Maintenance Test Procedures Battery Load Testing Specific Gravity Testing Disconnection and Connection Removal and Replacement Removal Replacement
Section E - Hydraulics Hydraulics Applications Table Systems and Schematics Introduction Systems Operation Overview Component Location Schematics Schematic - 506-36 Schematic - 507-42, 509-42 Schematic - 510-56 Flowshare Hydraulic SYSTEM Introduction Related Topics Specifications Flowshare Control Valve Block Operation Overview Component Location Hydraulic Operation and Schematics Hydraulic Circuit Operation No Services Operated Service Operation Multiple Service Operation Main System Pressure Relief Auxiliary Relief Valve (ARV) Operation Fault Finding Hydraulic Services System Parallel Lift Test Procedures Flow and Pressure Tests Parallel Hydraulic SYSTEM Introduction Related Topics Specifications Parallel Service Valve Block - 2 Section Parallel Service Valve Block - 5 Section Operation Overview Component Location Hydraulic Operation and Schematics No Services Operated Service Operation Main System Pressure Relief Auxiliary Relief Valve (ARV) Operation Fault Finding Tables Bleeding the Sway Ram Circuit Flowshare Control Valve Introduction Related Topics Component Location Hydraulic Operation and Schematics Individual Valve Slice No Service Selected (All Spools in Neutral) Operating a Service Operating an Individual Service Operating Multiple Services Auxiliary Relief Valve (ARV) Operation Removal Replacement Dismantle and Assemble Valve Block Sections Dismantle Assemble Spool Removal Spool Inspection Spool Assembly Load Sense Relief Valve Auxiliary Relief Valves (ARV's) Flow Regulator Valve Pressure Compensator Valves Load Hold Check Valves Parallel Control Valve - 2 Section Introduction Related Topics Hydraulic Operation and Schematics Removal Replacement Dismantle and Assemble Valve Block Sections Parallel Control Valve - 5 Section Introduction Related Topics Hydraulic Operation and Schematics Removal Replacement Dismantle and Assemble Valve Block Sections Servo Control Valves Introduction Related Topics Operation Overview Hydraulic Operation and Schematics Twin Axis Control Valve Single Axis Control Valve Removal and Replacement Pilot Pressure Supply Valve Introduction Related Topics Operation Overview 510-56 Machines Hydraulic Operation and Schematics Hydraulic Circuit Operation Service Operation 510-56 Machines Electrical Operation and Schematics 510-56 Machines Electrical Connectors Removal and Replacement Removal Replacement Main Pump Introduction Related Topics Specifications Operation Overview Hydraulic Operation and Schematics Fault Finding Test Procedures Checking Pump Flow Removal and Replacement Removal and Replacement Removal Replacement Cooling Fan Motor Introduction Related Topics Specifications Operation Overview Hydraulic Operation and Schematics Removal and Replacement Removal Replacement Dismantle, Inspection and Assemble Dismantle Inspection Assemble Extension Ram Introduction Related Topics Specifications Removal and Replacement Removal Replacement Lift Rams Introduction Related Topics Specifications Weight Removal and Replacement Removal Replacement Tilt Ram Introduction Related Topics Specifications Weight Removal and Replacement Removal Replacement Displacement Ram Introduction Related Topics Specifications Weight Removal and Replacement Removal Replacement Sway Ram Introduction Related Topics Specifications Weight Removal and Replacement Removal Replacement Stabiliser Rams Introduction Related Topics Specifications Weight Removal and Replacement Removal Replacement RAS Rams Introduction Related Topics Specifications Weight Removal and Replacement Removal Replacement Dismantle and Assembly Dismantle Assembly Ram Maintenance Introduction Related Topics Dismantle Assemble Ram Sealing Procedure Piston Head Retention Existing piston head and rod New piston head and rod Existing piston head and new rod New piston head and existing rod Drilling Dimensions
Section F - Transmission Transmission Applications Table CONFIGURATION Introduction Operation Overview Wheels and Tyres Introduction Related Topics Specifications Removal and Replacement Front Wheels Rear Wheels Wheel Studs Front Axles Introduction Related Topics Specifications Component Identification Removal and Replacement SD80 Pivot Sway Axle Dismantle, Inspection and Assembly Rear Axles Introduction Related Topics Specifications Component Identification SD80 3 Piece Steer Drive Axle - Integral Brakes SD55 1 Piece Steer Drive Axle Removal and Replacement SD80 3 Piece Steer Drive Axle - Integral Brakes SD55 1 Piece Steer Drive Axle Dismantle, Inspection and Assembly PS750 Gearbox SYSTEM Introduction Related Topics Specifications Component Identification Operation Overview Hydraulic Operation and Schematics Electrical Operation and Schematics Introduction Forward Gears Reverse Gears Neutral Transmission Dump Park Brake ON Electrical Connectors Drive Paths Forward Reverse Fault Finding Introduction Transmission Technical Data Check List Fault Finding Tables Test Procedures Torque Converter Stall Test Pressure and Flow Tests Flushing the Transmission Oil PS750 Mk IV Gearbox SYSTEM Introduction Related Topics Specifications Component Identification Operation Overview Start Up Drive Select ‘Manual’ Gear Select Park Brake ON Transmission Dump Hydraulic Operation and Schematics Electrical Operation and Schematics Introduction Forward Gears Reverse Gears Neutral Transmission Dump Park Brake ON Electrical Connectors Drive Paths Forward Reverse Fault Finding Introduction Transmission Technical Data Check List Fault Finding Tables Test Procedures Torque Converter Stall Test Pressure and Flow Tests Flushing the Transmission Oil Bevel Gearbox Introduction Related Topics Removal and Replacement Removal Replacement Dismantle, Inspection and Assembly Torque Converter Introduction Related Topics Specifications Component Identification Operation Overview Removal and Replacement Removal Replacement Transmission Oil Cooler - Liquid to Liquid Introduction Related Topics Removal, Testing and Replacement Removal Testing Replacement PS750 Gearbox Introduction Related Topics Specifications Component Identification Operation Overview Forward and Reverser Clutch Operation Mainshaft and Layshaft Clutch Operation Removal and Replacement Removal Replacement Dismantle, Inspection and Assembly PS750 Mk IV Gearbox Introduction Related Topics Specifications Component Identification Operation Overview Forward and Reverser Clutch Operation Mainshaft and Layshaft Clutch Operation Oil Pressure Switch - Removal and Replacement Removal Replacement Solenoid Control Valves - Removal and Replacement Gearbox Clutch Control Solenoid Valves 4 Wheel Drive Yoke and Oil Seal - Removal and Replacement Removal Replacement Removal and Replacement Dismantle, Inspection and Assembly Propshafts Introduction Related Topics Removal and Replacement Removal Replacement Speed Sensors Introduction Related Topics External Auxiliary Speed Sensor Component Identification Operation Overview Test Procedures Removal and Replacement Gearbox Speed Sensor P1 Test Procedures Removal and Replacement Gearbox Speed Sensor P2 Removal and Replacement
Section G - Brakes Brakes Applications Table Single Axle Service Brakes SYSTEM Introduction Related Topics Specifications Operation Overview Fault Finding Introduction Fault Finding Tables Test Procedures Brake Vacuum Test Brake Piston Seal Leakage Test Bleeding Axle Breather (Braked Axles) - Inspection Brake Light Switch (Reed Type) Operation Twin Axle Service Brakes SYSTEM Introduction Related Topics Specifications Operation Overview Fault Finding Introduction Fault Finding Tables Test Procedures Brake Vacuum Test Brake Piston Seal Leakage Test Bleeding Axle Breather (Braked Axles) - Inspection External Park Brake SYSTEM Introduction Related Topics Specifications Operation Overview Test Procedures Park Brake Performance Adjustment Lever Adjustment Cable Adjustment Switch Adjustment Renewing the Brake Pads Pad Removal Pad Inspection Pad Replacement Renewing the Park Brake Cable Removal Replacement Park Brake Calliper Introduction Related Topics Removal and Replacement Removal Replacement Torque Figures Dismantle, Inspection and Assemble Dismantle Inspection Assemble Park Brake Disc Introduction Related Topics Removal and Replacement Removal Replacement Park Brake Switch Introduction Related Topics Removal and Replacement Removal Replacement Servo Exhauster Unit Introduction Related Topics Removal and Replacement Removal Replacement Servo Unit, Single Axle Brakes Introduction Related Topics Removal and Replacement Removal Replacement Servo Unit, Twin Axle Brakes Introduction Related Topics Removal and Replacement Removal Replacement
Section H - Steering Steering Applications Table Steering SYSTEM Introduction Related Topics Specifications Component Location Operation Overview Hydraulic Operation and Schematics Steer Mode Valve Operation Fault Finding Fault Finding Tables Test Procedures Checking for Internal Hydraulic Leakage Hydraulic Pressure Tests Re-phasing the Road Wheels Bleeding the System Hydraulic Steering Unit Introduction Related Topics Operation Overview Hydraulic Operation and Schematics Removal and Replacement Removal Replacement Dismantle Inspection and Replacement Dismantle Inspection Assemble Priority Valve Introduction Related Topics Operation Overview Hydraulic Operation and Schematics Neutral Turning Cleaning Removal and Replacement Removal Replacement Steer Mode Valve Introduction Related Topics Operation Overview Removal and Replacement Removal Replacement Dismantle and Assemble Dismantle Assemble Steer Rams Introduction Related Topics Specifications Removal and Replacement Removal Replacement Dismantle and Assemble Steering Column Introduction Related Topics Removal and Replacement Steering Wheel Steering Column Switches Steering Column
Section K - Engine Engine Applications Table Start and Stop SYSTEM Introduction Related Topics Operation Overview Electrical Operation and Schematics Electrical Connectors Cold Start Heater SYSTEM Introduction Related Topics Operation Overview Electrical Operation and Schematics Electrical Connectors Fault Finding Diagnostic `Blink' Codes Starter Motor Introduction Related Topics Removal, Inspection and Replacement Removal Inspection Replacement Renewing the Brush Gear Renewing the Starter Solenoid Cooling Pack Introduction Related Topics Removal and Replacement Removal Replacement Dismantle and Assemble Coolant Expansion Tank Introduction Related Topics Removal and Replacement Tank Removal Tank Replacement Coolant Level Sensor Removal Coolant Level Sensor Replacement Exhaust Silencer Introduction Related Topics Removal and Replacement Removal Replacement Throttle Cable Introduction Related Topics Removal and Replacement Removal Replacement Cable Adjustment Throttle Pedal Stop Adjustment Machines with no Throttle Position Sensor (TPS) JCB Dieselmax Introduction Related Topics Specifications Removal and Replacement Removal Replacement Separating the Engine From the Bevel Box Dismantling Assembly
Section M - Electronic Network Electronic Network Applications Table CANbus SYSTEM Introduction Related Topics Operation Overview CANbus Communications System Electrical Operation and Schematics Electrical Connectors Loadall Monitoring SYSTEM Introduction Related Topics Operation Overview Fault Code Display Electrical Operation and Schematics Electrical Schematics Electrical Connectors Fault Code SYSTEM Introduction Related Topics Operation Overview Malfunction Indicator Light (MIL) Blink Codes CAN Enabled Display CANbus Connected Computer Loadall Monitoring System ECU Fault Codes Fault Code List - General "D" Codes Fault Code List - RAS "S" Codes Servicemaster SYSTEM Introduction Related Topics Why Use Servicemaster? Introduction Fault Finding Identify Poor Maintenance Access Machine Set Up Data Re-Programming ECUs Summary What is Servicemaster? Introduction CANbus Communications System Servicemaster Structure How to Set Up Servicemaster Install Servicemaster Start Servicemaster Load the DLA Laptop Driver Software Configure the DLA Type and Communications Port Check the DLA Firmware File Connect Servicemaster to the Machine CANbus Servicemaster Tools Introduction Related Topics Summary Rear Axle Stabilisation (RAS) Diagnostics Tool - User Guide Introduction Care and Safety Connecting RAS Diagnostics Starting RAS Diagnostics Navigating within Diagnostics Menu Bar - File Menu Page List Status bar LED Status Key RAS System Schematic Page ECU Status Page Software Download Page Loadall LMS Setup - User Guide Introduction Care and Safety Installing Connection Starting Loadall LMS Setup Navigating within Loadall LMS Setup Menu Bar - File Menu Menu Bar - Utilities Menu Menu Bar - Help Menu Build Options Powertrain Options Hydraulic Options Service Options Language Options Write Read Connection Problems