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Service Manual
Publication No.
9803/3640U-8
World Class
Customer Support
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.
Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
Section 0 - Service Manual
Notes:
General Information
Service Manual - 506C, 506CHL, 508C Loadalls
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
Publication No.
9803/3640U-8
World Class
Customer Support
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.
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
Notes:
Service Tools
Numerical List ........................................................................................ 1 - 16
Tool Detail Reference ............................................................................ 1 - 19
Section B - Frame and Bodywork ......................................................1 - 19
Section C - Electrics ..........................................................................1 - 23
Section E - Hydraulics .......................................................................1 - 24
Section F - Transmission ...................................................................1 - 29
Section H - Steering ..........................................................................1 - 30
Section K - Engine .............................................................................1 - 31
Service Consumables
Sealing and Retaining Compounds ....................................................... 1 - 32
1-i 1-i
Section 1 - General Information
Introduction
About This Manual
Machine Model and Serial Number Finally, please remember above all else safety must come
first!
This manual provides information for the following
model(s) in the JCB machine range: Units of Measurement
T1-001U_2
– 506C from SN 579781 In this publication, the units of measurement are standard.
– 506CHL from SN 579569 For example, liquid capacities are given in U.S. gallons.
The metric units follow in parentheses ( ) eg 7.4 gal (28
– 508C from SN 579569
liters).
These personnel should have a sound knowledge of 1 General Information - includes torque settings and
workshop practice, safety procedures, and general service tools.
techniques associated with the maintenance and repair of 2 Care and Safety - includes warnings and cautions
hydraulic earthmoving equipment. pertinent to aspects of workshop procedures etc.
The illustrations in this publication are for guidance only. 3 Maintenance - includes service schedules and
Where the machines differ, the text and/or the illustration recommended lubricants for all the machine.
will specify.
The remaining sections are alphabetically coded and deal
General warnings in Section 2 are repeated throughout the with Dismantling, Overhaul etc. of specific components, for
manual, as well as specific warnings. Read all safety example:
statements regularly, so you do not forget them.
A Attachments
Renewal of oil seals, gaskets, etc., and any component
showing obvious signs of wear or damage is expected as B Body and Framework, etc.
a matter of course. It is expected that components will be
cleaned and lubricated where appropriate, and that any Section contents, technical data, circuit descriptions,
opened hose or pipe connections will be blanked to operation descriptions etc. are inserted at the beginning of
prevent excessive loss of hydraulic fluid and ingress of dirt. each alphabetically coded section.
Fig 1.
Cab/Canopy
T1-003_2
Cross References
T1-004_2
E = England
Fig 2.
T011100-1
JCB Dieselmax:
J = SA Build K = SB Build L = SC Build
SA 320/40001 U 00001 04
1 2 3 4 5
1 Engine Type
3 Country of manufacture
U = United Kingdom
5 Year of Manufacture
U 00001 04
Fig 4.
Fig 5.
Fig 6.
Fig 7.
The two types of fasteners can be readily identified by Torque settings are given for the following conditions:
colour and part number suffix. K Table 1. Fastener Types
( T 1-8). Condition 1
Note: A Dacromet bolt should not be used in conjunction Verbus Ripp Bolts
with a Zinc or Yellow plated nut, as this could change the
torque characteristics of the torque setting further. For the
same reason, a Dacromet nut should not be used with a
Zinc or Yellow plated bolt.
Note: All bolts used on JCB machines are high tensile and
must not be replaced by bolts of a lesser tensile
specification.
Fig 8.
Note: Dacromet bolts, due to their high corrosion
resistance are used in areas where rust could occur. Torque settings for these bolts are determined by the
Dacromet bolts are only used for external applications. application. Refer to the relevant procedure for the
They are not used in applications such as gearbox or required settings.
engine joint seams or internal applications.
1 - 10 9803/3640U-8 1 - 10
Section 1 - General Information
Standard Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
Table 6. Torque Settings - Rivet Nut Bolts/Screws
Bolt Size
ISO Metric
Thread mm Nm kgf m lbf ft
M3 3 1.2 0.1 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
1 - 11 9803/3640U-8 1 - 11
Section 1 - General Information
Standard Torque Settings
Hydraulic Connections
Hydraulic Connections
T11-003
1 - 12 9803/3640U-8 1 - 12
Section 1 - General Information
Standard Torque Settings
Hydraulic Connections
Hoses Screwed into Adaptors
Fig 9.
Hoses 9-B screwed into adaptors 9-A seal onto an `O' ring Note: Dimension 9-D will vary depending upon the torque
9-C which is compressed into a 45° seat machined into the applied.
face of the adaptor port.
1 - 13 9803/3640U-8 1 - 13
Section 1 - General Information
Standard Torque Settings
Hydraulic Connections
Adaptors into Component Connections with Bonded Washers
1 - 14 9803/3640U-8 1 - 14
Section 1 - General Information
Standard Torque Settings
Hydraulic Connections
Fig 10.
`Torque Stop' Hoses 10-B screwed into adaptors 10-A seal Stop' Hoses have an additional shoulder 10-D, which acts
onto an 'O' ring 10-C which is compressed into a 45° seat as a physical stop.
machined in the face of the adaptor port. To prevent the 'O'
ring being damages as a result of over tightening, 'Torque Note: Minimum dimension 10-E fixed by shoulder 10-D.
1 - 15 9803/3640U-8 1 - 15
Section 1 - General Information
Service Tools
Numerical List
The tools listed in the table are special tools required for details of all tools, including the content of kits and sets,
carrying out the procedures described in this manual. refer to Tool Detail Reference, Section 1.
These tools are available from JCB Service.
Note: Tools other than those listed will be required. It is
Some tools are available as kits or sets, the part numbers expected that such general tools will be available in any
for parts within such kits or sets are not listed here. For full well equipped workshop or be available locally from any
good tool supplier.
1 - 16 9803/3640U-8 1 - 16
Section 1 - General Information
Service Tools
Numerical List
1 - 17 9803/3640U-8 1 - 17
Section 1 - General Information
Service Tools
Numerical List
1 - 18 9803/3640U-8 1 - 18
Section 1 - General Information
Service Tools
Tool Detail Reference
1 - 19 9803/3640U-8 1 - 19
Section 1 - General Information
Service Tools
Tool Detail Reference
1 - 20 9803/3640U-8 1 - 20
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