service repair manual

1. 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
9813/1800-2
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,
514-56
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

2. 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
9813/1800-2
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, 514-56
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

3. Section 1 - General Information
1-0 1-09813/1800-2
Notes:

4. Page No.Contents
Section 1 - General Information
1-i 1-i
Applications
Introduction ............................................................................................. 1-1-1
Tables ..................................................................................................... 1-1-2
Use
Introduction ............................................................................................. 1-2-1
Scope ..................................................................................................... 1-2-2
Format .................................................................................................... 1-2-3
Left and Right Sides ............................................................................... 1-2-4
Hydraulic Schematic Codes ................................................................... 1-2-5
Machine Identification
Introduction ............................................................................................. 1-3-1
Related Topics ........................................................................................ 1-3-2
Machine Identification Plate .................................................................... 1-3-3
Component Identification Plates ............................................................. 1-3-7
Torque Settings
Introduction ............................................................................................. 1-4-1
Zinc Plated Fasteners and Dacromet Fasteners .................................... 1-4-2
Hydraulic Connections ............................................................................ 1-4-6
`Positional Type' Hydraulic Adaptors .................................................... 1-4-10
Service Tools
Introduction ............................................................................................. 1-5-1
Numerical List ......................................................................................... 1-5-2
Tool Detail Reference ............................................................................. 1-5-5
Rivet Nuts ............................................................................................. 1-5-27
Slide Hammer Kit .................................................................................. 1-5-29
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
Stall Speed Combinations
Introduction ............................................................................................. 1-8-1
Related Topics ........................................................................................ 1-8-2
Specifications ......................................................................................... 1-8-3

5. Section 1-1 - General Information
1-1-1 1-1-19813/1800-2 (1-14-08)
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
5C J 514-56
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
Note: For full details of machine identification refer to Section 1 - Machine Identification.
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 1-1-7)
K Section G - Brakes ( T 1-1-8)
K Section H - Steering ( T 1-1-9)
K Section K - Engine ( T 1-1-10)
K Section M - Electronic Data Systems ( T 1-1-11)

6. Section 1-1 - General Information
Applications
Tables
1-1-2 1-1-29813/1800-2 (1-14-08)
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
514-56 5CJ
1-2 Use 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
1-8 Stall Speed Combinations All Machines
Machine models
Topic
Ref
Title Variant 506-36 5CD 507-42 5CE
509-42 5CF
510-56 5CG
512-56 5CH
514-56 5CJ
2-1 Safety Notices All Machines
2-2 General Procedures All Machines

7. Section 1-1 - General Information
Applications
Tables
1-1-3 1-1-39813/1800-2 (1-14-08)
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
514-56 5CJ
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
514-56 5CJ
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 Mudguards
B11 Stabilisers
B12 RAS SYSTEM
B13 Interlock SYSTEM
B14 Boom
B15 RAS ECU
B16 Interlock Components

8. Section 1-1 - General Information
Applications
Tables
1-1-4 1-1-49813/1800-2 (1-14-08)
Section C - Electrics
Machine models
Topic Ref Title VARIANT 506-36 5CD 507-42 5CE
509-42 5CF
510-56 5CG
512-56 5CH
514-56 5CJ
C1 Fuses and Relays
C2 Schematics
C3 Electrical Harness SYSTEM
C4 Battery Charging SYSTEM
C5 Alternator (C-04-02) Engine serial number
from U0193212
C6 Battery

9. Section 1-1 - General Information
Applications
Tables
1-1-5 1-1-59813/1800-2 (1-14-08)
Section E - Hydraulics
Machine models
Topic Ref Title VARIANT 506-36 5CD 507-42 5CE
509-42 5CF
510-56 5CG
512-56 5CH
514-56 5CJ
E1 Systems and Schematics
E2 Parallel Hydraulic SYSTEM (E-01-
32)
E3 LSP Hydraulic SYSTEM (E-01-31)
E4 Parallel Circuit Operation (E-60-01)
E5 LSP Circuit Operation (E-60-12)
E6 MRV/LSRV Operation
E7 ARV Operation
E8 Parallel Lift Operation
E9 Boom Pressure Balance System
E10 Universal Hydraulic Faults
E11 Parallel Circuit Faults
E12 Flowshare Servo Circuit Faults
E13 Hydraulic System Pressure Tests
E14 Pump Flow Tests - Gearpump
E15 Flowshare Control Valve
E16 Parallel Control Valve - 2 Section
E17 Parallel Control Valve - 5 Section
E18 Pilot Pressure Supply Valve
E19 Servo Control Valves
E20 Gearpump Operation
E21 Gearpump Removal and
Replacement
E22 Hydraulic Cooling Fan Motor - Fixed
Speed
E23 Extension Ram
E24 Lift Rams
E25 Tilt Ram
E26 Displacement Ram

10. Section 1-1 - General Information
Applications
Tables
1-1-6 1-1-69813/1800-2 (1-14-08)
E27 Sway Ram
E28 Stabiliser Rams
E29 RAS Rams
E30 Ram Maintenance
E31 Sway Ram Circuit - Bleed Procedure
Machine models
Topic Ref Title VARIANT 506-36 5CD 507-42 5CE
509-42 5CF
510-56 5CG
512-56 5CH
514-56 5CJ

11. Section 1-1 - General Information
Applications
Tables
1-1-7 1-1-79813/1800-2 (1-14-08)
Section F - Transmission
Machine models
Topic Ref Title VARIANT 506-36 5CD 507-42 5CE
509-42 5CF
510-56 5CG
512-56 5CH
514-56 5CJ
F1 Configuration
F2 Wheels and Tyres
F3 Front Axles SD80 3 Piece Steer
Drive Axle
SD70 3 Piece Steer
Drive Axle
F4 Rear Axles SD80 3 Piece Steer
Drive Axle
SD55 1 Piece Steer
Drive Axle
F5 PS750 Mk 4 Gearbox SYSTEM
F6 Torque Converter Operation
F7 Gearbox Systems Fault Finding
F8 Flushing The Transmission Oil
F9 Torque Converter Stall Tests
F10 PS750 Mk4 Gearbox - Hydraulic
Testing
F11 Torque Converter
F12 PS750 Mk 4 Gearbox
F13 Bevel Gearbox
F14 Transmission Oil Cooler - Liquid to
Liquid
PS750
F15 Propshafts

12. Section 1-1 - General Information
Applications
Tables
1-1-8 1-1-89813/1800-2 (1-14-08)
Section G - Brakes
Machine models
Topic Ref Title VARIANT 506-36 5CD 507-42 5CE
509-42 5CF
510-56 5CG
512-56 5CH
514-56 5CJ
G1 Single Axle Service Brakes SYSTEM
G2 Twin Axle Service Brakes SYSTEM
G3 External Park Brake SYSTEM
G4 Park Brake Calliper
G5 Park Brake Disc
G6 Park Brake Switch
G7 Servo Exhauster Unit
G8 Servo Unit - Single Axle Brakes
G9 Servo Unit - Twin Axle Brakes
G10 Master Cylinder Machines with Single
Axle Service Brakes
System
Machines with Twin Axle
Service Brakes System

13. Section 1-1 - General Information
Applications
Tables
1-1-9 1-1-99813/1800-2 (1-14-08)
Section H - Steering
Machine models
Topic Ref Title VARIANT 506-36 5CD 507-42 5CE
509-42 5CF
510-56 5CG
512-56 5CH
514-56 5CJ
H1 Steering SYSTEM
H2 Hydraulic Steering Unit
H3 Priority Valve
H4 Manual Steer Mode SYSTEM
H5 Manual Steer Mode Valve
H6 Steer Rams
H7 Steering Column

14. Section 1-1 - General Information
Applications
Tables
1-1-10 1-1-109813/1800-2 (1-14-08)
Section K - Engine
Machine models
Topic Ref Title VARIANT 506-36 5CD 507-42 5CE 509-42 5CF 510-56 5CG
512-56 5CH
514-56 5CJ
K1 Engine Start/Stop SYSTEM
K2 Cold Start Heater SYSTEM
K3 Starter Motor
K4 Cooling Pack (SH,SL,DH)
K5 Coolant Expansion Tank
K6 Throttle Position Sensor
(TPS) (K-07-21)
K7 Air Cleaner Housing
K8 Exhaust Silencer
K9 Fuel Cooler Matrix
K10 JCB EcoMax 55kW (SL)
81kW (SH)
93kW (SH)
108kW (DH)

15. Section 1-1 - General Information
Applications
Tables
1-1-11 1-1-119813/1800-2 (1-14-08)
Section M - Electronic Data Systems
Machine models
Topic Ref Title Variant 506-36
5CD
507-42
5CE
509-42
5CF
510-56
5CG
512-56
5CH
514-56
5CJ
M1 CANbus SYSTEM
M2 Blank
M3 Fault Code SYSTEM
M4 Servicemaster SYSTEM
M5 Servicemaster Tool Set
M6 JCB EcoMax (SH,SL,SH) Engine Set Up Tool
M7 JCB EcoMax (SH,SL,SH) Engine Diagnostic
Tool
M8 Cluster (LMS) Set Up Tool
M9 Datalogger Tool User Guide
M10 Machine Diagnostics Tool
M11 Immobiliser Set Up Tool User Guide
M12 Immobiliser Diagnostics User Guide
M13 Pulse Width Modulation Theory
M14 Electronic Control Unit Theory
M15 Blank
M16 Blank
M17 Devices
M18 Electronic Controllers
LMS ECU
Immobiliser ECU
Livelink ECU
RAS ECU
M19 Brake System Devices
Park Brake Switch
Footbrake Operated Switch
Footbrake Pressure Transducer

16. Section 1-1 - General Information
Applications
Tables
1-1-12 1-1-129813/1800-2 (1-14-08)
Charge Pressure Transducer
Transmission Disconnect (Footbrake Dump)
Switch
M20 Blank
M21 Engine and Fuel System Devices
Fuel Level Sender
Coolant Temperature Switch
Vacuum Switch
Fuel Lift Pump
WIF Sensor
TMAF Sensor
Inlet Manifold Heater/Cold Start Relay
Alternator
Throttle Position Sensor
Engine Compartment Fuse/Relay Box
Power Hold Relay
Engine ECU
Start Signal Relay
Fuel Lift Pump Relay
Exhaust Gas Re Circulation (EGR) Actuator
Variable Geometry Turbo (VGT) Actuator 81, 93 and 108 kW
engines
M22 General Control Devices
Ignition Switch
Info Operator Switch
Neutral Start Relay
Centre Cluster Warning Panel
Operator Present Switch
Direction Indicator/Turn Signal Lamps
Machine models
Topic Ref Title Variant 506-36
5CD
507-42
5CE
509-42
5CF
510-56
5CG
512-56
5CH
514-56
5CJ

17. Section 1-1 - General Information
Applications
Tables
1-1-13 1-1-139813/1800-2 (1-14-08)
Trailer Turn Signal Lamp Circuit
Hazard Lamps
Joystick (Thumbwheel and Button Type)
Joystick (Button Type)
Right Hand Column Switch
M23 Blank
M24 Blank
M25 Blank
M26 Blank
M27 Stabiliser and Sway Devices
Stabiliser Deployed Sensor
Stabiliser Isolation Solenoid (S1)
Stabiliser Isolation Solenoid (S2)
Stabiliser Isolation Switch
Stabiliser, Sway Relay
Sway/Fan Selector Solenoid (Sway Isolation
Solenoid (S1)
Sway/Fan Selector Solenoid (Sway Isolation
Solenoid (S2)
Sway Direction Solenoid (S1)
Sway Direction Solenoid (S2)
Sway Switch (S1)
Sway Switch (S2)
M28 Blank
M29 Blank
M30 Device Harness Interconnections
M31 Device Ground Points
Machine models
Topic Ref Title Variant 506-36
5CD
507-42
5CE
509-42
5CF
510-56
5CG
512-56
5CH
514-56
5CJ

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19. Section 1-2 - General Information
1-2-1 1-2-11-01-03 Issue 01
Use
Introduction
This topic contains information about the structure of the manual and how to use the manual.
K Scope ( T 1-2-2)
K Personnel ( T 1-2-2)
K Applications ( T 1-2-2)
K Newest Data ( T 1-2-2)
K Format ( T 1-2-3)
K Left and Right Sides ( T 1-2-4)
K Hydraulic Schematic Codes ( T 1-2-5)
K Colour Codes ( T 1-2-5)

20. Section 1-2 - General Information
Use
Scope
1-2-2 1-2-21-01-03 Issue 01
Scope
Personnel
This publication is designed for the benefit of JCB
Distributor Service Engineers who are receiving, or have
received, training by JCB Technical Training Department.
These personnel should have a sound knowledge of
workshop practice, safety procedures, and general
techniques associated with the maintenance and repair of
hydraulic earthmoving equipment. Finally, please
remember above all else SAFETY MUST COME FIRST!
Applications
This manual contains data relevant to a range of
machines. Make sure you reference the data for the
correct machine. Refer to the Applications topic in this
section.
Newest Data
From time to time new machines, systems or devices
require the manual to be re-issued. Make sure you have
the newest issue.
Always check the on-line JCB data system for relevant
technical information.

21. Section 1-2 - General Information
Use
Format
1-2-3 1-2-31-01-03 Issue 01
Format
The manual is compiled in sections, the first three are
numbered and contain information as follows:
1 General Information - Use the Applications Tables
at the front of the section to see which topic in the
manual is applicable to which machine model. The
section also includes general information such as
torque settings and service tools.
2 Care & Safety - includes warnings, cautions and
general procedures related to aspects of workshop
procedures contained in the manual.
3 Routine Maintenance - includes service schedules
and recommended lubricants for all the machine.
The remaining sections are alphabetically coded and deal
with dismantling, overhaul etc. of specific components, for
example:
The sections contain topics. Each topic is a self contained
set of data about a machine SYSTEM or Device.
Some topics are only applicable to some machine models.
Use the Applications Tables in this section to see which
topic is applicable to which machine model.
Each topic contains data such as specifications,
descriptions, fault finding and test procedures. Device
topics also contain removal, replacement, dismantle and
assemble procedures.
Some topics contain procedures and specifications for
different variants. This happens because of market
requirements, or when the machine specification changes
after a period of time. Where applicable, a table in the
introduction of each topic contains information to help you
identify the correct specifications or procedures.
Each topic also contains a Related Topics table. This
table lists all the topics that contain related data. For
example a hydraulic SYSTEM contains devices such as
valves and pumps. These devices have their own topics
and they are listed in the SYSTEM related topics table.
A Attachments
B Body and Framework...etc.