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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 1-0
9813/1800-2
Notes:

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5. 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

6. Section 1-1 - General Information
1-1-1 1-1-1
9813/1800-2 (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)

7. Section 1-1 - General Information
Applications
Tables
1-1-2 1-1-2
9813/1800-2 (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

8. Section 1-1 - General Information
Applications
Tables
1-1-3 1-1-3
9813/1800-2 (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
z z z
B2 Cab Air Conditioning SYSTEM z z z
B3 Cab z z z
B4 Air Conditioning Condenser z z z
B5 Cab HV and HVAC Unit z z z
B6 Air Conditioning Binary Switch z z z
B7 Heater Valve z z z
B8 Fuel Tank z z z
B9 Engine Cover z z z
B10 Mudguards z z z
B11 Stabilisers z
B12 RAS SYSTEM z z
B13 Interlock SYSTEM z z
B14 Boom z z z
B15 RAS ECU z z
B16 Interlock Components z z z

9. Section 1-1 - General Information
Applications
Tables
1-1-4 1-1-4
9813/1800-2 (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 z z z
C2 Schematics z z z
C3 Electrical Harness SYSTEM z z z
C4 Battery Charging SYSTEM z z z
C5 Alternator (C-04-02) Engine serial number
from U0193212
z z z
C6 Battery z z z

10. Section 1-1 - General Information
Applications
Tables
1-1-5 1-1-5
9813/1800-2 (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 z z z
E2 Parallel Hydraulic SYSTEM (E-01-
32)
z z z
E3 LSP Hydraulic SYSTEM (E-01-31) z z z
E4 Parallel Circuit Operation (E-60-01) z z z
E5 LSP Circuit Operation (E-60-12) z z z
E6 MRV/LSRV Operation z z z
E7 ARV Operation z z z
E8 Parallel Lift Operation z z z
E9 Boom Pressure Balance System z z z
E10 Universal Hydraulic Faults z z z
E11 Parallel Circuit Faults z z z
E12 Flowshare Servo Circuit Faults z z z
E13 Hydraulic System Pressure Tests z z z
E14 Pump Flow Tests - Gearpump z z z
E15 Flowshare Control Valve z z z
E16 Parallel Control Valve - 2 Section z z
E17 Parallel Control Valve - 5 Section z
E18 Pilot Pressure Supply Valve z z z
E19 Servo Control Valves z z z
E20 Gearpump Operation z z z
E21 Gearpump Removal and
Replacement
z z z
E22 Hydraulic Cooling Fan Motor - Fixed
Speed
z z z
E23 Extension Ram z z z
E24 Lift Rams z z z
E25 Tilt Ram z z z
E26 Displacement Ram z z z

11. Section 1-1 - General Information
Applications
Tables
1-1-6 1-1-6
9813/1800-2 (1-14-08)
E27 Sway Ram z z z
E28 Stabiliser Rams z
E29 RAS Rams z z
E30 Ram Maintenance z z z
E31 Sway Ram Circuit - Bleed Procedure z z z
Machine models
Topic Ref Title VARIANT 506-36 5CD 507-42 5CE
509-42 5CF
510-56 5CG
512-56 5CH
514-56 5CJ

12. Section 1-1 - General Information
Applications
Tables
1-1-7 1-1-7
9813/1800-2 (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 z z z
F2 Wheels and Tyres z z z
F3 Front Axles SD80 3 Piece Steer
Drive Axle
z z
SD70 3 Piece Steer
Drive Axle
z
F4 Rear Axles SD80 3 Piece Steer
Drive Axle
z z
SD55 1 Piece Steer
Drive Axle
z
F5 PS750 Mk 4 Gearbox SYSTEM z z z
F6 Torque Converter Operation z z z
F7 Gearbox Systems Fault Finding z z z
F8 Flushing The Transmission Oil z z z
F9 Torque Converter Stall Tests z z z
F10 PS750 Mk4 Gearbox - Hydraulic
Testing
z z z
F11 Torque Converter z z z
F12 PS750 Mk 4 Gearbox z z z
F13 Bevel Gearbox z z z
F14 Transmission Oil Cooler - Liquid to
Liquid
PS750 z z z
F15 Propshafts z z z

13. Section 1-1 - General Information
Applications
Tables
1-1-8 1-1-8
9813/1800-2 (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 z
G2 Twin Axle Service Brakes SYSTEM z z
G3 External Park Brake SYSTEM z z z
G4 Park Brake Calliper z z z
G5 Park Brake Disc z z z
G6 Park Brake Switch z z z
G7 Servo Exhauster Unit z z z
G8 Servo Unit - Single Axle Brakes z
G9 Servo Unit - Twin Axle Brakes z z
G10 Master Cylinder Machines with Single
Axle Service Brakes
System
z
Machines with Twin Axle
Service Brakes System
z z

14. Section 1-1 - General Information
Applications
Tables
1-1-9 1-1-9
9813/1800-2 (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 z z z
H2 Hydraulic Steering Unit z z z
H3 Priority Valve z z z
H4 Manual Steer Mode SYSTEM z z z
H5 Manual Steer Mode Valve z z z
H6 Steer Rams z z z
H7 Steering Column z z z

15. Section 1-1 - General Information
Applications
Tables
1-1-10 1-1-10
9813/1800-2 (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 z z z z
K2 Cold Start Heater SYSTEM z z z z
K3 Starter Motor z z z z
K4 Cooling Pack (SH,SL,DH) z z z z
K5 Coolant Expansion Tank z z z z
K6 Throttle Position Sensor
(TPS) (K-07-21)
z z z z
K7 Air Cleaner Housing z z z z
K8 Exhaust Silencer z z z z
K9 Fuel Cooler Matrix z z z z
K10 JCB EcoMax 55kW (SL) z z
81kW (SH) z z z z
93kW (SH)
108kW (DH)

16. Section 1-1 - General Information
Applications
Tables
1-1-11 1-1-11
9813/1800-2 (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 z z z
M2 Blank
M3 Fault Code SYSTEM z z z
M4 Servicemaster SYSTEM z z z
M5 Servicemaster Tool Set z z z
M6 JCB EcoMax (SH,SL,SH) Engine Set Up Tool z z z
M7 JCB EcoMax (SH,SL,SH) Engine Diagnostic
Tool
z z z
M8 Cluster (LMS) Set Up Tool z z z
M9 Datalogger Tool User Guide z z z
M10 Machine Diagnostics Tool z z z
M11 Immobiliser Set Up Tool User Guide z z z
M12 Immobiliser Diagnostics User Guide z z z
M13 Pulse Width Modulation Theory z z z
M14 Electronic Control Unit Theory z z z
M15 Blank z z z
M16 Blank z z z
M17 Devices z z z
M18 Electronic Controllers z z z
LMS ECU z z z
Immobiliser ECU z z z
Livelink ECU z z z
RAS ECU z z
M19 Brake System Devices z z z
Park Brake Switch z z z
Footbrake Operated Switch z z z
Footbrake Pressure Transducer

17. Section 1-1 - General Information
Applications
Tables
1-1-12 1-1-12
9813/1800-2 (1-14-08)
Charge Pressure Transducer
Transmission Disconnect (Footbrake Dump)
Switch
M20 Blank z z z
M21 Engine and Fuel System Devices z z z
Fuel Level Sender z z z
Coolant Temperature Switch z z z
Vacuum Switch z z z
Fuel Lift Pump z z z
WIF Sensor z z z
TMAF Sensor z z z
Inlet Manifold Heater/Cold Start Relay z z z
Alternator z z z
Throttle Position Sensor z z z
Engine Compartment Fuse/Relay Box z z z
Power Hold Relay z z z
Engine ECU z z z
Start Signal Relay z z z
Fuel Lift Pump Relay z z z
Exhaust Gas Re Circulation (EGR) Actuator z z z
Variable Geometry Turbo (VGT) Actuator 81, 93 and 108 kW
engines
z z z
M22 General Control Devices z z z
Ignition Switch z z z
Info Operator Switch z z z
Neutral Start Relay z z z
Centre Cluster Warning Panel z z z
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

18. Section 1-1 - General Information
Applications
Tables
1-1-13 1-1-13
9813/1800-2 (1-14-08)
Trailer Turn Signal Lamp Circuit
Hazard Lamps
Joystick (Thumbwheel and Button Type)
Joystick (Button Type)
Right Hand Column Switch z z z
M23 Blank z z z
M24 Blank z z z
M25 Blank z z z
M26 Blank z z z
M27 Stabiliser and Sway Devices z z z
Stabiliser Deployed Sensor z
Stabiliser Isolation Solenoid (S1)
Stabiliser Isolation Solenoid (S2) z
Stabiliser Isolation Switch z z z
Stabiliser, Sway Relay z z z
Sway/Fan Selector Solenoid (Sway Isolation
Solenoid (S1)
Sway/Fan Selector Solenoid (Sway Isolation
Solenoid (S2)
z z z
Sway Direction Solenoid (S1)
Sway Direction Solenoid (S2) z z z
Sway Switch (S1)
Sway Switch (S2) z z z
M28 Blank z z z
M29 Blank z z z
M30 Device Harness Interconnections z z z
M31 Device Ground Points z z z
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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20. Section 1-2 - General Information
1-2-1 1-2-1
1-01-03 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)

21. Section 1-2 - General Information
Use
Scope
1-2-2 1-2-2
1-01-03 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.

22. Section 1-2 - General Information
Use
Format
1-2-3 1-2-3
1-01-03 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.

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