Stop guessing when repairing your JCB 500 Series telehandler. This 701-page service manual (OEM #9803/3600U) bundles factory procedures for the 505-19, 505-22, 506-36, 508-40, 510-40, and 506B into one searchable reference. The documentation provides hydraulic circuit procedures with separate schematics for each variant, plus wiring diagrams for standard and IP67 electrical systems. Technicians will find fault-finding charts covering the PlaceAce and Servo control systems, alongside exploded views. Factory specifications are clearly laid out: set the Main Relief Valve to 220 bar (3,200 lbf/in²) on the 505-19 and 505-22, or 241 bar (3,500 lbf/in²) on the 508-40.
What's Inside This JCB 505-19 & variants Manual
| System | Pages | Key Topics |
|---|---|---|
| General | 5-30 | Fluids, Lubricants, Capacities & Specifications (-: 505-19/22, 506-36, 508-40 & 510-40, 506B, Torque Settings), Service Schedules |
| Hydraulics | 31-171 | Technical Data (-: 525-19/22, 508-40, 506-36, 510-40, 506B), Hydraulic Fluid Level & Filter (-: 505-19/22, 506-36 & Early 508-40, 508-40 Later Machines |
| Body and Framework | 172-226 | Boom Shimming - Typical Method, Boom Shimming - 505-19/22, Boom Shimming - 506-36, Boom Shimming - 508-40, 510-40, Boom Shimming - 506B, Inner Extension Ram Wear Pads - 508-40 |
| PlaceAce Control System | 227-290 | Technical Data (-: 508-40, 510-40), Control System Description, Valve Block Operation, Pulsar Block Operation, Valve Block Removal & Replacement |
| Servo Control System | 291-349 | Technical Data (-: 505-19/22, 506-36, 508-40), Basic Servo Control System Description (- 505-19/22), Servo Control System Description (- 506-36, Valve Block Operation |
| Engine | 350-372 | Technical Data, Engine Cover, Engine Oil Filter, Fuel Filter, Fuel Pump, Bleeding, Cooling System, Alternator Drive Belt |
| Transmission | 373-507 | Syncro Shuttle Technical Data, Syncro Shuttle General Description, Powershift Technical Data, Recovery Procedure, Checking & Changing Oil |
| Axles | 508-562 | Technical Data (-: 505-19/22, 508-40, 510-40, 506-36 & 506B), Road Wheel Removal & Replacement, Water Ballast Tires, Front Axle Breather Removal & Replacement, Axle Oil Level |
| Brakes | 563-582 | Technical Data (-: 505-19/22, 508-40, 510-40, 506-36, 506B), Parking Brake Adjusting & Testing, Parking Brake Dismantling & Assembly, Brake System Bleeding |
| Hydraulic Steering | 583-634 | Technical Data, Flow Regulating Valve Operation, Tandem Steering/Fan Pump Dismantling & Assembly, Steering/Fan Pump Removal & Replacement |
| Electrics | 635-676 | Introduction, Technical Data, Fuses, Relay Location, Test Methods, Batteries Testing, Alternator (-: Precautions, Testing, Removal & Replacement, Dismantling & Assembly) |
| Service Tools | 677-690 | Numerical List, Section List, Sealing and Retaining Compounds |
| Boom Float, Return to Dig Option | 691-701 | Numerical List, Schematic Hydraulic Circuit, Wiring Diagram, Relay Location, Fault Finding, Micro Switch Adjustment, Proximity Switch Adjustment |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| Wheel Studs Torque | 680 Nm | p. 513 |
| Axle Mounting Bolts Torque | 56 Nm | p. 521 |
| Electrical System Voltage | 12 volts, negative earth | p. 639 |
| Alternator Maximum Output | 65 amp | p. 639 |
| Normal Engine Coolant Temperature | 80-85 °C (175-185 °F) | p. 359 |
| 505-19, 505-22 | ||
| Main Relief Valve (M.R.V.) Operating Pressure | 220 bar (3200 lbf/in²) | p. 33 |
| Hydraulic Filter Filtration Size | 25 microns (0.001 in) | p. 33 |
| Hydraulic Filter Relief Valve Setting | 1.05 bar | p. 33 |
| Fuel Tank Capacity | 24 US Gal (90 Litres) | p. 6 |
| Engine Oil Capacity | 2.6 US Gal (10 Litres) | p. 6 |
| 508-40 | ||
| Main Relief Valve (M.R.V.) Operating Pressure | 241 bar (3500 lbf/in²) | p. 34 |
| 506-36 | ||
| Main Relief Valve (M.R.V.) Operating Pressure | 241 bar (3500 lbf/in²) | p. 35 |
JCB 505-19 & variants Common Problems This Manual Covers
JCB 505-19 lift and boom functions become intermittent or stop working completely after initial morning startup. p. 33
Test the main relief valve operating pressure. For this model, verify pressure reaches 220 bar (3200 lbf/in²) as specified on page 33. If pressure drops below specification, inspect the hydraulic fluid level and replace the filter element before retesting the circuit.
Manual Section: HydraulicsEngine requires repeated coolant top-offs and temperature gauge spikes into the red zone during heavy load operation. p. 8
Drain the cooling system and inspect for external leaks. Refill the radiator, checking page 8 to verify the 6.2 US Gal (23.5 Litres) capacity for 508-40 models. Run the machine and confirm normal engine coolant temperature stabilizes at 80-85 °C (175-185 °F) per page 359.
Manual Section: EngineTransmission slips in forward gears and makes a loud grinding noise when shifting under load. p. 10
Check the transmission oil passages for blockages. Drain the fluid and inspect the gear assemblies for damage. When reinstalling components, tighten all M12 metric grade 8.8 bolts to exactly 98 Nm (72 lbf ft) as outlined on page 10.
Manual Section: TransmissionStarter motor clicks repeatedly but fails to crank the engine during cold morning starts. p. 651
Test the 12-volt negative earth electrical system battery voltage. Remove the starter motor and measure the brushes. Replace the brush assembly if length falls below the 8mm (0.3in) minimum tolerance found on page 651. Inspect wiring harness connectors for corrosion.
Manual Section: ElectricsFrequently Asked Questions
How do I clear fault codes on a JCB telehandler?
To clear fault codes when the ERROR light illuminates on a JCB telehandler, depress the ERROR RESET switch. If the SYSTEM NORMAL light illuminates, the fault codes are cleared. This procedure is detailed in the PlaceAce Control System section.
What are the torque specs for wheel nuts on a JCB 508-40?
For JCB 508-40 telehandlers, the torque specification for roadwheel retaining nuts is 680 Nm (69 kgf m, 500 lbf ft). This information is found in the "Front Axle (Fixed) Removal & Replacement & Proximity Switch Setting" section.
How to reset error codes on JCB 506-36
To reset error codes on a JCB 506-36 telehandler, depress the ERROR RESET switch. If the SYSTEM NORMAL light illuminates, the fault codes are cleared. This procedure is detailed on page 270 in the "PlaceAce Control System - Fault Finding" section.
What are the replacement specifications for filters?
For the hydraulic tank, the filter type is 'spin on' with a filtration size of 25 microns (0.001 in). For other filters like engine oil and fuel filters, the manual generally states to replace them with the appropriate recommended grade or new elements at specified service intervals.
How will I receive this Service Manual?
A 701-page Service Manual in searchable PDF format, available the moment you complete checkout. View on computer, tablet, or phone — no shipping wait.
Can I print specific sections of this Service Manual?
Yes. The PDF has no DRM restrictions — print any page or section you need for your shop. Works with any standard printer.
Are electrical wiring diagrams included in this JCB 505-19 & variants manual?
Yes, this JCB 505-19 & variants Service Manual includes complete electrical wiring diagrams, wire routing, and connector pinouts.
Document Quality
This document is a scanned PDF, but it includes an accurate OCR layer, allowing you to search and copy the full text. The text quality is consistently crisp and easy to read across all pages. Diagrams and illustrations are scanned line drawings and color schematics; they are clear with all labels readable, though some exhibit slight skewing. Pages are generally clean with minimal scan artifacts or marks, and there are no notable blank or filler pages.
Reviews
There are no reviews yet.