Part of the JCB Repair Manuals.
This JCB Service Manual covers the 506C, 506CHL, and 508C Loadall telehandlers, publication number 9803/3640U-8, for machines built between 2005 and 2008. Its 717 pages give the full factory workshop coverage for these models, which were fitted with A Series, R Series, JCB 444 Series, or JCB Dieselmax engines.The manual is arranged by system: general information and torque settings, care and safety, attachments, body and framework, electrics, controls, hydraulics, transmissions, brakes, steering, and engine. Technical data tables provide the capacities, relief valve pressures, and torque figures for each variant.Use it to shim and service the boom, overhaul the hydraulics, set the main relief valve to 238 bar, service the Syncro Shuttle or Powershift transmission, and trace circuits through the electrical section.
What's Inside This JCB 506C, 506CHL, 508C Manual
| System | Pages | Key Topics |
|---|---|---|
| General Information | 2-39 | Introduction, Identifying Your Machine, Standard Torque Settings, Service Tools, Service Consumables, Terms and Definitions |
| Care and Safety | 40-57 | Safety Notices (Important Information, Operator Manual, Safety Warnings), Safety Check List (Safety - Yours and Others, Operating Safety, Maintenance Safety) |
| Attachments | 150-157 | Quick Release Couplings, Venting Hydraulic Pressure (Connecting and Disconnecting, Quick Release Couplings - Do's and Don'ts), Connecting Quick Release Couplings |
| Body and Framework | 158-191 | Service Procedures (Rivet Nuts, Slide Hammer Kit), Boom (Removal and Replacement, Shimming), Boom Chains (Servicing, Removal, Inspection and Replacement) |
| Electrics | 192-351 | Technical Data (Fuses and Relays), Basic System Operation (Circuit Schematics) |
| Controls | 352-359 | Dual Control Function Levers, Adjustment (Assembly), Fig 1, Fig 2, Fig 3, Fig 4 |
| Hydraulics | 360-459 | Technical Data (506C Machines, 506CHL and 508C Machines), Basic System Operation (Introduction to Hydraulic Schematic Symbols) |
| Transmissions | 460-641 | Technical Data (Syncro Shuttle, Powershift, Axles, Tyres, Recovery Procedure, Drive Paths), Fault Finding (Syncro Shuttle, Powershift) |
| Brakes | 642-671 | Technical Data (All Models), Basic Operation, Service Procedures (Brake Piston Seal Leakage, Introduction, Testing, Bleeding Procedure, Front Axle, Rear Axle) |
| Steering | 672-709 | Technical Data (506C, 506Chl & 508C), Basic System Operation (Hydraulic Steer Circuit) |
| Engine | 710-717 | Technical Data |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Metric Grade 12.9 Fasteners (M10, Condition 1) | 80.0 Nm | p. 15 |
| Drive shaft oil seal protrusion (if dimension V is 16 to 16.30 mm) | 2 mm | p. 635 |
| JCB Multi-Gasket quantity | 50 ml | p. 37 |
| BSP Hose (1/4 inch) torque setting | 24.0 - 27.0 Nm | p. 18 |
| Ram end cap (51-8) torque | 678 Nm | p. 454 |
| UNF Grade 'S' Fasteners (Condition 1) - 1/4 inch bolt torque | 11.2 Nm | p. 14 |
| UNF Grade 'S' Fasteners (Condition 1) - 1 inch bolt torque | 814.0 Nm | p. 14 |
| Metric Grade 8.8 Fasteners (Condition 1) - M5 bolt torque | 5.8 Nm | p. 14 |
| Metric Grade 8.8 Fasteners (Condition 1) - M36 bolt torque | 2399.0 Nm | p. 14 |
| Hydraulic BSP Adaptors Torque - 1/4 inch | 18.0 Nm | p. 17 |
| Hydraulic BSP Adaptors Torque - 1 1/4 inch | 206.0 Nm | p. 17 |
| Engine Oil Capacity | 10 liters | p. 80 |
JCB 506C, 506CHL, 508C Common Problems This Manual Covers
Boom loses power or will not lift
A boom that jerks, loses power, or will not reach rated height usually has hydraulic wear, low or contaminated oil, or leaking seals. The Hydraulics section covers the technical data and system operation for the 506C, 506CHL, and 508C.
Manual Section: Hydraulics p. 360Attachment hydraulics malfunction
Attachment changes or auxiliary functions that misbehave often come from the quick-release couplings or boom-end connections. The Attachments section covers venting hydraulic pressure and connecting the couplings correctly.
Manual Section: Attachments p. 150Fasteners loosening or backing out
Repeated fastener failure or components working loose usually means the wrong bolts or missed torque values. The General Information section lists the standard torque settings for the high-tensile fasteners these machines use.
Manual Section: General Information p. 2Oil leaks from driveline or hubs
Persistent leaks from the driveline or hydraulic components point to worn oil seals and gaskets. The Transmissions section covers the drive shaft oil seal service and related procedures.
Manual Section: Transmissions p. 460Boom wear and chain stretch
As the boom wears, the wear pads and boom chains need shimming, inspection, and replacement. The Body and Framework section covers boom removal, shimming, and boom chain servicing.
Manual Section: Body and Framework p. 158Brake performance drops
Spongy or weak brakes can come from piston seal leakage or air in the system. The Brakes section covers testing, the bleeding procedure, and front and rear axle brake service.
Manual Section: Brakes p. 642Steering heavy or wandering
Heavy or drifting steering points to the hydraulic steer circuit. The Steering section covers the technical data and basic system operation for the 506C, 506CHL, and 508C.
Manual Section: Steering p. 672Frequently Asked Questions
Which models does this manual cover?
It covers the JCB 506C, 506CHL, and 508C Loadall telehandlers, publication 9803/3640U-8, for machines built between 2005 and 2008.
What is the hydraulic main relief valve pressure?
The main relief valve is set to 238 bar on the 506C and on the 506CHL and 508C. The Hydraulics section gives the technical data for each model. p. 360
What engines were these machines fitted with?
Depending on build they used A Series, R Series, JCB 444 Series, or JCB Dieselmax engines. The Engine section provides the technical data. p. 710
Does it cover the electrical system?
Yes. The Electrics section covers the technical data, fuses and relays, and the circuit schematics for tracing faults on these Loadalls. p. 192
What format is this manual in?
Immediate download of the complete 717-page searchable Service Manual. Access it on any device: a laptop at your desk or your phone in the field.
Can I print this manual?
The PDF is DRM-free, so print whatever sections you need for the shop floor. Standard letter or A4 paper works.
Are there wiring harness diagrams in this JCB 506C, 506CHL, 508C manual?
Yes, this JCB 506C, 506CHL, 508C Service Manual includes complete electrical wiring diagrams, wire routing, and connector pinouts.
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