Part of the JCB Repair Manuals.
Pull up the 1,227-page JCB Loadall Service Manual (OEM #9803/3740-08) and you have the complete factory reference for five telescopic handler variants: 506-36, 507-42, 509-42, 510-56, and 512-56, covering 2007-2012. Inside: full wiring diagrams with colour-code and electrical device code references, hydraulic schematics routing every circuit from pump to boom, and a complete Electronic Data Systems section with fault code diagnostics. Torque tables cover zinc-plated and Dacromet fasteners, hydraulic connections, and the Torque Stop hose system, with troubleshooting procedures spanning transmission, brakes, steering, and hydraulics. The main services pump displaces 29 cc/rev; torque the telescopic cylinder piston head to 405 Nm (300 lbf ft) and the end cap to 678 Nm (500 lbf ft) on rebuild. Your boom is down and the clock is running. Jump to any section by bookmark and search any spec by keyword.
What's Inside This JCB 506–512 Manual
| System | Pages | Key Topics |
|---|---|---|
| Applications | 6-15 | - |
| Introduction to the Manual | 16-21 | Introduction, Scope, Personnel, Newest Data, Format, Left and Right Sides, Hydraulic Schematic Codes, Colour Codes |
| Machine Identification | 22-29 | Introduction, Related Topics, Machine Identification Plate, Typical Product Identification Number, Component Identification Plates, Typical Engine Identification Number |
| Torque Settings | 30-39 | Introduction, Zinc Plated Fasteners and Dacromet Fasteners (Introduction), Bolts and Screws, Hydraulic Connections, 'o' Ring Face Seal System, 'Torque Stop' Hose System |
| Service Tools | 40-63 | Introduction, Numerical List, Tool Detail Reference, Rivet Nuts, Fitting Procedure, Slide Hammer Kit |
| Service Consumables | 64-65 | Introduction, Sealing and Retaining Compounds |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Piston head torque (2-6) | 405 Nm (41 kgf m, 300 lbf ft) | p. 738 |
| End cap torque (2-8) | 678 Nm (69 kgf m, 500 lbf ft) | p. 738 |
| Main services pump theoretical displacement | 29 cc/rev (1.77 cu in/rev) | p. 672 |
| Steering pump theoretical displacement | 19 cc/rev (1.16 cu in/rev) | p. 672 |
| Boom pivot total gap Z | not more than 3mm | p. 386 |
| Load Sense Relief Valve (LSRV) pressure | 260 bar (265 kgf/cm², 3770.9 lbf/in²) | p. 584 |
| Boom Extend Ram Head Side Auxiliary Relief Valve (ARV) pressure | 200 (215(2)) bar (203 (219(2)) kgf/cm², 2900.7 (3118(2)) lbf/in²) | p. 584 |
| BSP Hose Torque (1/8 in.) | 14.0 - 16.00 Nm (1.4 - 1.6 kgf m, 10.3 - 11.8 lbf ft) | p. 36 |
| BSP Hose Torque (1/4 in.) | 24.0 - 27.0 Nm (2.4 - 2.7 kgf m, 17.7 - 19.9 lbf ft) | p. 36 |
| Fuel Tank Capacity | 35 US Gal (132 Liters) | p. 123 |
| Engine Oil Capacity (MAX) | 3.9 US Gal (15 Liters) | p. 123 |
| Engine Coolant Capacity | 5.3 US Gal (20 Liters) | p. 123 |
JCB 506–512 Common Problems This Manual Covers
JCB Loadall 506-36 telescopic boom grinds and refuses to extend or retract under load p. 738
Inspect the boom wear pads first: vertical clearance exceeding 3.0mm (0.12in) per page 338 causes rod contact and scoring under load. If clearance is within spec, remove the telescopic cylinder and check for internal seal failure. Torque the replacement piston head to 405 Nm (300 lbf ft) and end cap to 678 Nm (500 lbf ft) per page 738.
Manual Section: Flowshare Hydraulic System - Fault FindingHydraulic system overheats rapidly during lifting cycles, all services become slow and weak p. 584
Check the Load Sense Relief Valve pressure: it must hold 260 bar (3770.9 lbf/in²) per page 584; a stuck-open valve bleeds flow as heat under every lift cycle. Verify hydraulic tank level at the full 128-litre (34 US gal) mark. If pressure holds and cooler fins are unobstructed, test main pump output: 57.4 litres/min at 2200 rpm per page 672.
Manual Section: Flowshare Hydraulic System - Fault FindingSteering becomes unresponsive or drifts out of phase at full boom extension p. 738
Inspect the steering cylinder for external seal weep: leaks accelerate under the added load of full boom height. Remove and rebuild using specs on page 738, torquing the piston head to 405 Nm (300 lbf ft) and end cap to 678 Nm (500 lbf ft). After reassembly, cycle steering lock-to-lock three times to purge air before verifying phase.
Manual Section: Steering System - Fault FindingMain hydraulic pump fails prematurely, all services lose power and pressure drops off p. 672
Remove and test the pump: main services output should reach 57.4 litres/min at 2200 rpm with max pressure of 265 bar (3840 lbf/in²) at port EF per page 672. Flow below spec at correct rpm confirms internal wear, not a valve fault. Torque replacement mounting bolts to 96 Nm (70 lbf ft) per page 684, then test under full load.
Manual Section: Main Pump - Fault FindingFrequently Asked Questions
How to reset JCB 506-36 error code?
Fault codes are logged by the Loadall Monitoring System (LMS) ECU and can be accessed and erased using JCB Servicemaster diagnostic software. The engineer has a facility to erase the fault code log after connecting the computer to the machine's CANbus socket.
What are the torque specs for JCB 512-56 engine bolts?
For engine mounting, the torque for the lifting bracket setscrews is 44 Nm (33 lbf ft). When separating the engine from the bevel box, the torque for the 6 bolts 5-B is 67 - 72 Nm (49 - 53 lbf ft).
How to clear JCB 509-42 transmission fault code?
Fault codes are logged by the Loadall Monitoring System (LMS) ECU and can be accessed and erased using JCB Servicemaster diagnostic software. The engineer has a facility to erase the fault code log after connecting the computer to the machine's CANbus socket.
Torque specs for JCB 510-56 hydraulic pump mounting bolts?
The torque for the main pump mounting bolts (items 8-J and 8-K) is 96 Nm (9.7 kgf.m, 70 lbf.ft). Ensure the pump flange and gearbox mating face are clean and free from oil and grease before assembly, and use new O-ring seals.
Is this JCB 506-36 & variants Service Manual a digital download?
Instant PDF download. You get the full 1227-page searchable Service Manual immediately after payment. Open it on your laptop, tablet, or phone right in the shop.
Am I able to print pages from this JCB 506-36 & variants manual?
Absolutely. No DRM or copy protection. Print the whole manual or just the pages you need. Any home or office printer works.
Are hydraulic system diagrams in this JCB 506-36 & variants Service Manual?
Full hydraulic system diagrams are included, covering circuits, valve locations, and hydraulic component specs for the JCB 506-36 & variants.
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