JCB 505-19, 505-22, 506-36, 506B, 508-40 (PlaceAce) & 510-40 Telescopic Handler Service Manual 1997-2003

Official JCB 500 Series Telescopic Handler Service Repair Manual (Serial No. 561001-579999)

Keep your equipment running at peak performance with the definitive factory technical resource.

This comprehensive Service Manual (Publication No. 9803/3600U) is the essential guide for owners, fleet managers, and technicians working on the JCB 500 Series Loadall line. Whether you are performing routine maintenance or a complete transmission overhaul, this manual provides the professional-grade instructions required to ensure safety, reliability, and maximum uptime on the job site.

Unmatched Model-Specific Coverage

This manual is engineered specifically for the JCB 500 Series, covering both two-stage and three-stage boom configurations starting from Machine No. 561001. It includes dedicated data for:

• JCB 505-19 & 505-22: Full coverage for standard and Basic Servo Option variants.
• JCB 506-36 & 506B: Detailed procedures for these high-capacity handlers.
• JCB 508-40: Includes specialized sections for the PlaceAce Control System and advanced Servo Options.
• JCB 510-40: Complete technical specifications for the heavy-duty 510 series.

The Professional Advantage: What’s Inside

This is not a basic operator's guide. This is a deep-dive technical manual used by dealership technicians, containing over 800 pages of factory-verified data:

• Transmission & Driveline Mastery: Complete teardown and assembly instructions for the Syncro Shuttle transmission, torque converters, and layshaft assemblies.
• Advanced Hydraulics: Precision diagrams and service steps for tilt rams, sway rams, and main control valves. Includes pressure testing and circuit venting procedures to ensure safe operation.
• PlaceAce Control System: Exclusive technical breakdown of the Loadall PlaceAce system, including display unit removal, joystick calibration, and error code resetting.
• Electrical Systems: High-resolution wiring schematics and logic for 2-wheel steer, 4-wheel steer, and crab steer systems (including IP67 electronics).
• Engine & Torque Data: Specific torque multiplication ratios, stall speeds, and mounting procedures for various engine configurations (AA and AB series).

Engineered for Mobile Readiness

We understand that repairs often happen in the field. This manual is formatted for easy navigation:

• Clear Section Indexing: Quickly jump between Hydraulics, Transmission, and Chassis sections.
• Step-by-Step Visuals: Hundreds of technical illustrations and exploded views help you identify parts and follow complex assembly sequences.
• Safety First: Includes critical "General Safety" and "Maintenance Safety" sections (GEN-003/HYD 4-1) to protect your crew and your investment.

Detailed Technical Chapters:

• General Information: Machine identification, fluids, and capacities.
• Hydraulics: Pump performance, valve adjustments, and cylinder seal replacement.
• Transmission: Gearbox ratios, parking brake adjustment, and axle service.
• Steering & Brakes: Multi-mode steering calibration and braking system bleeding.
• Boom & Chassis: Two-stage and three-stage boom alignment and wear pad replacement.

Stop guessing and start fixing. With this official JCB Service Manual, you gain the confidence to handle everything from minor sensor issues to major mechanical failures. Ensure your JCB Telehandler remains a reliable asset for years to come.