JCB 500 Series Telehandler Service Manual (9803/3600U Issue16)

This service manual provides detailed technical information, maintenance procedures, and repair instructions for JCB 500 Series Telehandlers. It covers two-stage and three-stage boom machines with both basic and servo control systems.

Model Covers:

• 505-19 – Serial Number 561001 to 579365
• 505-22 – Serial Number 561001 to 579365
• 508-40 – Serial Number 562601 to 579365
• 506-36 – Serial Number 563359 to 579999
• 510-40 – Serial Number 564542 to 579365
• 506B – Serial Number 570000 to 579766

Information covers two-stage and three-stage boom machines, including PlaceAce and Servo control options.

Note: 📘 This service manual (9803/3600U Issue16) covers JCB 500 Series telehandlers such as 505-19, 506-36, and 508-40, with detailed procedures for Loadall PlaceAce Control System and Return to Dig option. For the wider range of 500 Series models, including 530-120 and 537-130, see:
👉 View JCB 500 Series Service Manual (9803/3600)

File Format: PDF

Size: 96.72 MB

No. of pages: 701

Language: English

Delivery Method: Instant Download - Access your file immediately after purchase.

📑 Included Sections:

General

• Introduction, machine identification, and color coding references
• Serial number locations and service tool requirements

Hydraulics

• Hydraulic schematics and flow diagrams for two-stage and three-stage booms
• Pump servicing, valve block testing, and hydraulic filter replacement procedures
• Pressure setting adjustments and diagnostic testing charts

Body & Framework

• Cab structure, glazing removal, and ROPS/FOPS inspections
• Access panels, engine cover maintenance, and chassis servicing

Control Systems

• Loadall PlaceAce Control System overview and servicing
• Servo Control System configuration and adjustment procedures

Engine

• Engine specifications for Perkins and Cummins models used in 500 Series Telehandlers
• Cooling, lubrication, and fuel system maintenance instructions
• Engine removal and installation procedures

Note: For further engine servicing details, refer to Engine Service Manual Publication No. 9806/0100.

Transmission

• Powershift transmission fault diagnosis and servicing procedures
• Clutch adjustments, oil change intervals, and filter replacement
• Gearbox disassembly and reassembly guidance

Note: For detailed transmission overhauls, refer to Transmission Manual Publication No. 9808/3100.

Axles

• Front and rear axle servicing including differential inspection and bearing replacement
• Propshaft maintenance and lubrication schedules

Brakes

• Service and parking brake adjustment procedures
• Hydraulic brake system bleeding and testing

Hydraulic Steering

• Hydraulic steering schematics and troubleshooting charts
• Steering cylinder removal and replacement

Electrics

• Wiring diagrams and circuit layouts for cab and chassis systems
• Battery testing, alternator and starter motor servicing
• Fuse and relay identification and replacement

Service Tools

• List of required service tools with part numbers and illustrations

Boom Options

• Servicing and adjustments for Float and Return-To-Dig options
• Two-stage and three-stage boom diagnostics

Designed for professional workshops, this JCB 500 Series Telehandler Service Manual gives you the confidence and technical precision to keep your machines operating at their best.