JCB 508-66, 509-45, 510-44, 510-55 Loadall (Rough Terrain Variable Reach Truck) Service Manual 9813/9450 - ISSUE 1 - 11/2017

This comprehensive service manual provides in-depth repair instructions, maintenance schedules, and diagnostic procedures for the JCB 508-66, 509-45, 510-44, and 510-55 Loadall machines. Covering all major systems including hydraulics, drivetrain, brakes, HVAC, engine, electrical, and operator components, this manual is a vital resource for technicians working on rough terrain variable reach trucks in the JCB Loadall series.

Model Covers:

JCB 508-66 (S/N 2902000 & Above)
JCB 509-45 (S/N 2902000 & Above)
JCB 510-44 (S/N 2902000 & Above)
JCB 510-55 (S/N 2902000 & Above)

File Format: PDF

Size: 321.90 MB

No. of pages: 2696

Language: English

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

📑 Included Sections:

Safety and General Information

• Safety protocols, warnings, maintenance and operation risks
• Manual navigation and serial number identification
• Component descriptions and service point access

Attachments and Load Handling

• Fork carriage and components
• Jib and hook configurations
• Snatch blocks, shackles, and attachment integration

Body and Framework

• Chassis structure and body panels
• Battery and engine compartments, front/rear/top covers
• Lift arm mechanics, pivot links, chains and indicators
• Stabilizers, fenders, counterweights, and ID plates

Operator Station

• Cab frame, windows, doors, locks, handles
• Seats, belts, trim panels, dashboard and pedals
• Steering system, floor mat, controls and switches

Heating and Air Conditioning (HVAC)

• HVAC unit, evaporator, thermostat, blower motor
• Compressor, condenser, expansion valve, receiver drier
• Fresh air filter, heater valve, pipes and fittings

Engine

• Crankcase, cylinder head, camshaft, pistons, valves
• Oil system: sump, filter, cooler, pump, sensors
• Fuel system: injection, rail, pump, sensors
• Timing gears, alternator, starter, glow plugs

Fuel and Exhaust System

• Fuel tank, sender units, filters, pre-filters
• Injectors, common rail, high-pressure valve
• EGR valve, SCR unit, VGT turbocharger
• DEF integration, exhaust aftertreatment, sensors

Cooling System

• Radiators, expansion tanks, thermostats
• Cooling pack, fan motor, oil cooler and pump

Brake System

• Service brake: master cylinder, servo, calipers
• Park brake: switch, cable, pad, disc, actuator

Steering System

• Manual and auto steer modes
• Pumps, priority valves, steer unit/valve
• Columns, sensors, link arms, track rods

Driveline

• Semi-automatic gearbox, torque converter
• Differentials, driveheads, hubs, wheels
• Clutches, shafts, mounts, seals, yokes

Hydraulic System

• Hydraulic tanks, pumps, filters, strainers
• Control valves: MRV, ARV, LHRV, joystick, sway
• Lift arm, stabiliser, steering cylinders
• Accumulator, counterbalance valves, hose fittings

Electrical System

• Wiring diagrams, fuse boxes, relays, batteries
• Harnesses: chassis, lift arm, engine, operator cab
• Modules: instrument, engine, gearbox, lighting
• Diagnostics, sensors (NOx, speed, oil temp)

Fasteners and Fixings

• Screws, bolts, threaded inserts, bearings
• Clips and worm drive fixings

Consumable Products

• Engine oils, greases, antifreeze, DEF fluids
• Locking fluids, adhesives, sealants, fuel types

After Sales

• Maintenance intervals and checklists
• Functional test procedures and PPE guidance
• Special tools and units of measurement

This JCB Loadall service manual is an essential tool for technicians and maintenance professionals, offering unmatched technical depth and procedural accuracy across all critical systems of the 508-66, 509-45, 510-44, and 510-55 models.