JCB Compact Loadall 520-40, 524-50, 527-55 Telehandler Service Manual
733 pages · Publication 9803-3690-8
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- Models
- Compact Loadall 520-40, 524-50, 527-55
- Serial coverage
- 520-40 from SN 1012000, 524-50 from SN 1068000, 527-55 from SN 1068000
- Manual type
- Service Manual
- Pages
- 733
- Publication
- 9803-3690-8
- Condition
- Brand new
What's inside
From the manual's own table of contents: 5 sections, 315 entries. See sample pages (PDF, 418 KB)
General81 topics
- About This Publication
- Machine Model and Serial Number
- Using the Service Manual
- Units of Measurement
- Section Numbering
- Left Side, Right Side
- Cross References
- Identifying Your Machine
- Machine Identification Plate
- Component Identification Plates
- Zinc Plated Fasteners and Dacromet Fasteners
- Introduction
- Bolts and Screws
- Hydraulic Connections
- O' Ring Face Seal System
- Torque Stop' Hose System
- Numerical List
- Tool Detail Reference
- Section B - Frame and Bodywork
- Section C - Electrics
- Section E - Hydraulics
- Section F - Transmission
- Section H - Steering
- Section K - Engine
- Sealing and Retaining Compounds
- Colour Coding
- Hydraulic Schematic Colour Codes
- Important Information
- The Operator Manual
- Safety Warnings
- Safety Checklist
- Safety - Yours and Others
- General Safety
- Operating Safety
- Maintenance Safety
- Safety Decals
- Safety Decal Recognition
- Service Requirements
- Owner/Operator Support
- Service/Maintenance Agreements
- Lifting Regulations - Inspections and Tests
- Obtaining Replacement Parts
- Health and Safety
- Lubricants
- Battery
- First Aid - Electrolyte
- Service Schedules
- How to Use the Service Schedules
- Calendar Equivalents
- Fluids, Lubricants and Capacities
- Coolant Mixtures
- Fuels (JCB Dieselmax Engine)
- Prepare the Machine for Maintenance
- How to Make the Machine Safe (Boom Lowered)
- How to Make the Machine Safe (Boom Lifted)
- Cleaning the Machine
- Preparing the Machine for Cleaning
- Checking for Damage
- Seat Belt
- Checking the Seat Belt Condition and Security
- ROPS/FOPS Structure
- Checking the ROPS/FOPS Structure
- Greasing
- Preparing the Machine for Greasing
- Every 50 Hours
- Every 500 Hours
- Every 1000 Hours
- Oiling
- Access Panels
- Engine Cover
- Battery Cover
- Rear Grille
- Seat Base
- Undershields
- Cab Heater Filter
- Cleaning the Cab Heater Filter
- Brakes
- Park Brake Adjustment
- Checking the Foot Brake Fluid Level
- Electrical System
- Jump Starting the Engine
Section 3 - Routine Maintenance52 topics
- Engine (JCB Dieselmax)
- Oil and Filter
- Cooling System
- Front End Accessory Drive Belt
- Air Filter
- Engine
- Alternator Drive Belt
- Fuel System (JCB Dieselmax)
- Water Separator and Engine Fuel Filter
- Bleeding the System
- Fuel System
- Cleaning the Lift Pump Gauze (520-40 Machines)
- Fuel Filter
- Priming the System
- Hydraulic System
- Changing the Hydraulic Tank Filler Cap
- Hose Burst Protection Valve
- Transmission
- Gearbox
- Axles
- Tyres and Wheels
- Tyre Inflation
- Checking the Wheel Nut Torques
- Wheel Alignment
- Permanent 4-Wheel Steer
- Electronic Steer Mode Selector
- Wear Pads
- Boom Wear Pad Clearance
- Windscreen Washer
- Fire Extinguisher (if fitted)
- Checking the Fire Extinguisher
- Load Moment Indicator (LMI)
- Fault Codes
- General Fault Finding
- Diagnostic Tests
- Rivet Nuts
- Fitting Procedure
- Slide Hammer Kit
- Glazing
- Direct Glazing
- Boom
- Adjusting Shovel Alignment
- Calibration Procedure
- Calibration Charts
- Removal and Replacement
- Removal
- Replacement
- Dismantling and Assembly
- Dismantling
- When Assembling
- Internal Components
- Instrument Panels
Section B - Body and Framework40 topics
- Adjustment
- Axle Transducer
- General Technical Data
- Fuses and Relays
- Fuses
- Primary Fuses
- Relays
- Pulse Width Modulated Controls
- Pulse Width Modulation
- Overall Operation
- Machine Connection Details
- Detailed Operation
- Input Filtering and Measurement
- Valve Operation
- Diagnostic Output
- Fault Detection
- Sheet 1 of 7
- Sheet 2 of 7
- Sheet 3 of 7
- Sheet 4 of 7
- Sheet 5 of 7
- Sheet 6 of 7
- Sheet 7 of 7
- LCS/LLMC Machines
- Using a Multimeter
- Measuring DC Voltage
- Measuring Resistance
- Measuring Continuity
- Measuring Frequency
- Testing a Diode or a Diode Wire
- Maintenance
- Testing
- Specific Gravity Testing
- Alternator
- General Description
- Service Precautions
- Charging Circuit Test
- Alternator Charging Test
- Starter Motor
- Starting Circuit Test
Section C - Electrics48 topics
- Wire and Harness Number Identification
- Wire Numbers and Functions
- Wiring Harness Repair
- Repair Procedure
- Removal, Inspection and Replacement
- Inspection
- Dismantle and Assemble
- Renewing the Voltage Regulator and Brushes
- Renewing the Drive Pulley
- Renewing the Brush Gear
- Renewing the Starter Solenoid
- Earth Points
- Drawings and Interconnection
- Machine Variants
- Harness Interconnection
- Harness Drawings (All Machines)
- Component Identification
- Joystick
- Basic Electrical Operation
- Control Assembly
- Control Rod Assembly
- Servo Control Unit
- Basic Hydraulic Operation
- Dismantle and Assembly
- Pump and Motor Test Points
- Early Machines (With Dropbox)
- Later Machines (Without Dropbox)
- Systems
- Circuit Descriptions
- Manual Control Machines
- Servo Control Machines
- Introduction to Hydraulic Schematic Symbols
- General (Basic and Functional Symbols)
- Control Valves
- Example of Schematic Circuit
- Machines with Integral Steer Priority Valve (up to SN TBA)
- Machines with Remote Steer Priority Valve (from SN TBA)
- Main Services Pump
- Transmission Pump
- Components
- Ports
- Operation
- Transmission Motor
- Main Services Valve
- Manual Controls
- Servo Controls
- Main Hydraulic Services
- Hydraulic Transmission
Section E - Hydraulics82 topics
- Hydraulic Contamination
- Hydraulic Fluid Quality
- Effects of Contamination
- Cleaning Operation
- Contaminant Standards
- Filters
- Connecting and Disconnecting Hydraulic Hoses
- Connecting the Hoses
- Disconnecting the Hoses
- Venting Hydraulic Pressure
- Hydraulic System Testing
- Main Services Pump Testing
- Relief Valve Testing
- Transmission System Testing
- Preparation
- Dismantling, Inspecting and Assembling
- Inspecting
- Assembling
- Pump and Engine Coupling
- Start-Up Procedure
- Tie Rods
- Precautions During Use
- Installation
- Caution During Use
- Maintenance, Inspection Points
- Lift Ram
- Displacement Ram
- Extension Ram
- Tilt Ram
- Typical Ram
- JCB Ram Sealing Procedure
- Piston Head Retention
- Drive Train
- Transfer Gearbox (if fitted)
- Front and Rear Axles
- SD40 (Without Brakes)
- SD55 (Without Brakes)
- Towing a Machine
- Crown Wheel and Pinion Adjustment
- Correct Tooth Marking
- Pinion Too Deeply in Mesh
- Pinion Too Far Out of Mesh
- Renewing the Pinion Oil Seal
- Wear Sleeve Fitting
- Axle and Gearbox Driveshaft Flange Seals
- Fitting a New Spacer to Drive Head
- Special Tools
- Wheel Hub Bearing Removal
- Removing and Replacement
- When Removing
- When Replacing
- Drive Head
- Hub and Driveshaft
- All Models
- Service Brakes
- Park Brake
- Service Brake
- Inspection and Renewing the Brake Pads
- Bleeding Procedure
- Renewing the Brake Pads
- Service Brake Calliper
- Dismantle, Inspection and Assemble
- Dismantle
- Assemble
- Hydraulic Operation
- Electrical Operation
- Steer Unit Operation
- Neutral
- Turning
- System Operation
- 2-Wheel Steering
- 4-Wheel Steering
- Crab Steering
- Mechanical and Hydraulic
- Re-phasing the Steer System
- System Bleeding
- Proximity Switch Setting
- Sensor Connections
- Testing and Adjustment
- Checking Solenoid Operation
- Link Arms
- When Dismantling
Section H - Steering7 topics
- Before Dismantling
- Pressure Relief Valve Cartridge
- Shock Valves
- Tier 2 and Tier 3
- Cold Start Heater
- Blink' Codes
- All Machines
Inside this manual
Real pages from this service manual (733 pages). Open the sample pages (PDF, 417 KB)
- Specifications, page 230: Technical Data
- Diagram, page 318: Harness Data
- Troubleshooting, page 516: Section E - Hydraulics
- Color page, page 265: Section C - Electrics
- Color page, page 489: Section E - Hydraulics
This is a service manual
Here's how it compares to the other manual types.
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 733 pages
Quantity one is the manual described above.
Fast free USA shipping
Ships in 1 business day.
60-day returns
Free if the mistake is ours. A manual ordered in error must come back unopened in its shrink-wrap; you pay return shipping and a 20% restocking fee applies. Return policy
Binder not included
Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.
Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).