This JCB service manual covers the 520-40, 524-50 and 527-55 Compact Loadalls built from 2003 to 2009, the machines carried under serial numbers 1012000 and 1068000 and powered by the JCB Dieselmax engine. It is the factory workshop document, publication number 9803/3690-10, running to 733 pages.Inside you get the full repair picture: torque settings and service tools, hydraulics with the 240 bar main relief valve, the electrical system with fuses and relays, transmission and axles, brakes, steering and engine work. Fault finding for the Load Moment Indicator and diagnostic tests are included.Whether you are chasing a hydraulic fault, tracing a wiring problem or overhauling a transmission, this PDF gives you the specifications and step by step procedures a JCB service engineer would use. Download it and keep it on the machine or in the workshop.
What's Inside This JCB 520-40, 524-50, 527-55 Manual
| System | Pages | Key Topics |
|---|---|---|
| General Information | 1-35 | Introduction, Standard Torque Settings, Service Tools, Service Consumables, Terms and Definitions |
| Care and Safety | 36-55 | Safety Notices (Important Information, Operator Manual, Safety Warnings), Safety Checklist (Safety - Yours and Others, Operating Safety, Maintenance Safety) |
| Attachments | 156-161 | Service Procedures (Quick Release Couplings, Connecting and Disconnecting, Quick Release Couplings - Do's and Don'ts, Connecting Quick Release Couplings, Disconnecting Quick Release Couplings) |
| Body and Framework | 162-223 | Service Tools (Numerical List), Basic Operation (Load Moment Indicator), Fault Finding (Load Moment Indicator, Fault Codes, Diagnostic Tests) |
| Electrics | 224-405 | Service Tools (Numerical List), Technical Data (Fuses and Relays, Fuses, Primary Fuses, Relays) |
| Controls | 406-427 | Manual Control Levers |
| Hydraulics | 428-579 | Service Tools (Numerical List), Technical Data (515-40, 520-40, 524-50, 527-55, Pump and Motor Test Points, Early Machines, Later Machines) |
| Transmissions | 580-621 | Service Tools (Numerical List), Technical Data (520-40, 524-50, 527-55), Basic Operation (Drive Train, Transfer Gearbox, Hg 310, Hg 700, Front and Rear Axles, Sd40, Sd55) |
| Brakes | 622-649 | Technical Data |
| Steering | 650-703 | Service Tools (Numerical List), Technical Data (All Models), Basic System Operation (515-40, 520-40, 524-50, 527-55, Hydraulic Operation, Electrical Operation) |
| Engine | 704-733 | Service Tools, Technical Data, Electrical Connections, Air Filter, Exhaust Assembly, Radiator Assembly |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| Wheel Nut Torque (Front) | 680 Nm | p. 149 |
| Wheel Nut Torque (Rear) | 680 Nm | p. 149 |
| BSP Adaptors Torque (1/2 in) | 98.00 Nm | p. 14 |
| SAE Connections Torque (3/4 - 16 thread) | 95.0 - 105.0 Nm | p. 14 |
| Battery Cold Crank Amps | 410 to 58 | p. 230 |
| Boom Wear Pad Replacement Clearance | less than 11 mm (0.43 in) thick | p. 152 |
| Service Brake Pad Minimum Thickness for Replacement | 3 mm (0.12 in) | p. 627 |
| 524-50, 527-55 | ||
| Engine Mounting Bolts Torque (Item S) | 80 Nm | p. 724 |
| Engine Mounting Bolts Torque (Item T) | 80 Nm | p. 724 |
| Alternator Maximum Output (from SN 1069457) | 95 amp | p. 230 |
| 515-40, 520-40 | ||
| Boom Lift Ram Bore | 100 mm | p. 437 |
| Hydraulic Filter Filtration Size (initial factory fit) | 5 microns | p. 437 |
JCB 520-40, 524-50, 527-55 Common Problems This Manual Covers
Weak or slow hydraulic functions
A loss of lift, crowd or extend power usually points to worn pump internals, a sticking priority valve or a main relief valve that is off its 240 bar setting. The Hydraulics section gives the test points and pressures to isolate the fault.
Manual Section: Hydraulics p. 428Fault codes and warning lights
Intermittent electrical faults and dash warnings on these Loadalls are traced through the fuses, relays and wiring covered here. The Electrics section lists the primary fuses and relays needed to find the failed circuit.
Manual Section: Electrics p. 224Load Moment Indicator faults
The Load Moment Indicator can throw fault codes or lock out the machine when a sensor or connection fails. Fault finding, fault codes and diagnostic tests for the system are set out in the Body and Framework section.
Manual Section: Body and Framework p. 162Service brake pad wear
Service brake pads worn below their minimum thickness reduce stopping performance and must be renewed. The Brakes section carries the technical data and replacement limits for the disc brakes.
Manual Section: Brakes p. 622Transmission and axle problems
Drive loss, harsh shifting or transfer gearbox noise are covered by the drive train and axle procedures for the 520-40, 524-50 and 527-55. The Transmissions section gives the technical data and basic operation for these units.
Manual Section: Transmissions p. 580Heavy or unresponsive steering
Heavy or unresponsive steering is diagnosed through the hydraulic and electrical steering circuits described here. The Steering section covers system operation and the relief valve pressures for each model.
Manual Section: Steering p. 650Frequently Asked Questions
Which machines does this manual cover?
It covers the JCB 520-40, 524-50 and 527-55 Compact Loadalls powered by the JCB Dieselmax engine, from serial numbers 1012000 and 1068000. It is publication 9803/3690-10 with 733 pages.
Does it include electrical and wiring information?
Yes. The Electrics section covers the wiring, fuses, primary fuses and relays and gives the technical data you need to trace intermittent faults and dead circuits on these Loadalls. p. 224
What engine work is covered?
The Engine section covers the JCB Dieselmax engine, with technical data, electrical connections, air filter, exhaust and radiator assembly procedures. Valve clearance and other settings are included for the 520-40. p. 704
How do I get the manual?
You download the PDF straight after purchase, so you can start using it right away and keep a copy on the machine or in the workshop.
How will I receive this Service Manual?
Right after checkout you download the 733-page searchable PDF instantly. It opens on a laptop, tablet, or phone, so you can carry it straight to the shop floor.
Can I print this manual?
Yes. Print as many copies as you want, with no restrictions. Plenty of mechanics print just the section they need and take it to the shop floor.
Does this Service Manual have electrical diagrams?
Complete wiring diagrams are included, covering all electrical circuits, harness routing, and connector pinouts for the JCB 520-40, 524-50, 527-55.
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