This JCB service manual covers the 520-40, 524-50 and 527-55 Compact Loadalls, 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.
Complete the set for your 520-40, 524-50, 527-55
- Operator Manual: JCB 524-50, 527-55 Loadall Operator Manual
- Operator Manual: JCB 520-40, 524-50, 527-55 Loadall Operator Manual
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 |
| 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 |
