JCB 515, 520, 524, 527 Compact Loadalls Service Manual – 9803/3690-10

This workshop repair service manual PDF download for the 515-40, 520-40, 524-50, 527-55 JCB Compact Loadalls has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

– JCB Compact Loadall 515-40 – from S/N: 1012000 Onwards
– JCB Compact Loadall 520-40 – from S/N: 1012000 Onwards
– JCB Compact Loadall 524-50 – from S/N: 1068000 Onwards
– JCB Compact Loadall 527-55 – from S/N: 1068000 Onwards

TABLE OF CONTENTS :

Section 1 – General Information
Section 2 – Care and Safety
Section 3 – Maintenance
Section A – Attachments
Section B – Body and Framework
Section C – Electrics
Section D – Controls
Section E – Hydraulics
Section F – Transmissions
Section G – Brakes
Section H – Steering
Section K – Engine

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9803/3690-10
Total Pages : 734

This complete JCB Telescopic Handler | Loadall | Telescopic Loader service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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9803-3690

Section 1 – General Information
Introduction
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
Typical Vehicle Identification Number (VIN)
Typical Product Identification Number (PIN)
Component Identification Plates
Typical Engine Identification Number
Transmission Identification Number
Standard Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
Introduction
Bolts and Screws
Condition 1
Condition 2
Verbus Ripp Bolts
Hydraulic Connections
‘O’ Ring Face Seal System
Adaptors Screwed into Valve Blocks
Hoses Screwed into Adaptors
Adaptors into Component Connections with Bonded Washers
‘Torque Stop’ Hose System
Service Tools
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
Service Consumables
Sealing and Retaining Compounds
Terms and Definitions
Colour Coding
Hydraulic Schematic Colour Codes

Section 2 – Care and Safety
Section 2
Safety Notices
Important Information
The Operator Manual
Safety Warnings
Safety Checklist
Safety – Yours and Others
General Safety
Operating Safety
Maintenance Safety
Safety Decals
Introduction
Safety Decal Recognition

Section 3 – Maintenance
Routine Maintenance
Service Requirements
Introduction
Owner/Operator Support
Service/Maintenance Agreements
Lifting Regulations – Inspections and Tests
Obtaining Replacement Parts
Health and Safety
Lubricants
Introduction
Hygiene
Storage
Waste Disposal
Handling
New Oil
Used Oil
First Aid – Oil
Eyes
Swallowing
Skin
Spillage
Fires
Battery
First Aid – Electrolyte
GETS INTO YOUR EYES
IS SWALLOWED
GETS ONTO YOUR SKIN
Warning Symbols
Service Schedules
Introduction
How to Use the Service Schedules
Calendar Equivalents
520-40 (All) and 524-50, 527-55 (Up to SN 1069456)
Pre-start Cold Checks, Service Points and Fluid Levels
Functional Test and Final Inspection
524-50, 527-55 (From SN 1069457)
Pre-start Cold Checks, Service Points and Fluid Levels
Functional Test and Final Inspection
Fluids, Lubricants and Capacities
Coolant Mixtures
Fuels (JCB Dieselmax Engine)
Acceptable and Unacceptable Fuels
Additives
Service Requirements for use of B5 Biodiesel
Warranty
Sulphur Content
Effects of Fuel Contaminates
Prepare the Machine for Maintenance
Introduction
How to Make the Machine Safe (Boom Lowered)
How to Make the Machine Safe (Boom Lifted)
Installing the Maintenance Strut
Removing the Maintenance Strut
Cleaning the Machine
Introduction
Detergents
Pressure Washing and Steam Cleaning
Preparing the Machine for Cleaning
Cleaning the Machine
Checking for Damage
Seat Belt
Checking the Seat Belt Condition and Security
ROPS/FOPS Structure
Checking the ROPS/FOPS Structure
Greasing
Introduction
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
Battery
Battery Disconnection/Connection
Disconnection
Connection
Checking the Electrolyte Level
Battery Isolator (if fitted)
Jump Starting the Engine
Engine (JCB Dieselmax)
Oil and Filter
Checking the Oil Level
Changing the Oil and Filter
Cooling System
Checking the Coolant Level
Changing the Coolant
Front End Accessory Drive Belt
Introduction
Inspecting the Drive Belt
Changing the Drive Belt
Air Filter
Cleaning the Air Filter Dust Valve
Changing the Elements
Engine
Oil and Filter
Checking the Oil Level
Changing the Oil and Filter
Cooling System
Checking the Coolant Level
Changing the Coolant
Alternator Drive Belt
Adjusting the Alternator Drive Belt
Air Filter
Cleaning the Air Filter Dust Valve
Changing the Elements
520-40 Machines
524-50, 527-55 Machines
Fuel System (JCB Dieselmax)
Water Separator and Engine Fuel Filter
Introduction
Draining the Water Separator and Engine Fuel Filter
Changing the Water Separator Pre-Filter
Cleaning Water Separator Pump (if fitted)
Changing the Engine Fuel Filter Element
Bleeding the System
Mechanical Fuel Injection System
Fuel System
Cleaning the Lift Pump Gauze (520-40 Machines)
Fuel Filter
Draining the Filter
520-40 Machines
524-50, 527-55 Machines
Changing the Filter Element
520-40 Machines
524-50, 527-55 Machines
Priming the System
520-40 Machines (Up to SN 1013699)
520-40 Machines (From SN 1013700)
524-50, 527-55 Machines
Hydraulic System
Oil and Filter
Checking the Fluid Level
Changing the Filter Element
Changing the Hydraulic Tank Filler Cap
520-40 Machines
Hose Burst Protection Valve
Checking the Hose Burst Protection Valves
Introduction
Boom Lift Rams
Boom Extension Ram
Carriage Tilt Ram
Transmission
Gearbox
Checking the Gearbox Oil Level
Changing the Gearbox Oil
Axles
Checking the Axle Oil Level
Changing the Axle Oil
Checking the Hub Oil Levels
Changing the Hub Oil
Tyres and Wheels
Tyre Inflation
Checking the Wheel Nut Torques
Wheel Alignment
Introduction
Permanent 4-Wheel Steer
Electronic Steer Mode Selector
Wear Pads
Boom Wear Pad Clearance
Windscreen Washer
Fire Extinguisher (if fitted)
Checking the Fire Extinguisher

Section A – Attachments
Section A
Service Procedures
Quick Release Couplings
Connecting and Disconnecting
Quick Release Couplings – Do’s and Don’ts
Connecting Quick Release Couplings
Disconnecting Quick Release Couplings

Section B – Body and Framework
Body and Framework
Service Tools
Numerical List
Basic Operation
Load Moment Indicator (LMI)
Fault Finding
Load Moment Indicator (LMI)
Fault Codes
General Fault Finding
Diagnostic Tests
Service Procedures
Rivet Nuts
Fitting Procedure
Slide Hammer Kit
Fitting Procedure
Glazing
Direct Glazing
Boom
Wear Pads
Adjusting Shovel Alignment
Load Moment Indicator (LMI)
Calibration Procedure
Calibration Charts
Boom
Removal and Replacement
Removal
Replacement
Inner Boom
Removal and Replacement
Removal
Replacement
Compact Q-Fit Tool Carrier
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Dismantling
When Assembling
Cab
Removal and Replacement
Removal
Replacement
Internal Components
Instrument Panels
Steering Column Cover
Side Console
Engine Cover
Removal and Replacement
540-50, 527-55
Engine Cover Lock
Removal and Replacement
Removal
Adjustment
Counterweight
Removal and Replacement
Removal
Replacement
Underfloor Cover
Removal and Replacement
524-50, 527-55
Load Moment Indicator (LMI)
Removal and Replacement
Axle Transducer

Section C – Electrics
Electrics
Service Tools
Numerical List
Technical Data
General Technical Data
Fuses and Relays
Fuses
Primary Fuses
Relays
Basic Operation
Pulse Width Modulated Controls
Introduction
Pulse Width Modulation
Overall Operation
Machine Connection Details
Detailed Operation
Input Filtering and Measurement
Valve Operation
Diagnostic Output
Fault Detection
Schematic Circuits
520-40
524-50, 527-55 (up to SN 1069456)
524-50, 527-55 (From SN 1069457 to 1418024)
524-50, 527-55 (From 1418025)
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
Service Procedures
Using a Multimeter
Measuring DC Voltage
Measuring Resistance
Measuring Continuity
Measuring Frequency
Testing a Diode or a Diode Wire
Battery
Maintenance
Testing
Specific Gravity Testing
Alternator
General Description
Service Precautions
Charging Circuit Test
Alternator Charging Test
Starter Motor
Starting Circuit Test
Wire and Harness Number Identification
Introduction
Wire Numbers and Functions
Wiring Harness Repair
Introduction
Repair Procedure
Alternator
Removal and Replacement
Removal
Replacement
Alternator (JCB Dieselmax Engine)
Removal, Inspection and Replacement
Removal
Inspection
Replacement
Dismantle and Assemble
Renewing the Voltage Regulator and Brushes
Renewing the Drive Pulley
Starter Motor
Removal and Replacement
Removal
Replacement
Starter Motor (JCB Dieselmax Engine)
Removal, Inspection and Replacement
Removal
Inspection
Replacement
Dismantle and Assemble
Renewing the Brush Gear
Renewing the Starter Solenoid
Harness Data
Earth Points
Drawings and Interconnection
Machine Variants
Harness Interconnection
Harness Drawings (All Machines)

Section D – Controls
Manual Control Levers
Component Identification
Joystick
Basic Electrical Operation
Removal and Replacement
Removal
Replacement
Control Assembly
Removal and Replacement
Removal
Boom (Lift/Lower) and Carriage Control Lever
Boom (Extend/Retract) Control Lever
Auxiliary Control Lever
Control Lever Pivot
Replacement
Control Rod Assembly
Removal and Replacement
Removal
Replacement
Servo Control Lever
Component Identification
Joystick
Basic Electrical Operation
Removal and Replacement
Removal
Replacement
Servo Control Unit
Basic Hydraulic Operation
Removal and Replacement
Removal
Replacement
Dismantle and Assembly
Dismantle
Assembly

Section E – Hydraulics
Hydraulics
Service Tools
Numerical List
Technical Data
515-40, 520-40
524-50, 527-55
Pump and Motor Test Points
Early Machines (With Dropbox)
Later Machines (Without Dropbox)
Basic System Operation
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
Schematic Circuits
515-40, 520-40
Machines with Integral Steer Priority Valve (up to SN TBA)
Machines with Remote Steer Priority Valve (from SN TBA)
524-50, 527-55
Manual Control Machines with Integral Steer Priority Valve (up to SN TBA)
Manual Control Machines with Remote Steer Priority Valve (from SN TBA)
Servo Control Machines with Integral Steer Priority Valve (up to SN TBA)
Servo Control Machines with Remote Steer Priority Valve (from SN TBA)
Circuit Descriptions
Main Services Pump
Transmission Pump
Components
Ports
Operation
Transmission Motor
Early Machines (with Dropbox)
Later Machines (without Dropbox)
Main Services Valve
Manual Controls
Servo Controls
Fault Finding
Main Hydraulic Services
Hydraulic Transmission
Introduction
Early Machines (with Dropbox)
Later Machines (without Dropbox)
Service Procedures
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
Test Procedures
Hydraulic System Testing
Main Services Pump Testing
Relief Valve Testing
Transmission System Testing
Later Machines (Without Dropbox)
Main Services Pump
Removal and Replacement
Preparation
Removal
Replacement
Dismantling, Inspecting and Assembling
Dismantling
Inspecting
Assembling
Transmission Pump
Removal and Replacement
Preparation
Removal
Replacement
Pump and Engine Coupling
Start-Up Procedure
Transmission
Removal and Replacement
Early Machines (with Dropbox)
Later Machines (without Dropbox)
Dismantling and Assembly
Later Machines (without Dropbox)
Control Valve Block
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Tie Rods
Rams
Precautions During Use
Installation
Caution During Use
Maintenance, Inspection Points
Removal and Replacement
Lift Ram
Displacement Ram
Extension Ram
Tilt Ram
Dismantling and Assembly
Typical Ram
JCB Ram Sealing Procedure
Piston Head Retention

Section F – Transmissions
Service Tools
Numerical List
Technical Data
520-40
524-50, 527-55
Basic Operation
Drive Train
Operation
Early Machines (with Dropbox)
Later Machines (without Dropbox)
Transfer Gearbox (if fitted)
HG 310
Operation
Component Identification
HG 700
Operation
Component Identification
Front and Rear Axles
SD40 (Without Brakes)
Component Identification
Assembly Notes
SD55 (Without Brakes)
Component Identification
Assembly Notes
Service Procedures
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
Installation of a Solid Spacer
Installation of a Collapsible Spacer
Wheel Hub Bearing Removal
Propshafts
Removing and Replacement
When Removing
When Replacing
Front Axles
Removal and Replacement
520-40
Removing
Replacing
Dismantling and Assembly
Drive Head
Hub and Driveshaft
Rear Axles
Removal and Replacement
520-40
Removing
Replacing
Dismantling and Assembly
Drive Head
Hub and Driveshaft
Transfer Gearbox
Removal and Replacement
Removal
Replacement
Dismantle and Assemble

Section G – Brakes
Section G
Technical Data
All Models
Service Brakes
Park Brake
Service Procedures
Service Brake
Inspection and Renewing the Brake Pads
Bleeding Procedure
Park Brake
Testing
Adjustment
Lever Adjustment
Cable Adjustment
Sensor Adjustment
Renewing the Brake Pads
Removal
Inspection
Replacement
Service Brake Calliper
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Service Brake Calliper
Service Brake Valve
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Service Brake Pedal
Removal and Replacement
Removal
Replacement
Park Brake Calliper
Removal and Replacement
Removal
Replacement
Torque Settings
Dismantle, Inspection and Assemble
Component Identification
Dismantle
Inspection
Assemble
Park Brake Brake Disc
Removal and Replacement
Removal
Replacement

Section H – Steering
Steering
Service Tools
Numerical List
Technical Data
All Models
Basic System Operation
515-40, 520-40
524-50, 527-55
Hydraulic Operation
Electrical Operation
Circuit Description
Steer Unit Operation
Neutral
Turning
System Operation
2-Wheel Steering
4-Wheel Steering
Crab Steering
Electrical Connections
524-50, 527-55
Fault Finding
Introduction
Contents
Mechanical and Hydraulic
Electrical (524-50, 527-55)
Service Procedures
Re-phasing the Steer System
515-40, 520-40
524-50, 527-55
System Bleeding
515-40, 520-40
524-50, 527-55
Proximity Switch Setting
Adjustment
Sensor Connections
Testing and Adjustment
Checking Solenoid Operation
Power Track Rod (524-50, 527-55)
Link Arms
Removal and Replacement
Dismantling and Assembly
When Dismantling
When Assembling
Steer Rams (515-40, 520-40)
Removal and Replacement
Removal
Replacement
Steer Mode Valve (524-50, 527-55)
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Before Dismantling
When Assembling
Steer Mode Control Unit (524-50, 527-55)
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Hydraulic Steer Unit
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Dismantling
Assembling
Pressure Relief Valve Cartridge
Shock Valves

Section K – Engine
Service Tools
Numerical List
Technical Data
520-40
Tier 2 and Tier 3
Typical Engine Identification Number
Specification
524-55, 527-55
Tier 2 (Up to SN 1069456)
Typical Engine Identification Number
Specficiation
Tier 2 and 3 (From SN 1069457)
Typical Engine Identification Number
Specification
Tier 2 Engine (From SN 1069457 to 1418024)
Tier 3 Engine (From SN 1418025)
Electrical Connections
Cold Start Heater
Introduction
Component Key
‘Blink’ Codes
Engine
520-40
Removal
Replacement
524-50, 527-55
Removal
Replacement
Air Filter
All Machines
Removal
Replacement
Exhaust Assembly
520-40
Removal
Replacement
524-50, 527-55 (Up to SN 1069456)
Removal
Replacement
524-50, 527-55 (From SN 1069457)
Removal
Replacement
Radiator Assembly
524-50, 527-55 (From SN 1069457)
Removal
Replacement

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