JCB 520-40 / 524-50 / 527-55 Service Manual
Comprehensive service manual for JCB 520-40, 524-50, and 527-55 telehandlers. Includes detailed diagrams, troubleshooting, and maintenance procedures. Part 9803/3690-10.
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Models Covered & Key Technical Specifications
JCB 520-40 / 524-50 / 527-55 Service Manual: JCB Telehandler Comprehensive Official Repair Manual Troubleshooting-Index | JCB Library
- Service Requirements: All routine service checks should only be carried out by a JCB trained specialist.
- Lubricants: Always use the recommended type of grease and keep types separate.
- Hydraulic Pressure: Residual hydraulic pressure trapped in the service hose line must be vented before connecting or removing hoses.
- Engine Oil Level: Check that the oil level is between the maximum and minimum marks on the dipstick.
- Tyre Inflation: Use an air supply system with a pressure regulator and a self-locking air chuck.
- Electrical Circuits: Understand the electrical circuit before connecting or disconnecting an electrical component.
Professional Workshop Service Manual & Technical Specifications
JCB 520-40 / 524-50 / 527-55 Service Manual: JCB Telehandler Comprehensive Official Repair Manual
Model Data: JCB 520-40, 524-50, 527-55 (All models) // Category: Telehandler Logic // Technical Details: Comprehensive coverage including maintenance, troubleshooting, and parts information.
| Table: Fluids, Lubricants and Capacities | Item | Capacity Litres (Gal) | Fluid/Lubricant | International Specification |
|---|---|---|---|---|
| Fuel Tank - 520-40 | 61 (13.4) | Diesel Oil | Acceptable and Unacceptable Fuels | |
| Fuel Tank - 524-50, 527-55 | 75 (16.5) | Diesel Oil | Acceptable and Unacceptable Fuels | |
| Engine (Oil) - 520-40 | 10.5 (2.3) | JCB High Performance 15W/40 | ACEA E2:B2:A2, API CF4/SG | |
| Engine (Oil) - 524-50, 527-55 | 8.5 (1.9) | JCB High Performance 15W/40 | ACEA E2:B2:A2, API CF4/SG | |
| Engine (Coolant) | 8 (1.8) | JCB HP Performance Antifreeze and Inhibitor/Water | ASTM D6210 | |
| Transfer Gearbox | 0.75 (0.17) | JCB HD90 Gear Oil | API GL 5 | |
| Axles - Housing (x 2) | 5.0 (1.1) | JCB HD90 Gear Oil | API GL 5 | |
| Axles - Hubs (x4) | 0.5 (0.1) | |||
| Hydraulic Tank(1) - 520-40 | 68 (15) | JCB High Performance 10W/30 | ACEA E2:B2:A2, API CF4/SG | |
| Hydraulic Tank(1) - 524-50, 527-55 | 33 (7.3) | JCB High Performance 10W/30 | ACEA E2:B2:A2, API CF4/SG | |
| Grease Points(2) | JCB HP Grease | Lithium complex NLGI No. 2 consistency including extreme pressure additives. | ||
| Wear Pad Runways | JCB Waxoyl | |||
| Braking System - 520-40 | JCB Light Hydraulic Fluid(3) | ISO 15 | ||
| Braking System - 524-50, 527-55 | 2.0 (0.4) | JCB Light Hydraulic Fluid(3) | ISO 15 |
Table of Contents Summary
- Section 1 - General Information: Covers torque settings and service tools.
- Section 2 - Care and Safety: Details warnings and cautions pertinent to workshop procedures.
- Section 3 - Maintenance: Includes service schedules and recommended lubricants.
- Section A - Attachments: Discusses quick release couplings and connecting/disconnecting procedures.
- Section B - Body and Framework: Covers Load Moment Indicator (LMI) troubleshooting and calibration.
Introduction
This service manual provides detailed information for the maintenance and repair of JCB Compact Loadalls. It is intended for trained service engineers and includes sections on general information, care and safety, maintenance schedules, engine, transmission, axles, hydraulics, brakes, electrics, bodywork, and attachments. The manual emphasizes the importance of using genuine JCB parts and following manufacturer-recommended procedures for optimal machine performance and safety. Consistent adherence to maintenance schedules ensures improved reliability and resale value. The manual also details the use of specialized tools and diagnostic procedures for troubleshooting various systems. Torque specifications are provided for fasteners, and fluid capacities and types are listed for essential maintenance tasks. Adherence to safety warnings and precautions is paramount throughout all procedures.
Engine
The engine section details maintenance for the JCB Dieselmax engine, including checking and changing the oil and filter, cooling system checks, drive belt inspection, and air filter maintenance. Procedures for cleaning the air filter dust valve and replacing elements are explained. The manual also covers fuel system maintenance, including draining the water separator and fuel filter, changing the pre-filter, and bleeding the system. Proper fuel handling and the use of approved fuels are emphasized to prevent damage to the fuel injection equipment.
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