Repair Time Schedule

515-40, 520-40, 524-50 and 527-55 Compact Loadalls

Repair Time Schedule

515-40, 520-40, 524-50 and 527-55 Compact Loadalls

Published by JCB Technical Publications, JCB Service,World Parts Centre, Beamhurst,

Uttoxeter, Staffordshire, ST14 5PA, England. Tel +44 1889 590312 Fax +44 1889 593377

Foreword TR-001 Labour Time Content TR-002

The times shown in this publication represent the total
required to perform a typical repair, replacement and/or
adjustment of components on these machines. The times
are representative for the average trained engineer, using
normally available tools and equipment.
It is assumed that:
– All essential JCB special service tools, as specified in
the manuals, are available to maintain consistent
quality repairs.
– Genuine replacement parts and assemblies are used.
– Repair procedures as described in the workshop
manual and Technical Service publications are
adhered to.
Each operation is complete in itself and times must not be
added together.
The time to complete a repair operation is the allowable
time given in this schedule and includes the following
principal elements.
1 Time for obtaining parts, special tools and equipment
- where required.
2 Time for the removal, dismantling, cleaning,
assembly, installation and/or adjustment of the
component involved, i. e. the actual work content of
the job.
3 Time allowance for the personal needs of the
engineer during a repair operation.
4 Time allowances to compensate for reasonable
variations in vehicle condition, engineer's speed, skill
and fatigue.
The times are based on normal working hours. Additional
time may be charged to cover extra costs incurred, if
repairs are complicated by poor site conditions etc. but
full justification of this should be given on the claim.

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515-40, 520-40, 524-50 and 527-55 Compact Loadalls

Repair Times
Section A - Attachments

Table 1. Attachments
Service Code Description Action Hours
A360 Q - Fit carriage R&R 0.50
A940 Fork (2 off) R&R 0.50
D240 Lever lock mechanism (manual) R&R 1.00
D240 Lever lock mechanism (hydraulic) R&R 1.00
D240 Lever (manual) R&R 0.50
D240 Lever (hydraulic) R&R 0.50
M200 Hydraulic ram R&R 0.50
A370 Tool carrier Reseal 1.00
A800 Locking pin (2 off) R&R 0.50
A300 Hydraulic tow hitch assembly R&R 1.00
A300 Hook (tow hitch) R&R 1.00
D100 Release cable (tow hitch) R&R 0.50
A370 Robot style tool carrier R&R 0.50
A370 Robot style tool carrier D&A 1.00

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Section B - Body and Framework

Table 2. Body and Framework

Service Code Description Action Hours
B280 Bonnet R&R 1.00
B281 Bonnet release cable R&R 0.50
B285 Bonnet gas strut R&R 0.25
B283 Bonnet hinge (x1) R&R 0.75
B210 Belly plates R&R 0.50
B122 Fuel tank cover plate & cap R&R 0.50
B125 Drain plug R&R 0.25
B151 Fender Assembly (Front right hand) R&R 0.50
B152 Fender Assembly (Front left hand) R&R 0.50
B153 Fender Assembly (Rear right hand) R&R 0.50
B154 Fender Assembly (Rear left hand) R&R 0.50
B130 Hydraulic tank R&R 2.50
B132 Hydraulic tank sight gauge R&R 0.50
B180 Counterweight R&R 1.00

Table 3. Boom
Service Code Description Action Hours
B420 Inner boom R&R 6.00
B430 Outer boom R&R 8.00
B428 Wear pad front (4 off) R & R/Shim 1.50
B428 Wear pad rear (4 off) R & R/Shim 3.00
B440 Main boom pivot Shim 0.75
B442 Boom pivot bush (1 off) R&R 0.75
B400 Boom assembly R&R 4.00

Table 4. Cab
Service Code Description Action Hours
B904 Glazing (per pane) R&R 0.75
B900 Front screen guard R&R 0.50
B900 Cab frame R&R 5.00
B987 Door lock R&R 0.50
B987 Door catch Adjust 0.50

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Table 5. Seat
Service Code Description Action Hours
B950 Seat R&R 0.50
B953 Seat guide (1 off) R&R 0.75

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515-40, 520-40, 524-50 and 527-55 Compact Loadalls
Section C - Electrics and Instruments

Table 6. Electrics and Instruments

Service Code Description Action Hours
C310 Alternator R&R 0.50
C310 Alternator support bracket R&R 0.50
C310 Alternator adjusting link R&R 0.50
C911 Main harness R&R 3.50
C390 Battery lead R&R 0.50
C390 Battery clamp R&R 0.50
C900 Engine earth lead R&R 0.50
C98 Transmission oil pressure switch R&R 0.50
C860 Air cleaner switch R&R 0.50
C800 Oil pressure switch R&R 0.50
C844 Water temperature switch R&R 0.50
C845 Transmission temperature switch R&R 0.50
C620 Horn R&R 0.50
C842 Brake light switch R&R 0.50
C400 Instrument panel R&R 2.00
C841 Parking brake switch R&R 0.50
C440 Warning light cluster cover R&R 1.00
C831 Start switch R&R 0.75
C840 Switch R&R 0.50
C824 Flasher unit R&R 0.50
C460 Warning buzzer R&R 0.50
C915 Panel harness R&R 3.50
C821 Forward/reverse switch R&R 0.50
C918 Engine harness R&R 2.00
C520 Heater assembly R&R 1.00
C522 Heater radiator R&R 1.50
C524 Heater motor/fan assembly R&R 1.50
C525 Heater hose R&R 0.50
C520 Heater tap R&R 0.50
C210 Starter motor (515-40, 520-40 only) R&R 1.25
C210 Starter motor (524-50, 527-55 only) R&R 1.50
C144 Interior light R&R 0.50
C110 Headlight (1 off) R&R 0.50
C752 Starter relay R&R 0.50
C510 Wiper motor front screen (515-40, 520-40 only) R&R 2.00

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515-40, 520-40, 524-50 and 527-55 Compact Loadalls

Service Code Description Action Hours

C510 Wiper motor front screen (524-50, 527-55 only) R&R 1.00
C512 Wiper motor rear screen R&R 0.50
C630 Wiper wash motor R&R 0.50
C410 Safe load indicator readout box (515-40, 520-40 only) R & R/Adjust 1.50
C410 Safe load indicator readout box (524-50, 527-55 only) R & R/Adjust 0.75
C400 Safe load indicator pad R & R & Set up 1.50
L371 Engine fuel shut off solenoid (515-40, 520-40 only) R&R 0.50
L371 Engine fuel shut off solenoid (524-50, 527-55 only) R&R 0.75

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515-40, 520-40, 524-50 and 527-55 Compact Loadalls
Section D - Controls

Table 7. Controls
Service Code Description Action Hours
D111 Throttle cable R&R 1.00
D253 Accelerator pedal (515-40, 520-40 only) R&R 1.00
D253 Accelerator pedal (524-50, 527-55 only) R&R 0.50

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515-40, 520-40, 524-50 and 527-55 Compact Loadalls
Section E - Hydraulics

Table 8. Pressure Testing

Service Code Description Action Hours
E316 M.R.V. Check Pressure & Adjust 1.00
E315 A.R.V. (1 off) Check Pressure & Adjust 1.00

Table 9. Pump
Service Code Description Action Hours
N400 Hydrastatic pump R&R 3.00
N120 Service pump Pressure & flow test 1.50
N120 Service pump R&R 1.00
N120 Service pump R & R, Strip, Inspect and 2.00
repair

Table 10. Motor

Service Code Description Action Hours
N600 Hydrastatic motor R&R 2.00

Table 11. Valves

Service Code Description Action Hours
E204 Valve block (4 spool) R&R 3.00
E216 M.R.V. assembly R&R 0.50
E215 A.R.V. cartridge (1 off) R&R 0.50
E211 Spool - valve block (1 off) R & R, check for damage 2.00
E217 Wiper seal - valve block bottom R&R 0.50
E500 Load hold non-return valve and 'O' ring R&R 2.00
E317 'O' rings and inter section seals R&R 2.00
D200 Lever R&R 0.50
E571 Hose burst protection cartridge R & R, Reseal 0.50

Table 12. Hydraulics

Service Code Description Action Hours
M020 Ram - lift, tilt, displacement, tow hitch/steer R&R 1.00
M030 Extension ram R&R 3.00
M025 / M026 Ram - lift, tilt, displacement, tow hitch Reseal 2.00
M035 / M036 Extension ram Reseal 4.00
M025 / M026 Piston rod - lift, tilt, displacement, tow hitch/steer R & R, Reseal ram 2.00
complete
M035 / M036 Piston rod - extension R & R, Reseal ram 4.00
complete

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515-40, 520-40, 524-50 and 527-55 Compact Loadalls

Service Code Description Action Hours

M021 Cylinder - boom lift, tilt, displacement, tow hitch/steer R & R, Reseal ram 2.00
complete
M031 Cylinder - extension R & R, Reseal ram 4.00
complete
M029 End cap - boom lift, tilt, displacement, tow hitch/steer R & R, Reseal ram 2.00
complete
M039 End cap - extension R & R, Reseal ram 4.00
complete
M012 Piston head R & R, Reseal ram 2.00
complete
M032 Piston head - extension R & R, Reseal ram 4.00
complete

Table 13. Hydraulic System

Service Code Description Action Hours
E600 Hose (1 off) R&R 0.50
E660 Hose - boom (1 off) R&R 1.00
E700 Steel pipe (1 off) R&R 0.50
E800 Hydraulic filter R&R 0.50
E133 Suction strainer R & R, clean 1.00
E600 Loop hose (1 off) R&R 1.00

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515-40, 520-40, 524-50 and 527-55 Compact Loadalls
Section F - Transmission

Table 14. Front Axle

Service Code Description Action Hours
F400 Axle assembly (515-40, 520-40 only) R&R 3.00
F400 Axle assembly (524-50, 527-55 only) R&R 2.00
M149 Steer ram and track rods (515-40, 520-40 only) R & R & Bleed 2.75
M149 Steer ram and track rods (524-50, 527-55 only) R & R & Bleed 2.75
M140 Steer ram R & R & Bleed 2.00
M145 Steer ram seals R & R, Reseal & Bleed 2.50
F445 Hub seal R&R 2.50
F444 Hub bearing R&R 2.50
F448 Planet carrier R&R 1.25
F420 Thrust button (planet carrier to half shaft) R&R 1.50
F440 Annulus R&R 2.25
F440 Wheel hub R&R 2.00
F700 Wheel stud R&R 1.00
F424 Half shaft oil seal - outer R&R 2.25
F422 Half shaft bearing - outer R&R 2.50
F424 Half shaft oil seal - inner R&R 2.25
F423 Half shaft bearing - inner R&R 2.50
F520 Half shaft - one side R&R 3.00
F421 Half shaft spider - one off R&R 3.25
F421 Half shaft spider - two off R&R 3.50
F440 Swivel hub R&R 3.00
F441 Trunnion - Front Top R&R 0.50
F442 Trunnion - Front Lower R&R 0.50
F443 Trunnion bearing R&R 1.50
F411 Differential housing assembly R&R 5.50
F415 Differential bearings R&R 5.50
F448 Differential side and planet gears R&R 6.50
F414 Crown wheel and pinion R&R 8.00
F460 Pinnion outer bearing R&R 6.25
F460 Pinnion inner bearing R&R 6.75
F430 Axle centre case R&R 8.00

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Table 15. Rear Axle
Service Code Description Action Hours
F500 Axle assembly R&R 3.00
M149 Steer ram and track rods R&R 2.75
M140 Steer ram R&R 2.00
M145 Steer ram seals R&R 2.50
F545 Hub seal R&R 2.50
F544 Hub bearing R&R 2.50
F544 Hub bearing carrier R&R 2.50
F548 Planet carrier R&R 1.25
F520 Thrust button (planet carrier to half shaft) R&R 1.50
F540 Annulus R&R 2.25
F700 Wheel stud R&R 0.50
F524 Half shaft oil seal - outer R&R 2.00
F522 Half shaft bearing - outer R&R 2.00
F524 Half shaft oil seal - inner R&R 2.00
F523 Half shaft bearing - inner R&R 2.00
F520 Half shaft - one side R & R, Strip & Rebuild 3.00
F520 Half shaft - one side R&R 2.00
F540 Swivel hub R&R 3.00
F441 Trunnion - Rear Top R&R 0.50
F442 Trunnion - Rear Lower R&R 0.50
F544 Trunnion bearing set - pair R&R 1.50
F511 Differential housing assembly R&R 2.50
F515 Differential bearings R&R 3.50
F548 Differential side and planet gears R&R 4.50
F514 Crown wheel and pinion R&R 6.50
F560 Pinnion outer bearing R&R 4.25
F560 Pinnion inner bearing R&R 4.75
F530 Axle centre case R&R 7.50
F500 Input flange R&R 0.75

Table 16. Propshafts

Service Code Description Action Hours
F610 Propshaft to front axle R&R 0.50
F620 Propshaft to rear axle R&R 0.50
F600 Universal joint - one end R&R 1.25
F600 Universal joint - both ends R&R 1.75

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515-40, 520-40, 524-50 and 527-55 Compact Loadalls
Table 17. Transfer Gearbox
Service Code Description Action Hours
F310 Gearbox R & R including cab 6.00
removal
F310 Gearbox D&A 4.00

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515-40, 520-40, 524-50 and 527-55 Compact Loadalls
Section G - Brakes

Table 18. Brakes

Service Code Description Action Hours
G212 Service brake pads - Front R&R 1.00
G222 Service brake pads - Rear R&R 1.00
G213 Service brake caliper - Front R&R 1.00
G223 Service brake caliper - Rear R&R 1.00
G320 Master cylinder R&R 1.50
G322 Master cylinder R&R, Re-seal 2.50
G321 Master cylinder push rod Adjust 0.75
G530 Fluid reservoir and adaptor R&R 0.50
G700 Fluid reservoir pipe R&R 0.50
G703 Brake pipe (1 off) - Front R&R 0.75
G704 Brake pipe (1 off) - Rear R&R 0.75
G611 Parking brake caliper assembly R&R 1.00
G617 Parking brake pads R&R 1.50
G610 Parking brake Adjust 0.10
G614 Parking brake cable R&R 1.50
G616 Parking brake lever R&R 0.50
G310 Brake pedal R&R 0.75
G313 Pedal spring R&R 0.10
G100 Brakes Adjust 0.50
G200 Differential valve R&R, Bleed 1.50

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515-40, 520-40, 524-50 and 527-55 Compact Loadalls
Section H - Steering

Table 19. Steering

Service Code Description Action Hours
E600 Hose (1 off) R&R 0.50
M140 Steering ram R&R 0.50
M149 Steering ram R&R, Strip & rebuild 1.50
M145 Steering ram R&R, Re-seal 1.25
H210 Orbitrol steering unit R&R 1.50
H211 Orbitrol steering unit R&R, Re-seal 2.75
H520 Steering column R&R 2.00
H510 Steering wheel R&R 0.50
H300 Steer valve R&R 1.00

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515-40, 520-40, 524-50 and 527-55 Compact Loadalls
Section K - Engine

Table 20. Engine

Service Code Description Action Hours
L830 Engine mounting (1 off) (515-40, 520-40 only) R&R 0.75
L830 Engine mounting (1 off) (524-50, 527-55 only) R&R 1.00
L800 Rubber mounting (1 off) R&R 1.75
L410 Radiator R&R 2.00
K001 Engine complete R&R 6.00
L700 Exhaust R&R 0.50
C310 Alternator belt R&R 0.50
L430 Radiator bottom hose (515-40, 520-40 only) R&R 0.50
L430 Radiator bottom hose (524-50, 527-55 only) R&R 1.00
L420 Radiator top hose R&R 0.25

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