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Service/Inspection Checklist and Report520-40, 524-50 and 527-55 Compact Loadalls
1 19814/0461-6
Service/Inspection Checklist and Report520-40, 524-50 and 527-55 Compact Loadalls
766650-4
Note: Original copy to customer, Photocopy to distributor.
Dealer Stamp Machine Type
Serial No.
Distributor
Depot
Job No.
Hourmeter Reading Hrs
Date of Registration
Date of Service
Customer Name
Engineer Name
Copyright © 2004 JCB Service. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior
permission from JCB SERVICE.
JCB Service, World Parts Centre, Waterloo Park, Beamhurst, Staffordshire, England, ST14 5PA
Service/Inspection Checklist and ReportService Schedules
2 29814/0461-6
Service Schedules
IntroductionT3-036
A badly maintained machine is a danger to the operator and the people working around him. Make sure that the regular maintenance and lubrication jobs listed in the service schedules are done to keep the machine in a safe and efficient working condition.
!MWARNINGMaintenance must be done only by suitably qualified and competent persons. Before doing any maintenance make sure the machine is safe. It should be correctly parked on firm level ground.
To prevent anyone starting the engine, remove the starter key. Disconnect the battery and block the wheels when you are working beneath the machine.
If you do not take these precautions you could be killed or injured.9-3-1-1
Apart from the daily jobs, the schedules are based on machine running hours. Keep a regular check on the hourmeter readings to correctly gauge service intervals. Do not use a machine which is due for a service. Make sure any defects found during the regular maintenance checks are rectified immediately.
How to Use the Service SchedulesT3-012_3
In the example shown, A shows all service requirements to be carried out every 10 hours and B shows the requirements to be carried out every 500 hours.
Important: Services should be carried out at either the hourly interval or calendar interval, whichever occurs first. Refer to Calendar Equivalents.
795390-1
Calendar Equivalents
Every 10 Hours = Daily
Every 50 Hours = Weekly
Every 500 Hours = Six Months
Every 1000 Hours = Yearly
Every 2000 Hours = 2 Years
Every 6000 Hours = 6 Years
Service/Inspection Checklist and ReportService Schedules
3 39814/0461-6
520-40 (All) and 524-50, 527-55 (up to SN 1069456)
Pre-start Cold Checks, Service Points and Fluid Levels
All jobs should be marked and logged:
No fault found job complete. Fault found and corrected. Detail on Service/Inspection Report.
Follow up required. Detail on Service/Inspection Report.
Operation 10 50 500 1000 2000ENGINEOil Level Check
Oil and Filter Change(1)
Engine Breather Change
Air Cleaner Dust Valve Clean
Air Cleaner Outer Element Change(2)
Air Cleaner Inner Element Change
Fuel Filter Drain
Fuel Filter Change
Fuel Sedimenter Drain and clean
Coolant Level Check
Coolant Change
Antifreeze Strength Check
Fan Belt Tension/Condition Check
Fan Belt Change
Valve Clearances (520-40) Check/Adjust(3)
Valve Clearances (524-50, 527-55) Check/Adjust(3)
Engine and Pump Mount Security Check
TRANSMISSION AND AXLESTransfer Gearbox Oil Level Check
Transfer Gearbox Oil Change
Axles Differential Oil Level Check(4)
Axles Differential Oil Change
Hub Oil Level Check(4)
Service/Inspection Checklist and ReportService Schedules
4 49814/0461-6
Hub Oil Change(5)
Drive Shafts and Universal Joints(6) Security/Grease
Axle Pivots and Linkages Grease
Axle Breathers Check
Tyre Pressures/Condition Check
Wheel Nut Security Check
Wheel Alignment Check
Trunnion Bearings Check/Adjust(3)
Steering Stops (if fitted) Security
Transfer Gearbox Mount Security (if fitted)(6) Check
Axle Mount Security Check
HYDRAULICSOil Level Check
Oil Filter Change
Oil Sample/Change(3)
Suction Strainer Clean(3)
Crowd Ram Trunnion Bolts for Security(6) Check
Rams, Hoses and Pipework for Damage or Leaks Check
Breather Change
BRAKESBrake System Fluid Check Level
Brake System Fluid Change(3)
Brake Pad Condition Check
ELECTRICSBattery Electrolyte Level Check
Battery Charge and Condition Check
Battery Terminals for Condition & Tightness Check
Wiring for Chaffing/Routing Check
BODYWORK AND CABWing Mirrors Condition & Security Check
All Pivot Pins Check/Grease
Door and Hinge (bottom hinge only) Lubricate
Operation 10 50 500 1000 2000
Service/Inspection Checklist and ReportService Schedules
5 59814/0461-6
Control Lever Linkages Lubricate
Wear Pad Runways Waxoyl
Boom Wear Pad Clearance Check/Adjust
Wear Pad Condition/Security(6) Change as required
Windscreen Washer Fluid Level Check
Cab Heater Filter (if fitted) Clean(2)
Seat Belt Condition/Security Check
ATTACHMENTSCarriage Lock Pins Grease
(1) In arduous conditions (eg. refuse re-handling, waste paper reclamation etc.) change the oil and filter after every 250 Hours or three months (whichever comes first).
(2) Change outer element more frequently in dusty operating environments.(3) Jobs which should be done by a specialist.(4) Inspect magnetic plug for debris, if necessary change oil.(5) After a hub repair, the new oil should be run to temperature and changed again to remove any contamination which
entered during the repair. Change the oil again after a further 100 hours to remove any bedding-in wear.(6) Initial service only.
Operation 10 50 500 1000 2000
Service/Inspection Checklist and ReportService Schedules
6 69814/0461-6
Functional Test and Final Inspection
All jobs should be marked and logged:
No fault found job complete. Fault found and corrected. Detail on Service/Inspection Report.
Follow up required. Detail on Service/Inspection Report.
Operation 10 50 500 1000 2000ENGINEIdle Speed Check/Adjust(1)
Max. No Load Speed Check(1)
Throttle System and Control Cable Check/Adjust(1)
Exhaust Smoke (Excessive) Check
Exhaust System Security Check
Air Inlet System Security Check
Engine for Vibration/Noise Check
TRANSMISSION, AXLES AND STEERINGTransmission Operation Check
Steer Operation/Phasing Check
Forward/Reverse/Speed Range - Operation Check
Neutral Start Operation Check
HYDRAULICSOperation Of All Services Check
Hose Burst Protection Valves (if fitted) Check
MRV Pressure Check/Adjust
ARV Pressure Check/Adjust
Steer Circuit MRV Pressure Check/Adjust
Piston Rods Chrome Check
Boom Extension Check
Parallel Lift/Lower Check
BRAKESFoot Brake Operation Check
Parking Brake Check/Adjust
ELECTRICS
Service/Inspection Checklist and ReportService Schedules
7 79814/0461-6
Starter Motor Check(1)
Alternator Check Output(1)
Gauges and Warning Lights Check
Front Wiper Motor (if fitted) Check
Cab Switches Check
Horn Check
Heater (if fitted) Check
Reverse Alarm (if fitted) Check
Lights and Indicators (if fitted) Check
Load Moment Indicator Check/Calibrate
BODYWORK AND CABInclinometer (if fitted) Check
Seat/Seat Belts Check
Air Conditioning (if fitted) Check
Forks - Fit and security Fit and Check Security
Generally for damage, leaks & wear (inc. ROPS/FOPS structure for cracks, welding, etc)
Check
PAINTWORKAttachment Operation Check
GENERALCheck for Fluid Leaks (e.g. coolant, engine oil, hydraulic oil, etc.)
Registration/Certificate, SWL Stickers and Load Chart (to suit territorial requirements)
(1) Jobs which should be done by a specialist.
Operation 10 50 500 1000 2000
Service/Inspection Checklist and ReportService Schedules
8 89814/0461-6
524-50, 527-55 (from 1069457)
Pre-start Cold Checks, Service Points and Fluid Levels
All jobs should be marked and logged:
No fault found job complete. Fault found and corrected. Detail on Service/Inspection Report.
Follow up required. Detail on Service/Inspection Report.
Operation 10 50 500 1000 2000 6000ENGINECoolant Quality and Level - Check
Cooling System - Drain and Refill
Oil level - Check
Oil and Filter(1)(2) - Change
Air Cleaner Dust Valve(3) - Clean
Air Cleaner Outer Element(3) - Change
Air Cleaner Inner Element - Change
Pre-Cleaner (if fitted) - Check
Water Seperator and Engine Fuel Filter - Drain
Water Seperator Fuel Filter(4) - Change
Engine Fuel Filter(4) - Change
Front End Accessory Drive (FEAD) Belt Condition - Check
Front End Accessory Drive (FEAD) - Change
Engine Mounting Bolts for Tightness - Check
All Hoses - Condition - Check
Radiator(3) - Clean
Breather Gauze - Clean
Valve Clearances(5) - Check and Adjust
Oil Filler and Dipstick Seals - Change
Rocker Cover and Injector Seals(5) - Change
Injectors(5) - Change
Injector(s) Leak Off Rail(5) - Change
High Pressure Fuel Lines(5) - Inspect
TRANSMISSION AND AXLES
Service/Inspection Checklist and ReportService Schedules
9 99814/0461-6
Axles Differential Oil Level Check(6)
Axles Differential Oil Change
Hub Oil Level Check(4)
Hub Oil Change(7)
Drive Shafts and Universal Joints Security/Grease
Axle Pivots and Linkages Grease
Axle Breathers Check
Tyre Pressures/Condition Check
Wheel Nut Security Check
Wheel Alignment Check
Steering Stops (if fitted) Security
Axle Mount Security Check
HYDRAULICSOil Level Check
Oil Filter Change
Oil Sample/Change(5)
Suction Strainer Clean(3)
Crowd Ram Trunnion Bolts for Security Check(8)
Rams, Hoses and Pipework for Damage or Leaks Check
Breather Change
BRAKESBrake System Fluid Check Level
Brake System Fluid Change(5)
ELECTRICSBattery Electrolyte Level Check
Battery Charge and Condition Check
Battery Terminals for Condition & Tightness Check
BODYWORK AND CABWing Mirrors Condition & Security Check
All Pivot Pins Check/Grease
Door and Hinge (bottom hinge only) Lubricate
Control Lever Linkages Lubricate
Operation 10 50 500 1000 2000 6000
Service/Inspection Checklist and ReportService Schedules
10 109814/0461-6
Boom Wear Pad Runways Waxoyl
Boom Wear Pad Clearance Check/Adjust
Boom Wear Pad Condition/Security Change as required(8)
Windscreen Washer Fluid Level Check
Cab Heater Filter (if fitted) Clean(3)
Seat Belt Condition/Security Check(8)
ATTACHMENTSCarriage Lock Pins Grease
(1) If operating under arduous conditions, change the engine oil and filter every 250 hours.(2) The oil service interval will be affected if there is a high sulphur content in the fuel. Refer to Fuel System for more
information.(3) More frequently if operating in dusty working environments.(4) If the engine is difficult to start or the engine has poor performance, fit new filters.(5) Jobs which should only be done by a specialist.(6) Inspect magnetic plug for debris, if necessary change oil.(7) After a hub repair, the new oil should be run to temperature and changed again to remove any contamination which
entered during the repair. Change the oil again after a further 100 hours to remove any bedding-in wear.(8) Complete this operation at the initial 50 hour interval, then at 500 hour intervals.
Operation 10 50 500 1000 2000 6000
Service/Inspection Checklist and ReportService Schedules
11 119814/0461-6
Functional Test and Final Inspection
All jobs should be marked and logged:
No fault found job complete. Fault found and corrected. Detail on Service/Inspection Report.
Follow up required. Detail on Service/Inspection Report.
Operation 10 50 500 1000 2000 6000ENGINEIdle Speed(1) - Check and Adjust
Max. No-Load Speed(1) - Check and Adjust
Exhaust System Security(1) - Check
Air Inlet System Security - Check
TRANSMISSION, AXLES AND STEERINGTransmission Operation Check
Steer Operation/Phasing Check
Forward/Reverse/Speed Range - Operation Check
Neutral Start Operation Check
HYDRAULICSOperation Of All Services Check
Hose Burst Protection Valves (if fitted) Check
MRV Pressure Check/Adjust
ARV Pressure Check/Adjust
Steer Circuit MRV Pressure Check/Adjust
Piston Rods Chrome Check
Boom Extension Check
Parallel Lift/Lower Check
BRAKESFoot Brake Operation Check
Park Brake Check/Adjust
ELECTRICSAlternator Check Output(1)
Gauges and Warning Lights Check
Front Wiper Motor (if fitted) Check
Service/Inspection Checklist and ReportService Schedules
12 129814/0461-6
Cab Switches Check
Horn Check
Heater (if fitted) Check
Reverse Alarm (if fitted) Check
Lights and Indicators (if fitted) Check
Load Moment Indicator Check
BODYWORK AND CABInclinometer (if fitted) Check
Seat/Seat Belts Check
Air Conditioning (if fitted) Check
Forks - Fit and security Fit and Check Security
Generally for damage, leaks & wear (inc. ROPS/FOPS structure for cracks, welding, etc)
Check
PAINTWORKAttachment Operation Check
GENERALCheck for Fluid Leaks (e.g. coolant, engine oil, hydraulic oil, etc.)
Registration/Certificate, SWL Stickers and Load Chart (to suit territorial requirements)
(1) Jobs which should only be done by a specialist.
Operation 10 50 500 1000 2000 6000
Service/Inspection Checklist and ReportService/Inspection Report
13 139814/0461-6
Service/Inspection Report
Remarks/Action Implemented During Service
Outstanding Action Required
Service/Inspection Checklist and ReportService/Inspection Report
14 149814/0461-6
Paintwork Defects
448000-1
Fig 1.
Remarks (Note and mark appropriate diagram)
Recommended