520-40, 524-50 and 527-55 Compact Loadallsourknowledgefarm.com/JCB Loadall 520-524-527 Service Schedule.pdf · permission from JCB SERVICE. JCB Service, World Parts Centre, Waterloo

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

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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


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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)


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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


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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


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Functional Test and Final Inspection




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


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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


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524-50, 527-55 (from 1069457)

Pre-start Cold Checks, Service Points and Fluid Levels




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


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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


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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


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Functional Test and Final Inspection




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


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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

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Service/Inspection Report

Remarks/Action Implemented During Service

Outstanding Action Required

Service/Inspection Checklist and ReportService/Inspection Report

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Paintwork Defects

448000-1

Fig 1.

Remarks (Note and mark appropriate diagram)

Documents

520-40, 524-50 and 527-55 Compact Loadallsourknowledgefarm.com/JCB Loadall 520-524-527 Service Schedule.pdf · permission from JCB SERVICE. JCB Service, World Parts Centre, Waterloo