Service/Inspection Checklist and Report

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Fastrac 2155 and 2170 Service/Inspection Checklist and Report Fastrac 2155 and 2170 Issued by JCB Technical Publications, JCB Service, World Parts Centre, Beamhurst, Uttoxeter, Staffordshire, ST14

1 Fastrac 2155 and 2170 Service/Inspection Checklist and Report Fastrac 2155 and 2170 Issued by JCB Technical Publications, JCB Service, World Parts Centre, Beamhurst, Uttoxeter, Staffordshire, ST14 5PA, England. Tel Fax Dealer Stamp Note: Original copy to customer, Photocopy to distributor. Machine Type Serial No. Distributor Depot Job No. Hourmeter Reading Date of Registration Date of Service Customer Name Engineer Name s 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

2 Service/Inspection Checklist and Report Introduction T 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.!mwarning Maintenance must be done only by suitably qualified and competent persons. How to Use the T3-012_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. Before doing any maintenance make sure the machine is safe, it should be correctly parked on level ground. To prevent anyone starting the engine, remove the starter key. Disconnect the battery when you are not using electrical power. If you do not take these precautions you could be killed or injured 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 Calendar Equivalents Every 10 Hours = Daily Every 50 Hours = Weekly Every 500 Hours = Six Months Every 1000 Hours = Yearly Every Hours = 2 Years Every 8000 Hours = 8 Years T

3 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. Pre-start Cold Checks, Service Points and Fluid Levels Operation (1) ENGINE Oil level - Check Oil and Filter (2) (3) - Change Air Cleaner Outer Element (3) - Change Air Cleaner Inner Element (3) - Change Air Cleaner Dust Valve - Clean Fuel Filter (3) - Change Coolant Level - Check Coolant Antifreeze Quality (4) - Check Coolant - Change Fuel Pre-filter (5) - Drain Fuel Pre-filter - Change Fan Belt Condition - Check Fan Belt Tensioner Condition (4) - Check Fan Hub End Play (4) - Check Valve Clearances (4) - Check and Adjust Air Conditioning Compressor Belt Tension and Condition - Check Engine Mounting Bolts for Tightness (4) - Check Radiator and Intercooler (when fitted) - Clean and Check Condition Pipework Routing and Security (4) - Check Intercooler Hose and Clamp Security - Check Air Cleaner Hose and Clamp Security - Check All Hoses - Condition - Check

4 Vibration Damper (4) - Check Crankcase Breather Condition - Check Air Compressor Housing (4) - Check for Leaks, Cracks and Security Air Compressor Mountings - Check Air Compressor Output Line, Air Dryer and Pressure Regulator (4) - Check for Carbon Deposits and Air Leaks Injection Pump Security (4) - Check TRANSMISSION, AXLES AND STEERING Transmission Oil Level - Check Transmission Oil (6) - Change Transmission Strainer - Clean Transmission Filter - Change Axle Oil Level (incl. Hubs when applicable) (7) - Check Axle Hub Oil (8) - Change Axle Beam Oil - Change Tyre Pressures/Condition - Check Oil Cooler and Pipework - Check and Clean Driveshafts - Security/Grease Rear PTO Shaft Bearings - Grease Steer Axle Pivots - Grease Steering Column Universal Joints - Grease Steering Axle Wheel Alignment - Check Track Rod End and Damper Condition and - Check Security (4) (9) 4WS Power Track Rod and Ball Joints - Check Condition and Security (4) (9) 4WS RH Side Trunnion Seals (4) - Check Wheel Nut Security - Check HYDRAULICS Operation (1) Oil Level - Check Oil (4) - Sample/Change Oil Filter - Change

5 Hydraulic System - Check for Leaks Hydraulic Lift and 3 Point Linkage, Front and Rear - Grease Ram Piston Rods Condition - Check Hydraulic Oil Cooler and Pipework - Check and Clean Hydraulic Oil Strainer (4) - Clean Hydraulic Coupling Drain Reservoir - Empty Security of Front Weights - Check BRAKES Air System Tank - Drain Air System Drier Canister (4) - Change Trailer Brake Control Line Air Filter (4) - Clean Brake System Fluid Level - Check Brake System Fluid (4) - Change Park Brake - Check and Adjust Park Brake Pad Condition and Security - Check Service Brake Pad Condition and Security - Check Calliper Bolt Torque (4) - Check Pipework Security - Check ELECTRICS Battery Electrolyte Level (if applicable) - Check Wiring for Chaffing/Routing - Check Battery Terminals for Condition and Tightness - Check Battery Charge Condition - Check Headlamp Alignment - Check BODY AND FRAMEWORK Chassis Fabrication Operation (1) - Visually Inspect for Damage Seat Belt Condition and Security - Check Air Conditioning Condensor - Clean ROPS Structure (4) - Check

6 Operation (1) Air Conditioning Filter (standard type - Clean only) (10) Heater Filter - Clean Door Locks - Check Windscreen Washer Fluid Level - Check Condition of Paintwork - Check Machine Generally - Check and Clean Automatic Trailer Coupling (if fitted) - Grease Roller Drawbar (if fitted) - Grease SUSPENSION Cylinder Pivots - Grease Rear Anti-roll Bar Ball Joints - Grease Rear Anti-roll Bar Condition and Torque - Check Tightness (4) (9) Panhard Rod Condition and Torque - Check Tightness (4) (9) Control Arms Condition and Torque - Check Tightness (4) V Link Condition and Torque Tightness (4) - Check Accumulator Pressure (4) - Check Gas Spring Pressure (4) - Check (1) First 100 Hours Service only, to be completed by your JCB Distributor. (2) Applies only if recommended oil and Stratopore filter are available. If these are not available, this job should be carried out every 250 hours. See Fluids, Lubricants and Capacities for suitable alternative oil. (3) If the machine is operating in ambient temperatures below -18 C [0 F] or above 38 C [100 F], change engine oil and filter, air and fuel filters at shorter intervals. Shorter maintenance intervals are also required if the machine is operated in a dusty environment or if frequent stops are made. (4) Jobs which should only be done by a specialist. (5) Replaceable element type filters only. One piece filters cannot be drained (6) After a major transmission repair, the new oil should be run to operating temperature and changed again to remove any contamination which entered during the repair. Change the oil and filter after a further 100 hours if the oil was heavily contaminated because of, or from the failure (e.g. water contamination). (7) Check for leaks every 50 hours, check level if leaking. (8) After a hub repair, the new oil should be run to operating 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. This is particularly important if new brake plates have been fitted. (9) After any of these items are refitted, recheck the torque tightness after a short road test. (10) Heavy duty carbon type filters must be changed at 250 hour intervals

7 Functional Test and Final Inspection ENGINE Operation (1) Idle Speed (2) - Check and Adjust Field Speed Control (2) - Check Maximum No-Load Speed (2) - Check and Adjust Exhaust Smoke (excessive) - Check Exhaust System Security (2) - Check Cooling System for Leaks - Check Fuel System for System for Leaks and Contamination - Check Lubrication System for Leaks - Check Stop Control - Check TRANSMISSION, AXLES AND STEERING 2WD/4WD/Differential Lock Selection - Check Oil Leakage - Check Transmission Lubrication Pressure (2) - Check Transmission Pressure Relief Valve (2) - Check Differential Lock Pressure Relief Valve (2) - Check Accumulator Pressure (2) - Check Neutral Start Operation - Check Splitter and Wet Clutch Pack Calibration (2) - Check PTO Selection and Operation - Check Selectronic Range Change Speed - Check Gear Change and Selection - Check Clutch Operation - Check Steering Operation - Check Steering Pressure Relief Valve (2) - Check HYDRAULICS MRV Pressure (2) - Check and Adjust Operation All Services - Check System for Oil Leakage - Check

8 Oil Cooler and Pipework for Damage or Leakage BRAKES Service/Inspection Checklist and Report - Check Foot Brake - Operation - Check Park Brake - Operation - Check Air System for Leaks (by Warning Lights) - Check ABS (2) - System Test ELECTRICS Starter Motor - Check Alternator - Output (2) - Check All Electrical Equipment Operation, (e.g. warning lights, beacon, alarms, horn, wipers etc.) Error Codes for all systems, Engine, ABS, Electronic Draft Control etc. (2) EMS Datalog (2) - Check - Download and Rectify - Download and Rectify Brake Light Switch Input to ABS ECU using - Check computer diagnostic tool (2) SUSPENSION Operation (1) Circuit Pressure (2) - Check Rear Axle to Chassis Clearance (2) - Check Ride Height and Corrector Valve Operation (2) - Check (1) First 100 Hours Service only, to be completed by your JCB Distributor. (2) Jobs which should only be done by a specialist

9 Service/Inspection Report Remarks/Action Implemented During Service Service/Inspection Checklist and Report Service/Inspection Report Outstanding Action Required

10 Paintwork Defects Service/Inspection Checklist and Report Service/Inspection Report Remarks (Note and mark appropriate diagram)

Service/Inspection Checklist and Report

Service/Inspection Checklist and Report 500 Series Loadalls (JCB Dieselmax SA, SB, SC, SD and SF Engines) 500 Series Loadalls (JCB Dieselmax SA, SB, SC, SD and SF Engines) 795270 Dealer Stamp Note: Original copy to customer, Photocopy to distributor.