Service/Inspection Checklist and Report

Transcription

1 Workmax 800D Workmax 800D T 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 Hrs 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 Introduction!MWARNING T3-036_3 Maintenance 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 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 How to Use the T3-012_4 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. Important: The intervals given in the schedules must not be exceeded. If the machine is operated under severe conditions (high temperature, dust, water, etc.), shorten the intervals. 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. 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. When there is no hourmeter fitted, use the calendar equivalents to determine the service intervals. Refer to Calendar Equivalents. Do not use a machine which is due for a service. Make sure any defects found during the regular maintenance checks are rectified immediately

3 Operating Conditions Introduction The service intervals should go by hours or mileage according to the tables below, in the operating conditions which are most applicable to your machine use. Use the tables as a guide to make sure that your machine is serviced at the correct intervals, by which condition occurs first. Hours and Distance Equivalents Every 10 Hours or Daily First 100 Hours or 1000 miles (1,600 kilometres) Every 125 Hours or 1,250 miles (2,000 kilometres) Every 250 Hours or 2,500 miles (4,000 kilometres) Every 500 Hours or 5,000 miles (8,000 kilometres), Every 1,000 Hours or 10,000 miles (16,000 kilometres) Every 2,000 Hours or 20,000 miles (32,000 kilometres)

4 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. ENGINE Operation (1) Engine Mount - Security - Check Engine Oil and Filter (2) - Change Engine Oil - Check Engine Valve Rocker Arms - Clearance (3) - Check/Adjust Injector Settings (3) - Check/Clean Coolant - Level and Antifreeze Strength - Check Coolant (4) - Change Air Cleaner and Pre-cleaner - Clean Air Cleaner Outer Element (5) - Check and Change if necessary Air Cleaner Inner Element - Change Air Cleaner Dust Valve - Clean Alternator Drive Belt - Tension/Condition - Check Alternator Drive Belt (6) - Change Fuel Filter - Change Cooling System Hoses - Condition/Security - Check Air Cleaner and Intake Manifold Hose - Condition/Security - Check Fuel System - Leaks and Contamination - Check External Oil Leaks - Check Radiator - Clean Fuel Pipes - Change Engine Timing Belt (7)(3) - Change Accelerator Linkage - Grease Injectors - Clean and Test

5 Crankcase Breather System ELECTRICS - Check and Clean Battery - Electrolyte Level (If Applicable) - Check Battery - Charge Condition - Check Battery Terminals - Condition/Tightness - Check Wiring for Chafing/Routing - Check TRANSMISSION, AXLES AND STEERING Steering System - Check Wheel Nut - Security - Check Hub Nut - Security - Check Wheel Bearings - Condition/Play - Check Tyre Condition and Pressures (refer to Specifications) - Check Gearbox Oil - Check Gearbox Oil (1)(8) - Change Gearbox Control Cables and Linkage (1) - Check/Adjust/ Grease Propshafts - Front and Rear - Check/Grease Front Differential Oil (and Rear for 4WD) - Check Front Differential Oil (and Rear for 4WD) (1) - Change CVT Belt - Condition - Check/Change CVT Joints (4WD) - Check BRAKES Brake Fluid - Change SUSPENSION Front Suspension - Condition and Security - Check Rear Suspension - Condition and Security - Check BODYWORK AND CAB Operation (1) General Damage - Check Wing Mirrors - Condition/Security - Check ROPS Structure - Mounting/Security - Check Seat Belt - Condition/Security - Check/Adjust

6 (1) First 100 Hours Service only, to be completed by your JCB Dealer. (2) Fill slowly, make sure the correct quantity is used, in low use conditions change every year. (3) To be done by your JCB Dealer. (4) Change every 1000 hours or two years. (5) The air cleaner outer element should be changed every 100 Hours if the machine is working in dusty conditions or more frequently depending on conditions. (6) Change every 500 hours or two years. (7) Change every 4000 hours or four years. (8) Fill slowly, make sure the correct quantity is used

7 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 (1) ENGINE Idle Speed - Check/Adjust Exhaust System - Security/Fouling - Check Exhaust Smoke - Excessive - Check/Adjust Throttle System and Control Cable - Check Speed Control and Governor Adjustment - Check BRAKES Park Brake - Operation - Check/Adjust Brake System - Leaks - Check Brake Fluid - Check Brake Disks and Pads - Check/Change Service Brake - Operation - Check ELECTRICS Gauges and Warning Lights - Check Horn - Operation - Check Lights and Indicators (If Fitted) - Check STEERING AND SUSPENSION Steering Universal Joints - Play - Check Steering Universal Joints - Bolts - Check/Tighten Track Arm Ball Joints - Bolts - Check/Tighten Rack Gaiters - Check Front Suspension Lower Ball Joint - Security - Check Rack - Security/Condition - Check Steering Operation - Check PAINTWORK Condition - Check

8 GENERAL Fluid Leaks (For Example Coolant, Oil) - Check Cables (For Example 4WD, Differential Lock Cable) Operation (1) Check/Adjust Driveshaft CV Joint Gaiters - Condition - Check/Clean Front Wheels - Tracking/Alignment - Check (1) First 100 Hours Service only, to be completed by your JCB Dealer. Fluids, Lubricants and Capacities Table 1. Oil Capacity Litres JCB Part Container Item (Gal) Fluid/Lubricant Number size Fuel Tank 32 (7) Diesel Oil (refer to Types of Fuel) Engine Oil 2.5 (0.55) JCB Engine Oil EP 15W40 (above -10 C) 4001/ litres Front Differential Oil (4WD only) 0.55 (0.12) JCB Gear Oil EP 80W / litres Rear Differential Oil 0.29 (0.06) JCB Gear Oil EP 80W / litres Engine (Coolant) 2.8 (0.6) JCB Antifreeze HP/Coolant + Water (refer 4006/ litres to Coolant Mixtures) Gearbox 1.0 (0.22) JCB Gear Oil EP 80W / litres Brake Fluid JCB Brake Fluid, Dot / litre Grease JCB HP Grease or 4003/ g JCB Special MPL-EP Grease 4003/ g

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

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