Service/Inspection Checklist and Report
426, 434, 436, 456
Service/Inspection Checklist and Report
426, 434, 436, 456
Issued by JCB Technical Publications, JCB Service, World Parts Centre, Beamhurst, Uttoxeter, Staffordshire, ST14 5PA,
England. Tel +44 1889 590312 Fax +44 1889 593377
Dealer Stamp Machine Type
Serial No.
Distributor
Depot
Job No.
Hourmeter Reading Hrs
Date of Registration
Date of Service
Note: Original copy to customer, Photocopy to distributor.
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
1 9814/0650-3 1
Service/Inspection Checklist and Report
Service Schedules
Service Schedules
Introduction How to Use the Service Schedules
T3-036_3 T3-012_4
!MWARNING In the example shown, A shows all service requirements to
be carried out every 10 hours and B shows the
Maintenance must be done only by suitably qualified requirements to be carried out every 500 hours.
and competent persons.
Important: Services should be carried out at either the
Before doing any maintenance make sure the machine hourly interval or calendar interval, whichever occurs first.
is safe, it should be correctly parked on level ground. Refer to Calendar Equivalents.
To prevent anyone starting the engine, remove the Important: The intervals given in the schedules must not
starter key. Disconnect the battery when you are not be exceeded. If the machine is operated under severe
using electrical power. If you do not take these conditions (high temperature, dust, water, etc.), shorten
precautions you could be killed or injured. the intervals.
8-3-1-1
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.
795390-1
Calendar Equivalents
T3-037
Every 10 Hours = Daily
Every 50 Hours = Weekly
Every 500 Hours = Six Months
Every 1000 Hours = Yearly
Every 2000 Hours = 2 Years
Every 8000 Hours = 8 Years
2 9814/0650-3 2
Service/Inspection Checklist and Report
Service Schedules
Service Schedules
All jobs should be marked and logged:
No fault found job complete. Fault found and corrected. Follow up required. Detail on
Detail on Service/Inspection Service/Inspection Report.
Report.
Pre-start Cold Checks, Service Points and Fluid Levels
Table 1. Engine
Operation 10 50 100(1) 100 500 1000 2000
Oil Level and Condition Check
Oil and Filter (2) Change
Coolant Change
Coolant Level Check
Coolant Strength and Condition Check
Coolant Filter (If Fitted) Change
Air Filter and Dust Valve(3) Clean
Air Filter Outer Element (4) Change
Air Filter Inner Element Change
Fuel Filter Change
Fuel Sedimenter/Water Seperator Drain
Fuel Sedimenter/Water Seperator Change
Radiator Matrix Check/Clean
Fan Belt Condition (5) Check
Valve Clearances(6) Check/Adjust
Air Compressor Belt Tension/Condition Check
(If Fitted)
(1) First 100 Hours Service only, to be completed by your JCB Dealer.
(2) In arduous conditions change the oil and filter after every 250 hours or three months (whichever comes first).
(3) Clean more often when working in dusty operating environments
(4) Change outer element more frequently in dusty operating environments.
(5) Change if necessary.
(6) Check/adjust every 5000 hours.
3 9814/0650-3 3
Service/Inspection Checklist and Report
Service Schedules
Table 2. Brakes
Operation 10 50 100(1) 100 500 1000 2000
Park Brake Operation Check
Foot Brake Operation Check
(1) First 100 Hours Service only, to be completed by your JCB Dealer.
Table 3. Transmission and Axles
Operation 10 50 100(1) 100 500 1000 2000
Transmission Oil Level Check
Transmission Oil and Filter Change
Differential Oil Level (Graziano) Check
Differential Oil (Graziano) Change
Hub Oil (Graziano) Check
Hub Oil (Graziano) Change
Hub Oil (ZF Axle Standard Brake Pads Check
Hub Oil (ZF Axle Standard Brake Pads(2)) Change
Hub Oil (ZF Axle Sintered Brake Pads) Check
Hub Oil (ZF Axle Sintered Brake Pads) Change
Axle Breathers Clean/Check
Tyre Pressures and Condition Check
Wheel Nut Security Check
Axle Mount and Driveshaft Security Check
Bevel Ring Gear Deflection Plunger Check
Driveshaft and Universal Joints Grease(3)
(1) First 100 Hours Service only, to be completed by your JCB Dealer.
(2) Change the oil every 1500 hours.
(3) Grease more frequently when operating in arduous conditions.
4 9814/0650-3 4
Service/Inspection Checklist and Report
Service Schedules
Table 4. Hydraulics
Operation 10 50 100(1) 100 500 1000 2000
Oil Level Check
Oil Filter Change
Oil Sample
Oil Change
Servo Filter (If Fitted) Change
Tank Breather Check
Tank Breather Change
Tank Suction Strainers (x2) Clean
Hoses, Rams and Pipe-Work for Damage Check
(1) First 100 Hours Service only, to be completed by your JCB Dealer.
Table 5. Bodywork and Cab
Operation 10 50 100(1) 100 500 1000 2000
Machine Condition - General Check
Autolube Reservoir Level (If Fitted) (2) Check
Autolube Reservoir Filler Filter (If Fitted) Change
Hinges Lubricate
All Pivot-Pins(3), Steer Rams and the Quickhitch Grease
Locking-Pins
Window Washer Fluid Level Check
Cab Heater Intake Filter(s) Clean(4)
Seat/Seat Belt Condition and Security Check
ROPS/FOPS Structure Check
Check for Fluid Leaks (For Example Engine Oil, Check
Hydraulic Fluid)
(1) First 100 Hours Service only, to be completed by your JCB Dealer.
(2) Top-up as necessary.
(3) Grease every 10 hours when operating in arduous conditions.
(4) Clean more frequently in dusty operating environments.
5 9814/0650-3 5
Service/Inspection Checklist and Report
Service Schedules
Table 6. Electrics
Operation 10 50 100(1) 100 500 1000 2000
Battery Electrolyte Level (If Applicable) Check
Instrument Panel Operation Check
Battery Charge and Condition Check
Battery Terminals for Condition and Tightness Check
Wiring for Chaffing and Routing Check
(1) First 100 Hours Service only, to be completed by your JCB Dealer.
Table 7. Lifting Equipment
Operation 10 50 100(1) 100 500 1000 2000
Fit for Purpose Test(2) Complete
(1) First 100 Hours Service only, to be completed by your JCB Dealer.
(2) This may be required every six months or at least annually in some countries to meet and comply with legislation and
for insurance purposes.
6 9814/0650-3 6
Service/Inspection Checklist and Report
Service Schedules
Functional Test and Final Inspection
Table 8. Engine
Operation 10 50 100(1) 100 500 1000 2000
Idle Speed Check
Torque Converter Stall Speed Check
Combined Stall Speed Check
Maximum No Load Speed Check
Throttle System Check
Exhaust Smoke Check
Exhaust System Security Check
Air Inlet System Security Check
(1) First 100 Hours Service only, to be completed by your JCB Dealer.
Table 9. Transmission, Axles and Steering
Operation 10 50 100(1) 100 500 1000 2000
Transmission Operation Check
Forward/Reverse/Speed Range Check
Operation
Neutral Start Operation Check
Oil Cooler and Pipe-Work Check
Steering Operation Check
(1) First 100 Hours Service only, to be completed by your JCB Dealer.
Table 10. Hydraulics
Operation 10 50 100(1) 100 500 1000 2000
Piston Rods and Gland Seals Check
(1) First 100 Hours Service only, to be completed by your JCB Dealer.
7 9814/0650-3 7
Service/Inspection Checklist and Report
Service Schedules
Table 11. Electrics
Operation 10 50 100(1) 100 500 1000 2000
Gauges and Warning Lights Check
Wiper Motors Check
Cab Switches Operation Check
Horn Check
Heater (If Fitted) Check
Reverse Alarm (If Fitted) Check
Lights and Indicators (If Fitted) Check
Starter Motor Connections Check
Alternator Connections Check
Proximity Sensor Function Check
(1) First 100 Hours Service only, to be completed by your JCB Dealer.
Table 12. Bodywork and Cab
Operation 10 50 100(1) 100 500 1000 2000
Glazing for Correct Fit Check
Doors and Hinges Check
Toolkit and Handbook Check
Locks and Keys Check
Air Conditioning (If Fitted) Check
Generally for Damage, Leaks and Wear Check
Paintwork Condition Check
(1) First 100 Hours Service only, to be completed by your JCB Dealer.
Table 13. Attachments
Operation 10 50 100(1) 100 500 1000 2000
Attachment Condition and Operation Check
(1) First 100 Hours Service only, to be completed by your JCB Dealer.
8 9814/0650-3 8
Service/Inspection Checklist and Report
Service/Inspection Report
Service/Inspection Report
Remarks/Action Implemented During Service
Outstanding Action Required
9 9814/0650-3 9
Service/Inspection Checklist and Report
Service/Inspection Report
Paintwork Defects
Remarks (Note and mark appropriate diagram)
10 9814/0650-3 10
