Service

circuits.When working on trucks with any panels open, adhere to all regulations governing electrical and hydraulic maintenance.

When performing maintenance procedures on or near batteries, take special care to protect yourself and your environment.The battery fluid in battery cells is a corrosive acid solution, which will burn if it comes into contact with bare skin or eyes. Never handle a naked flame or smoke a cigarette near batteries. Be careful with conductive tools near batteries, especially if any battery contacts are exposed. Always disconnect the battery from the truck before removing it.

Do not attempt a maintenance procedure unless you have all the necessary tools and equipment required by the task. Use only spare parts approved by the manufacturer. Use only the correct fluids and lubricants. Refer to Section 3.9 Lubricant and fluid recommendations for the recommended lubricants and fluids.

Use jacks of suitable design and sufficient capacity to lift the truck. Remember balance when lifting with a jack: position the jack so that the truck’s weight rests evenly on the supports and there is no risk of it overturning. Always secure the truck after lifting it with a jack. Do not work underneath a truck that is supported only by jacks.

Always turn off the main power of the truck and release hydraulic pressure before opening any covers. If any cover is open, turn on the main power or use the hydraulic system only if it is necessary for accomplishing the maintenance task. Disconnect the main battery connector unless electrical power is required. Take extreme care when working near electrical components. Even if the main power is switched off, there may be considerable electrical charges in truck components, such as in the batteries and in power capacitors.

Note that some components become hot during operation. Allow the truck to cool down after use before opening any covers. Especially the components of the electrical and the hydraulic system can heat up considerably during operation.

When larger repairs are involved, for example, when welding, the battery should be disconnected or removed.When welding is necessary, remove any paint or other finishing over a radius

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of at least 100 mm from the welding point to reduce the possibility of toxic gases being produced.

Adhere to all local (national and site-specific) regulations and recommendations governing the working area and the maintenance procedures that you are performing.This includes regulations on personnel safety, the handling of materials, environmental safety and disposal of waste.

Do not perform a maintenance procedure, if you are uncertain of how it should be carried out. Do not modify the truck in any way that might reduce its structural integrity or affect its safe use. If you have doubts or concerns about a procedure described in this manual, contact the local product representative or the manufacturer’s technical support.

Return a truck to normal use only after all regular and other necessary maintenance procedures have been completely carried out and the truck is deemed to be in full working order.

3.2. Maintenance guidelines

Reserve a sufficiently large area for servicing the truck.The area should be large enough for you to be able to test all of the truck’s normal operating functions, such as driving and lifting.

Determine the model of the truck under maintenance from the identification plate that is located on the underside of the tiller arm (when viewed from the driving position).The identification plate should be easily readable when the tiller arm is in the upright position.The three truck models covered by this manual are distinguished by their nominal lifting capacity.The identification plate indicates the capacity of the truck as 1,300, 1,600 or 2,000 kg.The truck models differ slightly in both regular and irregular maintenance and repair procedures. Most of the regular maintenance is identical for the three models, and the differences are indicated where necessary.

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Figure 3.1. Identification plate

All the truck models have two main covers that can be opened: the main cover and the top cover. In addition, the 1,600 and 2,000 kg capacity trucks have a separate battery compartment cover on top of the truck between the top cover and the forks. This battery compartment cover is hinged and can be opened by lifting it.The main and top panels are held in place by screws on both sides of the truck chassis.The two topmost screws on either side hold the top cover, while the two lower screws on either side hold the main cover in place.

Figure 3.2. Main cover fixing screws

To open the main or the top cover on any truck model, loosen the fixing screws enough for the cover to be removed, but do not remove the screws entirely.The screws move a fixing bracket, which holds the cover in place.

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All of the covers on a truck should be closed when its functions are tested. Open the covers only when it is necessary for accomplishing the maintenance or repair task.

Some maintenance and repair tasks require the truck to be lifted. Only suitable lifting equipment should be used to lift a truck. Use only marked lifting points.When this is not possible, make sure that you choose lifting points that can securely support the weight of the truck without being damaged. Remember to secure a lifted truck so that it does not pose a risk to personnel safety.

3.3. Periodic maintenance procedures

The periodic maintenance procedures are grouped based on the intervals after which they must be performed.This section lists the procedures for your convenience. If faults or damage are encountered during any of the periodic maintenance procedures, the maintenance process should be halted and the fault or damage fixed. After the truck has been repaired, the maintenance process should be restarted from the beginning. Always begin with the daily maintenance checks before using the truck after any repairs or modifications.

The regular maintenance schedule:

Daily maintenance

• Check the operation of the main key switch and the emergency stop.

• Check that the battery is charged.

• Visually check the truck for any apparent damage.

• Check the condition of the wheels.

• Check the fastening of the two batteries on 1,300 kg capacity trucks and that the battery is securely in place on 1,600 and 2,000 kg capacity trucks.

• Check the level of battery fluid in each battery cell (does not apply to 1,300 kg capacity trucks).

• Check the transmission for leaks.

• Visually check the condition of hydraulic tubing and couplings.

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