operating state

3. Regular maintenance

Regular maintenance is the best way of keeping a truck fully operational and safe for the users.The procedures described in this chapter should be carried out according to the schedule outlined in Section 3.3 Periodic maintenance procedures.

Even though daily maintenance checks can be carried out without special training, this manual assumes that the reader is a professional trained in the service of trucks.Therefore, the presented maintenance and repair instructions should be followed only by professional service personnel.

3.1. Safety guidelines and preparation

Do not attempt any maintenance or repair procedure unless you are authorised and qualified to carry it out.To service trucks you must be qualified to work on both electrical and hydraulic systems. Before planning maintenance actions on a truck, ensure that you are sufficiently familiar with the operation and use of the truck type and model. Make sure that you have the most current version of this service manual, as well as all the necessary and most current versions of schematic diagrams, charts and any other information needed for the maintenance tasks.

Perform maintenance and repair tasks only in a suitable environment.The service area must be safe for the servicing personnel, as well as for any other persons in its vicinity.The area must also be safe and suitable for performing electrical, hydraulic and mechanical maintenance procedures.The area must be kept clean. Any fluid stains, waste and unnecessary equipment must be cleared from the service area before and during maintenance. Make sure that the service area is well ventilated.

To uphold personal working safety, make sure that you are appropriately prepared to perform servicing. Ensure that you have the appropriate clothing for the tasks.This includes protective clothing, footwear and gloves, as well as other protective equipment required by the task, such as eyewear, a mask and hearing protection.Take the appropriate precautions when handling harmful, corrosive or toxic chemicals. Never use bare hands or other parts of your body to test for leaks etc. Remove personal jewellery to reduce the risk of causing short

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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 1,000, 1,200 or 1,600 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

The trucks have two openable covers: the main cover and the battery compartment cover.The battery compartment cover is hinged and can be openned by lifting it.The main cover is held in place by two screws, one on each side of the truck.To open the main cover, unscrew the fixing screws completely with a 5 mm Allen key and then lift the cover off.

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Figure 3.2. Main cover fixing screws

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:

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