Contents
iii iii
Page No.Contents
Routine Maintenance
Service Requirements .................................................................................87
Introduction .............................................................................................87
Owner/Operator Support ........................................................................87
Service/Maintenance Agreements .........................................................87
Initial Service and Inspection ..................................................................87
Fit for Purpose Tests for Lifting Equipment .............................................88
Obtaining Replacement Parts .................................................................88
Health and Safety ........................................................................................89
Lubricants ...............................................................................................89
Battery ....................................................................................................91
Service Schedules .......................................................................................93
Introduction .............................................................................................93
How to Use the Service Schedules ........................................................93
Calendar Equivalents .............................................................................93
Pre-start Cold Checks, Service Points and Fluid Levels ........................94
Functional Test and Final Inspection ......................................................97
Fluids, Lubricants and Capacities ................................................................99
Coolant Mixtures ..................................................................................100
Fuels .....................................................................................................101
Prepare the Machine for Maintenance ......................................................104
Introduction ...........................................................................................104
How to Make the Machine Safe (Mast Lowered) .................................105
How to Make the Machine Safe (Mast Lifted) ......................................105
Cleaning the Machine ................................................................................108
Introduction ...........................................................................................108
Preparing the Machine for Cleaning .....................................................108
Cleaning the Machine ...........................................................................109
Checking for Damage ................................................................................ 111
Check the Machine Body and Structure ............................................... 111
Check the Tyres ................................................................................... 111
Check the Seat and Seat Belt .............................................................. 111
Check the Hydraulic Hoses and Fittings .............................................. 111
Check the Electrical Circuits ................................................................. 112
Checking the ROPS/FOPS Structure ................................................... 112
Check the Screen Guard and Load backrest extension (if fitted) ......... 112
Greasing .................................................................................................... 113
Introduction ........................................................................................... 113
Preparing the Machine for Greasing .................................................... 113
Daily ..................................................................................................... 114
250 Hours ............................................................................................. 118
Oiling ......................................................................................................... 119
Park Brake Cable ................................................................................. 119
Control Levers ...................................................................................... 119
Cylinder Bores and Rods .....................................................................120
Access Panels ...........................................................................................121
Introduction ...........................................................................................121
Engine Cover ........................................................................................121
Engine Side Panels ..............................................................................122
Brakes .......................................................................................................123
Park Brake ............................................................................................123
Foot Brake ............................................................................................125