Cabin & Operator Safety Procedures

This page lists 66 maintenance procedures for cabin & operator safety, drawn from HIT Srl's internal procedure library extracted from manufacturer service manuals.

HIT Srl supplies cabin, seat and HVAC spare parts for this class of machine.

General guidance only — always follow the operation and maintenance manual for your specific machine.

Safety Devices & interlocks

• What is the correct sequence for safely entering and exiting the tractor cab?

  1. Entry and exit should be made slowly and carefully.
  2. Use a three-point stance: three out of the four extremities (hands and feet) should be in contact with the vehicle at all times.
  3. Face inward toward the steps when entering and exiting.
  4. Keep steps, walkways and handholds in good condition.
  5. Keep steps, handholds, walkways and shoes free of grease, mud, dirt, fuel, ice and snow.
  6. Use extra care during bad weather, especially when steps and handholds may be icy or wet.

  Notes:

  • To avoid serious injury or death, read the instructions and warnings before entering and exiting the vehicle.
  • Do not remove or modify factory-installed walkways, steps or handholds; do not operate the vehicle unless they are all installed and in good working condition.

• What is the correct sequence to tilt the cab for service access?

  The cab tilt control switch is located on the left-hand frame rail, with the safety prop release cable nearby.

  1. Locate the cab tilt control switch and safety prop release cable.
  2. Pull the safety prop release cable and hold the cable to the rear.
  3. While holding the cable to the rear, move the tilt control switch to the UP position.
  4. After the cab has traveled about 15 inches (381 mm), release the safety prop cable and continue tilting the cab.
  5. As the cab approaches the 45-degree position, watch for the safety prop to drop over the tilt cylinder on the driver's side of the frame, then STOP.
  6. After the safety prop has dropped over the cylinder, move the tilt control switch to the DOWN position and lower the cab slightly until the safety prop rests fully on top of the tilt cylinder.
  7. Make sure the safety prop is resting properly on top of the tilt cylinder: pull on the safety prop release cable and ensure the safety prop is secure; it should not move with the weight of the cab on the prop.

  Notes:

  • Ensure that no part of the body is under the cab while tilting; stand clear of the rear of the cab.
  • Ensure the safety prop is properly engaged before working under the cab.
  • Never work under the cab unless the safety prop is properly engaged; the cab could fall and cause serious injury or death.
  • Only tilt the cab far enough past the 45-degree point to engage the safety bar; attempting to fully extend the cylinder past 45 degrees can cause pump and motor damage.

• What is the correct sequence to lower the cab after tilting it?

  1. Move the cab tilt switch to the UP position and raise the cab slightly until the safety prop is free from the top of the tilt cylinder.
  2. Pull the safety prop release cable to the rear and hold in the rearward position.
  3. Move the tilt switch to the DOWN position with the safety prop disengaged and allow the cab to lower onto the rear cab latch.
  4. Hold the cab tilt switch in the DOWN position for 5 seconds after the cab has come to rest on the lower latch units, to ensure the mechanical cab latches are fully engaged.

  Notes:

  • Ensure the cab latch is fully engaged after lowering the cab; if not properly locked down, the cab could tilt while the vehicle is in motion.
  • If a cab latch fails or the tilt system malfunctions, the safety prop is designed to act as a secondary hold down; ensure the release cable operates freely and the safety prop rests against the tilt cylinder when the cab is lowered and latched.

• How should the fire extinguisher be checked before use?

  Periodicity: the fire extinguisher must be refilled every 36 months

  1. Make certain the extinguisher is in its designated location, clearly visible and ready for immediate use, with no obstructions hindering access.
  2. Check that the appliance has not been interfered with or rendered unusable.
  3. Check that the safety seal preventing accidental operation is in place and the tamper indicators are intact.
  4. Check that nameplates and labels are exposed to view and clearly legible.
  5. Check the extinguisher is in faultless working order: no clogging of nozzles, no leakage, no traces of corrosion, hoses securely connected with no signs of cracking.
  6. Check the pressure gauge indicates a value within the green sector; if not, notify the maintenance service.

• What is the correct sequence of actions when administering first aid for a serious injury?

  1. Call a doctor immediately in all cases of serious injury.
  2. Remove the patient from the harmful environment.
  3. Put the patient in the best possible conditions for rest; loosen clothing, collar, belt and, if necessary, cover with a blanket.
  4. Before touching any wounds, wash your hands with soap and water and, if possible, disinfect them.
  5. Disinfect any wounds if you know how to do this correctly; otherwise cover with sterile gauze and apply pressure with a cotton wool wad impregnated with alcohol and a tight bandage.
  6. In the case of heavy bleeding from an arm or leg, apply a tourniquet above the wound and take the patient to the nearest accident unit.
  7. After administering first aid, send the patient to a doctor.

  Notes:

  • Never attempt any medical procedures of which you are unsure, as this could harm the patient.
  • Never give any drink to someone who is unconscious.

• What is the correct sequence of first-aid actions for a person whose clothing has caught fire?

  1. Extinguish the flames on the victim's clothing by flooding with water, using a powder extinguisher (avoiding directing the jet at the face), or covering the victim with a blanket or rolling them on the ground.
  2. Do not pull off pieces of fabric stuck to the skin.
  3. In case of scalding by liquids, quickly but carefully remove the wet clothing.
  4. Cover the burn with a proper anti-burn dressing or sterile bandage.

• What should be done in the event of a fire on board the machine?

  1. Extinguish the fire using extinguishers.
  2. Do not use water to put out a fire on board the machine; this could spread an oil fire further or cause an electric shock if the fire is of electrical origin.
  3. Use a carbon dioxide, dry chemical or foam extinguisher.
  4. Call the fire brigade immediately; firefighters should use oxygen masks.

  Note: If the machine is equipped with an extinguisher, have it checked regularly and keep it in the cab.

• How is the rear window removed as an emergency exit from the cab?

  Besides the right-hand door, in case of extreme necessity the rear window of the cab can be removed as an emergency exit.

  1. Firmly grip the end of the rubber core protruding from the rear window gasket (located on the upper part, marked with a specific label).
  2. Pull hard until the rubber core is completely removed from the gasket, then push the glass outward.

Seat

• What is the correct sequence to replace an operator's seat with a simple four-screw mounting?

  1. Put the machine in service position.
  2. Remove the four screws that hold the seat in place.
  3. Unplug the electrical connections.
  4. Remove the driver's seat.
  5. Fit in reverse order.

• What is the correct sequence to replace an operator's seat with a sliding-rail mounting (front and rear screw pairs)?

  1. Put the machine in service position.
  2. Slide the seat fully backwards and remove the two front screws that hold the seat in place.
  3. Slide the seat fully forwards and remove the two rear screws that hold the seat in place.
  4. Undo the necessary connectors for the cables.
  5. Remove the seat.
  6. Fit in reverse order.

• What is the correct sequence to install the wiring to an operator's seat without a seat column?

  1. Put the machine in service position.
  2. Check that the wiring has sufficient slack when the seat is in the forward position; if too slack, it can get caught between the rails when the seat is slid back.
  3. Position the seat in the maximum upward position.
  4. Strap the wiring in place on the seat cross-bar, forming a sufficient slack arch across the cross-bar.
  5. Strap the wiring at the rear edge of the seat undercarriage.

  Note: Check that the wiring is not pinched between the rails when seat height or length is adjusted.

• What is the correct sequence to install the wiring to an operator's seat with a seat column?

  1. Put the machine in service position.
  2. Secure the wiring for the seat orientation sensor with a self-adhesive cable tie mounting; the seat switch wiring is routed inside the seat column.
  3. Position the seat in the maximum upward position.
  4. Strap the wiring in place on the seat cross-bar, forming a sufficient slack arch across the cross-bar.

  Note: Check that the wiring is not pinched between the rails when seat height or length is adjusted.

• What is the correct sequence to replace the seat cushion?

  1. Put the machine in service position.
  2. Remove the protective bellows by undoing the plastic rivets.
  3. Unhook the upholstery fastening section from the seat frame and remove the upholstery, then remove the seat cushion.
  4. If the seat has electric heating, unplug it before removal.
  5. Fit in reverse order.

  Note: The seat heater element is glued to the seat cushion; be careful if replacing the cushion foam while reusing the heater element, or replacing only the heater element.

• What is the correct sequence to replace the backrest?

  1. Put the machine in service position.
  2. Undo the protective bellows by removing the plastic rivets on the rear of the seat and fold the rubber bellows down.
  3. Remove the backrest by first removing the socket cap screws on the right and left sides of the seat, then removing the seat belt screws on the right and left sides.
  4. If the seat has a 3-point seat belt, move the top belt guide to the new backrest by removing its cover and undoing the screw.
  5. If the seat has an armrest, move it to the new backrest by removing the three screws for the armrest.
  6. Install the new backrest: first install the front socket cap screws without tightening them, then the rear seat belt screws; then torque the rear seat belt screws to 42 Nm and the front socket cap screws to 33 Nm.
  7. On the new backrest, cut the corresponding holes in the upholstery before installing the seat belt or armrest.
  8. Fit in reverse order.

• What is the correct sequence to replace the seat's shock absorber?

  Replace if the shock absorber does not function satisfactorily, makes a noise, or leaks.

  1. Put the machine in service position.
  2. Unscrew the driver's seat and lift it out of the machine.
  3. Unscrew the backrest and remove the seat cushion.
  4. Remove the nuts and screws for the shock absorber.
  5. Replace the shock absorber.
  6. Fit in reverse order.

• What is the correct sequence to replace the seat suspension compressor located under the cab floor?

  1. Put the machine in service position.
  2. Undo the air hoses and electric connectors for the compressor.
  3. Remove the screws that hold the compressor in place on the compressor bracket.
  4. Remove the compressor.
  5. Fit in reverse order.

Cab Structure

• What is the correct sequence to replace a cab door that simply lifts off?

  1. Put the machine in service position.
  2. Lift off the door in question by hand.
  3. Replace the door.

• What is the correct sequence to replace a cab door on a cab where the roof must be raised first?

  1. Put the machine in service position.
  2. Remove the screws securing the roof.
  3. Lift the roof slightly (40-50 mm) using an overhead crane.
  4. Lift off the door in question by hand.
  5. Replace the door.
  6. Fit in reverse order.

• What is the correct sequence to replace the cab mounting rubber bushings?

  1. Put the machine in service position.
  2. Tilt the cab.
  3. Remove the four bolts that secure the rubber bushings to the cab floor.
  4. Remove the nut to split the locating pin and the rubber bushing.
  5. Replace the rubber bushing.

• What is the correct sequence to replace the door stop on a FlexCab door?

  1. Put the machine in service position.
  2. Remove the domed nut which fixes the door stop components on the inside of the door.
  3. Remove the door stop components.
  4. Remove the three screws that fix the interior trim to the inside of the cab wall, to gain access to the nuts for the door stop section on the cab side.
  5. Remove the screws and nuts that fix the door stop section to the cab side behind the door on the left side.
  6. Remove the door stop components.
  7. Fit in reverse order.

• What is the correct sequence to replace the door stop on a Spirit Delta cab door?

  1. Put the machine in service position.
  2. Remove the interior door panel.
  3. Remove the nut which fixes the door stop components on the inside of the door.
  4. Remove the components for the door stop.
  5. Remove the three screws that fix the interior trim to the inside of the cab wall, to gain access to the nuts for the door stop section on the cab side.
  6. Remove the screws and nuts that fix the door stop section to the cab side behind the door on the left side.
  7. Remove the components for the door stop.
  8. Fit in reverse order.

• What is the correct sequence to replace a catch-strap type door stop?

  1. Put the machine in service position.
  2. Remove the screw which holds the catch strap in the cab.
  3. Remove the two screws that fix the catch strap anchorage to the door.
  4. Remove the catch strap from the anchorage.
  5. Fit in reverse order.

• What is the correct sequence to replace a gas-spring damped door stop?

  1. Put the machine in service position.
  2. Place the door in the fully open position.
  3. Remove the screws which fix the lever to the door and the gas damper device.
  4. Remove and replace the lever or the necessary parts of the gas damping device.
  5. Fit in reverse order.

  Note: Lock the lever's screws with thread locking fluid before installation.

• What is the correct sequence to check the cab structure?

  1. Carefully check the integrity of the cab shell for cracks or deformation.
  2. Carefully check the integrity of the cab door structure for wear, deformation, or excessive play.
  3. Check all welds.
  4. Carefully check that all fastening pins and similar parts are secured in their seats, without wear, deformation, or excessive play.
  5. Check the condition of the elastic mounts and their fastening.
  6. Check the condition of the doors and their fastening hinges.
  7. Check the tightness of all bolted joints.

  Notes:

  • Switch off the engine and make sure the parking brake is applied before starting any check or repair work.
  • If the cab must be lifted off the frame, sling it with the appropriate straps, taking care not to damage it, and never stand between the cab support structure and the cab while it is raised.

Hvac & air Quality

• How is the HVAC system checked during a preventative maintenance inspection?

  1. Blower motor operation: with the key on, ensure the blower motor operates at each position of the blower speed switch.
  2. Temperature control: confirm proper operation of the temperature control switch.
  3. Defroster operation: with the engine running and the defroster control turned on, confirm air flow from the defroster vents.
  4. Air conditioner operation (if applicable): with the engine running and the air conditioner control on, confirm cooled air flow.
  5. Auxiliary fan(s) (if applicable): with the key on, turn on the auxiliary fans and confirm operation.

• How should the air conditioning evaporator and condenser be cleaned?

  Periodicity: every 250 working hours, or more often in dusty environments

  1. Remove and clean the evaporator filter using compressed air, unless replacement is necessary.
  2. Use compressed air to clean the elements of the evaporator.
  3. Keep the condenser free from dust, dirt and insects, cleaning it with compressed air and adequate washing liquids.

  Note: Any object reducing air flow through the condenser can damage the fans and other A/C system components.

• What is the correct sequence to test the performance of the air conditioning system?

  1. Start the engine at max 2,000-2,500 RPM.
  2. Adjust the thermostat to the max position.
  3. Open the cab doors.
  4. Start the fan at max speed for ten minutes.
  5. Close the cab doors and windows.
  6. Check the high pressure (gauge on the discharge line) and low pressure (gauge on the suction line).
  7. Check the temperature inside the cab.

• What should be checked before running a functional diagnostic test on the air conditioning system?

  1. Adjust belt tension.
  2. Check hoses and fittings for leakage.
  3. Check the condenser.
  4. Check all the air ducts.
  5. Check the evaporator.
  6. Check the fans.
  7. Check the air filter.
  8. Check the drier coolant filter (outside hoarfrosting indicates inside clogging).

  Note: For deeper analysis, specific instruments and skilled personnel are necessary.

• What is the correct rescue procedure for someone poisoned by carbon monoxide in an enclosed space?

  1. Immediately ventilate the enclosed space to reduce the gas concentration.
  2. The rescuer must wear a mask before entering the space, and must not light flames, lights, or activate electric bells or telephones, to avoid explosions.
  3. Bring the poisoned person to a ventilated area or outdoors.
  4. Lay the person on their side if they are unconscious.

  Note: Carbon monoxide from engine exhaust gases is odourless and dangerous; in enclosed spaces it can reach critical concentration quickly and, mixed with air, forms an explosive mixture.

• What settings quickly defrost or demist the windscreen?

  1. Direct air distribution to the windscreen.
  2. Set maximum ventilation speed.
  3. Activate the compressor.
  4. Close all windows.

• How often must the climate control system be run to prevent compressor damage?

  Periodicity: at least 5 minutes every week

  1. Run the climate control system for at least 5 minutes every week.

  Note: This prevents poor lubrication of the compressor's internal parts and ensures optimal system operation.

Seat & controls

• What should be checked on the seat belt system during a scheduled safety inspection?

  Periodicity: every 20,000 miles (32,187 km), or more often if exposed to severe environmental conditions or vocation

  1. Inspect the belt on the entire system for cuts, fraying, extreme or unusual wear, especially at the buckle/latch area and shoulder loop area; replace the entire belt system if necessary.
  2. Inspect the buckle for proper operation by inserting the latch and listening for an audible click; verify it is not damaged, cracked or broken; replace the entire belt system if necessary.
  3. Inspect the buckle cable (optional component): the black coating must not be damaged and internal cable wires must not be exposed, frayed or broken; replace the entire system if necessary.
  4. Inspect the latch for proper operation by inserting into the buckle; it must insert smoothly with an audible click and must not be worn, deformed or corroded; replace the entire belt system if necessary.
  5. Inspect the shoulder loop web guide (optional component): the belt must move freely through it; adjust shoulder loop hardware and/or remove obstruction if necessary.
  6. Inspect the seat belt height adjuster (optional component) for damage; it must move freely and lock at different height positions; replace the entire belt system if necessary.
  7. Inspect retractor operation: when pulled and released slowly, the belt must spool out and retract without locking; replace the entire belt system if necessary.
  8. Inspect mounting hardware on both sides of the seat: it must be tight and must not be missing, rusted, corroded or damaged; replace or tighten as necessary.
  9. Inspect tethers for cuts, fraying, extreme or unusual wear, and for proper attachment and adjustment; replace defective tethers.
  10. Inspect the cab door retaining latch (optional component) for function and ability to clamp on the web; replace the entire system if necessary.

  Note: Failure to check the seat belt system could lead to serious injury or death.

• What is the correct sequence to adjust the driver's seat position?

  1. Change the air pressure in the suspension to adjust the seat height.
  2. Move the seat cushion back on its slides to obtain the fore and aft position.
  3. Once the position is achieved, tighten the seat belt tether securely on both sides (the tether restrains the seat from raising above this position).
  4. Adjust the seat air suspension to the operator's desired firmness.

  Note: Do not adjust the driver's seat unless the vehicle is parked; the seat could move suddenly and unexpectedly, resulting in loss of control of the vehicle, serious injury or death.

• What is the correct sequence to adjust the operator's seat on a container stacker?

  1. Adjusting seat height: turn the knob anticlockwise to lift the seat, clockwise to lower it.
  2. Adjusting the seat dampers: push the lever to the right to increase damper resistance, to the left to reduce it.
  3. Distance of seat from control panel: lift the metal bar and slide the seat.
  4. Inclining the seat back: lift the lever and regulate the back position as required.

• What are the available driver's seat adjustments on this class of machine?

  1. Weight adjustment: rotate the knob to set for driver weight from 40 to 130 kg.
  2. Seat height adjustment: lift the lever, set the desired height (up to +65 mm), then release the lever.
  3. Seat tilt adjustment: lift the lever, set the desired tilt (up to +65 mm), then release the lever.
  4. Backrest tilt adjustment: lift the lever, set the desired angle (up to 41.4° rearward), then release the lever.
  5. Longitudinal (fore-aft) adjustment: lift the lever and slide the seat to the desired position (150 mm travel), making sure the mechanism is locked afterward.

• How is the driver's seat belt fastened and released?

  1. To fasten, grip the latch tongue and insert it into the buckle housing until the locking click is heard.
  2. To release, press the button on the upper end of the buckle.

  Notes:

  • The seat belt webbing must not be twisted, and must fit snugly against the pelvis, not the abdomen, to avoid the risk of sliding forward.
  • Periodically check that the anchor screws are fully tightened and that the webbing is not cut or frayed.
  • After a significant accident, replace the belt worn at the time even if it does not appear damaged.

• What is the correct sequence to adjust the tilt position of the steering wheel or side control column?

  1. Loosen the lock lever, turning it anticlockwise.
  2. Take hold of the steering wheel or column with both hands and move it to the desired, most ergonomic position.
  3. Tighten the lock lever again, turning it clockwise.

  Notes:

  • This operation must be carried out only with the vehicle stopped and the parking brake applied.
  • When adjusting the side control column, do not operate the joystick lever.

Wiper System

• What is the correct sequence to replace the front wiper motor?

  The exact cover-plate screw count and layout vary by cab type, but the underlying sequence is common.

  1. Put the machine in service position.
  2. Raise the nut protector and remove the nut(s) securing the wiper arm.
  3. Remove the screws securing the cover plate and remove the cover plate.
  4. Disconnect the washer hose.
  5. Remove the washer fluid hose and unplug the connector from the wiper motor.
  6. Remove the nuts or screws securing the motor to the cover plate (or remove the wiper motor from the inside, on cabs where it is mounted that way).
  7. Replace the wiper motor.
  8. Fit in reverse order, tightening the wiper arm nuts to 16-20 Nm.

  Note: When fitting, ensure the drive grooves are free of metal filings or similar, and tighten the wiper arm nuts to 16-20 Nm so the grooves press into the bracket and work as drivers.

• What is the correct sequence to replace the washer pump?

  1. Put the machine in service position.
  2. Unscrew the reservoir and empty out the washer fluid.
  3. Remove the hoses from the pumps.
  4. Undo the connector on the electric cable for the pumps.
  5. Remove the pumps from the reservoir (a rubber bushing seals between the pumps and the reservoir).
  6. Replace the pump.
  7. Fit in reverse order.
  8. Fill the reservoir with screenwasher fluid.

• What is the correct sequence to replace the roof or rear wiper motor?

  The exact cover and fastener layout vary by cab type and wiper location, but the underlying sequence is common.

  1. Put the machine in service position.
  2. Remove the plastic cover over the wiper motor.
  3. Disconnect the washer hose and unplug the wiper motor connector, and the earth cable where fitted.
  4. Undo the lock nut or nut securing the wiper arm and remove the wiper arm.
  5. Remove the nuts or screws securing the wiper motor.
  6. Replace the wiper motor.
  7. Fit in reverse order, tightening the wiper arm to 16-20 Nm.

  Note: When fitting, ensure the drive grooves are free of metal filings or similar, and tighten the wiper arm to 16-20 Nm so the grooves press into the bracket and work as drivers.

• What is checked on the windscreen wipers during the 500-hour Type A preventive maintenance service?

  There are four preventive maintenance cards (A, B, C, D) covering the machine's complete maintenance plan, on a 500-hour frequency, cycling in the order B-A-B-C-B-A-B-C-B-D before repeating. Service times assume normal operating conditions and may vary with type of use, road surface, and environment.

  1. Check the operation of the upper, front and rear windscreen wipers.
  2. Check the wear of the upper, front and rear wiper blades.

  Note: Maintenance must be carried out only by qualified, authorised personnel, working in conditions of maximum safety.

Cab Removal

• What is the correct sequence to remove the cab?

  1. Park the machine on a level surface, block the wheels, shut off the battery master disconnect switch, then open the battery compartment and disconnect the battery cables (negative first), isolating them.
  2. Disconnect all the electrical wiring harnesses, particularly those under the cab.
  3. Disconnect the electrical cables placed inside the drag chain.
  4. Disconnect the hydraulic connections placed inside the drag chain.
  5. Remove the steering hydraulic connections.
  6. Remove the pilot hydraulic system connections.
  7. Disconnect the brake system hoses.
  8. Remove the cab, either by disconnecting it from its support and removing the relevant bolts and washers, or by disconnecting the drag chains and sliding the cab on its tracks.
  9. Use a suitable fork truck to move the cab to a prepared working area.

  Note: Bleed all brake system air pressure to 0 psi before disconnecting any hydraulic hoses, by pumping the brake pedal until it no longer comes back up.

• What is the correct sequence to install the cab?

  Installation is achieved by reversing the removal procedure, plus the following additional steps.

  1. Apply the proper torque values from the manual's torque table during installation.
  2. Test the operation of all controls before returning the machine to active service.
  3. Check all hydraulic hose connections for leaks.
  4. Check all coolant hose connections for leaks.
  5. Check hydraulic hose connections for leaks by applying a soapy water solution to the connections.

  Note: Use extra caution when clamping all hoses, since restriction of flow could result in faulty brake operation.

• What is the correct sequence to disassemble the cab's internal components?

  1. Remove the AC/heater unit.
  2. Remove the control panels.
  3. Remove the front instrument panels.
  4. Remove the operator's seat and side panel.
  5. Remove the windscreen wiper group.
  6. Remove the steering column and command levers.
  7. Remove the parking brake lever and pedal.
  8. Remove the accelerator pedal.

• What is the correct sequence to reinstall the cab's internal components after disassembly?

  Installation is achieved by reversing the disassembly procedure, plus the following additional steps.

  1. Apply the proper torque values from the manual's torque table during installation.
  2. Test the operation of all controls before returning the machine to active service.
  3. Check all hydraulic hose connections for leaks.
  4. Check all coolant hose connections for leaks.
  5. Check hydraulic hose connections for leaks by applying a soapy water solution to the connections.

  Note: Use extra caution when clamping all hoses, since restriction of flow could result in faulty brake operation.

Reversible Seat

• What is the correct sequence to calibrate a reversible driver's station?

  1. Select calibration of the reversible driver's station from the setup menu.
  2. Apply the parking brake and confirm to proceed.
  3. Turn the driver's seat to the end position facing straight ahead and confirm to save the position.
  4. Turn the driver's seat to the position that shifts it from forward-facing to backward-facing (within the range of 80-120°) and confirm to save the position.
  5. Turn the driver's seat to the end position facing straight behind and confirm to save the position.

  Note: The parking brake must be applied before calibration can proceed.

• What is the correct sequence to replace the reversible operator's seat electric motor?

  1. Put the machine in service position.
  2. Undo the connector for the electric motor.
  3. Remove the four screws that hold the electric motor in place.
  4. Remove the electric motor.
  5. Fit in reverse order.

• What is the correct sequence to replace the reversible driver's station electric motor?

  1. Put the machine in service position.
  2. Tilt the cab.
  3. Undo the connector for the electric motor.
  4. Remove the four screws that hold the electric motor in place.
  5. Remove the electric motor.
  6. Fit in reverse order.

Windows

• What is the correct sequence to replace the windscreen or roof window on a cab bonded with silicone adhesive?

  1. Put the machine in service position.
  2. Remove the locking strip.
  3. Remove the broken window pane and check that no glass or other particles remain in the pane's groove on the glazing gasket, cutting apart the silicone joints with a sharp tool; if replacing the roof window, remove all its bolts before cutting away the silicone adhesive, and make sure no silicone remains between the window pane and the strip at the pane's lower front edge.
  4. Clean all surfaces thoroughly, removing old silicone remains with a razor blade or similar.
  5. Fit masking tape on the inside and outside of the window panes at the surfaces to be glued.
  6. When replacing the windshield or a side window, adjust the window panes so the upper edge of the side window is level with the top edge of the roof and the distance between windshield and side window is correct, using spacers against the roof member to obtain the distances.
  7. Install the locking strip around the whole window pane.
  8. Apply silicone adhesive around the window panes from the outside of the joints, making the new joint wider than the old one, ensuring there is silicone between the window panes to prevent them touching.
  9. Remove excess silicone adhesive from the outer vertical corners with a cardboard tool, then smooth out the joints on the inside with a finger wet with water or soapy water.
  10. Apply silicone adhesive between the strip and window pane at the bottom edge of the front corners (top sealing).
  11. If replacing the roof window, apply silicone adhesive at the cab frame where it was glued before.
  12. Put the roof window into place, checking for a uniform gap of one or more millimetres along the pane's edges and the frame's side protection, then tighten the corner bolts for the window pane.
  13. Apply silicone adhesive along the edges and smooth out the joints with a finger wet with water or soapy water.
  14. Remove the masking tape immediately after applying the adhesive to avoid edge formation.

  Notes:

  • Read the silicone adhesive handling advice before starting work: it is a quick-curing two-component adhesive, mixed 1:10 in a static mixer, with the mixer changed after any interruption longer than 5 minutes because of its short setting time.
  • Acetone must not contact a polycarbonate roof window, as it chemically weakens the plastic.
  • Mark the window panes with a note that the adhesive is new and must not be touched.
  • Curing time depends on ambient temperature; plan the change to minimise downtime.

• What is the correct sequence to replace a rubber-gasket side window?

  General procedure for a side window secured with a rubber glazing gasket and locking strip, not the silicone-bonded windscreen.

  1. Put the machine in service position.
  2. Use special tools to detach the locking strip.
  3. Remove the locking strip which runs around the whole window.
  4. Carefully remove any remaining glass from the rubber strip.
  5. Fit the new window, securing it at the bottom edge inside the rubber gasket.
  6. Spray soap solution on the window and glazing rubber to facilitate fitting.
  7. Thread the rubber gasket around the whole window using special tools.
  8. Secure the locking strip with a special tool, using soap solution at the locking strip and the glazing rubber.
  9. Pull the locking strip around the whole window, avoiding stretching it.
  10. Cut off the locking strip approximately 2 cm too long.
  11. Push the remaining part of the locking strip into the glazing gasket, towards the opposite end of the locking strip.
  12. Adjust the locking strip so that the correct fit is obtained.

• What is the correct sequence to check the roof window?

  1. Check that the roof window is not damaged or cracked, changing it immediately if defective.
  2. Check the outside surface of the roof window at regular intervals, cleaning only with windscreen washer fluid or a mild cleaning agent and rinsing thoroughly with plenty of lukewarm water.

  Notes:

  • The roof window's strength can be substantially reduced by exposure to aromatic hydrocarbons, ketones, esters or chlorinated hydrocarbons.
  • Replace a damaged roof window immediately if it is cracked or scratched.

Cab Interior

• What is the correct sequence to replace the cab instrument panel?

  1. Put the machine in service position.
  2. Remove the nine clips holding the instrument panel by pressing in the centre pin on each clip (about 3 mm) to unlock it.
  3. Raise the instrument panel slightly and unplug all electric connectors, then remove the instrument panel.
  4. Transfer all equipment mounted on the instrument panel, such as switches and gauges, to the new instrument panel.

  Note: Reuse the clips by re-inserting the centre pin and pressing it flush with the head on fitting.

• What is the correct sequence to replace the cab floor covering?

  1. Put the machine in service position.
  2. Open the doors on both sides.
  3. Undo the screws which hold the sill moulding in the cab entry, and remove the sill moulding.
  4. Undo and remove all equipment in the cab which is screwed through the floor matting, such as the seat and pedal base.
  5. Replace the floor matting.
  6. Fit in reverse order.

• What cabin operations are checked during the 500-hour Type A preventive maintenance service?

  There are four preventive maintenance cards (A, B, C, D) covering the machine's complete maintenance plan, on a 500-hour frequency, cycling in the order B-A-B-C-B-A-B-C-B-D before repeating. Service times assume normal operating conditions and may vary with type of use, road surface, and environment.

  1. Check the condition of the cab.
  2. Check the air conditioning system's operation.
  3. Clean the air conditioning filters.
  4. Check the heating system's operation.

  Note: Maintenance must be carried out only by qualified, authorised personnel, working in conditions of maximum safety.

Wipers

• What is the correct sequence to remove the windscreen wiper arms?

  1. Loosen the securing nuts.
  2. Tap and carefully rock the arms to and fro to remove them from the motor shafts.

• What is the correct sequence to fit the windscreen wiper arms?

  1. Check that the splines on the motor shaft are free from the softer material from the wiper arm mounting, cleaning them if necessary so they can be pressed fully into the mounting.
  2. Fit the wiper arms onto the motor shafts and tighten the nuts to a torque of 16-20 Nm, holding the wiper arm to take up the torque pressure so it is not transferred to the motor.

  Note: The nuts must be tightened sufficiently hard, otherwise the shafts may start to slip inside the wiper arm mounting, resulting in damage.

• What is the correct sequence to check and top up the windscreen washer fluid?

  Periodicity: Every day.

  1. Check the fluid level in the reservoir.
  2. Top up as necessary through the cap on top of it, using a detergent-antifreeze washer fluid mixed with water in the ratio appropriate to the ambient temperature (or following another product's own manufacturer mixing instructions).

  Note: Avoid letting dirt and impurities enter the reservoir during topping up, to avoid clogging the circuit.

Visibility & signalling

• What cab items should be checked during a scheduled safety inspection?

  Periodicity: during each scheduled maintenance interval or at least once a month

  1. Operate the defroster to make sure sufficient air is directed against the windshield, and that the blower is operating.
  2. Check door latches for positive closing, latching and locking.
  3. Check that all factory-installed walkways, platforms and steps are installed securely, are not damaged or loose, and are free of dirt, debris, ice, mud and other hazardous obstructions.
  4. Check that all handholds are installed and are not loose or damaged.
  5. Check the glass for cracked, broken, scratched or dirty condition.
  6. Check that all mirrors are installed, clean, undamaged and properly adjusted.

• What is the correct sequence to clean the front and upper windscreens with the wiper/washer controls?

  1. Spray liquid onto the glass by pressing the switch upward, or pushing the control lever knob inward; the liquid stops when the switch or knob is released.
  2. Operate the wipers by turning the knob to the desired position: intermittent speed for the front wiper, continuous speed for the front wiper, or continuous speed for both the upper and front wipers.

  Notes:

  • The wiper/washer controls only work with the main switch in the ON position.
  • Do not operate the wipers on dry glass.

Other Cabin & Operator Safety procedures

• What is the correct sequence to check and lubricate the brake pedal?

  Periodicity: Every 1000 hours.

  1. Check and tighten the locking screws so the brake pedal is securely fitted in the console.
  2. Lubricate the brake pedal shaft through the lubricating nipples.

• What is the correct sequence for the 500-hour lubrication of the brake pedal and door/cover hinges?

  Periodicity: Every 500 hours.

  1. Lubricate the brake pedal's hinge with grease and wipe off excess grease.
  2. Lift the left-hand door slightly and lubricate the hinges with grease, then let the door down and wipe off excess grease.
  3. Repeat on the right-hand door.
  4. Lift the battery cover slightly and lubricate the hinges with grease, then let the cover lid down and wipe off excess grease.

  Note: Do not lift the doors or cover lid off their hinges.

• What is the correct sequence to check the cab doors?

  1. Put the machine in service position.
  2. Visually inspect the door's mounting points, lubricating the hinges if necessary.
  3. Check the door's locking mechanism for function and wear.

• What is the correct sequence to check the cab undercarriage?

  1. Put the machine in service position.
  2. Check that the welding seams at the cab's mounting points are intact and free of visible cracks.
  3. Check that the isolators are intact, replacing any that are damaged.
  4. Check that bolted joints are tightened and brackets undamaged, attending to any issues as needed.

• What is the correct sequence to replace the cab interior/reading light bulb?

  Carry out with the machine parked on flat, compact ground, the engine off, and the parking brake applied.

  1. Remove the light fixture by inserting a screwdriver between one side edge of the fixture and the roof lining, then pressing lightly and levering.
  2. Insert a screwdriver (or similar tool) between the lens of the interior or reading light and the fixture body.
  3. Lever and remove the lens, taking care not to break it.
  4. Replace the interior or reading light bulb as needed.
  5. Refit the removed lens onto the fixture, pressing it into place.
  6. Refit the fixture into its seat on the roof lining, making sure it clips into place.

  Note: Do not press excessively on the lens, to avoid breaking it.

• What is the correct daily general cleaning and check routine?

  Periodicity: Every day.

  1. Wash the windows, rear-view mirrors, headlights and lights, indicator lamps, instruments and display with neutral products and water, to remove traces of corrosive agents (salt, sand, etc.).
  2. Dry thoroughly with compressed air, so as to completely eliminate any pockets of water.

• Servicing the anemometer on a rubber tyred gantry crane

  1. Use an allen wrench to loosen the setscrew on the side of the wind cups.
  2. Remove the wind cups and clean the exposed portion of the shaft with a damp cloth or cotton swab.
  3. Clean the wind cups with water and a mild liquid detergent.
  4. Rinse thoroughly before replacing.
  5. When replacing the wind cups, slide them up the shaft as far as possible.
  6. Tighten the setscrew.
  7. Make sure the wind cups spin freely; if they do not, the bearings may be worn and need factory replacement.

  Note: The anemometer is exposed to impurities such as sand and salt that can get inside the rotating cup; impurities cause friction that can break the anemometer. Do not use or add grease, oil or a spray lubricant of any kind.

Looking for general maintenance tips and checklists? See Cabin & Operator Safety.