Maintenance Strategy & Procurement Procedures

This page lists 29 maintenance procedures for maintenance strategy & procurement, drawn from HIT Srl's internal procedure library extracted from manufacturer service manuals.

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

Planning & intervals

• What other chassis systems should be checked during a scheduled monthly safety inspection?

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

  1. Front axle: check that the axle mounting bolts are securely tightened, and check for damage, binding or worn parts, and adequate lubrication, paying special attention to the axle stops and rubber snubbers.
  2. Rear axle: check that the axle mounting bolts are securely tightened, and check for damage and oil leaks; unusual noises and signs of extreme heat may indicate axle damage.
  3. Electrical: operate the horn to check operation; check operation of all instruments and gauges; check that all lights function properly; check that all wiring is properly secured and protected, and replace worn, cracked or chafed wires and looms.
  4. Exhaust system: maintain the integrity of mufflers, pipes, stacks and joints to ensure no exhaust fumes can enter the cab; look for loose, damaged or missing components.
  5. Frame: check for cracks and signs of damage, paying close attention to highly stressed areas such as the boom pivot area.
  6. Fuel system: check that the throttle operates smoothly; check the fuel system for leaks and hose chafing; check the DEF system for leaks and hose chafing.
  7. Propeller shaft: check the universal joints for wear.
  8. Steering: check for loose, damaged or worn parts if a change in steering feel is noticed; check the power steering system for leaks and hose chafing; regularly inspect all steering linkages.
  9. Suspension: check the condition of front and optional rear suspension components such as mounting brackets and bushings for wear and damage; check and maintain the specified torque on all mounting bolts and nuts; check the springs and replace broken or distorted springs.
  10. Wheels/tires: check the condition and maintain the specified torque on all wheel mounting nuts; replace missing or broken studs and nuts; check tire inflation and wear.

  Notes:

  • Do not operate the vehicle without the proper axle stops in place.
  • If propeller shaft vibrations occur, stop the vehicle immediately to prevent serious damage to the drivetrain.
  • Do not operate the vehicle with broken, damaged, worn or non-OEM steering system components.
  • Do not operate this vehicle with badly worn or damaged tires, or with damaged wheels.

• How is each cab-interior item verified during a preventative maintenance inspection?

  1. Check operation of neutral start: move the gear selector to any position other than "N" and attempt to start the engine; it should not crank in any position other than "N".
  2. Check operation of all gauges: with the engine running, verify that all gauges are functional.
  3. Check low air buzzer and light: apply and release the brake pedal until air pressure drops below 90 P.S.I.; the low air buzzer and dash warning light should come on.
  4. Check windshield wiper operation: turn on the wiper and confirm full and smooth travel of the arm, listening for noises that might indicate a worn wiper motor.
  5. Check windshield washer operation (if applicable): depress the washer button and confirm the flow and pattern of the washer fluid.
  6. Check throttle operation: depress and release the foot throttle and check for binding and ease of operation.
  7. Check horn(s) operation: sound the electric and air horns (if applicable) to confirm proper operation.
  8. Check air system minimum/maximum pressure: start the engine and run at fast idle; system pressure should be limited to a minimum of 120 P.S.I. (8.27 bar) and a maximum of 130 P.S.I. (8.96 bar).
  9. Check operation of back-up alarm: with the engine running, move the gear selector to reverse and listen for the alarm.

• What exterior cab items are checked with the cab down during a preventative maintenance inspection?

  1. Check side door hinge (if applicable) for wear or damage.
  2. Check cab access steps and handles for proper mounting and absence of cracks.
  3. Clean heater/AC filter: remove and vacuum or blow clean with low-pressure air.
  4. Check rear door roller/slide adjustment for wear or damage.
  5. Check gladhand seals and trailer air lines for tears, wear, kinks or cracks.
  6. Check trailer light cord (if applicable) for cuts and abrasions, confirming a connected trailer's lights work.
  7. Check headlights/marker lights: start the engine, turn on the light switches and confirm illumination.
  8. Check turn signals: with the key on, activate the switch and flasher to confirm operation.
  9. Check strobe light (if applicable): with the key on, confirm operation.
  10. Check spotlights: with the key on, confirm operation.
  11. Check wiper blades for tears or excessive wear.
  12. Check windshield washer fluid level and fill as necessary.
  13. Check transmission fluid level with the engine running, using the dipstick per the Transmission Operator's Manual guidelines.
  14. Check engine oil level.

• What items are checked with the cab up during a preventative maintenance inspection?

  1. Check operation of cab tilt pump: pull the safety prop release cable and activate the cab tilt switch; the cab should rise.
  2. Check cab safety prop: it should drop freely into place to support the cab when raised; inspect the lower cab cylinder pin and bracket for signs of fatigue.
  3. Check cab suspension and latch: inspect the linkages for excessive wear and proper alignment, the air bag for leaks or abrasion, and the lock jaw for excessive wear.
  4. Check engine intake ducting for leaks: inspect all clean air tubes and hoses; check clamps for proper torque and joints for alignment.
  5. Check radiator for leaks: inspect the core and tanks for signs of coolant leaks.
  6. Check radiator mounts for wear or excessive looseness.
  7. Check coolant level and concentration: coolant should be visible in the sight glass; test and maintain the proper anti-freeze concentration.
  8. Check and adjust coolant additive (if applicable) using the appropriate test method for the supplemental additive used.
  9. Change engine coolant: flush the cooling system and replace with clean coolant of the appropriate concentration.
  10. Check coolant hoses and clamps for abrasion, cracks, holes and routing, and clamps for proper torque.
  11. Check fan clutch for operation (if applicable): run the engine to confirm it engages at the proper temperature.
  12. Check engine cooling fan for cracks with the engine off.
  13. Check engine belts and tensioner for cracking, wear and proper operation.
  14. Change engine coolant filter (if applicable), using one containing the proper supplemental coolant additive.
  15. Check engine and transmission for leaks visible from above.
  16. Drain fuel water separator: open the drain valve and allow water to drain from the filter.
  17. Change fuel water separator following the Engine Operator's Manual instructions.
  18. Check air restriction gauge (if applicable): record the reading, reset, start the engine, run to high idle, shut off, and check the reading returns to zero; investigate if it does not.
  19. Change air filter as needed, or when the restriction gauge indicates.
  20. Change air dryer desiccant (if applicable) as needed, or as soon as water is evident when tanks are drained.
  21. Check exhaust system components visually for leaks and damage.
  22. Clean transmission breather: confirm it is clean and the passage is open, without spraying directly with high pressure or solvents.

• What items are checked and serviced under the vehicle during a preventative maintenance inspection?

  1. Check steering gear for fluid leaks and excessive play; inspect the steering linkage for wear or looseness.
  2. Check brake linings and drums for wear and cracks; if lining thickness is 0.25 inch (6.35 mm) or less anywhere, replace or reline the shoes.
  3. Check leaf springs for cracking or excessive deflection.
  4. Check shock absorbers (if applicable) for leaks.
  5. Torque front axle mounting bolts to 210 ft. lbs. (284.7 N·m).
  6. Torque front axle kingpin draw key nut(s).
  7. Check hydraulic pump for leaks.
  8. Check starter mounting and connections: confirm mounting bolts are tight and inspect electrical connections at the starter terminals.
  9. Check engine and transmission for leaks visible from below.
  10. Change engine oil and filter, using oil meeting at least the Engine Operator's Manual minimum specification.
  11. Change transmission filters (this does not include the pan screen, replaced only during overhaul).
  12. Change transmission fluid, using fluid meeting at least the Transmission Operator's Manual minimum specification.
  13. Check engine and transmission mounts: re-torque and inspect the isolator material, replacing if deteriorated.
  14. Check wheel seals for leaks at the front and rear hubs, replacing if leaking.
  15. Clean the rear axle breather, ensuring the vent turns freely.
  16. Check differential for leaks in the rear axle housing.
  17. Check differential oil level per the component manufacturer's instructions.
  18. Change differential oil, using oil meeting at least the component manufacturer's minimum specification.
  19. Check lift cylinders for leaks.
  20. Torque rear axle mounting bolts: nut to 400 ft. lbs. (542 N·m), bolt to 600 ft. lbs. (813 N·m).

• What chassis items are checked and serviced during a preventative maintenance inspection?

  1. Check front wheel bearings: raise and support the front axle and check for excessive play.
  2. Check front axle oil level (if applicable) in the hubcaps, filling as necessary.
  3. Repack front wheel bearings (if applicable), using grease meeting at least the component manufacturer's minimum specification.
  4. Check battery cables and holddowns for abrasion or breaking, repairing and rerouting as needed, and ensure batteries are properly secured.
  5. Check batteries for cracks or acid damage, replacing as necessary.
  6. Clean battery cable connections: remove the terminals, clean the connections, and reattach.
  7. Check battery box cover holddowns to ensure the cover is secured.
  8. Drain water from air tanks: with the system charged, open each manual drain until all moisture is removed.
  9. Check and torque all wheel nuts for signs of wear or damage, re-torquing to 450-500 ft. lbs. (610-678 N·m).
  10. Check wheels for signs of damage including oversized holes and cracks.
  11. Check tire air pressure, tread depth and condition, adjusting to the proper pressure.
  12. Check rear axle planetary fluid level (if applicable) per the component manufacturer's instructions.
  13. Inspect platforms for proper mounting and absence of cracks and trip points.
  14. Check frame for cracks in the rails and crossmembers.
  15. Check mud flaps/fenders (if applicable) for proper mounting and damage.
  16. Change hydraulic system filter: remove and replace the external hydraulic filter.
  17. Check hydraulic fluid level: start the engine, raise and lower the boom two to three times, lower it to FULL DOWN, shut off the engine, and check the fluid level on the tank gauge.
  18. Change hydraulic fluid: drain the tank and refill with Dexron III automatic transmission fluid.
  19. Clean hydraulic tank vent of any collected dirt.
  20. Check cab hinge pins and bushings for wear or damage.

• What lubrication points are checked and greased during a preventative maintenance inspection?

  1. Check/lubricate rear door rollers: inspect the upper rollers, replace if binding or damaged, then lubricate.
  2. Check/lubricate steering slip joint for wear or damage, lubricating with lithium grease.
  3. Check/lubricate steering U-joints for wear or damage, lubricating with lithium grease.
  4. Check/lubricate all steering lube points (kingpins, tie rod ends, drag link ends) for wear or damage, lubricating with lithium grease.
  5. Check/lubricate slack adjusters: inspect for wear or damage and measure the brake actuator stroke; if it exceeds the component manufacturer's recommendation, check the lining and adjuster and repair as necessary.
  6. Check/lubricate driveline U-joints for wear or damage, lubricating with lithium grease.
  7. Clean, check, adjust and lube fifth wheel jaws: remove dirt and excess grease, measure the free play with a jaw gauge, and repair or replace the jaws if free play exceeds 1/8 inch (3.175 mm).
  8. Check/lubricate fifth wheel top plate: clean and inspect for cracks or damage, then apply lithium grease.
  9. Check/lubricate fifth wheel pivot pins for wear or damage, lubricating with lithium grease.
  10. Check/lubricate boom pivot bearings for wear or damage, lubricating with lithium grease.
  11. Check/lubricate upper boom cylinder bearings for wear or damage, lubricating with lithium grease.
  12. Add grease to the autolube reservoir (if equipped): inspect all lubrication points for sufficient grease and fill the reservoir per the component manufacturer's recommendation.

• What are the standard preventive maintenance schedule intervals for this class of machine?

  Periodicity: 250h / 500h / 1500h / 3000h routine; 6000h / 12000h / 24000h special (approx.)

  1. Standard preventive routine maintenance schedules: 250h, 500h, 1500h, 3000h.
  2. Preventive special maintenance schedules (approx.): 6000h, 12000h, 24000h.

  Note: These schedules can be changed depending on the type of machine and on how hard the environmental and operating conditions are.

Documentation & compliance

• What general precautions must be observed when servicing or repairing a container stacker?

  1. Always hang up a notice showing "Maintenance work in progress" or "repairs in progress".
  2. Do not allow unauthorised persons to come near the truck during maintenance.
  3. Use appropriate equipment and tools; repair or replace broken or worn equipment and tools.
  4. Do not attempt to weld pipes or ducts containing hydraulic fluid or inflammable substances.
  5. Never pour inflammable liquids into open, large and low vessels.
  6. Never pile up rags soaked in oil or grease, as these represent a fire hazard; place these in a closed metal container.
  7. Do not keep inflammable material on or in the immediate vicinity of the truck.
  8. Keep an extinguisher handy when performing jobs that could cause flames.
  9. Wear proper accident-prevention clothing (helmet, eye-wear, gloves, footwear, etc.).
  10. Wear adequate, fairly tight-fitting clothing; do not wear chains or bracelets as these could become trapped.
  11. Do not touch or go near fans, belts, chains or cables when these are moving.
  12. Always immediately clean platforms, walkways, steps and handrails if dirtied by oil or grease.
  13. Always use degreasing solutions cautiously.
  14. Do not loosen pipes or unions if there is any chance of these being pressurised.
  15. Take care when working underneath the arm.
  16. Never operate the truck in closed premises without adequate ventilation.
  17. Before repairing major truck structures, check the material used and obtain the manufacturer's approval.
  18. Do not make alterations to the structures; aim only at restoring the original condition.
  19. Never change the settings of the safety valves of the hydraulic system; maintain the factory settings.
  20. When using compressed air, use suitable means of protection, especially on the eyes; maximum air pressure should be 2 kg/cm2.

  Note: If fluid under pressure exits from even a small hole, the jet can penetrate the skin; in this case immediately contact a doctor.

• What safety precautions apply before troubleshooting a machine fault?

  1. Always read and follow the general safety regulations in the manual and the warning notices on the machine itself.
  2. Wear protective clothing, accident-prevention footwear, eyewear, gloves and a helmet.
  3. Inform the operators, using warning notices, that the machine is not operative and is undergoing maintenance.
  4. Before disconnecting hydraulic pipes, lower the spreader so the hydraulic circuit no longer has to bear any weight.

• What must be done if an elastomeric seal component has been exposed to temperatures above 300°C?

  Some seals and shaft seals on this class of machine contain elastomeric materials (such as Viton, Fluorel and Technoflon) that can produce highly corrosive acids when exposed to high temperatures.

  1. Do not touch the component or the surrounding area if signs of decomposition (e.g. burning) are visible.
  2. Wear heavy rubber gloves and special protective goggles.
  3. Remove the material and place it in plastic bags.
  4. Wash the contaminated area with a solution containing 10% calcium hydroxide (slaked lime) or another alkaline solution, using a net if necessary to remove scale adhering to the metal.
  5. Wash then with water and detergent.
  6. Place all contaminated material used in this operation in plastic bags and dispose of it according to applicable law.

  Notes:

  • These acids can cause serious burns.
  • Do not burn fluoroelastomeric materials.
  • In case of skin or eye contamination, rinse abundantly with clean water or calcium hydroxide solution for 15-60 minutes, then seek immediate medical attention.

• What must be done before starting maintenance operations on this class of machine?

  1. Maintenance must be carried out by qualified, trained and documented personnel.
  2. Before starting maintenance operations, place the vehicle in conditions of maximum safety.
  3. Park the vehicle on level, compact ground and stop the engine (or otherwise apply the parking brake).
  4. Consult the maintenance chapter of the manual in every case.

• What information should be provided when contacting service assistance for a machine fault?

  1. Specify your name, address and telephone number.
  2. Indicate the model and chassis number of the vehicle.
  3. Indicate the purchase date and the operating hours.
  4. Explain the type of fault.

• What must be done before performing any maintenance, repair or inspection work on the machine?

  1. Put the transmission in neutral.
  2. Lower and fully retract the boom.
  3. Apply the parking brake.
  4. Switch off the engine and remove the key from the ignition switch.

  Note: Never leave the cab without having applied the parking brake.

• What does placing a machine in "service position" mean before starting maintenance work?

  1. Machine parked, that is, parking brake applied.
  2. Forks and lifting carriage in totally lowered position.
  3. Engine off.
  4. Main electric power off (with battery disconnector).

Periodic Supervision

• What items are checked during daily supervision of the machine?

  Periodicity: Daily, or when refuelling.

  1. Check the function of the brakes and steering.
  2. On machines with the mechanical overload protection system, check that the rear steered axle suspension is clean and that its sensor is free from grease.
  3. Check the function of all instruments, blinkers, brake lights, horn, headlights and reflectors.
  4. Check the boom pivot suspension and sliding plates for damage.
  5. Check the operation of the attachment and rotator.
  6. Listen for noises from the engine, gearbox and drive axle.
  7. Check the hydraulic hoses for oil leakage.
  8. Check the fuel amount (the fuel meter must never show 0).
  9. Check the engine oil level.
  10. Check the air cleaner indicator.
  11. Check the coolant level.
  12. Check the hydraulic oil level.
  13. Check the gearbox oil level.
  14. Check the wiper fluid level.
  15. Check the wheels for damage and check the tyre pressure (1 MPa).

• What items are checked during the 200-hour service?

  Periodicity: Every 200 operating hours.

  1. Wash the machine, without using high pressure on bearings or bearing housings.
  2. Clean the radiator fins with water and detergent, without high pressure.
  3. Check the engine's oil and coolant connections for leakage.
  4. Check the air cleaner indicator, replacing the element if required.
  5. Check the brakes for oil leakage and test brake performance.
  6. Clean the battery cable terminals and fuses, apply petroleum jelly, and replace cables or terminals if necessary.
  7. Check the V-belt tension.
  8. Check the telescope boom and attachment for damage, retighten bolted joints, check sliding plates for wear, apply special lubricant, and specially check for cracks in welds on the boom and mountings.
  9. Check the steering axle for play or damage.
  10. Tighten the wheel nuts and inspect tyres and rims for damage.
  11. Tighten the drive axle and propeller shaft bolt joints and check for leakage.
  12. Check the gearbox for oil leakage.
  13. On machines with air conditioning, check its performance.
  14. On machines with exhaust gas emission control, inspect the catalyst and top up as necessary.
  15. Lubricate points and change oil and filters according to the lubrication chart; on machines with automatic lubrication, check that all lubrication lines are undamaged and all points are correctly lubricated.
  16. Check the setting of the inductive sensors and clean them, checking for damage.

  Note: Always attend to any damage, wear or fault important to the machine's performance, service life, or personnel safety.

• What items are checked during the 600-hour service?

  Periodicity: Every 600 operating hours, in addition to the 200-hour service.

  1. Change the air cleaner filter element if the indicator shows red.
  2. Check the turbocharger for leakage.
  3. Check the exhaust system for leakage.
  4. Check the steered wheels' alignment, and check for deformation or bearing play.
  5. Check that the telescope boom and attachment hose guide runs freely and that the hoses are in good condition.
  6. Lubricate points and change oil and filters according to the lubrication chart.
  7. Perform the 200-hour service.

  Note: Always attend to any damage, wear or fault important to the machine's performance, service life, or personnel safety.

• What items are checked during the 1000-hour service?

  Periodicity: Every 1000 operating hours, in addition to the 600- and 200-hour services.

  1. Change the fresh-air filter element.
  2. Check the engine's valve clearances, cooling system, starter motor, alternator and fuses, referring to the engine manufacturer's workshop manual.
  3. Drain the fuel tank.
  4. Change the fuel filter and bleed the fuel system.
  5. Check the injectors, referring to the engine manufacturer's workshop manual.
  6. Check the V-belts and change as necessary.
  7. Check the batteries.
  8. Check the wheels for damage.
  9. Check the propeller shaft's bolted joints and the universal joints for play.
  10. Clean the gearbox and drive axle breather.
  11. Check the steered axle knuckle pin bearings' tightening torque.
  12. Check the brakes.
  13. Touch up painting and safety marking.
  14. Test-drive and check all functions.
  15. On machines with air conditioning, check the refrigerant level and clean the fans and condenser flanges.
  16. Lubricate points and change oil and filters according to the lubrication chart.
  17. Check the hydraulic pressure and adjust if necessary.
  18. Perform the 600- and 200-hour services.

  Note: Always attend to any damage, wear or fault important to the machine's performance, service life, or personnel safety.

Scheduled Maintenance

• What checks should be performed on a new machine after the first 50 hours of operation?

  Periodicity: Performed once, after 50 hours of operation on a new machine.

  1. Check for leakage of oil, coolant, and the exhaust system on the engine.
  2. Check the coolant level.
  3. Change the engine oil and oil filter.
  4. Inspect the air filter main cartridge.
  5. Inspect the air filter safety cartridge.
  6. Check the drive belt tension.
  7. Check bolted joints, attachments, mountings, hose clamps, and wear or chafing of hoses and cable harnesses.
  8. Drain water from the fuel pre-filter.
  9. Check for leakage on the transmission.
  10. Check the transmission oil level.
  11. Change the transmission oil filter.
  12. Check-tighten the propeller shaft mounting.
  13. Inspect the drive axle mounting.
  14. Check the power-assisted brake function.
  15. Check the parking brake function.
  16. Check for brake system leakage.
  17. Check the tyre system.
  18. Check-tighten the wheel nuts.
  19. Check-tighten the hose connections on the load handling system.
  20. Check and adjust the spreader extension chain tension.
  21. Check that there are no active error codes.
  22. Check the mechanical cab lock.
  23. Check for leakage on the common hydraulic system, check-tightening as needed.
  24. Check the hydraulic oil level.
  25. Change the hydraulic oil fine filter.
  26. Check the batteries.

  Notes:

  • During the first work week on a new machine, check-tighten the wheel nuts every 4-5 operating hours until they stay securely tightened (up to approximately 40-50 operating hours).
  • The warranty is not valid if service intervals are not followed.

• What checks should be performed during and after a test-run following scheduled service?

  1. During the test-run, check the boom.
  2. Check the attachment.
  3. Check the hydraulic sliding cab.
  4. Check cab lift and lowering.
  5. Check the support jacks.
  6. Check the instruments.
  7. Check the brakes.
  8. Check gearshifting.
  9. Check all load handling functions.
  10. Check the steering.
  11. Listen for any noise.
  12. After the test-run, check for sealing (no leakage).
  13. After the test-run, check fluid levels.

  Note: On machines with a manual sliding cab, the cab must be secured in the rear position with both locks before operation.

• Daily inspection routine before each shift on a rubber tyred gantry crane

  1. Carry out the daily inspection of the machine before each shift.
  2. If any defects are found, report them immediately to the superior or to those responsible for the machine's maintenance.
  3. Do not commence work with a defective machine.

  Note: Performed by the operator or the person responsible for maintenance, before each shift.

• Troubleshooting with an error code shown on the display

  1. Read the message on the display.
  2. Check the details from the error code list.
  3. Use the function group to find more information if needed. Function descriptions cover components, their positions, and in certain cases work instructions for checking and adjusting components.
  4. If possible, exclude a component malfunction by testing the suspected component separately. Electric components can usually be checked by resistance measurements using a multimeter; hydraulic components are most often checked by measuring pressure -- this is described in the relevant function group or in connection with preventive maintenance.

Other Maintenance Strategy & Procurement procedures

• What checks should be performed before and after starting the engine at the beginning of a shift?

  1. Prior to starting the engine, check the engine crankcase oil level.
  2. Check the radiator coolant level.
  3. Check the hydraulic reservoir oil level.
  4. Visually check for oil leaks.
  5. Check the structure, chassis and spreader for loose or missing fasteners, cracks and deformation.
  6. Check the tyres' general condition and check for low pressure.
  7. Clean the operator's cab thoroughly, including the windows.
  8. Check that the fire extinguisher(s) are fully charged.
  9. After starting the engine and running it at idle, check the hydraulic filters' visual indicators, if available.
  10. Check the transmission oil level once warm.
  11. Check the fuel level; the fuel tank should be topped up at the end of each day or shift.
  12. Check that the work, drive and indicator lights operate properly.
  13. Check that the horn, strobe lights and back-up alarm operate properly.
  14. Check that the windscreen wipers operate properly.
  15. Check that the operator's controls operate properly.
  16. Make sure the brakes operate before driving.
  17. Check all dash display indicator lights and gauges for proper operation of their respective systems.
  18. Listen for unusual sounds or noises from the engine, transmission, or hydraulic system.

• What checks are performed on a new machine after the first 50 operating hours?

  Periodicity: Once, after the first 50 operating hours of a new machine.

  1. Engine: check performance and exhaust smoke; check bolted joints, attachments, mountings, hose clamps, and wear/chafing of hoses and cable harnesses; check sealing of oil, coolant, and exhaust system; drain condensation from the fuel pre-filter; check the air filter indicator and inspect the main and safety cartridges; check drive belt tension; check coolant level; change the engine oil and oil filter; check oil pressure.
  2. Transmission: check for leakage; check the oil level; change the transmission oil filter.
  3. Driveline/axle: check and tighten the propeller shaft mounting; inspect the drive axle mounting.
  4. Brakes: check for leakage; check the power-assisted brake function; check the parking brake function.
  5. Suspension: check tyres and rims; check and tighten the wheel nuts.
  6. Load handling: check and tighten hose connections and bolted joints; check the function of the mast wheels, slide plates and support rollers; check that all sensors are undamaged and free of grease; check the attachment for damage; check and adjust the lifting chains; check and adjust the chain tension spreading.
  7. Control system: check that there are no active error codes.
  8. Common hydraulics: check for leakage and tighten as required; check the hydraulic oil level; change the hydraulic oil fine filter.
  9. Common electrics: check the batteries.

• What is checked during a test-run after service work?

  1. Test-run the machine and check the instruments, brakes, gearshifting, all load handling functions, steering, and any abnormal noise.
  2. After the test-run, check for sealing (no leakage) and check fluid levels.

• What is the correct sequence to check the central lubrication system?

  The central lubrication does not grease the propeller shaft's universal joint or the brake pedal; these must still be greased during preventive maintenance.

  1. Check that no grease has been forced out through the safety valve, which would indicate a system blockage; locate the blocked line by feeling the connections at the distribution block, since a blocked hose remains pressurised and its connection becomes firm.
  2. Turn the start key to position I.
  3. Operate the pump manually (loosening the cover and pressing the manual operation switch) and check that the indicator pin moves in and out on the distribution blocks; if it does not move, troubleshoot the pump unit.
  4. Fill grease in the pump unit through the filler nipple.

• General troubleshooting entry sequence for a rubber tyred gantry crane

  1. Check that there is battery voltage available; check that the fuses are intact.
  2. Check that all oil and fluid levels are normal: fuel, engine, gears, hubs, hydraulic (spreader), coolant.
  3. Check the error codes on the display.
  4. If error codes are displayed, refer to the error code list (see the error-code troubleshooting procedure).
  5. If no error codes are displayed, check the appropriate function description in the relevant chapter (see the no-error-code troubleshooting procedure).

  Note: The person doing the troubleshooting must be very familiar with the operation of the machine and its main components, and must be able to read the machine circuit diagrams in a professional manner.

• Troubleshooting without an error code, using function descriptions

  1. Select the appropriate function-description section for the system involved.
  2. Read the description of the function in question to understand which components are affected and how they interact.
  3. Use the function description and check the signals for the function to find where in the function chain the signal or reaction is incorrect.
  4. The malfunction is probably between the two units where the signal is incorrect; start by checking the component that should send the signal.
  5. If the component that should send the signal is intact, check the transmission of the signal in the cables or hydraulic hoses (see the cable-checking procedure for more information about cables).
  6. If the cables or hoses between components seem to be intact, check the component receiving the signal.

Looking for general maintenance tips and checklists? See Maintenance Strategy & Procurement.