Preventative Maintenance Procedures and Safety Guidelines

To ensure the safe operation and regulatory compliance of equipment, a comprehensive preventative maintenance program is essential. This program should include regular inspections, servicing, and adherence to safety guidelines. The following outlines recommended procedures and guidelines based on industry best practices and manufacturer recommendations.

General Safety Practices

Before servicing any equipment, it is crucial to follow general safety practices to prevent accidents and injuries.

• Read the entire maintenance procedure section to understand the tasks involved.
• Familiarize yourself with all safety precautions outlined in the equipment's safety manual.
• Pay close attention to all safety alert symbols, which indicate potential hazards.
• Ensure you fully understand the procedures detailed in the maintenance section.
• Wear appropriate protective equipment, such as gloves, safety glasses, and hearing protection.
• Remove rings and jewelry to prevent them from getting caught in machinery.
• Move the machine to a safe, level work area to ensure stability.
• Lower the boom or any raised equipment and support it properly to prevent accidental lowering.
• Shut down the machine completely before starting any maintenance work.
• Remove the key from the ignition to prevent unauthorized operation.
• Exercise caution when handling fuels and lubricants to avoid spills.
• Never fuel the tank while the engine is running or hot, as this could cause a fire or explosion.
• Refrain from smoking while refueling or working with fuel to prevent fire hazards.
• Clean up any spilled fuel or lubricants immediately to prevent environmental contamination and slip hazards.

Daily (Pre-Use) Inspections and Maintenance

Daily inspections are critical for identifying potential issues before they escalate into major problems. These inspections should be performed before each work shift to ensure the equipment is in safe operating condition.

• Ensure all operation and safety decals are in place and easy to read. Replace any missing or damaged decals to maintain clear safety instructions.
• Check the hydraulic tank fluid level and add oil as required to maintain proper system function.
• Check the water level in the batteries and add water as needed to ensure optimal battery performance.
• Inspect for loose or worn hardware, wire connections, etc. Repair or replace any damaged or missing components.
• Inspect the controls for proper operation, ensuring they function smoothly and respond correctly.
• Check for and correct any hydraulic leaks to prevent fluid loss and potential system failures.
• Check for and correct any cracked welds or other structural damage that could compromise the equipment's integrity.
• Check for good overall performance, noting any unusual noises, vibrations, or performance issues.
• Check engine oil level and add oil if required, following the engine manufacturer's recommendations.
• Check for wear on electrical cables and hoses, replacing them if necessary to prevent electrical shorts or hydraulic failures.
• Make sure the operating controls perform correctly.
• Check fuel level.
• Test instability alarm system (slope sensor/mercury switches).
• Indicator light on lower control box is off (Diesel Particulate Filter (D.P.F)).
• Sounds tilt alarm (Level Sensor).
• Proper operation (Flashing Light).
• Sounds when machine is operated and/or driven (All Motion Alarm).
• Between full and add marks (Oil level).
• Proper fluid level (Coolant).
• Cap tight, good condition and clean (Radiator).
• Tank full, cap in place and tight/ no leaks (Fuel tank and line).
• Condition and charged for proper operation (Battery).
• Proper level/clean, connectors tight (Battery fluid level and terminals).
• No wear or physical damage (Cables and wiring harness).
• Between full and add marks (Fluid level).
• No leaks (Hose, tubes and fittings).
• Proper operation (Cold weather warm-up kit).
• Good condition (Tires).
• All wheel lug nuts present and properly torqued (Wheels).
• Proper operation (Operating controls).
• Shuts off lower controls/proper operation (Emergency stop and emergency power).
• Welds intact, no damage or deformation (Weldments Chassis, turntable, booms, platform, etc.).
• In place, no damage or deformation (Slide pads).
• In place and tight (Fasteners).
• Welds intact, no damage or deformation (Guardrail system and lanyard anchors).
• Proper operation (Operating controls - Boom functions, drive, brakes, etc.).
• Shuts off upper controls/proper operation (Emergency stop and emergency power).
• Sounds when activated (Horn).
• Proper operation (Snorkel Guard).
• In place and readable (Placards and Decals).

Weekly (or 50 Hours) Maintenance

In addition to daily checks, weekly maintenance tasks are essential for maintaining equipment reliability and safety.

• Perform all daily preventive maintenance items.
• Check the condition of the tires, ensuring they are free of serious cuts or defects.
• Check for proper brake operation to ensure reliable stopping power.
• Record the hour meter reading to track usage and schedule maintenance intervals.
• Clean the unit by removing all dirt, oil, and grease. The machine may be washed with soap and water, but avoid electrical panels and charging units.
• Check for signs of wear on electrical cables and hoses, repairing or replacing them if necessary.
• Check and lubricate components as necessary, following the manufacturer's recommendations.
• Check battery condition to ensure it is holding a charge properly.
• Check that operation and safety decals are in place and readable.
• Check overall performance.

Monthly (or First 50 Hours) Maintenance

• Change the hydraulic oil return filter (first 150 hours of operation).
• Check engine oil and filter. Change per engine manufacturer's recommendations.

Frequent Inspection and Maintenance (Every 90 Days or 150 Hours)

These inspections require a more in-depth look at critical components.

The following table outlines key inspection procedures:

Check	OK
Chassis
Structural (1)
Steering cylinder pin caps and tie wire (2,6)
Steering linkage (4)
Tires, foam filled (5)
Hydraulic tubes and hoses (3,5)
Decals and placards (2,8)
Torque drive wheel lug nuts per placard on wheel (6)
Torque steer wheel lug nuts per placard on wheel (6)
Right drive motor (3)
Left drive motor (3)
Lubrication points
Turntable
Structural (1)
Torque turntable top bolts @180 ft. lbs. (6)
Torque turntable bottom bolts @180 ft. lbs. (6)
Hydraulic tubes and hoses (3,5)
Riser lift cylinder pin caps and tie wire (2,6)
Riser lift cylinder and holding valve (2,6)
Riser boom emergency bleed down valve (4)
Cowling (5,6)
Wire harness (2,5)
Decals and placards (2,8)
Master level cylinder pin caps (2,6)
Torque master level cylinder bolts @80-100 ft. lbs.
Rotation backlash (5)
Correct operators manual in document holder
System pressure
Lubrication points
Rotation brake (4)
Centerpost (3,6)
Booms
Structural (1)
Main boom pin caps and tie wire (2,6)
Main boom emergency bleed down valve (4)
Hydraulic tubes and hoses (3,5)
Extension cylinder pin caps and tie wire (2,6)
Extension cylinder and holding valve (3,4)
Hose carrier tube and support (7)
Plastic hose track
Electrical wires (5)
Extend retract wire ropes and sheaves (2,5,6)
Main lift cylinder pin caps and tie wire (2,6)
Main lift cylinder holding valve (3,4)
Riser boom pin caps and tie wire (2,6)
Follower arm pin caps and tie wire (2,6)
Jib cylinder pin caps and tie wire (2,6)
Jib cylinder holding valve (3,4)
Booms (Continued)
Jib boom leveling pin caps and tie wire (2,6)
Leveling bellcrank pin caps and tie wire (2,6)
Decals and placards (2,8)
Follower arm "X" bars (1,2,6)
Platform
Structural (1)
Decals and placards (2,8)
Platform gate (4)
Hydraulic tubes and hoses (3,5)
Slave level cylinder pin caps and tie wire (2,6)
Slave level cylinder holding valves (3,4)
Platform mounting bolts (2,6)
Platform rotator
Structural (1)
Hydraulic rotator actuator (3)
Platform rotation holding valve (4)
Pylon pin caps and tie wire (2,6)
Mounting bolts and pin caps (2,6)
Upper control station
Foot switch, unit will not start when engaged (4)
Foot switch, functions operate when engaged (4)
Engine START-STOP (4)
Electric throttle, if equipped (4)
Turntable rotation (4)
Riser boom UP-DOWN (4)
Main boom UP-DOWN (4)
Jib boom UP-DOWN (4)
Boom extension IN-OUT (4)
Platform leveling (4)
Platform rotation (4)
Drive range HIGH-MID-LOW, boom stowed (4)
Drive speed SLOW, boom raised (4)
Emergency power, all functions (4)
Emergency shutdown control (4)
Gradual start to stop lift/swing/drive controls (4)
Drive speed limit switch, boom lift (4)
Drive speed limit switch, boom extend (4)
5° tilt alarm (4)
110 volt AC power to platform (2,4)

Inspection Procedures Codes: (1) Weld cracks, dents and/or rust (2) Installation (3) Leaks (4) Operation (5) Condition (6) Tightness (7) Residue buildup (8) See placards and decals inspection chart

Annual (Yearly) Inspection

Annual inspections are more comprehensive and should be performed by qualified service personnel. These inspections ensure that all systems are functioning correctly and that the equipment meets safety standards.

• Platform Controls: Check for proper operation.
• Ground Controls: Check for proper operation.
• Function Control Locks, Guards, or Detents
• Footswitch
• Emergency Stop Switches (Ground & Platform)
• Function Limit or Cutout Switch Systems
• Drive Brakes
• Swing Brakes
• Auxiliary Power
• Engine Idle, Throttle, and RPM
• Engine Fluids (Oil, Coolant, Fuel)
• Air/Fuel Filter
• Exhaust System
• Batteries
• Battery Fluid
• Battery Charger
• Fuel Reservoir, Cap, and Breather
• Hydraulic Pumps
• Hydraulic Cylinders
• Cylinder Attachment Pins and Pin Retainers
• Hydraulic Hoses, Lines, and Fittings
• Hydraulic Reservoir, Cap, and Breather
• Hydraulic Filter
• Hydraulic Fluid
• Electrical Connections
• Instruments, Gauges, Switches, Lights, Horn
• Operation and Safety Manuals in Storage Box
• ANSI and AEM Manuals/Handbooks Installed (ANSI Markets Only)
• Capacity Decals Installed, Secure, Legible
• All Decals/Placards Installed, Secure, Legible
• Annual Machine Inspection Due
• No Unauthorized Modifications or Additions
• All Relevant Safety Publications Incorporated
• General Structural Condition and Welds
• All Fasteners, Pins, Shields, and Covers
• Grease and Lubricate to Specifications
• Function Test of All Systems
• Paint and Appearance

Every 2 Years

• Hydraulic Reservoir, Cap, and Breather

Before Servicing

• Read entire Maintenance Procedure Section.
• Familiarize yourself with all safety precautions listed in section 1.
• Pay close attention to all safety alert symbols.
• Be sure you understand the procedures detailed in this section.
• Wear protective equipment.
• Remove rings and jewelry.
• Move machine to a safe level work place.
• Lower boom and support all raised equipment.
• Shut down machine.
• Remove key from ignition.
• Be careful with fuels and lubricants so as not to spill.
• Do not fuel tank while engine is running or hot. Doing so could cause a fire and/or a explosion.
• Do not smoke while refueling or working with fuel to avoid a fire and/or an explosion.
• IMPORTANT! Always clean up spilled fuel and/or lubricants to avoid polluting the earth.

Note:

Any machine not in safe operating condition must be removed from service until it is repaired by a qualified service person. [1]

By following these preventative maintenance procedures and safety guidelines, you can ensure the safe operation of equipment, minimize downtime, and maintain regulatory compliance.

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