9.1 Basic Requirements for Maintenance Work

Maintenance, inspection, servicing, and repair work on a Telescro telehandler must be carried out only under controlled, safe, and suitable conditions.

Basic Requirements

• before maintenance begins, it must be confirmed that the work area is well ventilated;
• the maintenance area must be kept clean so that debris, oil contamination, and obstacles do not affect safety;
• maintenance personnel must be familiar with the machine’s basic structure, hazard points, and work requirements;
• all maintenance work must be carried out in accordance with the specified procedures, and no safety step may be omitted at will;
• if an abnormal condition is found, the risk must be eliminated before work continues.

9.2 Clothing Requirements for Maintenance Personnel

During maintenance work, personnel must wear clothing and personal protective equipment suitable for repair work.

Requirements

• wear work clothing suitable for the task;
• wear slip-resistant safety shoes;
• wear protective gloves where necessary;
• wear safety glasses where necessary;
• wear a safety helmet where necessary;
• long hair must be tied back and properly protected to prevent entanglement with moving parts.

Prohibited Actions

• wearing rings, necklaces, bracelets, watches, or other jewelry;
• wearing loose clothing during maintenance;
• allowing clothing, hair, or personal items to approach rotating, driven, or hot components.

9.3 Shutdown and Isolation Requirements Before Maintenance

Before adjustment, inspection, repair, or servicing, the machine must first be placed in a safe condition.

The Following Must Be Carried Out

• stop the engine;
• disconnect machine power;
• remove the ignition key;
• confirm that the machine cannot be started unintentionally;
• confirm that the machine cannot move, drop, or operate unexpectedly.

Principle

Before any maintenance work begins, the machine must first be shut down, isolated, and protected against operating errors.

9.4 Principle of Timely Repair

Any fault, abnormal condition, or damage found during use of a Telescro telehandler must be dealt with promptly.

Requirements

• all repair work must be carried out as soon as possible;
• even minor faults must not be delayed for a long period;
• if there is any doubt about the machine’s condition, operation with a known fault is prohibited;
• small faults must be corrected before they develop into system-level failures.

Risk Statement

Failure to repair in time may result in:

• further damage to mechanical components;
• expansion of hydraulic system faults;
• escalation of electrical faults;
• reduced machine performance;
• increased risk of safety accidents.

9.5 Leakage Handling Requirements

If any leakage appears on the machine, it must be inspected and corrected immediately.

Types of Leakage Requiring Special Attention

• hydraulic oil leakage;
• engine oil leakage;
• coolant leakage;
• fuel leakage;
• leakage of other working fluids.

Requirements

• even minor leakage must not be ignored;
• the source of the leakage must be identified and repaired as soon as possible;
• the leakage area must be cleaned promptly to prevent contamination and slipping hazards;
• after repair, reinspection must be carried out to confirm that the leakage has stopped.

Risk Statement

Failure to correct leakage promptly may result in:

• reduced system pressure;
• lubrication failure;
• overheating or damage to components;
• increased fire risk;
• environmental contamination.

9.6 Maintenance Interval Requirements

To keep the Telescro telehandler in good working condition, maintenance must be carried out at the specified intervals.

Requirements

• daily inspections, periodic servicing, and planned repairs must be carried out as required;
• required maintenance must not be skipped on the grounds that the machine can still operate temporarily;
• maintenance intervals must be managed within the machine management system;
• where attachments are used in operation, they must also be included in the scope of inspection and maintenance.

Principle

Maintenance is not a remedial action after failure, but a basic requirement for ensuring safe, reliable, and stable machine operation.

9.7 Maintenance Log Requirements

All servicing, repairs, inspections, and modification work must be recorded in the maintenance log.

Types of Work That Must Be Recorded

• routine servicing;
• periodic inspection;
• fault repair;
• parts replacement;
• adjustment work;
• attachment repair;
• modification or configuration changes.

Each Record Must Include

• the date of the work;
• the machine model or machine identification number;
• the work performed;
• the fault symptoms or inspection results;
• the corrective actions taken;
• the name and quantity of replaced parts;
• the name of the maintenance person;
• if the work was performed by an external organization, the company name must also be recorded;
• recommendations for the next inspection where necessary.

Purpose of the Maintenance Log

• tracking machine health status;
• supporting fault traceability;
• managing maintenance intervals;
• supporting after-sales service and quality management;
• improving machine reliability and manageability.

9.8 Lubricant Use Requirements

During machine maintenance, lubricants and working fluids that meet Telescro requirements must be used.

Requirements

• use only specified or recommended lubricants;
• contaminated lubricants must not be used;
• oils and fluids of unknown origin or incorrect specification must not be used;
• during filling and replacement, prevent contaminants, moisture, and dust from entering the system;
• different types of oil and fluid must not be mixed arbitrarily.

Risk Statement

Using unsuitable or contaminated lubricants may result in:

• lubrication failure;
• increased component wear;
• hydraulic or engine system faults;
• shortened machine service life.

9.9 Fuel Management Requirements

Fuel filling and fuel management must strictly follow fire prevention, misfueling prevention, and spill prevention requirements.

Refueling Requirements

• refueling is prohibited while the engine is running;
• the engine must be shut down before refueling;
• the machine must be in a safe parked condition before refueling;
• fuel may be added only through the designated fuel filler opening;
• fuel must not be added mistakenly into any other system opening;
• the fuel tank must not be overfilled, and expansion space must be left;
• after refueling, confirm that the fuel cap has been closed and tightened.

Fire Prevention Requirements

• smoking is prohibited whenever the fuel tank is open or refueling is in progress;
• open flames, sparks, and hot heat sources must not approach the machine;
• welding, cutting, or other spark-producing work is prohibited in the refueling area;
• the refueling area must be kept well ventilated.

9.10 Hydraulic System Maintenance Requirements

The hydraulic system is a high-pressure system. Risk must be strictly controlled during maintenance and repair.

Basic Requirements

• unauthorized personnel must not disassemble, adjust, or repair the hydraulic system;
• hydraulic system maintenance must be carried out by personnel with the necessary competence;
• no connection part may be removed from a hydraulic circuit before it has been confirmed that the pressure has been released.

Prohibited Actions

• loosening hydraulic fittings while the system is pressurized;
• removing hydraulic hoses while the system is pressurized;
• removing valves, piping, or other hydraulic components while the system is pressurized;
• handling high-pressure hydraulic components without proper confirmation.

Risk Statement

Disassembly of a pressurized hydraulic system may result in:

• injury from high-pressure oil injection;
• skin penetration injuries;
• burns;
• sudden movement of the working equipment;
• uncontrolled dropping of the attachment or load;
• severe machine damage.

9.11 Requirements for Counterbalance Valves, Safety Relief Valves, and Hydraulic Accumulators

Counterbalance valves, safety relief valves, and hydraulic accumulators are critical safety components within the hydraulic system.

Requirements for Counterbalance Valves and Safety Relief Valves

• setting values must not be adjusted without authorization;
• these components must not be removed without authorization;
• these components must not be modified without authorization;
• they must not be replaced with parts of non-original specification.

Requirements for Hydraulic Accumulators

• the hydraulic accumulator is a pressurized device;
• non-professional personnel must not disassemble, discharge, modify, or repair it;
• hydraulic accumulators and their connected fittings must be handled only by qualified professionals.

Principle

Any work involving counterbalance valves, safety relief valves, hydraulic accumulators, or other safety-critical components must be carried out by Telescro-approved professional technicians.

9.12 Electrical System Maintenance Requirements

Electrical system maintenance must give priority to controlling the risks of unintended starting, short circuit, and electric shock.

Basic Requirements

• before working on the electrical circuit, the battery must first be disconnected;
• before electrical repair begins, confirm that the machine is shut down and the key has been removed;
• electrical system maintenance must be carried out by personnel with the necessary competence;
• after restoring electrical connections, functional confirmation must be carried out to prevent miswiring or polarity errors.

Prohibited Actions

• forcing the engine to start by shorting the starter relay;
• carrying out non-standard starting procedures before confirming that the machine is in a safe condition;
• placing or dropping metal tools or metal parts onto the battery;
• using substitute fuses, electrical components, or wires that do not meet specification.

Risk Statement

Incorrect electrical work may result in:

• sudden machine movement;
• short circuit;
• sparks;
• battery damage;
• fire or explosion risk;
• burned electrical components.

9.13 Starting System Hazard Warning

Engine starting work must be carried out only under safe conditions.

Hazard Conditions

If the machine is in any of the following conditions, forced starting may cause sudden movement:

• the forward/reverse control is not in neutral;
• the parking brake is not applied;
• the transmission system remains in a drive-ready state;
• the control system is not in safe mode.

Principle

The starting system must be operated only in accordance with the standard procedure. Shorting, jump-starting by bypass, or any other non-standard method must not be used as a substitute.

9.14 High-Temperature Component Hazard Warning

After machine operation, some components may remain at high temperature. Maintenance work must prevent burns and the ejection of hot fluids.

Components That May Be Hot

• the exhaust system;
• the radiator;
• external engine surfaces;
• cooling system components;
• some hydraulic components.

Requirements

• before inspection or disassembly, confirm that the relevant components have cooled down;
• hot surfaces must not be touched directly;
• before opening the cooling system, confirm that the system has cooled and that there is no pressure hazard;
• during maintenance, prevent injury from hot fluids, steam, or hot surfaces.

9.15 Environmental Protection and Waste Disposal Requirements

Waste generated during maintenance work must be handled in accordance with safety and environmental protection requirements.

Items That Must Be Properly Managed

• waste engine oil;
• waste hydraulic oil;
• waste coolant;
• waste fuel;
• used filters;
• used batteries;
• waste hoses, seals, and damaged parts.

Prohibited Actions

• discharging waste oil or waste fluids directly onto the ground;
• discharging contaminants into sewers or bodies of water;
• mixing hazardous waste with general refuse;
• discarding contaminated parts and consumables arbitrarily.

Requirements

• waste must be collected by category;
• compliant containers must be used for storage;
• disposal must follow local regulations and company management requirements;
• hazardous waste must be handled by qualified organizations.