By Brian Hatch and Susan Doyle
Where would we be without reminders? For machinery, it’s those pesky lights, that show up on the dashboard, and occasional warning sounds that remind us we need to do something soon if not right now, or we won’t be doing anything, now or in the near future. Many times, those reminders are about machine maintenance.
Machine maintenance that includes preventive actions as a part of your DAILY routine ensures your machine will be up and performing for many, many hours. And, keep those pesky reminders away.
THE SERVICE MANUAL
It may be big and bulky. It may have lots of pages segmented in confusing ways. It may be in small type. Never forget though, the service manual is your friend. Take the time to find the maintenance schedule for your machine, its particular engine, and its recommendations. Read through the pertinent sections on machine and engine maintenance. Hour requirements may differ a little bit from model to model; overall the information is similar enough that in any engine service manual look for the following:
- New machine break in (hours 10-100). After the first 100 hours, just like your car, some machines will signal maintenance with a light on your dash. (Pay attention, please.)
- Routine maintenance (500 hours, 1,000 hours, 1500 hours+). These are good benchmarks for average environmental conditions. If your machine is operating in particularly adverse or heavy conditions, maintenance should be carried out in shorter intervals. You decide. Suggestion: Err on the side of caution. Taking a few minutes today can save you hours of downtime tomorrow (and the days after that).
With Merlo’s service manuals, there is usually a page or more dedicated to suggested maintenance intervals starting at 10 hours up to 1500 hours. Look for the section that visually shows each warning light and its meaning. If you have a used machine and the manuals are missing, contact your machine manufacturer or distributor to obtain a copy of the manual or, at a minimum, the schedules. Copy those pages showing the maintenance intervals and the dash lights explanation. Put them somewhere where you can see it as a DAILY reminder as to what needs to be done when. Plug the interval information into your cell phone calendar.
Merlo recommends a particular action occur at EVERY benchmark to ensure your machine, and its engine, are running in top performance. Pay attention to that EVERY day. The following are good reminders about keeping your engine running smoothly.
Heavy equipment engine maintenance is all about consistency. Keep in stock in the shop: oils, coolants, greases, filters and the manuals. Our techs suggest having at least one full set of oil and air filters in stock all the time. Your machine will thank you by performing well.
The daily walk around (start the practice with new machines, too!)
Exterior of your machine.
- Look for leaks
- Check the hydraulic oil level gauge
- Ensure caps are tight
- Check your tire pressure and that tire bolts are secure
Pop the hood.
- Look for leaks, belt conditions, debris blocking air filters
- Check the engine exhaust duct for blockage and or damage
- Check all fluid levels-engine coolant, brake, hydrostatic transmission, (include the windshield wiper fluid—this is not water—if applicable); top off as necessary
- Check the antifreeze quality and level in the radiator; look for radiator debris blockage
- Check the battery, its electrolyte level, and terminals condition
- Use the oil dipsticks daily
Reminder about radiator coolants: What has been used all summer may not be good enough for the colder months. Make sure to check those glycol levels (there is a gauge for this).
After the break in period, every 50 hours. The first routine benchmark action starts at the 50-hour mark. If the machine is new to you and way past this mark, ask yourself when was the last time this machine had the following service?
Build upon the daily check list:
- Look at the air filter and cabin air filter. Any debris blocking the efficiency? If you choose to clean them out beyond knocking the debris off, use care when using an air hose that you do not distort the filter folds.
- Check the brake fluid
- Add the action of removing water from the diesel fuel filter. By the way, Merlo does suggest every time you refuel, you drain the water from the fuel filter.
Draining the water only takes a few minutes, and adds hours to your engine. Though we describe here what steps to take for an example engine, many diesel engines are set up the same way.
- Put a pan under the filter
- Disconnect the drain sensor
- Turn the ring, and drain the liquid
- Look when liquid turns to all fuel
- Retighten the ring securely
- Reconnect the sensor
Ready to go for the next 50 hours.
Every 500 hours. All of the above, and add in:
- Replacing the hydraulic sump bleeder filter
- Check the fuel tank for water and any sediments; drain if necessary
- Change engine oil
- Replace oil filter and fuel filter
- Replace fuel filter
Those warning lights mentioned above? After you performed the corrective action, restart the machine, that light should go dark.
CLOSING THOUGHT
And, so it goes. Every interval builds upon the previous. Check fluids, check filters, check tires, check, check, check, then take an action. This is a routine that keeps your heavy equipment in tip-top shape and able to perform well every time you need it.
About the author:
Brian Hatch is the service training manager with AMS-Merlo, importer and distributor of Merlo telehandlers. All machines are available through direct sale, rentals, and a growing dealer network. Floorplanning and retail financing opportunities are available. Susan Doyle is with the AMS-Merlo marketing department. For more, visit ams-merlo.com.
Modern Contractor Solutions, October 2020
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