Terexlift 51-19M Handler with telescopic boom Operator Manual - PDF DOWNLOAD

INDEX

OPERATOR MANUAL Document 51-19-M-2-OM - 2ND Edition 10/2000

Handler with telescopic boom

TEREXLIFT 51-19M CONTRACT NO. M67854-00-C-3014

INDEX

Highway 501 East / P.O. Box 260002 Conway, SC 29528-26002 Phone: 843-349-6900 Fax: 843-349-7078

DEALER’S OR ASSISTANCE CENTRE STAMP

Operator Manual 51-19-M-2-OM 10/2000 All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means without prior written permission from TEREXLIFT In pursuing a policy of constant quality improvement, TEREXLIFT reserves the right to make changes at any time and without undertaking to give prior notice; therefore, also this publication may be subject to modifications. © Copyright 2000 TEREXLIFT - All rights reserved.

Document 51-19-M-2-OM - 2ND Edition 10/2000

INDEX GENERAL INDEX Handler with telescopic boom TX51-19-M series

INTRODUCTION ...................................

SYMBOLS .............................................

Sec. A

3 4

B-3.2 B-3.3 Sec. C

Getting ready to work ............................

During work or maintenance ..................

19 20

OPERATING INSTRUCTIONS

GENERAL REMARKS C-1

A-1 A-1.1 A-1.2

MACHINE REFERENCES ....................

Machine position ...................................

Labels and warning plates applied on the machine .....................................

A-1.3 Explanation of the different symbols used on the machine .............................

A-2 MACHINE IDENTIFICATION .................

A-2.1 Machine model and type ......................

A-2.2 Manufacturer .........................................

A-2.3 Machine identification plates ..................

A-2.4 Chassis serial number ...........................

A-2.5 Identification plates of the main parts ....

A-3 ALLOWED USE ....................................

A-3.1 Allowed use ...........................................

A-3.2 Improper use .........................................

A-3.3 Applicable standards .............................

A-4 GENERAL DESCRIPTION ....................

A-4.1 List of the main components ..................

A-4.2 Description of the main components .....

A-4.3 Optional Accessories .............................

A-5 TECHNICAL DATA AND PERFORMANCE ...................................

A-5.1 Main dimensions ...................................

A-5.1.1 Characteristic angles ............................

A-5.2 Weight ...................................................

A-5.3 Speed ....................................................

A-5.4 Payload and reach ................................

A-5.5 Diesel engine .........................................

A-5.6 Electric system ......................................

A-5.7 Machine noise levels .............................

6 6 7 10 11 11 11 11 11 11 12 12 12 12 13 13 14 14 15 15 15 15 16 16 16 16 16

Sec. B

SAFETY

B-1 B-2

GENERAL REMARKS ........................... 18 QUALIFICATIONS OF THE PERSONNEL IN CHARGE ........................................... 18 Qualification of the operator ................... 18 Qualification of the maintenance staff .... 18 Working garments ................................. 19 Personal protection equipment .............. 19 SAFETY PRECAUTIONS ...................... 19 Job site .................................................. 19

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B-2.1 B-2.2 B-2.3 B-2.4 B-3 B-3.1

BEFORE GETTING INTO THE MACHINE ..............................................

C-2 GETTING INTO THE MACHINE ............

C-2.1 Getting into the cab ..............................

C-2.2 Adjusting the seat .................................

C-2.3 Fastening the safety seat belts .............

C-2.4 Adjusting the steering column ..............

C-2.5 Adjusting the rear view mirrors .............

C-3 Operator Cab ........................................

C-3.1 Controls and instruments .......................

C-3.2 Engine controls and instruments ...........

C-3.2.1 Ignition switch ........................................

C-3.2.2 Forward/reverse speed selector switch .

C-3.2.3 Turn signals - lights - horn switch. .........

C-3.2.4 Brakes ...................................................

C-3.2.5 Accelerator control ................................

C-3.2.6 Hydraulic gearbox .................................

C-3.2.7 Steering mode selection ........................

C-3.2.8 Auxiliary drive controls ..........................

C-3.3 Light instruments and indicators ............

C-3.3.1 Light instruments ...................................

C-3.3.2 Light indicators ......................................

C-3.4 Control lever ..........................................

C-3.4.1 Selecting the function ............................

C-3.4.2 Boom controls .......................................

C-3.4.3 Emergency stop ....................................

C-3.4.5 Lifting/lowering the boom .......................

C-3.4.6 Tilting the attachment coupling plate forward/back .........................................

C-3.4.7 Extending/retracting the boom .............

C-3.4.8 Quick-coupling the attachments ............

C-3.4.9 Side-shifting...........................................

C-3.4.10 Fork swaying .........................................

C-4 SETUP ..................................................

C-4.1 Before starting the engine .....................

C-4.2 Starting the engine ................................

C-4.3 Jump-starting the engine .......................

C-4.4 Disconnecting the battery ......................

C-4.5 Starting the machine ..............................

C-4.6 Stopping and parking the machine ........

C-5 USING THE HANDLER .........................

C-5.1 Using the load charts .............................

C-5.2 Overload warning system display ..........

C-5.3 Handling loads .......................................

C-5.3.1 Adjusting the forks .................................

C-5.3.2 Working phases.....................................

C-5.4 Replacing the attachment ......................

Document 51-19-M-2-OM 2ND Edition 10/2000

Page 1

22 23 23 24 24 25 25 27 27 28 28 28 29 30 30 31 31 32 33 33 33 34 35 36 36 37 38 39 40 41 42 43 43 43 44 45 45 46 47 47 48 49 49 50 51

INDEX GENERAL INDEX Handler with telescopic boom TX51-19-M series

C-6 C-6.1 C-6.2 C-6.3 C-6.4

TRANSPORTING THE MACHINE ........

Moving a disabled machine ...................

Road or site transfer ..............................

Lifting the machine ................................

Transporting the machine on other vehicles .................................................

C-6.5 Parking and storage ..............................

C-6.5.1 Short inactivity .......................................

C-6.5.2 Machine storage ....................................

C-6.6 Machine disposal ...................................

Sec. D

52 52 52 53 53 54 54 54 54

MAINTENANCE

D-1

56 57 59 59 60 61 62 62 62 63 64 65

D-4 D-4.1 D-4.2 D-4.3 D-5 D-5.1 D-5.2 D-5.2.1 D-5.2.2 D-5.2.3 D-5.2.4 D-5.2.5 D-6 D-6.1

Steering/ Tire Alignment ........................

Adjusting the sensor distance ................

Adjusting the sliding pads of the telescopic elements ...............................

ELECTRIC SYSTEM .............................

Battery ...................................................

Fuses ....................................................

Lamps ...................................................

REFUELING ..........................................

Refueling ...............................................

Product specifications ...........................

Engine oil ..............................................

Lubrication oils and filtering elements ....

Fuel .......................................................

Greases ................................................

Engine coolant .......................................

FAULTS AND TROUBLESHOOTING ...

Fault - Cause - Solution .........................

Sec. E

TABLES AND ENCLOSURES

E-1

TORQUE WRENCH SETTINGS ...........

69 70 71 72 72 73 73 75 75 75 75 75 76 76 76 77 77

79

66 66 66 67 67 67 68

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LUBRICANTS - HEALTH AND SAFETY PRECAUTIONS ......................

D-2 ORDINARY MAINTENANCE ................

D-3 MAINTENANCE and Repairs ................

D-3.1 Disconnecting the battery ......................

D-3.2 Access to the engine and fuel tank compartments .......................................

D-3.3 Greasing ................................................

D-3.4 Tires and wheels ...................................

D-3.5 Brakes ...................................................

D-3.5.1 Checking the brake oil level ...................

D-3.6 Engine air filter ......................................

D-3.7 Engine cooling system ..........................

D-3.8 Checking the oil level in the reservoir ....

D-3.9 Checking and changing the oil filter in the suction line ...................................

D-3.9.1 Transmission oil filter .............................

D-3.9.2 Service oil filter ......................................

D-3.10 Oil level in the differential gears .............

D-3.10.1 Front differential gear ............................

D-3.10.2 Rear differential gear .............................

D-3.11 Oil level in the (front and rear) wheel reduction gears ......................................

D-3.12 D-3.13 D-3.14

Page 2

Document 51-19-M-2-OM - 2ND Edition 10/2000

INDEX INTRODUCTION Handler with telescopic boom TX51-19-M series

■ INTRODUCTION This handbook provides information for a safe and proper operation and maintenance of the machine.

STRICTLY COMPLY WITH THE INSTRUCTIONS GIVEN IN THIS HANDBOOK! READ AND UNDERSTAND THIS HANDBOOK BEFORE STARTING, USING AND CARRYING OUT ANY OPERATION WITH AND ON THE MACHINE. The handbook is divided into six sections: Section Section Section Section Section Section

A B C D E F

GENERAL INFORMATION SAFETY OPERATING INSTRUCTIONS MAINTENANCE OPTIONAL ATTACHMENTS TABLES AND ENCLOSURES

Section A introduces general concepts which are decisive for the knowledge of the main parts of the machine.

Additionally, it contains all necessary data for a correct identification, it explains the technical features of the machine, etc.

Section C is mainly addressed to the operators who drive and work with the machine. This section illustrates all control devices. Additionally, it contains the main use instructions -i.e. engine starting, machine parking, machine storing.

Section D is addressed to the workshop responsible and the operators who must service the machine.

The section describes the maintenance schedule and the relevant intervals. Specific chapters are dedicated to the failure diagnostics, the tables and the reference specifications to be used for the maintenance schedule.

Section E makes a list of the main interchangeable attachments to be coupled to the machine: dimensions, weight, application field and limits of the different attachments.

Sections are subdivided into chapters and paragraphs which are numbered progressively.

The quickest way to look for an information is the reference to the general index or the titles of the single chapters and paragraphs which represent keys for an easy consultation.

Take care of this handbook and keep it in an accessible place within the machine, even after its reading, so that it will always be within reach if in doubt.

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Section B is especially addressed to both the personnel, who shall set up and repair the machine, and, in case of companies with a wide fleet of machines, the safety responsible.

It describes the essential compulsory qualities of the

personnel in charge and other important information for the safety of persons and things.

Document 51-19-M-2-OM 2ND Edition 10/2000

Page 3

INDEX SYMBOLS Handler with telescopic boom TX51-19-M series

SYMBOLS When using the machine, operators could have to face some situations requiring special care and particular knowledge.

When these situations involve the safety of operators or bystanders, the machine efficiency and proper utilization, this handbook stresses these specific instructions by means of SPECIAL SYMBOLS

There are special (or safety) symbols in this manual, always combined with keywords which class the situations according to their danger degree.

The symbols are always followed by a text explaining the situation taken into account, the attention which must be paid to such situation, the method and the behaviour which should be adopted. When necessary, it stresses prohibitions or supplies instructions to prevent dangers.

Sometimes, it can be followed by illustrations.

We list below the special (or safety) symbols according to the relative seriousness of the hazard situation:

DANGER

DANGER – Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING – Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION – Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

ATTENTION – Indicates a situation which, if not avoided, may result in property or equipment damage.

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THIS SYMBOL MEANS YOUR SAFETY IS INVOLVED! READ, UNDERSTAND, AND FOLLOW ALL DANGER, WARNING, AND CAUTION DECALS ON YOUR MACHINE.

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Document 51-19-M-2-OM - 2ND Edition 10/2000

INDEX

Handler with telescopic boom TX51-19-M series

Section

A

A

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GENERAL INFORMATION

Document 51-19-M-2-OM 2ND Edition 10/2000

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INDEX

A

MACHINE REFERENCES Handler with telescopic boom TX51-19-M series

A-1 ■ A-1.1

MACHINE REFERENCES

MACHINE POSITION

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The machine should be considered positioned as shown in the figure.

If it is necessary to make any reference of this handbook to different machine parts (front, rear, etc.) clear and unmistakable. Any exception to this rule will always be specified.

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Document 51-19-M-2-OM - 2ND Edition 10/2000

INDEX CONVENTIONAL REFERENCES Handler with telescopic boom TX51-19-M series

■ A-1.2

LABELS AND WARNING APPLIED ON THE MACHINE

A

PLATES

This paragraph lists the labels and warning plates normally applied on standard machines or which can be found when special attachments are coupled to the machine.

CAUTION The familiarization with these labels is never a waste of time.

Make sure they are easy to read. For this purpose, clean them or replace those which become unreadable (either graphic or text).

To clean labels, use of a soft cloth, water and soap.

Never use solvents, petrol, etc.

When a label is applied on a part to be replaced, make sure that the replaced part is already labeled as required or apply a new label.

Meaning: when the machine is running, entering the working range of the machine is prohibited.

Location: on the telescopic boom, both on the right and on the left.

DANGER ELECTRIC CABLES AND POWER LINES KEEP EVERY PART OF THE MACHINE, LOADS AND ACCESSORIES AT LEAST 20 feet FROM OVERHEAD POWER LINES.

Description: label with transparent background “Use limits close to electric lines”.

Meaning: it defines the minimum distance to be kept when the machine is used close to aerial electric lines.

Location: within the cab, on the windsheild, to the right of the operators position.

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Description: red/white label “Keep out of the working range of the machine”.

Document 51-19-M-2-OM 2ND Edition 10/2000

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INDEX

A

CONVENTIONAL REFERENCES Handler with telescopic boom TX51-19-M series

Location: Within the operators cab, on a cable / chain.

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Meaning: it defines the exact working limits of the machine (in terms of payload and reach) to be strictly respected by the operator when using the machine.

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Document 51-19-M-2-OM - 2ND Edition 10/2000

INDEX MACHINE REFERENCES Handler with telescopic boom TX51-19-M series

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Description: label with transparent background “General application limits”.

Location: within the cab, on the side window, to the right of the operator position.

Meaning: it defines the main limits to be strictly obeyed by the operator when using the machine.

Document 51-19-M-2-OM 2ND Edition 10/2000

A

Page 9

INDEX

A

MACHINE REFERENCES Handler with telescopic boom TX51-19-M series

A-1.3 EXPLANATION OF THE DIFFERENT SYMBOLS USED ON THE MACHINE This paragraph illustrates those symbols which are normally applied on the main control devices and instruments of a standard machine, and those which can be applied on accessories or special attachments. They are mainly (ISO) standardized symbols which are now part of the common life. But we consider useful to explain them once again.

ATTENTION

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Spend the necessary time to become familiar with these symbols and to learn their meaning.

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Document 51-19-M-2-OM - 2ND Edition 10/2000

INDEX MACHINE IDENTIFICATION Handler with telescopic boom TX51-19-M series

A-2 MACHINE IDENTIFICATION

ATTENTION

B

A

Service Lubracation Chart.

Placed on the inside door of the operators cab.

This should be used to locate all lubraction points and will tell you what type of lubraction is required.

Check that the operator and maintenance handbook refers to the delivered machine.

When asking for information or technical assistance, always specify model, type and serial number of the machine.

■ A-2.1 MACHINE MODEL AND TYPE Handler with telescopic boom: model Terexlift 51-19-M

■ A-2.2 MANUFACTURER TEREXLIFT CONWAY Highway 501 East / PO Box 260002 Conway, SC 29528-26002 Phone: 843-349-6900 Fax: 843-349-7078

■ A-2.3 MACHINE IDENTIFICATION PLATES Identification plates are applied on the machine. They are located inside operators cab.

■ A-2.4 CHASSIS SERIAL NUMBER The chassis serial number is punched on the front left part of the chassis side member (D Fig. A10).

■ A-2.5

IDENTIFICATION PLATES OF THE MAIN PARTS The plates of the main components, which are not directly manufactured by Terexlift (for instance, engines, pumps, etc.), are located where originally applied by the manufacturers.

D

A

Machine Lifting Diagram.

Driver side, rear of machine,left of the indentification plate.

This is to be used only as a reference. You should always use the current rating

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Fig. A10

Document 51-19-M-2-OM 2ND Edition 10/2000

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INDEX ALLOWED USE Handler with telescopic boom TX51-19-M series

A-3

ALLOWED USE

-

■ A-3.1 ALLOWED USE The handlers have been designed and manufactured for lifting, handling and transporting agricultural or industrial products by means of specific attachments (see section E).

Any other use is considered contrary to that established and, therefore, improper.

The compliance with and the strict respect of the operation, maintenance and repair conditions, indicated by the Manufacturer, represent an essential part of the allowed use.

The use, maintenance and repair of the handler shall be carried out by skilled operators only who know well the special characteristics of the machine and the safety precautions to be taken.

-

WARNING The Manufacturer disclaims any responsibility for damage to persons or things arising from arbitrary modifications carried out on the machine.

■ A-3.2 IMPROPER USE Improper use means a utilization of the handler following working criteria which do not comply with the instructions of this manual, and, in general, may result in risks for both operators and bystanders.

WARNING We list below some of the most frequent and hazardous situations of improper use: Carrying passengers on the machine Not strictly complying with the operation and maintenance instructions of this handbook Working beyond the handler working limits Working on unstable edges of ditches Working on steep slopes Using attachment other than those recommended

Page 12

Using attachments which are not approved or directly manufactured by Terexlift Working in potentially explosive environments.

■ A-3.3 APPLICABLE STANDARDS For ensuring the operator’s safety, the following standards were followed during the risk analyse of the handler with telescopic boom:

Directive 89/392 CEE 98/39 CEE 86/295 CEE - 91/368 CEE 86/296 CEE - 91/368 CEE 88/465 CEE 98/40 CEE 73/23 CEE - 93/68 CEE 74/151 CEE 79/532 CEE 80/720 CEE - 97/54 CEE 89/391 CEE 89/336 CEE - 92/31 CEE 96/627 CEE

Title Machine Directive Steering devices ROPS - FOPS Driving place Seats - Type-approval Rear view mirrors for agricultural machines Low Voltage Directive Tractors - Weight, plate, etc.

Tractors - Lighting and signalling devices Tractors - Working ranges Safety and health of workers at work Electromagnetic compatibility Agricultural tractors - Noise levels within the driving cab

Standard EN 292-1/2 EN 294 EN 418 EN 457 EN 563 EN 574 EN 811 EN 349 EN 842 EN 982 EN 1032/5007/5008 EN 1033/1037

Title Machine safety - Designing principles Machine safety - Safety distance Machine safety - Emergency stop Machine safety - Audible hazard signalling devices Machine safety - Surface temperature Machine safety - Control devices Machine safety - Safety distance Machine safety - Minimum spaces Machine safety - Visible hazard signalling devices Machine safety - Hydraulic systems Measurement of vibrations Machine safety - Prevention of accidental starting Machine safety - Risk evaluation Machine safety - Locking devices Acoustics Steering devices Braking devices Seat reference point Pictorial signs for the operator s controls Access to the operation controls Minimum access dimensions Safety standard for rough terrian forklift trucks

EN 1050 EN 1088 EN 4871/ISO 5131/7216 NC 337-01/ISO 5010 NC 344-01/05/10 UNI EN 25353 ISO 3767-1/2 EN ISO 6682 EN 22860/ISO 4252/4253 ASME B56.6 STABILITY

Document 51-19-M-2-OM - 2ND Edition 10/2000

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A

INDEX GENERAL DESCRIPTION Handler with telescopic boom TX51-19-M series

A-4 GENERAL DESCRIPTION ■ A-4.1

LIST OF THE MAIN COMPONENTS

J

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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 -

2ND BOOM SECTION ELECTRICAL REEL ENGINE HOOD FRONT WINDSHEILD WIPER DRIVING CAB ACCORDING TO ROPS-FOPS PROVISIONS LEFT REARVIEW MIRROR RIGHT REARVIEW MIRROR 1ST BOOM BASE SECTION ATTACHMENT HOLDING FRAME ATTACHMENT LOCKING CYLINDER LEFT REAR WHEEL MUDGUARD LEFT FRONT WHEEL REDUCTION GEAR CAB DOOR LEFT REAR WHEEL REDUCTION GEAR REAR WINDSHIELD WIPER

Document 51-19-M-2-OM 2ND Edition 10/2000

Page 13

A

INDEX

A

GENERAL DESCRIPTION Handler with telescopic boom TX51-19-M series

■ A-4.2 DESCRIPTION OF THE MAIN COMPONENTS Transmission It consists of a pump with variable displacement directly applied on the engine.

From the power distributor, through a Drive shaft transmission, the motion is transmitted to the rear axle of the handler.

Steering axles/(front and rear) differential gears The differential axles transmit the motion to the wheels.

Less maintained surfaces on the front axle enables the machine to move. Limited slip differential lock.

Tires The machine is equipped with tires suitably sized for the maximum load allowed on the handler.

When replacement is necessary, they shall be replaced with new ones having the same dimensions and loading capacity.

Overload warning system The standard overload warning system installed on the vehicle enables the operator to work under the safest conditions. A five-LD display shows the stability variation.

When the 5th red LED lights up, all machine movements are stopped, but for the boom retraction under safe conditions.

Boom hydraulic circuit It consists of a gear pump connected to the engine which, through a special valve, dispenses oil to the hydraulic drive and a distributor for the following functions: - boom lifting/lowering - telescopic boom sections extension/retraction - attachment rotation - attachment locking - fork titlting Braking circuit It consists of an independent circuit: the pedal directly acts on the brake pump which dispenses oil to the brake cylinders of the front axle.

■ A-4.3

OPTIONAL ACCESSORIES

The machine can be fitted with a wide range of optional accessories: please address to Terexlift sales network.

ATTENTION Please check the accessories which can be fitted on your machine.

TECHNICAL

DATA

AND

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A-5

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Document 51-19-M-2-OM - 2ND Edition 10/2000

INDEX TECHNICAL DATA AND PERFORMANCE Handler with telescopic boom TX51-19-M series

A

PERFORMANCE

■ A-5.1

MAIN DIMENSIONS

Agrilift Telelift

TERELIFT 51-19-M 236 2306 A B C D E F G H I •

Overall height Height of steering wheel Overall width Inside cab width Track Wheelbase Length at front wheels Length at fork-holder plate Ground Clearance Outside turn raduis

ft. in. ft. in. ft. in. ft. in. ft. in. ft. in. ft. in. ft. in. ft. in. ft. in.

7' 6" 4' 11" 6' 6" 3' 0" 4' 11" 7' 7" 12' 0" 13' 6" 1' 4" 26' 8"

■ A-5.1.1 Characteristic angles ·

•

Angle of approach Departure angle

90° 70°

■ A-5.2 WEIGHT Weight in running order

lb (kg)

1150

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•

Document 51-19-M-2-OM 2ND Edition 10/2000

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INDEX

A

TECHNICAL DATA AND PERFORMANCE Handler with telescopic boom TX51-19-M series

TEREXLIFT 51-19-M ■ A-5.3 SPEED -

Working speed (*) Travel speed (*) Max. slope with full load

mph mph

5.0 20 45%

ft. in. ft. in. ft. in. lb lb

18' 9" 14' 8" 10' 9" 135° 2755 1765

cu in hp

PERKINS 704-30T Diesel 4 strokes direct injection 4 cylinders in line 3.8 x 3.9 (97 x 100) 180.4 (2956) 80

V V Ah

24 24 2 x 80

(*) = either forward or reverse motion ■ A-5.4 PAYLOAD AND REACH -

Max. lifting height Reach at max. height Max. reach forward Implement holding plate rotation Payload at max. height Payload at max. reach

Overturning factor according to the stability regulations pr EN 1459, annex B. ■ A-5.5 DIESEL ENGINE -

Make Model/type Features:

-

Cylinders Bore x Stroke Total displacement Power at 2600 rpm (*)

(*) = Gross power, calculated according to the DIN 70020 standard.

■ A-5.6 ELECTRIC SYSTEM -

Voltage Self-regulated alternator (on Diesel engine) Battery

■ A-5.7 MACHINE NOISE LEVELS -

Acoustic power (*) Acoustic pressure (*)

dB dB

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(*) = Values calculated according to the EC-directive 86/662.

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Document 51-19-M-2-OM - 2ND Edition 10/2000

INDEX

Handler with telescopic boom TX51-19-M series

B

Section

B

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SAFETY

Document 51-19-M-2-OM 2ND Edition 10/2000

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INDEX SAFETY Handler with telescopic boom TX51-19-M series

SAFETY GENERAL REMARKS

Most accidents which occur while working, repairing or maintaining operation machines, are caused by not complying with the basic safety precautions.

Therefore, it is necessary to pay steady attention to the potential hazards and the effects which may come of operations carried out on the machine.

If you recognize hazardous situations, you can prevent accidents!

For instance, this handbook makes use of special safety symbols to stress any potentially hazardous situation.

The instructions given in this handbook are the ones established by TEREXLIFT. They do not exclude other safe and most convenient ways for the machine installation, operation and maintenance which take into account the available spaces and means.

If you decide to follow instructions other than those given in this manual, you shall absolutely: • be sure that the operations you are going to carry out are not explicitly forbidden; • be sure that the methods are safe, say, in compliance with the rules and provisions given in this section; • be sure that the methods cannot damage the machine directly or indirectly or make it unsafe; • contact TEREXLIFT Assistance Service for any suggestion and the necessary written permission.

If in doubt, it is always better to ask! For this purpose, contact TEREXLIFT : the assistance service is at your disposal. Addresses, phone, fax and telex numbers are given in the cover and in the title-page of this manual.

B-2 ■ B-2.1

QUALIFICATIONS OF THE PERSONNEL IN CHARGE

QUALIFICATION OF THE MACHINE OPERATORS

The operators who use the machine regularly or occasionally (i.e. for transport reasons) shall have the following qualification: health: before and during any operation, operators shall never Page 18

consume alcoholic beverages, medicines or other substances which may alter their psycho-physical conditions and, consequently, their working abilities. physical: good eyesight, acute hearing, good co-ordination and ability to carry out all required operations in a safe way, according to the instructions of this manual. mental: ability to understand and apply the enforced rules, regulations and safety precautions. They shall be careful and sensible for their own as well as for the others’ safety and shall desire to carry out the work correctly and in a responsible way. emotional: they shall keep calm and always be able to evaluate their own physical and mental conditions. training: they shall read and familiarize with this handbook, its enclosed graphs and diagrams, the identification and hazard warning plates. They shall be skilled and trained about the machine use.

The operator might be required to have a licence (or a driving licence) when provided for by the laws enforced in the country where the machine works.

Please, ask the competent bodies.

■ B-2.2

QUALIFICATIONS OF THE MAINTENANCE STAFF

The staff charged with the machine maintenance shall be qualified, specialized in the maintenance of these machines, and shall have the following prerequisites: physical: good eyesight, acute hearing, good co-ordination and ability to carry out all required maintenance operations in a safe way, according to this manual. mental: ability to understand and apply the enforced rules, regulations and safety precautions. They shall be careful and sensible for their own as well as for the others’ safety and shall desire to carry out the work correctly and in a responsible way. training: they shall read and familiarize with this handbook, its enclosed graphs and diagrams, the identification and warning plates. They shall be skilled and trained about the machine functioning.

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B-1

INDEX SAFETY Handler with telescopic boom TX51-19-M series

B

SAFETY

WARNING From a technical point of view, the ordinary maintenance of the machine is not complex. And can be carried out by the machine operator, too, provided that he has a basic knowledge of mechanics.

■ B-3.1

JOB SITE

Always take into account the features of the job site where you are going to work: • Always examine the working area and compare it with the machine dimensions in the different configurations.

D ANGER ■ B-2.3

WORKING GARMENTS

During work, but especially when maintaining or repairing the machine, operators must wear suitable protective clothing: • Overalls or any other comfortable garments.

Operators should wear neither garments with large sleeves nor objects which could get stuck in any moving part of the machine.

• Protective helmet.

• Protective gloves.

• Working shoes.

WARNING

Pay the greatest attention to overhead electric lines.

Always keep at a minimum safe distance of at least 20 feet from the telescopic boom and the lifted load.

Electrical hazards!

• When assembling the machine or part of it on site, you need a well-equipped area of suitable dimensions. The surface shall be even, compact and stable.

• Look for the best route to the job site.

• When the machine is running, nobody can enter its working range.

• While working, keep the working area in order. Never leave objects scattered: they could hinder the machine movements and represent a danger for personnel.

■ B-3.2

Use only type-approved personal protective equipment in good condition.

■ B-2.4

PERSONAL PROTECTIVE EQUIPMENT

Under special working conditions, the following personal protective equipment should be used: • Breathing set (or dust mask).

• Ear-plugs or hearing protection.

• Goggles or protection masks.

SAFETY PRECAUTIONS

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GETTING READY TO WORK

Before any operation, following precautions should be taken: • First of all, make sure that all maintenance have been carried out with care according to the established schedule (see section D - Maintenance).

• Ensure you have enough fuel to avoid a sudden stop of the engine, especially during a crucial maneuver.

• Clean instruments, data plates, lights and the cab windsheild thoroughly.

• Check the correct functioning of all the safety devices installed on the machine and in the job site.

• In case of troubles or difficulties, inform the supervisor at once. Never start working under unsafe conditions.

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INDEX SAFETY Handler with telescopic boom TX51-19-M series

■ B-3.3

DURING WORK OR MAINTENANCE

Any repairs made on the hydraulic circuit must be carried out by authorized personnel.

The hydraulic circuit of this machine is fitted with pressure accumulators. You and others could be seriously injured if accumulators are not completely depressurized.

For this purpose, shut the engine down and step on the brake pedal 8-10 times.

• • •

• • •

•

• • • • •

Neither smoke nor use open flames in areas subject to fire dangers and in presence of fuel, oil or batteries.

Do not leave fuel cans or bottles in unsuitable places.

Do not empty catalytic mufflers or tanks containing burning substances without taking the necessary measures.

Carefully handle all flammable or dangerous substances.

Do not tamper with fire-extinguishers or pressure accumulators: explosion hazard!

After any maintenance or repair work, make sure that no tool, cloth or other object has been left within machine compartments, fitted with moving parts, or where suction and cooling air circulates.

When working, do not give instructions or signals to several people at the same time. Instructions and signals must be given by one person only.

Always pay the due respect to the instructions given by the supervisor.

Never distract the operator during working phases or crucial maneuver.

Avoid to call an operator suddenly, if unnecessary.

Avoid to frighten an operator or to throw objects by no means.

After work, never leave the machine under potentially dangerous conditions.

- Forlì

During work, and especially maintenance, always pay the greatest attention: • Do not pass or stop under raised loads or machine parts supported by hydraulic cylinders or ropes only.

• Keep the machine handholds and access steps always clean from oil, grease or dirt to prevent falls or slips.

• When entering/leaving the cab or other raised parts, always face the machine; never turn the back.

• When carrying out operations at hazardous heights (over 5 feet from the ground), always use typeapproved safety belts or fall preventing devices.

• Do not get into or off the machine while it is running.

• Do not leave the operators seat when the machine is running.

• Neither stop nor carry out repairs under or between the machine wheels when engine is running. When maintenance in this area is required, stop the engine.

• Do not carry out maintenance or repair works without a sufficient lighting.

• When using the machine lights, the beam should be oriented in order not to blind the personnel at work.

• Before applying voltage to electric cables or components, check their connection and proper functioning.

• Do not carry out repairs on electric components with voltage over 48V. • Do not connect wet plugs or sockets.

• Plates and hazard warning stickers shall never be removed, hidden or become unreadable.

• Except for maintenance purposes, do not remove safety devices, shields, protection cases, etc. Should their removal be necessary, stop the engine, remove them with the greatest care and always remember to refit them before starting the engine and using the machine again.

• Before any maintenance or repair work, stop the engine and disconnect the batteries.

• Do not lubricate, clean or adjust moving parts.

• Do not carry out operations manually when specific tools are provided for this purpose.

• Absolutely avoid to use tools in bad conditions or in an improper way i.e. pliers instead of adjustable wrenches, etc.

• Before carrying out operations on hydraulic lines under pressure or disconnecting hydraulic components, ensure the relevant line has been previously depressurized and does not contain any hot fluid.

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INDEX

Handler with telescopic boom TX51-19-M series

C

Section

C

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OPERATING INSTRUCTIONS

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INDEX

C

OPERATING INSTRUCTIONS Handler with telescopic boom TX51-19-M series

INTRODUCTION This section provides the operator a practical guide for the gradual learning of the machine use.

The operator should get into the operators cab and carry out the preliminary adjustments, then memorize the position of the different controls and instruments.

The familiarization with the controls ensures not only a correct use during the working phases, but also a prompt and timely responce of the operator, when he shall carry out sudden manoeuvres to safeguard his safety and the machine integrity.

It is necessary to learn how to use and foresee the machine reactions. Learn how to operate the machine controls in an safe and open place, without obstacles and anybody standing around. Do not ram the controls.

Operate them slowly to understand their effect on the machine.

C-1

BEFORE GETTING INTO THE MACHINE

Checks and cleaning • Clean glasses, lights and rear view mirrors.

• Check that pins, joints and bolts are well tightened in position.

• Check for oil, fuel or coolant leaks.

Checking the tires • Check the correct inflation of the tires; see par. “Tire inflation” in the Maintenance section.

• Make sure that the tire plies are not cut or worn.

D ANGER

- Forlì

A tire burst may result in serious injury; never use the machine if tires are worn, wrongly inflated or damaged.

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INDEX OPERATING INSTRUCTIONS Handler with telescopic boom TX51-19-M series

C-2 GETTING INTO THE MACHINE ■ C-2.1 GETTING INTO THE CAB

CAUTION

C

Door closing from inside: • Pull the door with force: it locks automatically.

Door opening from inside: • Lift lever 2 and release the lock to open the door completely.

• Rotate handle 3 to open the upper door section and lock it against the special catch.

Always make sure that your hands and shoe soles are clean and dry before getting into the driving cab.

Always face the machine when entering and leaving it and hold to the suitable handles.

3

The cab is fitted with an access door on the left side.

Door opening from outside: •

Press the button and open the door.

2 •

Operate lever 4 to unlock and close the upper door section.

4

- Forlì

1

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OPERATING INSTRUCTIONS Handler with telescopic boom TX51-19-M series

■ C-2.2 ADJUSTING THE SEAT

■ C-2.3 FASTENING THE SEAT BELTS

A correct adjustment of the seat ensures the operator a safe and comfortable driving. The operators seat is fitted with devices which allow for the adjustment of springing, backrest angle and distance from the controls.

Sit correctly in the driving seat; then: •

Check that belts are not tangled, then push tab 1 into buckle 2 until it latches.

•

•

To release the belt, push button 3 and remove the tab from the buckle.

•

Adjust the belt across the hips and not on the stomach.

•

The two ends of the buckle can be adjusted separately, by holding the buckle in central position.

Seat distance from the controls The operators seat is fitted with an adjusting device that allows sliding the same seat forward or back with respect to the steering column.

To slide the seat, pull lever 1 outwards and push the seat as required. Then release the lever and make sure that the seat locks in position.

•

Springing adjustment Rotate knob 2 clockwise or counterclockwise until obtaining the required springing. Rotate clockwise to increase the seat springing or counterclockwise to reduce it.

•

Height adjustment The seat height can be set to three different positions.

To adjust, lift the seat until hearing the characteristic “clack” coupling sound. To lower the seat, raise to stroke end to unlock the mechanism, then release the seat; it automatically sets to the lowest position.

•

Backrest angle adjustment The backrest can be adjusted by means of knob 4.

Rotated clockwise, it increase the backrest angle; counterclockwise it reduces it.

3

1 2

4

3 1

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2

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INDEX OPERATING INSTRUCTIONS Handler with telescopic boom TX51-19-M series

■ C-2.5

C

ADJUSTING THE REAR VIEW MIRRORS

■ C-2.4 ADJUSTING THE STEERING COLUMN The machine is fitted with two rear view mirrors: Both steering column and dashboard can be set to a different angle. For this purpose: •

•

Loosen lever 1 and adjust as required, then re-tighten lever 1.

•

WARNING

Rear view mirror 2 is located on a special supporting bracket in advanced position and allows checking the area behind the machine, on the right-hand side.

To adjust its position, manually rotate the joint it is fitted with.

Rear view mirror 3 is placed on the left upper post of the windsheild and allows checking the area behind the machine, on the left- hand side. To adjust its position, manually rotate the joint it is fitted with.

Before driving the machine, ensure the steering wheel is properly clamped.

3 2

- Forlì

1

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- Forlì

C

Fig. C7 Page 26

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INDEX OPERATING INSTRUCTIONS Handler with telescopic boom TX51-19-M series

C-3

OPERATOR CAB

C-3.1 CONTROLS AND INSTRUMENTS Emergency stop button Dashboard Brake oil reservoir Fresh air flap Fuse compartment Forward/reverse speed selection lever Ignition switch Turn signals - lights - horn switch Brake pedal Steering column locking lever Hazard light switch Not used Steering selection switch Not used Gas pedal Overload / Stability warning system display Boom operation joystick Machine level Fan switch Road/Cab switch Cab heater control valve Hydraulic function switch Blank Storage Tray Windsheild water reservoir Seat Parking brake lever B.O. Lighting Control Switch Rear Wipper

- Forlì

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

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C

INDEX

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OPERATING INSTRUCTIONS Handler with telescopic boom TX51-19-M series

C-3.2 ENGINE CONTROLS AND INSTRUMENTS ■ C-3.2.1 Ignition switch Four-position switch:

■ C-3.2.2

Forward/reverse speed selection lever

Three-position switch with locking in neutral position: N

Neutral position; no gear engaged

No circuit under voltage, key can be removed and engine is stopped.

F

Raise and shift lever to pos. F to select the forward gear

Thermal starter for cold climates. Rotate the key to this position and hold it for 10-15 seconds.

R

Raise and shift lever to pos. R to select the reverse gear

Circuits under voltage, pre-setting for the engine starting. Board controls and instruments are on.

Engine starting; when released, key springs back to pos. I automatically.

F

N

8

- Forlì

R

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INDEX OPERATING INSTRUCTIONS Handler with telescopic boom TX51-19-M series

■ C-3.2.3 Turn signal - windsheild washer - horn light switch ■ Horn function: By pressing the lever built-in button, horn switches on, independently from other pre-set functions.

C

■ Light function: To switch the handler lights, lever is fitted with three position along its vertical axis: 0

position lights ON,

1

low beam ON,

2

low beam ON for intermittent signalling; by releasing the lever, it springs back to position 0.

■ Windsheild washer function: Push the second stage of the lever along its axis to direct a jet of water onto the cab windsheild.

2 0 1

■ Turn signal function: Set lever to pos. 1 to indicate a turn left or to pos. 2 to indicate a turn to the right.

1

■ Windsheild wiper function: To operate the windsheild wiper, rotate the lever tip to one of the four positions: Wiper OFF

J

Timed wiper (if fitted)

1

Low speed

2

High speed

2

- Forlì

0

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OPERATING INSTRUCTIONS Handler with telescopic boom TX51-19-M series

■ C-3.2.4

9

Brakes

Service brake pedal

Gradually step on the brake pedal to decelerate and stop the machine. The pedal operates on the front axle.

27

WARNING

Parking brake

■ C-3.2.5

15

Accelerator control

Gas pedal

Controls the engine r.p.m. and, in combination with the gearbox, the machine speed. It is fitted with an adjustable stop located behind the pedal in cab.

- Forlì

To engage the parking brake, pull the lever upward while holding the locking button pressed. Release the button when reaching the required braking tension.

This brake when engaged, by means of a proximity switch that controls the power distributor, cuts off both forward and reverse gear.

Never use the parking brake to slow down the machine, unless in an emergency, since this might reduce the brake efficiency.

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INDEX OPERATING INSTRUCTIONS Handler with telescopic boom TX51-19-M series

C

■ C-3.2.7 Attachment safety lock pushbutton ■ C-3.2.6

Steering selection 20

13

Steering selection switch Three-position switch for selecting the steering mode:

0 1

2

1

Crab steering

0

Two-wheel steering

2

Four-wheel steering

Selection button

D ANGER Every time you change the attachement, press the safety lock button to prevent an accidental release of the attachment and the fall of the load.

Two-position button: 1 Press to select the road setting. This disables all boom functions except boom raise,lower and tilt.

- Forlì

2 Press the button again to select the site setting and enable the boom control.By reactivating the switch will enable all disable hydraulic functions.

25

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OPERATING INSTRUCTIONS Handler with telescopic boom TX51-19-M series

■ C-3.2.8

Auxiliary drive controls

11

Hazard lights switch Fitted with on-off position, it switches on the hazard indicator lights simultaneously.

19

Fan switch Three-position switch: 0 OFF 1 Low speed 2 High speed

21

Cab heater cock Located on the right side of the driving seat base.

• Rotate clockwise for fresh air • Rotate counterclockwise for warm air • Adjust the amount of warm air within the cab by the air conditioning fan switch 19.

- Forlì

23

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C-3.3 LIGHT INSTRUMENTS AND INDICATORS ■ C-3.3.1

54

Instruments

Engine coolant temperature indicator Signals the engine coolant temperature.

80 120

40

61

∞

53

Fuel gauge Signals the fuel level within the tank.

62

Hourmeter Signals the total running time of the machine.

Indicator - air filter clogged When this lamp sets to on, change the filter immediately.

64

Indicator - low battery charge Signals a low charge of the alternator.

65

Indicator - low engine oil pressure 'It lights up when the engine oil pressure is too low.

66

Indicator - parking brake engaged Indicates that the parking brake is engaged.

67

Available

68

Turn signal indicator Green indicator signaling when turn signals are ON.

01234567

51 80 40

120 ∞C

Hydraulic oil temperature indicator Signals the oil temperature within the reservoir.

■ C-3.3.2 Light indicators

60

Position light indicator Green indicator signaling when position lights are ON. Water temperature indicator When this warning lamp and the indicator 31 switch on, the engine coolant is getting overheated.

63

01234567

52

High beam indicator Blue indicator signaling when high beam is ON.

60 61 62 63 64 65 66 67 68

80 40

80 40

120

120

°C

°C

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01234567

51

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C

52 53

54 Page 33

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OPERATING INSTRUCTIONS Handler with telescopic boom TX51-19-M series

C-3.4 CONTROL LEVER Handlers are equipped with an hydraulically driven servo-controlled lever.

The lever is equipped with a two-position button that returns to central position for the selection of the functions.

Additionally, when operated in the four directions (right/ left, forward/back) it allows for the control of the mast lifting/lowering and the attachment forward/back tilting.

WARNING Smoothly move the control lever. The motion speed of the actuators depends on the lever position: a small motion results in a slow control movement of the actuators; vice versa, a full range motion of the lever corresponds to the max. speed of the actuator.

WARNING The control lever must be operated only when correctly seated in the operator's seat.

WARNING

- Forlì

Before operating the control lever, make sure that nobody is within the working range of the machine.

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INDEX OPERATING INSTRUCTIONS Handler with telescopic boom TX51-19-M series

■ C-3.4.1

Selecting the functions

The control lever is enabled to carry out the following functions: • Boom lifting/lowering by shifting the lever to position A - B • •

•

Boom retraction/extraction by shifting lever to position C - D Fork tilting attachment forward/back tilting by pressing button 3 to X and by shifting lever to position A - B .

Attachment coupling/release by pressing button 3 to Y and by shifting lever to position A - B .

WARNING

- Forlì

Before performing any motion with the boom, make sure there are no persons within the working range of the machine. Otherwise, wait until they are clear of the working range before operating the lift.

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INDEX

C

OPERATING INSTRUCTIONS Handler with telescopic boom TX51-19-M series

■ C-3.4.2

Boom controls

Perform the required function by shifting the lever to position A - B - C - D

Press button 3 to Y and shift the control lever to position A or B to tilt the carriage/fork attachment.

With indicator on switch 22 green must be lit on the side console.

■ C-3.4.3

Press button 3 to Y and shift the attachment lever to position A or B to lock / release the attachemnt or to sideshift and / or sway the forks by pressing button 22.

Emergency stop

Any operated function can be stopped by pressing the emergency stop button 1.

This button allows shutting the engine down.

To reset, rotate the button clockwise.

- Forlì

1

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INDEX OPERATING INSTRUCTIONS Handler with telescopic boom TX51-19-M series

■ C-3.4.5

Lifting/lowering the boom

WARNING Before operating the boom, make sure that nobody is within the working range of the machine.

To lift or lower the boom: Smoothly shift the lever to position B to lift the boom or to position A to lower it.

- Forlì

•

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INDEX

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OPERATING INSTRUCTIONS Handler with telescopic boom TX51-19-M series

■ C-3.4.6

Tilting the implement holding frame forward/back

WARNING Before operating the boom, make sure that nobody is within the working range of the machine.

To tilt the attachment holding frame: •

Press button 3 to X and shift the control lever to position A to tilt the frame forward or to B to tilt back.

- Forlì

.

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INDEX OPERATING INSTRUCTIONS Handler with telescopic boom TX51-19-M series

■ C-3.4.7

Extending/retracting the boom

WARNING Before operating the boom, make sure that nobody is within the working range of the machine.

To extend or retract the telescopic sections of the boom: •

Smoothly shift the control lever to position D to extend the boom or to position C to retract it.

ATTENTION

- Forlì

When the servo-controlled lever is hydraulically driven, the extension/retraction of the telescopic boom is not fitted with proportioning control.

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INDEX

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OPERATING INSTRUCTIONS Handler with telescopic boom TX51-19-M series

■ C-3.4.8

Quick-coupling the attachment

WARNING Before operating the boom, make sure that nobody is within the working range of the machine.

Y

3

To lock/unlock the attachment couplings, it is necessary to change the connection of the hydraulic lines to the control valve placed in the terminal of the first boom section on the end: •

Disconnect both quick couplings L controlling the fork swaying.

•

Connect hoses R that feed the locking cylinder whose quick couplings are coupled to the hose holding attachment.

•

Press button 3 to Y and shift the control lever to position A to lock the attachment coupling or to position B to unlock the attachment coupling.

L

R

B A

- Forlì

22

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Handler with telescopic boom TX51-19-M series

■ C-3.4.9

Side - shifting

WARNING X

Before operating the boom, make sure that nobody is within the working range of the machine.

For a more exact and rapid collection of the load or release in the desired position, the handler is equipped with fork side-shift feature.

3

For this operation: •

When the green light of button 22 is off, press button 3 to X and shift the control lever to position A to shift the forks to the right or to direction B to shift the forks to the left.

L

R

20

- Forlì

22

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INDEX

C

Handler with telescopic boom TX51-19-M series

■ C-3.4.10 Fork swaying

WARNING X

Before operating the boom, make sure that nobody is within the working range of the machine.

To sway the forks:

3 Press button 22 (the built-in green light switches on); press button 3 to X and shift the control lever to position A to lower the right side of the forks or to position B to raise the right side.

L

R

22

- Forlì

•

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INDEX OPERATING INSTRUCTIONS Handler with telescopic boom TX51-19-M series

C-4 STARTING THE MACHINE

ATTENTION

C-4.2 STARTING THE ENGINE •

Thoroughly read chapter C-4.1 before starting the engine.

•

Put the gear switch to neutral.

•

Step on the gas pedal.

•

To start the engine, rotate the ignition switch to position and release when the engine starts. If the engine does not start within 20 seconds, release the key and wait at least 2 minutes before attempting again.

•

After the engine starting, slow down the r.p.m. and wait some seconds before engaging a gear; this allows for a gradual warm up of the engine oil and a better lubrication.

•

In case of engine jump-starting, remove the connecting cables (see following chapter).

C-4.1 BEFORE STARTING THE ENGINE •

To ensure safe conditions to the operators and the bystanders, and a longer life to your machine, perform a walk-around inspection before starting the engine.

•

Remove any dirt or rubbish from the cab interior, and especially from pedals and control levers.

•

Remove oil, grease and mud from pedals and control levers.

•

Make sure that your hands and shoe soles are clean and dry.

•

Check the seat belts can be fastened properly.

•

Check that lights, indicators, side/tail lights, hazard indicator lights, wipers and horn are in working order.

•

Adjust the driving seat so that you can reach all control levers comfortably and fully depress the brake pedal without moving your back from the driving seat.

•

Adjust the rear view mirrors to give you a good view close behind the machine when you are correctly seated.

•

Check the parking brake is engaged.

C

ATTENTION If the light indicators do not switch off/on when engine is running, immediately stop the machine and find and rectify the fault.

ATTENTION

- Forlì

Engine cannot be started if the parking brake is not engaged.

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OPERATING INSTRUCTIONS Handler with telescopic boom TX51-19-M series

frame earth, the terminals are well tightened and the electrolyte level is regular.

C-4.3 JUMP-STARTING THE ENGINE •

Connect the two batteries as shown. Connect first the positive terminals of the two batteries, then the negative terminal of the booster supply B to the machine frame earth.

•

When jump-starting the engine through the battery of another machine, make sure that the two vehicles cannot collide to prevent formation of sparks.

Batteries give off a flammable gas and sparks may burn it and cause an explosion.

If the booster supply is installed on a second vehicle, make sure that the latter does not touch the handler; then star t the vehicle and reach an r.p.m. corresponding to 1/4 of full throttle.

•

Rotate the ignition key and start the handler, then follow the procedure explained in chapter C-4.2 “Starting the engine”.

Do not smoke when checking the electrolyte level.

•

Disconnect the cables. Remove first the negative terminal from the frame earth, then from the booster supply. Disconnect the positive terminal from the machine battery, then from the booster supply.

WARNING

Keep any metal object like buckles, watch straps, etc. clear of the battery positive (+) terminal. These elements can short between the terminal and nearby metal work and the operator can get burned.

The booster supply must have the same rated voltage and output of the battery installed on the handler.

To jump-start the engine with Nato Slave Connection: Check that the brake is set on disabled machine.

•

Remove cover from Nato slave connection.

•

Install the slave connection support cable into the disabled unit.

•

Check that brakes on supporting machine are set.

•

Then install the supply end to the supporting machine. Start the supporting machine to supply maximum voltage to the disable system.

•

Only from the operator's seat of disabled unit, attempt to start the unit, using proper starting procedures.

•

Upon the starting of disabled machine disconnect the slave cable from the supporting machine. Then from the machine that was disabled.

•

Re-install weather cover on both units.

To jump-start the engine: •

Turn any users off by the special control levers.

•

Set the gear switch to neutral and engage the parking brake.

•

Ensure the machine battery A is connected to the

Page 44

B A

WARNING

Use only two 12V powered batteries connected in series to 24V; other devices like battery chargers, etc. may cause an explosion of the battery or result in damage to the electric system of the machine.

- Forlì

•

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C-4.4 DISCONNECTING THE BATTERY During maintenance or repair work, and especially while welding, cut out the battery main switch A, located in an accessible position behind the rear right wheel.

C

C-4.5 STARTING THE MACHINE When the engine reaches the running temperature, ensure all parts are in transfer position and the speed change lever is in neutral. Then: • • • •

Select the required steering mode.

Select the motion direction (forward or reverse).

Release the parking brake.

Slowly step on the gas pedal to start moving off.

WARNING Only operate the forward/reverse speed selection lever when the machine is running from the operator's position. Failure to do so could, you could be seriously injured.

- Forlì

A

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OPERATING INSTRUCTIONS Handler with telescopic boom TX51-19-M series

C-4.6

STOPPING AND PARKING THE MACHINE

When possible, stop the machine on a dry, level and solid ground. Then: •

Bring the machine to a smooth stop by easing up the gas pedal and stepping down on the brake pedal.

•

Set the forward/reverse speed selection lever to neutral.

•

Engage the parking brake and ensure its indicator lights up.

•

Release the service brake pedal.

•

Rest the attachment coupled to the boom flat on the ground.

•

Get out the operators cab and lock the cab door.

•

Set the battery cutout switch to OFF position .

C-5 USING THE HANDLER This chapter describes some techniques and provides instructions for a safe use of the machine fitted with standard forks. For different attachments please refer to the specific chapter: “Optional attachments”.

WARNING Before using the machine, inspect the job site and check for possible hazardous conditions. Make sure that there are no holes, moving banks or debris which may cause you to lose the control of the machine.

D ANGER

CAUTION

Pay the greatest attention when working close to electric lines. Check their position and ensure that no part of the machine operates at less than 20 feet from the power lines.

Always face the machine when getting off the driving cab; make sure that your hands and shoe soles are clean and dry, and hold to the handholds to prevent falls or slips.

WARNING

- Forlì

Always engage the parking brake when stopping the machine to prevent any accidental motion of the vehicle.

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WARNING For a safe use of the machine, always check the weight of the loads going to be handled.

Always refer to the load charts, located in the cab.

C-5.1 USING THE LOAD CHARTS The load charts indicating the maximum allowed payload with respect to the boom extension are attached on inside of the cab.

WARNING The load charts illustrated in this manual are given only as a mere example. To define the payload limits, refer to the load charts applied within the cab of your machine.

CAUTION The load charts applied within the cab refer to a stationary machine stopped on a solid and level ground.

Raise the load a few inches and check its stability before raising it completely.

- Forlì

Always refer to these charts to operate under safe conditions.

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C

OPERATING INSTRUCTIONS Handler with telescopic boom TX51-19-M series

19 C-5.2 OVERLOAD WARNING SYSTEM DISPLAY The operator cab dashboard is equipped with a 5-LED warning display 19. The 5 LEDs switch on in sequence from the right to the left and indicate the gradual variation of the machine stability as it follows: 1 green LED • instrument ON • machine stable 2 green LED • machine stable but tending to variation 3

green LED

•

machine stable but strongly tending to variation

4

yellow LED

•

machine unstable

5

red LED

•

hazardous overload; machine stops and allows only for the load return within safety limits.

S

yellow

•

outriggers at work (if equiped)

5

4

3

2

1

At the machine starting, the overload warning system carries out a diagnostics of all LEDs, then sets to the first green LED signaling the proper functioning of the instrument.

Examples of use of the overload warning system

WARNING

Boom extension

Before using the machine, make sure that the first green LED of the overload warning system is ON.

Such unbalances may also be caused by an abrupt operation of the levers during the load handling. If, during work, several indicators light up, operate the levers more smoothly.

ATTENTION This machine is equipped with overload warning, when machine is on side slope and rear axle reaches maximum angle.

Page 48

Overload warning system in alarm

Boom retraction Alarm ceases

Reduction of the load to be handled

New working cycle

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- Forlì

The overload warning system must not be used to check the load going to be lifted: it has only been designed to signal possible unbalances of the machine along its motion axis.

INDEX

OPERATING INSTRUCTIONS Handler with telescopic boom TX51-19-M series

C-5.3 HANDLING LOADS

WARNING

■ C-5.3.1 Adjusting the forks Forks shall be spaced to suit the load going to be handled. For this purpose: Lift the clamping lever of the forks (A).

•

Slide the forks to the desired position, then reset the lever in locking position.

•

The center of gravity of the load must always be halfway between the forks.

•

Ensure you exactly know the weight of the load before handling it.

•

When extending the boom, do not exceed the payload limit.

•

Refer to the payload limits given in the rating chart book, which is in the opeator’s cab.

•

Space the forks as wide as possible to suit the load being handled.

- Forlì

•

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C

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OPERATING INSTRUCTIONS

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Handler with telescopic boom TX51-19-M series

■ C-5.3.2 Working phases When forks are correctly spaced, the handler is ready to use.

Work can be subdivided into three different phases: loading, transfer and unloading.

Loading phase •

Approach the load to the handled perpendicularly.

•

Insert the forks under the load and raise the load a few inches to check its stability.

•

Tilt the forks back and make sure that the stability warning system LEDs are in limits.

possible you have to raise or lower the boom as the forks come out.

•

When forks are clear of the load, reset them to transfer position.

•

Choose direction required and move F/R selector as needed.

•

Release the chassic brakes.

CAUTION Do not raise the load being handled more than1 1/2 feet. Risk of overturning or load fall.

Transfer phase •

Do not start or brake abruptly.

•

Drive to the unloading point cautiously and keep the load as close to the ground as possible.

•

Adjust the machine speed to the ground conditions to avoid dangerous jumps, side skids of the vehicle and possible load falls.

•

When driving on slopes or ramps, hold the load uphill.

WARNING Do not drive on slopes sideways; this wrong maneuver is one of the main reasons for accidents due to vehicle overturning.

•

Drive to the unloading point with straight wheels and smoothly stop the machine leaving enough space to operate the boom.

•

Apply the chassic brake and move the drive selector to neutral position.

•

Position the load a few inches above the desired position and set the forks level.

•

Lower the load and make sure it is level.

•

Carefully withdraw the forks by operating the boom retraction control. According to the load height, it is

Page 50

- Forlì

Unloading

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OPERATING INSTRUCTIONS Handler with telescopic boom TX51-19-M series

•

C

Couple the connectors of the attachment, if any to the quick couplings of the frame.

C-5.4 REPLACING THE ATTACHMENTS

WARNING

CAUTION Use only attachments directly designed and manufactured by Terexlift for its handlers and detailed in the manual section “Optional Attachments”.

After substitution, visually check the attachment is correctly coupled to the boom, before operating the machine. A wrongly coupled attachment may result in damage to persons or things.

To change an attachments, operate as follows: • Drive to the place where you will release the mounted attachments (when possible, a solid and sheltered site).

•

Disconnecting the quick connectors of the attachment, if any, and connect the hydraulic locking pipes R of the attachment to couplings L.

•

Operate the Joystick function (see section C-3.4.8) to unlock attachment pins.

•

Rest the attachment flat on the ground.

•

Tilt the holding frame forward and lower the boom to release the implement upper lock.

•

Move back with the machine (or with the boom) and drive to the new attachment going to be coupled.

•

Hold the frame tilted forward and hook the upper lock of the new attachment.

•

Retract and raise the attachment some inches.

Attachment will center automatically on the quick coupling frame.

•

Operate the joystick function (see section C-3.4.8) to lock the attachment.

- Forlì

L

R

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C

OPERATING INSTRUCTIONS Handler with telescopic boom TX51-19-M series

C-6 TRANSPORTING THE MACHINE

•

When possible, start the engine and use the hydraulic drive and the braking system.

■ C-6.1 MOVING A DISABLED MACHINE

■ C-6.2 ROAD OR SITE TRANSFER

Tow the machine only when no alternative is possible, since this operation may result in serious damage to the transmission. When possible, repair the machine on site.

When traveling on public roads, strictly obey the local or national road traffic regulations.

When the machine shall absolutely be towed:

•

Set the “ROAD/CAB” switch to “ROAD” position.

•

Tow the machine for short distances and at a low speed only.

•

Select the two-wheel steer.

•

Use a rigid drawbar.

•

Retract both boom and attachment to transfer position.

•

Select the two-wheel steer.

•

•

Move the speed selection lever to neutral.

Make sure that lights, horn and turn signals are in working order.

•

Engage the gear.

•

The motion speed of the vehicle will depend on the engine r.p.m. and the engaged gear.

Additionally, always take into account the following general precautions:

ATTENTION

- Forlì

Public road use is allowed only for transferring unloaded machines.

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C

WARNING ■ C-6.4 ■ C-6.3LIFTING THE MACHINE When the machine shall be lifted, use only means having a suitable capacity. The characteristic data are detailed in the chapter of this manual and on the identification plate.

•

Put chocks at the transporting vehicle wheels.

•

Ensure ramps are correctly positioned.

•

Retract the handler boom to transfer position.

•

Carefully drive the handler onto the transporting vehicle.

•

Put the parking brake and rest the attachment flat on the vehicle platform.

•

Ensure the overall dimensions do not exceed the allowed limits.

•

Shut the engine down and close the operators cab of the handler.

•

Secure the handler to the vehicle platform by wheelchocks.

•

Anchor the handler to the transporting vehicle with suitable chains.

- Forlì

For the machine lifting, anchor the chains to the special lugs on the machine (Lift/Tie down).

TRANSPORTING THE MACHINE ON OTHER VEHICLES To transport the machine on another vehicle, follow the steps below:

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OPERATING INSTRUCTIONS Handler with telescopic boom TX51-19-M series

C-6.5 PARKING AND STORAGE ■ C-6.5.1 Short inactivity

•

Refuel the tank to prevent internal oxidation.

Always park the machine in a safe way after a working day, a shift and at night.

•

Store the machine in a sheltered and wellventilated place.

Take all precautions to prevent damage to those persons who will approach the machine while stationary:

•

Start the engine for about 10 minutes at least once a month.

•

Park the machine so that it does not hinder other operations.

•

When weather is particularly cold, empty the radiator.

•

Lower the boom fitted with attachment on the ground.

•

Wrap and lubricate cylinder rods.

•

Engage the parking brake.

•

Remove the key from the ignition switch and lock the cab door.

•

Disconnect the battery by the special cutout control (“Battery cutout switch”).

■ C-6.5.2 Machine storage In case of extended inactivity of the machine, follow the above precautions. Additionally: •

Wash the machine thoroughly. For a better cleaning, remove grills and protection casings.

•

Carefully dry all machine parts.

•

Lubricate the machine thoroughly.

•

Do a walk-around inspection and replace any worn or damaged part.

Re-paint any worn or damaged part.

•

Remove the battery, apply protection to its terminals with vaseline and store it in a dry place, if the battery can be used for other purposes.

Otherwise, periodically check its charge level.

Always remember that the ordinary maintenance must be carried out even during the machine inactivity. Pay particular attention to the fluid levels and to those parts subject to ageing. Before restarting the machine, preform a maintenance schedule and carefully check all mechanical, hydraulic and electrical components.

C-6.6 MACHINE DISPOSAL At the end of the machine life, dispose of it properly.

Address to a specialized firm for scrapping the machine in compliance with the local or national regulations.

- Forlì

•

CAUTION

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INDEX Handler with telescopic boom TX51-19-M series

Section

D

D

- Forlì

MAINTENANCE

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D

MAINTENANCE Handler with telescopic boom TX51-19-M series

D-1

INTRODUCTION A thorough and regular maintenance keeps the machine in a safe and efficient working condition.

For this reason, it is advisable to wash, grease and service the machine properly, especially after having worked under particular conditions (muddy or dusty environments, heavy operations, etc.).

LUBRICANTS - HEALTH AND SAFETY PRECAUTIONS

Health A prolonged skin contact with oil can cause irritation.

Use rubber gloves and protective goggles. After handling oil, carefully wash your hands with soap and water.

Always ensure all machine components are in good condition. Check for oil leaks or loosening of guards, and make sure that the safety devices are efficient. In case of defects, find and rectify them before using the machine again.

Storage Always keep lubricants in a closed place, out of the children’s reach. Never store lubricants on the open air and without a label indicating their contents.

The maintenance schedule are based on the machine working hours. Regularly check the hourmeter and keep it in good condition to define the maintenance intervals correctly.

Disposal New or exhausted oil is always polluting! Never drain oil on the ground. Store new oil in a suitable warehouse.

Pour exhausted oil into cans and deliver them to specialised firms for disposal.

Not-respecting the ordinary maintenance schedule of this manual automatically voids Terexlift warranty.

ATTENTION

Oil leaks In case of accidental oil leaks, cover with sand or typeapproved granulate. Then scrape off and dispose of it as chemical waste.

First aid Eyes

Intake For the engine maintenance, please refer to the specific Operation and Maintenance handbook supplied with the machine.

Skin

: In case of accidental contact with the eyes, wash with fresh water. If the irritation persists, seek medical advice. : In case of oil intake, do not induce vomiting, but seek medical advice. : In case of a prolonged contact, wash with soap and water.

- Forlì

Fire In case of fire, use carbon dioxide, dry chemical or foam extinguishers. Do not use water.

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D-2 ORDINARY MAINTENANCE Wrong or neglected maintenance can result in possible risks for both operator and bystanders. Make sure maintenance and lubrication are carried out according to the manufacturer’s instructions to keep the machine safe and efficient.

The maintenance schedule are based on the machine working hours. Regularly check the hourmeter and keep it in good conditions to define the maintenance intervals correctly. Make sure any defect detected during the maintenance is promptly rectified before using the machine.

3 4 5 6

Check the engine coolant level Clean the radiator, if necessary Check the hydraulic oil level within the reservoir Ensure the overload warning system functions properly 7 Ensure the lighting electric system is efficient 8 Ensure the braking system and parking brake are efficient 9 Ensure the steering selection system is efficient 10 Ensure the fork balance system is efficient.

Every 50 working hours or weekly Jobs to be carried out in addition to those above.

WARNING All operations marked by the " ▲ " symbol must be carried out by a skilled technician.

During the first 10 working hours 1 Check the oil level within reduction and differential gears and the power distributor 2 Regularly check the tightening of the lug nuts 3 Check the tightening of all bolts and nuts 4 Check for oil leaks from the couplings.

Within the first 50 working hours 1 Change the hydraulic oil filter element

7 8

Check the level of the battery electrolyte Check the tension of the alternator belt Check the tire inflation Check the tightening of the lug nuts Check the tightening of the Drive shaft screws Make sure that the boom telescopic elements are well -greased close to the sliding pads Grease the attachment holding plate Grease all boom joints, the rear axle shaft joint, the transmission shafts, both front and rear axles and any equipment of the machine

Every 250 working hours or monthly Jobs to be carried out in addition to those above.

1

Change the engine oil and relevant filter

2

Check the oil level in both front and rear differential gears

3

Check the oil level in the four wheel reduction gears

4

Check the integrity of the main filter element of the engine air filter. Replace, if necessary

5

Check the clamping of the cable heads to the battery terminals

- Forlì

Every 10 working hours or daily 1 Check the engine oil level 2 Clean the air suction filter

1 2 3 4 5 6

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MAINTENANCE Handler with telescopic boom TX51-19-M series

6

Check the integrity of the air suction hose between engine and filter

7

Check the conditions of the cylinder chromiumplated rods

8

Check the hydraulic lines are not worn because of rubbing against the frame or other mechanical components

9

Ensure electric cables are not rubbing against the frame or other mechanical components

10 Check the wear of the sliding pads of the boom sections 11 Adjust the slack of the sliding pads of the boom sections

Every 1000 working hours or yearly Jobs to be carried out in addition to those above.

1 2 3 4

Change the safety element of engine air filter Change the oil in the front and rear differential gears Change the oil in the four wheel reduction gears Change the hydraulic oil

Every 2000 working hours or every 2 years Jobs to be carried out in addition to those above.

1

Change the engine coolant

12 Remove any old grease from the boom, then regrease the sliding parts of the boom sections.

Every 500 working hours or every six months Jobs to be carried out in addition to those above.

2 3 4 5 6 7

Visually check the quantity of smoke from the engine exhaust Check the tightening of the engine motor mounts Check the tightening of the cab mounts Check the backlash between pins and bushings in all joints Change the hydraulic oil filter of the transmission Have the hydraulic system checked by a qualified technician Change the main filter element of the engine air filter

- Forlì

1

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D

D-3 MAINTENANCE SCHEDULES

CAUTION All maintenance or repairs must be carried out with engine stopped, parking brake engaged, working attachments flat on the ground and speed selection lever in neutral.

WARNING When raising a component for maintenance purposes, secure it in a safe way before any maintenance or repairs are preformed.

WARNING

Before any operation on hydraulic lines or components, make sure there is no residual pressure.

For this purpose, stop the engine, engage the parking brake and operate the control levers of the distributors in both working directions (alternately) to depressurize the hydraulic circuit.

ATTENTION High-pressure lines must be replaced by qualified personnel only. Any foreign matters entering the closed circuit may result in a sudden deterioration of the transmission.

ATTENTION The qualified staff charged with the maintenance of the hydraulic circuit must clean all areas around with care before any repairs.

D-3.1 DISCONNECTING THE BATTERY During maintenance or repair works, and while welding, turn off the battery cutout switch, located behind the rear right wheel (see C-4.4, p. 43).

- Forlì

Any repair on the hydraulic circuit must be carried out by skilled personnel.

The hydraulic circuit of this machine is fitted with pressure accumulators. You and others could be seriously injured if accumulators are not completely depressurized.

For this purpose, shut the engine down and step on the brake pedal 8-10 times.

ATTENTION

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MAINTENANCE Handler with telescopic boom TX51-19-M series

D-3.2

ACCESS TO THE ENGINE AND FUEL TANK COMPARTMENTS

■ Engine compartment For any operation within the engine compartment, open the hood.

The hood is equipped with lock & key and a supporting rod to hold it in position.

From the engine compartment, you get access to: • Engine • Engine air filter C • Hydraulic oil reservoir plug D • Radiator fluid compensation cup E • Battery To get access to the engine compartment: • Shut the engine down and put the parking brake.

• Unlock the engine hood (A).

• Lift the hood using the special handle B. • Position the supporting rod F into its seat.

A B

E

D A

C

F

H

CAUTION

G

Take all precautions when approaching the engine compartment. Some parts of the engine may be very hot.

Always use protective gloves.

- Forlì

■

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D

D-3.3 GREASING

ATTENTION Before injecting grease into the zirts, thoroughly clean them to avoid that mud, dust or other matters can mix with the lubricant and reduce or annihilate the lubrication effect.

Regularly grease the machine to keep it in efficient conditions and lengthen its life.

By means of a pump, inject grease into the special zirts.

As the fresh grease comes out, stop the operation.

The greasing points are shown in the following figures: -

the symbol

represents the points to be greased

by a pump -

the symbol

represents the points to be

greased by a brush.

SERVICE INTERVAL Running-in period ____________________ None

- Forlì

Ordinary maintenance _______ Every 10 hours

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MAINTENANCE Handler with telescopic boom TX51-19-M series

D-3.4 TIRES AND WHEELS

D-3.5 BRAKES •

D ANGER Over-inflated or overheated tIres can burst. Do not flame-cut or weld the wheel rims. For any repair work, call in a qualified technician.

For the tire inflation or substitution, please refer to the table below:

If a fault of the braking system is detected (adjustment and/or substitution of the brake discs), call in a specialized technician.

The malfunctioning of the braking system may depend on the presence of air within the hydraulic circuit.

To bleed the circuit, proceed as follows: • Make sure that the oil is level within the feeding reservoir A. • Operate the brake pedal repeatedly.

• Step on the brake pedal, slowly unscrew valve B and re-close it as soon as oil mixed with air bubbles comes out.

• Repeat the operation until bubble-free oil comes out.

• Bleed from both sides of the machine.

TX51-19-M Standard Dimensions

375/75 R20 XM27

Load index

155A

Rim

B

11” X 20”

Wheel disc Pressure

8 holes DIN 70361 bar Psi

1.8 (soft) 26 (soft)

2.8 (standard) 40 (standard)

On new machines, and when a wheel has been disassembled or replaced, check the nut torque of the wheels every 2 hours until they stay correct. See torque chart page 86.

D-3.5.1 Checking the brake oil level The oil within the braking circuit must be at about 1/8" from the reservoir cap (A).

ATTENTION A Always use tires having the dimensions indicated in the vehicle registration document.

Level

SERVICE INTERVAL - Forlì

Running-in period ___ Within the first 10 hours Ordinary maintenance ______ Every 250 hours Page 62

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D

Handler with telescopic boom TX51-19-M series

D-3.6 ENGINE AIR FILTER Clean the engine air filter; replace the elements, if necessary.

1 Cleaning and changing the filtering element: - Shut the engine down and engage the parking brake.

B

- Unscrew wing nut A and remove cover B. - Unscrew wing nut C and remove the filtering element D.

A

- Clean the filter bowl.

- Dry clean the cartridge (at max. 6 bar pressure) and direct the air jet from inside to outside.

- Check for cracks in the filter element by introducing a lamp inside.

- Apply a small amount of grease to the seal, then refit the element.

- Re-tighten wing nut C, close cover B and tighten it with wing nut A.

D C

ATTENTION Daily check it and remove any collected dust.

G

SERVICE INTERVAL

To remove the dust bowl, unscrew wing nut G. Running-in period ____________________ None Cleaning __________________ Every 10 hours

- Forlì

Filtering element substitution _ Every 500 hours

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MAINTENANCE Handler with telescopic boom TX51-19-M series

D-3.7

ENGINE COOLING SYSTEM

WARNING

B

When the coolant is hot, the cooling system is under pressure. With warm engine, loosen the radiator plug slowly and carefully, without removing it, to drain the pressure. Use protection gloves and keep your face at a safe distance.

•

Weekly check the coolant level within pan A before starting working (when the coolant is cold).

•

When necessary, add clean water or an antifreeze mixture through cap B.

•

Change the antifreeze mixture every two years.

A

To drain the antifreeze: - Let the engine cool down.

- Unscrew cock C, allow the fluid to flow out into a special container, then re-close the cock.

- After emptying, pour new antifreeze (50% waterantifreeze). This proportion will provide protection up to 40°F. Daily clean the radiator grille.

SERVICE INTERVAL Running-in period ____________________ None Ordinary maintenance _______ Every 50 hours

- Forlì

•

C

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D-3.8

CHECKING THE OIL LEVEL IN THE RESERVOIR

WARNING Fine jets of hydraulic oil under pressure can penetrate the skin. Do not use your fingers, but a piece of cardboard to detect oil leaks.

A

Check the hydraulic oil level through level B fitted on the reservoir.

If necessary, add new oil through filler A.

ATTENTION Check the oil level with handler set to transfer position (lowered boom and retracted telescopic element).

SERVICE INTERVAL Running-in period ___ Within the first 10 hours

B

Ordinary maintenance _______ Every 50 hours If oil must be changed, proceed as follows: 1

Stop the machine on a level ground and engage the parking brake.

2

Eliminate any residual pressure from the hydraulic circuit.

3

Place a container of suitable size under the drain plug to collect any oil leaks.

4

Remove the drain plug and allow oil to flow out into the container.

5

Remove the inspection hatch of tank C.

C

- Forlì

SERVICE INTERVAL Running-in period ____________________ None Ordinary maintenance ____ Every 1000 hours

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INDEX

D

MAINTENANCE Handler with telescopic boom TX51-19-M series

6

Wash the tank thoroughly with solent and a jet of compressed air.

7

Refit the oil drain plug and the inspection hatch.

8

Add new oil until it is level with the hole after having checked it corresponds to the type indicated in paragraph D-5.2.2.

D-3.9 CHANGING THE OIL FILTER ELEMENTS ■ D-3.9.1 Transmission oil filter Every 50 hours, check the clogging degree of the filtering element using the vacuometer A. The indexed scale of the vacuometer is divided into 3 areas: 1 - Green area: Normal condition 2 - Red area: Shut the engine down to prevent damage to the hydraulic system. Change the filter and/or check for the fault reasons.

ATTENTION The hydraulic oil filtering elements cannot be cleaned or washed and refitted.

They must be replaced with new ones of the type recommended by the manufacturer (see par. D5.2.2).

ATTENTION Handling and disposal of exhausted oils may be ruled by local or national regulations. Dispose of the exhausted oils through the special authorized centers.

SERVICE INTERVAL Running-in period ___ Within the first 50 hours Ordinary maintenance ______ Every 500 hours

A

When the dashboard indicator switches on

To change the hydraulic oil filter element on the suction line, proceed as follows: 1 Stop the machine on a level ground and engage the parking brake.

2 Place a container of suitable size under the filter to collect any oil leaks, then close valve B. 3 Remove the filtering element C using a wrench.

4 Change the filtering element, then, before fitting a new one, thoroughly clean and grease both seat and gasket.

5 Hand-tighten and re-open valve B.

B

ATTENTION When changing the oil, drain it when it is still hot and the polluting substances are in suspension.

■ D-3.9.2 Service oil filter To change the service filtering element, proceed as follows: 1

D - Forlì

C

Stop the machine on a level ground and engage the

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parking brake.

D

plug B.

2

Remove the inspection hatch D and unscrew the oil filter fitted inside the tank.

•

Loosen both drain plug and level plug A and allow oil to flow out from the reduction gear.

3

Check the tank is clean, then fit a new filtering element and refit the inspection hatch.

•

Refit and tighten drain plug B.

•

4

Check the oil level within the tank. Add new oil, if necessary.

Add new oil through plug A until it is level with the hole.

D-3.10 OIL LEVEL IN THE DIFFERENTIAL GEARS ■ D-3.10.1 Front differential gear To check the oil level in the front differential gear:

• Refit and tighten level plug A. ■ D-3.10.2 Rear differential gear To check the oil level in the rear differential gear: •

Stop the machine on a level ground and engage the parking brake.

•

Stop the machine on a level ground and engage the parking brake.

•

Loosen level plug C and check if oil reaches the hole.

•

Loosen level plug A and check if oil reaches the hole.

•

If necessary, add new oil through the hole of the level plug until it comes out.

•

If necessary, add new oil through the hole of the level plug until it comes out.

•

Refit and tighten plug C.

•

Refit and tighten plug A.

For the oil change: •

Place a container of suitable size under the drain

B

For the oil change: •

Place a container of suitable size under the drain plug D.

•

Loosen both drain plug and level plug C and allow oil to flow out from the reduction gear.

•

Refit and tighten drain plug D.

•

Add new oil through plug C until it is level with the hole.

•

Refit and tighten level plug C. D-3.11 OIL LEVEL IN THE (front/rear) WHEEL

SERVICE INTERVAL A

Running-in period ___ Within the first 10 hours Ordinary maintenance ______ Every 250 hours

C

- Forlì

D

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MAINTENANCE Handler with telescopic boom TX51-19-M series

REDUCTION GEARS To check the oil level within the wheel reduction gears: •

Stop the machine on a level ground and ensure the parking brake is engaged and plug A finds on the horizontal axis.

•

Clean the plug all around, then remove it and check if oil is level with the hole.

•

If necessary, add new oil through hole A until it is level.

•

Refit the plug.

ATTENTION When changing the oil, drain it when it is still hot and the polluting substances are in suspension.

ATTENTION

For the oil change: • Stop the machine and ensure the plug is oriented toward the vertical axis.

•

Place a container of suitable size under the reduction gear plug.

•

Unscrew plug A and drain any oil from the reduction gear.

•

Rotate the wheel by 90° until the plug finds again on the horizontal axis.

•

Add new oil through hole A.

•

Refit and tighten plug A.

Handling and disposal of exhausted oils may be ruled by local or national regulations. Dispose of the exhausted oils through the special authorized centers.

D-3.12 STEERING / TIRE ALIGNMENT

A

SERVICE INTERVAL Running-in period ___ Within the first 10 hours Ordinary maintenance ______ Every 250 hours

- Forlì

B

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D

During operation, the alignment of both front and rear axles of the machine can be subject to variations. This can depend on an oil bypass from the steering control circuit, or on a steering of both axles when front and rear wheels are not perfectly aligned.

To fix this problem, follow the procedure below rather than checking the alignment visually: •

Move to a solid and level ground.

•

Set the steering selection switch 15 to “four-wheel steer” (pos. 2)

•

Rotate the steering up to its stop (either to the right or to the left)

•

Set the steering selection switch to “two-wheel steer” (pos. 0)

•

Rotate the steering up to its stop in the opposite direction to the above

•

Reset the steering selection switch to “four-wheel steer” (pos. 2)

•

Rotate the steering so that the rear axle reaches its stop (either to the right or to the left)

•

Reset the steering selection switch to “two-wheel steer” (pos. 0)

•

Rotate the steering so that the front axle reaches its stop (see rear axle)

• •

Reset the steering selection switch to “four-wheel steer” (pos. 2) Set the wheels parallel to the longitudinal axis of the machine and move forward for 5 to 10 feet, then reset the steering selection switch to “two-wheel steer” (pos. 0).

1

0

2

SERVICE INTERVAL Running-in period ____________________ None Ordinary maintenance ______ When necessary

- Forlì

D-4 ELECTRIC SYSTEM

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D

MAINTENANCE Handler with telescopic boom TX51-19-M series

D-3.13 ADJUSTING THE SENSOR DISTANCE

A

In case of a failure or complete malfunctioning of the sensors due to a loosening of their fixing ring nuts, readjust their position: 1

Loosen nuts A which fix sensor B.

2

Set the mobile part C of the machine, controlled by the sensor, as close as possible to the same sensor.

Near the sensor to the component until the LED indicator D lights up.

Further near the sensor by 1/8".

Smoothly tighten the sensor fixing nut and the relevant lock nut.

3

The machine is equipped with a proximity switch located in the parking brake. This prevents any starting when the parking brake is not engaged.

SERVICE INTERVAL

A B

1 C D

2 1-2 mm

Running-in period ____________________ None Ordinary maintenance ______ When necessary

- Forlì

3

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D-3.14 ADJUSTING THE SLIDING PADS OF THE BOOM SECTION

Any boom section is fitted with adjustable pads located on the four sides of the profile. These pads are secured to both fixed and mobile part of every section.

All pads can be adjusted by the special shims supplied

by Terexlift parts.

Adjusting the pads: •

Remove the screws which fix the pads.

•

Fit the necessary shims or, when necessary, replace them.

•

Refit and tighten the pad fixing screws.

ATTENTION Pads must absolutely be replaced when their thickness is 1/2" as shown in the drawing below.

SERVICE INTERVAL Running-in period ____________________ None Ordinary maintenance ______ When necessary

New pad thickness .78” Max. wearing thichness .27”

- Forlì

Min. wearing thickness .50”

Document 51-19-M-2-OM 2ND Edition 10/2000

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D

INDEX

D

MAINTENANCE Handler with telescopic boom TX51-19-M series

D-4.1 BATTERY

WARNING All maintenance or repairs must be carried out with engine stopped, parking brake engaged, working attachments on the ground and speed selection lever in neutral.

•

Check the electrolyte level every 50 working hours; if necessary, add distilled water.

•

Ensure the fluid is 1/4" above the plates and the cell levels are correct.

•

Check the cable clips are well secured to the battery terminals. To tighten the clips, always use a box wrench, never pliers.

•

Protect the terminals by appling them with pure vaseline to them.

•

Remove the battery and store it in a dry place, when the machine is not used for a long time.

WARNING

WARNING

When raising a component for maintenance purposes, secure it in a safe way before carrying out any maintenance.

•

Battery electrolyte contains sulphuric acid. It can burn you if it touches your skin and eyes. Always wear goggles and protective gloves, and handle the battery with caution to prevent spillage. Keep metal objects (watch straps, rings, necklaces) clear of the battery leads, since they can short the terminals and burn you.

•

Before disconnecting the battery, set all switches within the cab to OFF.

•

To disconnect the battery, disconnect the negative (-) lead from the frame earth first.

•

To connect the battery, connect the positive (+) lead first.

WARNING

- Forlì

Before any operation on hydraulic lines or components, make sure there is no residual pressure. For this purpose, stop the engine, engage the parking brake and operate the control levers of the distributors (in both working directions alternately) to depressurize the hydraulic circuit.

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MAINTENANCE

D

Handler with telescopic boom TX51-19-M series

D-4.2 FUSES The electric system is protected by fuses placed into the driving cab, on the left. Before replacing a blown fuse with a new one having the same amperage, find out why the fuse has blown.

Fuses Amp. Ref.

Ref. Circuit F1

F15

Interiorlamp-Beaconswitch

Circuit

Amp.

Parkingbrakesensorpowersupply RelayE1/2enablingcontrol

15

F2

RelayE9powersupply

10

F3

RelayE4powersupply

10

F4

Frontright/rearleftpositionlights-Licenseplate

Warninglamps-Watertemperatureindicator

lights-Positionlightindicator-Hydraulicoil

RelayE3enablingcontrol

10

F17

Emergencyswitchandturnsignalpowersupply

10

F18

Powersupply:lightsswitch,windsheild

temperatureindicatorlighting RelayE4enablingcontrol F5

10

F16

Hydraulicstoppowersupply-Hydraulicoil temperatureindicator-Fuelgauge-Hourmeter

Frontleft/rearrightpositionlights-Fuelgauge

washerswitch,windscreenwashermotor

15 25

indicator,hourmeter,warninglamp,water

F19

Airconditioningsystempowersupply

temperatureindicatorlighting

F20

Roadsafetyswitchpowersupply Highspeedswitch

15

F21

Available

15

7.5

F22

Enginestopmushroom-headbuttonpowersupply

15

Righthighbeam-Highbeamwarninglamp

10

F23

RelayE2/E5powersupply

15

F9

Lefthighbeam

10

F24

RelayE8powersupply

5

F10

Horn

10

F25

Available

5

F11

Windsheildwasherkit

10

F26

Available

5

F12 F13

Available Available

15 10

F27

Available

5

F28

Available

5

F14

Available

F6

Positionlightswitchlighting Rightlowbeam

10 7.5

F7

Leftlowbeam

F8

ATTENTION E6

•

- Forlì

•

Do not use fuses having a higher amperage than that recommended, since they can damage the electric system seriously.

If the fuse blows after a short time, look for the fault source by checking the electric system.

•

Always keep some spare fuses for an emergency.

•

Never try to repair or short blown fuses.

•

5

Emergencyswitch-Turnsignals

Make sure the contacts of fuses and fusesockets ensure a good electric connection and are not oxidized.

Document 51-19-M-2-OM 2ND Edition 10/2000

E7

E8

E9

E10 E11

E1

E2

E3

E4

E5

F15

F1

F16

F2

F17

F3

F18

F4

F19

F5

F20

F6

F21

F7

F22

F8

F23

F9

F24

F10

F25

F11

F26

F12

F27

F13

F28

F14

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MAINTENANCE Handler with telescopic boom TX51-19-M series

Engine compartment fuses Ref. Circuit

Amp.

F29 Glow plug

70

F30 Dashboard power supply

50

Relé Ref. Involved circuit

Rif.

Involved circuit

E1

Starting enabling control

E6

Parking brake indicator power supply enabling

E2

Relay E3 power supply enabling control with

E3

control - Relay E1 / E2 enabling control

parking brake engaged

E7

Boom extraction solenoid valve enabling control

Steering column switch power supply enabling

E8

ARB solenoid valve enabling control

control with seat switch pressed down

Relay E7 enabling control

E4

Work light switch power supply enabling control

E9

ARB control unit power supply enabling control

E5

Back-up horn cut-out switch power supply

E10

Available

enabling control - Back-up lamp D-4.3 12V DC LAMPS

Use • • • • • •

Voltage

Power

Front low/high beam ............................................................ 24 V ..................................................................

Front position lights ............................................................. 24 V ..................................................................

Side/tail turn signals ............................................................ 24 V ..................................................................

Stop lights and rear position lights ...................................... 24 V ..................................................................

Dashboard and light indicators ............................................ 24 V ..................................................................

Interior lamp ........................................................................ 24 V ..................................................................

CAUTION

Never touch the bulb of halogen lamps (mount type H3) with your fingers: this may damage the lamp (use of a clean cloth or a paper tissue). If you touch it accidentally, thoroughly clean with a paper tissue and some ethyl alcohol.

- Forlì

When switched on, lamps get hot. Before touching a lamp with your fingers, let it cool down.

CAUTION

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MAINTENANCE Handler with telescopic boom TX51-19-M series

D

D-5. REFUELING D-5.1 REFUELING

Part

Product

Diesel engine Engine cooling system Fuel tank Hydraulic system reservoir Front differential gear with reduction gear Front differential gear Front wheel reduction gears Rear wheel reduction gears Brake oil reservoir

Engine oil Water+antifreeze Diesel fuel Hydraulic oil Oil Oil Oil Oil Oil

Capacity (litres) 8.5 Qts. 6.6 Gal. 26.0 Gal. 18.5 Gal. 6.3 Qts. 5.3 Qts. 1.6 Qts. 1.5 Pint 1 Pint

Product specifications see par.

D-5.2.1 D-5.2.5 D-5.2.3 D-5.2.2 D-5.2.2 D-5.2.2 D-5.2.2 D-5.2.2 D-5.2.2

D-5.2 PRODUCT SPECIFICATIONS D-5.2.1 Engine oil Use the oil recommended by the Diesel engine Manufacturer (see the relevant handbook delivered with the machine).

At the delivery, the machine is refilled with: SHELL MYRINA D SAE 15W-40

(API CD-CF ; MIL-L 2104 F)

D-5.2.2 Lubrication oils and filtering elements Refill the machine with following lubricants:

Use

Product

Definition

Power distributor Differential gears - Reduction gears Hydraulic system and brakes

SHELL SUPER GEAR 90 LS SHELL TELLUS T 46

SAE 90 W MIL-L 2105B DENISON HF-1 DIN 51524 parts 2 & 3

ATTENTION Never mix oils of different type or features: this may result in troubles and component breaks.

- Forlì

The machine is fitted with the following filter elements:

Filter

Flow rate l/1'

Filtering

Coupling

Transmission oil filter Service oil filter

150 100

10 µ 60 µ

1"1/4 BSP 2" NPT

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D

MAINTENANCE Handler with telescopic boom TX51-19-M series

D-5.2.3 Fuel Use only Diesel fuel with less than 0.5% sulphur content, according to the specifications of the diesel engine operation handbook.

ATTENTION In cold climates (temperature under 0°F) use only “Arctic” type Diesel fuel, or oil-diesel fuel, or oil-diesel fuel mixtures. The composition of the latter can vary in relation to the ambient temperature up to max. 80% oil.

D-5.2.4 Greases For the machine greasing, use: SHELL lithium-based grease, type SUPER GREASE EP When greasing by pump AGIP graphitized grease, type GR NG 3 When greasing by brush Grasso INTERFLON FIN GREASE LS 2 For the telescopic boom

ATTENTION Avoid mixing greases of different type or features: this may result in troubles and component breaks.

D-5.2.5 Engine coolant

- Forlì

It is advisable to use an antifreeze mixture (50% water-50% antifreeze). At the delivery, the machine is refilled with: CALTEX POLAR ANTIFREEZE (ASTM D3306-74)

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D-6

D

FAULTS AND TROUBLESHOOTING

This chapter represents a practical guide for the operator for fixing the most common failures and, at the same time, detecting those repairs which must be carried out by qualified technical engineers.

If you are unsure about anything, do not carry out operations on the machine, but call in a skilled technician.

WARNING Any repair work, maintenance or troubleshooting must be carried out with machine stopped, boom in rest position or laid on the ground, parking brake engaged and ignition key removed.

D-6.1 Fault - Cause - Solution FAULT DASHBOARDDOESNOTTURNON

CAUSE • The 50A fuse F30 supplying power to the dashboard is blown (engine comparment) • Battery disconnected • Battery down • Battery cut-out switch OFF

ENGINE DOES NOT START Starter does not run

• Forward/reverse gear selector not in neutral position

- Forlì

• • • •

Parking brake not engaged Proximity switches inefficient Battery down Battery cut-out switch OFF

SOLUTION • Replace the fuse • Connect the battery using the relevant switch • Check the battery condition • Switch it on • Selector to neutral position • Engage the parking brake and ensure the relevant light on the dashboard switches on • Check and adjust the distance (see paragraph D-3.13, page 68) • Recharge or replace the battery • Switch it on

ENGINE DOES NOT START Starter runs, but engine does not start

• Fuse F15 blown • No Fuel • Diesel fuel filter clogged • Diesel fuel hose empty (fuel used up)

• • • •

MACHINE DOES NOT MOVE

• Steering column switch in neutral • Parking brake engaged • Fuse F3 blown

• Set the steering column switch correctly • Disengage • Check the fuse; replace, if necessary

THE MACHINE DRIVE IS NOT ENOUGH

• Hydraulic oil filter clogged

• Replace the filter

NO SELECTION OF THE STEERING MODE “ROAD” FUNCTION ON, EVEN

• Fuse F20 controlling the steering selection blown

• Replace the fuse

Check the fuse Refuel See Perkins engine operator manual Refuel, then refer to Perkins engine operator manual

• Set to “CAB” • “ROAD/CAB” switch set to “ROAD”

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D

MAINTENANCE Handler with telescopic boom TX51-19-M series

FAULT

CAUSE

SOLUTION

WHEN SELECTING THE “CAB” FUNCTION

• No “ROAD/CAB” selection

• Check and replace fuse F20, if necessary

LOW PARKING BRAKE ACTION

• Insufficient cable tensioning

• Check and adjust the cable tension by means of the hollow screws • Check and adjsut the lead tightening on the cable heads

NO BOOM LOWERING AND EXTENSION, NO HOLDING FRAME TILTING

• Fuse blown • Emergency button ON

• Replace fuses F2 and/or F24 • Reset the button

ARB SYSTEM IN ALARM (red LED ON)

• Alarm of the overload warning system

• Retract the boom within safety limits

THE HYDRAULIC OIL THERMOMETER DOES NOT WORK

• This is normal, when the outside temperature is low and/or the machine is used for short periods, since the hydraulic oil cannot warm up operating temp.

THE PARKING BRAKE LIGHT DOES NOT LIGHT UP

• Fuse blown

• Replace fuse F15

THE OVERLOAD WARNING SYSTEM DOES NOT WORK

• Fuse blown

• Check and replace fuse F2, if necessary

BOOM DOES NOT MOVE

• Fuse blown • “ROAD/CAB” switch set to “ROAD” • Emergency button ON

• Check and replace fuse F22, if necessary • Set to “CAB” • Reset the button

• Fuse blown

• Replace fuse F20

NO SHIFTING BETWEEN LOW AND HIGH HYDRAULIC GEAR

For all faults which are not listed in this chapter, address to the TEREXLIFT Technical Assistance, your nearest authorised workshop or dealer.

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Document 51-19-M-2-OM - 2ND Edition 10/2000

- Forlì

ATTENTION

INDEX Handler with telescopic boom TX51-19-M series

Section

E

E

- Forlì

TABLES AND ENCLOSURES

Document 51-19-M-2-OM 2ND Edition 10/2000

Page 79

INDEX TABLES AND ENCLOSURES

E-1 TORQUE WRENCH SETTINGS

Dxp

Torque wrench setting (Nm) 4.8

8.8

10.9

12.9

M 4 x 0,7

1.2

2.3

3.2

3.9

M 5 x 0,8

2.3

4.5

6.3

7.5

M6x1

3.9

7.7

10.8

12.10

M 8 x 1,25

9.1

18.2

25.6

30.7

M8x1

9.6

19.2

26.8

32.4

M 10 x 1,5

18.6

36.10

54.10

62.5

M 10 x 1,25

19.4

38.7

54.4

65.3

M 12 x 1,75

31.3

62.6

87.8

105.6

M 12 x 1,25

33.5

66.9

93.8

112.10

M 14 x 2

49.8

99.7

140.3

168.3

M 14 x 1,5

52.9

105.6

149.1

178.6

M 16 x 2

75.3

151.3

212.6

255.4

M 16 x 1.5

78.10

157.10

222.9

267.2

M 18 x 2,5

104.8

208.9

293.8

352.8

M 18 x 1,5

113.7

227.3

320.3

383.8

M 20 x 2,5

147.6

295.2

414.8

497.4

M 20 x 1,5

159.4

318.1

447.10

537.3

M 22 x 2,5

196.3

392.7

552.1

661.10

M 22 x 1,5

211.1

421.4

592.7

711.5

M 24 x 3

254.6

509.10

716.6

863.5

M 24 x 2

269.4

539.5

760.2

907.8

M 27 x 3

372.7

745.4

1047.10

1254.6

M 27 x 2

394.1

789.7

1107

1328.4

M 30 x 3,5

506.3

1011.1

1424.4

1704.8

M 30 x 2

544.7

1092.3

1535.1

1837.7

ATTENTION Sensor maximum driving torque: 15 Nm.