Terex Telelift 3713 SX Service Manual Download

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TELELIFT 3713 SX

TROUBLESHOOTING

Document 57.4402.9200 - 1

Edition 10/2006

INDEX

Section 5

TROUBLESHOOTING

SECTION INDEX

5.1

Introduction

...........................................................................................

page

About this section

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Electrical faults

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5.4

Hydraulic faults

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Courtesy of Crane.Market

Summary of Contents for Telelift 3713 SX

Page 1: ...INDEX Handler with telescopic boom Telelift 3713 SX From serial n 09944 to serial n 16244 SERVICE MANUAL Code 57 4402 9200 1st Edition 10 2006 English Edition Courtesy of Crane Market...

Page 2: ...Document 57 4402 9200 1st Edition 10 2006 INDEX TELELIFT 3713 SX Intentionally blank page Courtesy of Crane Market...

Page 3: ...to unauthorised workshops and third parties in general and not to photocopy or reproduce this manual or parts of the same in any way without the prior written authorisation of TEREXLIFT to do so If bu...

Page 4: ...Courtesy of Crane Market...

Page 5: ...losing the information in the same in any way to unauthorised workshops and third parties in general and not to photocopy or reproduce this manual or parts of the same in any way without the prior wri...

Page 6: ...X Revision Revised pages Notes Issued by No Date 1 10 2006 Publication 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 30 31 32 33 34 35 36 37 38 39 40 TELELIFT 3713 SX LIS...

Page 7: ...INTRODUCTION Sect 1 SAFETY RULES Sect TECHNICAL SPECIFICATIONS Sect SCHEDULED MAINTENANCE INSPECTIONS Sect 4 SCHEDULED MAINTENANCE PROCEDURES Sect 5 TROUBLESHOOTING Sect 6 SCHEMES Sect 7 REPAIR PROCE...

Page 8: ...ocument 57 4402 9200 1st Edition 10 2006 INDEX Machine denomination Literature valid up to serial number Telelift 3713 SX 11321 TELELIFT 3713 SX SERIAL NUMBER IDENTIFICATION 6 Courtesy of Crane Market...

Page 9: ...rocedures However several procedures require specialized skills as well as specific tools and equipment Intheseinstances westronglyrecommendlettingservice and repair the machine at an authorized TEREX...

Page 10: ...ircuit for the telescopic boom movements secondary side The assembly of the two pumps involves they have a rotation velocity equal to the speed of the diesel engine A third Casappa open loop gear pump...

Page 11: ...ar These two valves are intended to limit possible shocks on the steering wheel due to overstress on the steering cylinders The three pressure reducing valves are installed in the hydraulic drive 14 a...

Page 12: ...nergised by the activation of the pushbutton placed at the top of the main lever in the cab the oil coming from section 1 of the main valve is sent to the extension cylinders 6 and 8 ofthetelescopicbo...

Page 13: ...the left outrigger cylinder 4 equipped with double acting compensation valve 5 serving also as a safety valve through the lateral displacement of the special lever placed in the driving place Section...

Page 14: ...switch set at 70 bar and connected to port F sends an electrical warning signal when the pressure inside the feeding circuit of the brake line is too low to guarantee the minimum braking efficiency T...

Page 15: ...Document 57 4402 9200 1st Edition 10 2006 INDEX vii TELELIFT 3713 SX INTRODUCTION Telelift 71 SX hydraulic schematic Courtesy of Crane Market...

Page 16: ...Document 57 4402 9200 1st Edition 10 2006 INDEX TELELIFT 3713 SX INTRODUCTION viii Intentionally blank page Courtesy of Crane Market...

Page 17: ...ETY INFORMATION SECTION INDEX 1 1 Safety rules page 1 1 1 Personal safety 1 1 Workplace safety 1 General remarks 4 1 Servicemen s requisites 4 1 1 Personal protective equipment 5 1 4 General safety pr...

Page 18: ...volve your own as well as the others safety and that can result in serious or lethal injury Draws the attention to situations that involve your own as well as the others safety and that can result in...

Page 19: ...into machine components and cause damage Be sure that your workshop or work area is properly ventilated and well lit Be sure any forklift overhead crane or other lifting or supporting device is fully...

Page 20: ...tact TEREXLIFT the assistance service is at your disposal Addresses phone and fax numbers are given in the cover and in the title page of this manual 1 SERVICEMEN S REQUISITES The operators who use th...

Page 21: ...nd represent a danger for personnel 1 4 PRECAUTIONS DURING WORK Do not walk or stop under raised loads or machine parts supported by hydraulic cylinders or ropes only Keep the machine handholds and ac...

Page 22: ...k for pressure leaks Fine jets of air oil or fuel can injure you Neither smoke nor use open flames if there is a risk of fire or close to fuel oil or batteries Do not leave fuel cans or bottles in uns...

Page 23: ...system 4 10 Machine sound levels 4 11 Vibration levels 5 1 Refuelling 5 1 Tightening torques 6 14 Drill diameters for threads 8 2 15 Standard tightening torques for fitting seals 9 16 Locking materia...

Page 24: ...0 G Length to the front tyres mm 3910 H Length to the attachment holding plate mm 5610 I Ground clearance mm 460 J Max width with extended outriggers mm 2930 Internal steering radius mm 1300 External...

Page 25: ...h 0 8 Travel speed km h 0 30 Max slope with full load 54 either forward or reverse motion TELELIFT 51 4010 6 PAYLOAD AND REACH Telelift 71 SX Max lifting height with outriggers mm 12640 without outri...

Page 26: ...4 cylinders in line 4 strokes direct injection Diesel 4 cylinders in line 4 strokes direct injection Bore x Stroke mm 103x127 105x127 Total displacement cc 4232 4400 Power at 2300 rpm kW 63 5 74 4 TEL...

Page 27: ...h device can cause radio disturbance In such cases the operator is required to take suitable measures 1 REFUELLING Telelift 71 SX Diesel engine l 11 5 Engine cooling system l 15 Fuel tank l 135 Hydrau...

Page 28: ...4 4 353 0 317 7 1 5 24 14 10 8 218 3 196 5 308 1 277 3 369 3 332 4 18 2 5 27 14 12 8 288 7 259 8 406 1 365 5 487 7 436 9 1 5 27 14 12 8 314 2 282 8 442 8 398 5 530 6 477 5 20 2 5 30 17 12 10 408 1 367...

Page 29: ...0 120 0 170 0 1 5 210 0 295 0 130 0 185 0 18 2 5 270 0 390 0 170 0 245 0 1 5 305 0 425 0 190 0 265 0 20 2 5 305 0 540 0 190 0 340 0 1 5 425 0 600 0 260 0 375 0 22 2 5 510 0 720 0 320 0 450 0 1 5 570 0...

Page 30: ...5 10 44 10 10 10 20 x 1 5 10 68 10 38 10 50 M 14 x 2 12 21 11 83 12 00 x 1 5 12 68 12 38 12 50 M 16 x 2 14 21 13 84 14 00 x 1 5 14 68 14 38 14 50 M 18 x 2 5 15 74 15 29 15 50 x 1 5 16 68 16 38 16 50 M...

Page 31: ...1 5 8 12 225 1 7 8 12 270 2 12 245 2 1 4 12 360 FRONT O LOK Parker SEALS Thread TIGHTENING diameter TORQUES 0 10 FRONT O LOK Parker SEALS inc mm Nm 9 16 18 25 11 16 16 40 13 16 16 55 1 14 80 1 3 16 1...

Page 32: ...5 L 42 245 G 1 4 M12x1 5 S 6 50 G 1 4 M14x1 5 S 8 50 G 3 8 M16x1 5 S 10 80 G 3 8 M18x1 5 S 12 80 G 1 2 M22x1 5 S 16 105 G 3 4 M27x2 S 20 220 G 1 M33x2 S 25 370 G 1 1 4 M42x2 S 30 500 G 1 1 2 M48x2 S...

Page 33: ...573 Formed in place gasket 150 0 2 Slow Excellent Loctite 574 Formed in place gasket 150 0 5 Rapid Excellent Loctite 510 Formed in place gasket 200 0 2 Moderate Excellent Loctite 5699 Formed in place...

Page 34: ...PES Use ropes or other hoisting accessories suitable to the weight of the part to be handled For ropes refer to the following table STRANDED ROPES Rope diameter Max admissible load mm kg 10 1000 11 2...

Page 35: ...otection equipment e g goggles gloves facial screen etc Wrap up the end of the pipe to be disconnected with some rags and slowly loosen the pipe connector so that air comes out as slow as possible 1 B...

Page 36: ...1 07 0703 0424 Indicator light 1 07 0703 0426 Indicator light 1 07 0703 0427 Fuel indicator light 1 07 0703 0029 Start switch 1 638226 Selector switch 1 07 0703 0430 Switch 1 07 0703 0433 Switch 1 07...

Page 37: ...610 0002 Rear view mirror 1 09 0803 0023 Lock 1 09 0803 0024 Hook latch 1 53 3000 8200 Manifold 1 04 4210 0001 Female coupling optional 1 04 4210 0000 Male coupling optional 1 639395 Seals kit optiona...

Page 38: ...ion 10 2006 INDEX 0 MACHINE PAINT COLOUR STANDARD machines GREY RAL 7012 WHITE RAL 1013 MAT BLACK RAL 9005 from June 2004 for cylinders AUSA machines ORANGE RAL 2004 GENIE machines BLUE GENIE GREY GEN...

Page 39: ...h is the external pulley of the output shaft BOOM LIFTING LOWERING 1 CHECKING THE CYLINDER MOVEMENT TIMES BOOM EXTENSION RETRACTION ATTACHMENT DUMPING Telelift 71 SX Time s up down Max engine speed 13...

Page 40: ...00 1st Edition 10 2006 INDEX OUTRIGGERS MOVEMENT MACHINE SWAY Telelift 71 SX Time s up down Max engine speed 6 7 Min engine speed 14 19 Telelift 71 SX Time s right to left left to right Max engine spe...

Page 41: ...al engine running at max speed Also calibrate the fork inclination safety valves position B of the Walvoil main valve encl 1 Move one of the cylinders to end of stroke and act on valve A to set the pr...

Page 42: ...Connect a 0 60 bar manometer to port ref C encl 3 to measure the low pressure Connect a 0 600 bar manometer to port ref D to measure the high pressure Hold the selector to neutral position and make su...

Page 43: ...sure is not reached with the engine running at 2000 revs adjust the spark advance valve G encl 3 The spark advance screw must never be rotated beyond the vertical axis of the pump observe the referenc...

Page 44: ...NG THE POWER STEERING Connect a 0 250bar pressure gauge to position Z encl 5 Select the front wheel steering mode Move the steering cylinder to end of stroke and make sure the value of the power steer...

Page 45: ...electric valve which activates at any pressure of the deadman button on the joystick If the deadman button is defective and it is not possible to activate the joystick functions press the valve cap up...

Page 46: ...TELELIFT 3713 SX TECHNICAL SPECIFICATIONS 4 Document 57 4402 9200 1st Edition 10 2006 INDEX HYDRAULIC SYSTEM LIFTING Encl 1 B W A 5 Courtesy of Crane Market...

Page 47: ...TELELIFT 3713 SX TECHNICAL SPECIFICATIONS 5 Document 57 4402 9200 1st Edition 10 2006 INDEX HYDRAULIC SYSTEM FORK BALANCE Encl L L Courtesy of Crane Market...

Page 48: ...FT 3713 SX TECHNICAL SPECIFICATIONS 6 Document 57 4402 9200 1st Edition 10 2006 INDEX HYDRAULIC SYSTEM TRANSMISSION Encl F D C F I G H E H 0 600 00 00 100 500 400 0 60 0 0 10 50 40 Courtesy of Crane M...

Page 49: ...TELELIFT 3713 SX TECHNICAL SPECIFICATIONS 7 Document 57 4402 9200 1st Edition 10 2006 INDEX HYDRAULIC SYSTEM SERVICE AND PARKING BRAKES Encl 4 0 00 150 100 50 50 00 T R Courtesy of Crane Market...

Page 50: ...TELELIFT 3713 SX TECHNICAL SPECIFICATIONS 8 Document 57 4402 9200 1st Edition 10 2006 INDEX HYDRAULIC SYSTEM POWER STEERING Encl 5 X Z 0 00 150 100 50 50 00 A Courtesy of Crane Market...

Page 51: ...a display The main module A Fig 1 contains the electronics and the trimmers for calibrating the system The 8 pin screw connector B connects the main module to the electric system of the machine and to...

Page 52: ...ector B This output is connected to the coil of a relay which upon opening controls a solenoid valve that locks out the extension and descent movements of the boom The alarm is deactivated when the st...

Page 53: ...machine is clear of persons or objects The upper and lower ends of the readout scale are adjusted with multiturn trimmers The system allows to choose between two ranges depending whether the stabilis...

Page 54: ...t through the shield Do not pull on the flat cable that connects the display The electronic circuit inside the main module is extremely sensitive Soot dust fingerprints oil or grease can compromise th...

Page 55: ...d This value is given as a reference and can vary according to cell model ADOS or NBC Find the value with the boom horizontal and full retracted without any weight applied on the forks C A B D E 8 7 6...

Page 56: ...tage is present when the alarm is not activated S load cell shield not connected to the instrument The shield of the cable is connected to the body of the load cell once the cell is fitted on the rear...

Page 57: ...fuse from the fuse holder on the power supply of the system see connection diagram gather the load cell cable and the wires coming from the dashboard near the connector on the side of the main module...

Page 58: ...s are secure connectthewiresonthescrewconnectorBfollowing the diagram Tighten the screws on the connector checking that all wires are securely fastened Tie the wires with a cable tie Fig 10 after chec...

Page 59: ...the display and secure the flat cable Fig 13 insert the display in the hole on the dashboard the display must be locked Otherwise it should be secured to the dashboard with RTV silicone or hot melt gl...

Page 60: ...nt of the tyres to the center of gravity of the load Fig 14 shows an example load chart without stabilisers on the right side with stabilisers down on the left When the stabilisers are up the maximum...

Page 61: ...D5 turns on while the boom is being extended and therefore the boom locks out turn trimmer VR clockwise approximately five turns 6 Lower the boom with an abrupt movement of the control lever in order...

Page 62: ...case and the display are firmly in place inside the cab and are not touching hydraulic hoses or any moving part Make sure all cables are firmly held in place in order to prevent them from rubbing or...

Page 63: ...und Ensure every wire from the load cell is insulated from ground the reading must show resistance greater than 20 M Smaller measured values can be caused by a damaged insulation usually a result of a...

Page 64: ...of the load cell is the ratio between the output voltage in milliVolt and the excitation voltage in Volt when the cell is loaded with a weight equal to its capacity All load cells fitted in the rear a...

Page 65: ...TELELIFT 3713 SX TECHNICAL SPECIFICATIONS 4 Document 57 4402 9200 1st Edition 10 2006 INDEX DLE SYSTEM COMPONENTS POSITION MAIN UNIT AND CONTROL PANEL LOAD CELL WITH PIN Courtesy of Crane Market...

Page 66: ...8 GND 12V in work condition 0V in overload condition Pin 7 GND feedback ok 12V Pin 9 positive Pin10 boom retracted with forks in horizontal position without load 1 1 1 4 mV boom extended with forks in...

Page 67: ...signal Electrical power to load cell equal to 5 V Channel 1 Pin 16 positive Pin 17 negative Load cell signal in range 0 1 5 mV Channel 1 Pin 10 positive Pin 9 negative Machine without load on the fork...

Page 68: ...e keys to use and the relevant meaning are shown below Press to enter number 0 Press to enter number 1 Press to confirm the sequence entered The access code currently used is 1001 Therefore you should...

Page 69: ...ad Press to confirm the LOADED calibration of the machine and check that the alarm triggers The audible alarm will sound to confirm the command has been executed Move the boom fully in while holding t...

Page 70: ...t weights after a calibration strictly respect the values shown on the load diagram lengths are referred to the distance between the front part of the wheels and the centre of the load on the forks lo...

Page 71: ...t Edition 10 2006 INDEX DIAGRAM TELELIFT 71 SX WITH STABILISERS LOWERED TO THE GROUND 1000 kg at 7 0 metres 1 8 9 10 m 0 1 4 5 6 7 8 9 1010 5900 1840 4 5 6 7 8740 1 0 700 12640 1500 kg 0 0 0 k g 7 0 0...

Page 72: ...2 9200 1st Edition 10 2006 INDEX DIAGRAM TELELIFT 71 SX ON WHEELS 1000 kg at 5 10 metres 6 5 4 1 0 1 m 10 9 8 7 6 5 4 1840 1 0 8720 000 kg 740 5820 1290 12470 1 11 10 9 8 7 4 0 1 00 kg 1000 kg 1500 kg...

Page 73: ...er disconnect key is turned LED4 ON if the interlock relay is active machine safe without alarms D Software version existing in the DLE unit this function allows you to see the software version includ...

Page 74: ...ing The alarm triggers even in the absence of malfunctions if the load limiter cutout key is used when the instrument is started Action The relay or the cable can be shorted check The limiter s output...

Page 75: ...st Edition 10 2006 INDEX If you want to check or save the system parameters and variables you have to open the relevant windows and check the values contained in these Pict 1 Pict Pict Pict 4 Pict 5 P...

Page 76: ...select Prj Selection Type in the correct path of file CFG IT or look for the same in the Windows folders suing the Browse function The file must not necessarily be in the path shown in the following e...

Page 77: ...type of machine you must select adequate parameters that is DLE_01 version _01 or higher Hardware Type RS Port COM1 usually this is the port but it can change in relation to the connected PC Baudrate...

Page 78: ...download a setting of the machine onto a PC or Carica Load if you want to transfer a setting saved in the PC into the machine The following window will be displayed so you can type in the password Fo...

Page 79: ...ters and variables no password is needed All you have to do is connecting the DLE display with the power cord supplied by TEREXLIFT code 07 0736 0014 and proceed as explained below Connect the DLE con...

Page 80: ...n the variables window as shown in picture 8 Clicking with the mouse another window opens see picture 9 which will display the real variations on the machine so you can compare the same with the param...

Page 81: ...02 9200 1st Edition 10 2006 INDEX DLE MONITORING WITH B6 WINSCOPE PARAMETERS Displaying the parameters Simulation of the variables load calculated in relation to the calibration value of the analog si...

Page 82: ...ta between readings of analog channels 1 and 2 expressed as a default 10 current 20 11 SpanForche Limiter intervention percentage in case of work with stabilised machine and forks Default 100 as per c...

Page 83: ...y to the platform Value saved in analog channel 1 during calibration with empty machine 21 C1NavicellaCarico Value saved in analog channel 1 during calibration with loaded machine 22 C2NavicellaVuoto...

Page 84: ...ription 05 PCorder 0 You can save changes effected to the parameters by setting this variable to 1 The variable will return to 0 once the value has been saved 10 C1swl Load percentage of cell 1 0 cali...

Page 85: ...E INSPECTIONS 1 Document 57 4402 9200 1st Edition 10 2006 INDEX Section SCHEDULED MAINTENANCE INSPECTIONS SECTION INDEX 1 Introduction page About this section Maintenance table 4 4 Maintenance inspect...

Page 86: ...ntenance of this machine Scheduled maintenance must be carried out at the intervals indicated in the MAINTENANCE REPORT Failure to properly complete each inspection when required may cause death serio...

Page 87: ...very two months A B C D Every six months A B C D E Yearly A B C D E F Every 5 years afterwards every 2 years G Maintenance table The maintenance table contains general information on the type of inter...

Page 88: ...clean the radiator A 10 Check the hydraulic oil level in the tank A 11 Check the greasing of the boom section pads A 1 Grease the forks A 1 Grease all joints of the boom the rear axle shaft joint the...

Page 89: ...e four wheel reduction gears C 4 Check the main filtering element of the engine air filter Replace if necessary C 5 Check the clamping of the cableheads to the battery terminals C 6 Check the air suct...

Page 90: ...7 Clean the air filter in the cab D 8 Change the hydraulic oil filter of the transmission TABLE E Every 1000 working hours or every six months E 1 Change the safety element of engine air filter E Cha...

Page 91: ...the boom the rear axle shaft joint the transmission shafts the front and rear axles and any equipment of the machine A 14 Lighting electric system A 15 Efficiency of braking system and parking brake A...

Page 92: ...the maintenance tables in this sectionandthestep by stepprocedures in section 4 to learn how to perform these inspection If any inspection receives an N tag and remove the machine from service repair...

Page 93: ...X Section 4 SCHEDULED MAINTENANCE PROCEDURES SECTION INDEX 4 1 Introduction page 4 About this section 4 TABLE A procedures 4 4 4 TABLE B procedures 5 4 5 TABLE C procedures 0 4 6 TABLE D procedures 4...

Page 94: ...NCE REPORT Failure to properly complete each inspection when required may cause death serious injury or substantial machine damage Immediately tag and remove from service a damaged or malfunctioning m...

Page 95: ...wn as well as the others safety and that can result in serious or lethal injury Draws the attention either to situations that involve your own as well as the others safety and that can result in minor...

Page 96: ...s 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 Place a container of suitable size under the...

Page 97: ...evel in the power divider Stop the machine on a level ground and engage the parking brake Clean the plug A all around then remove it and check if oil is level with the hole If necessary add new oil th...

Page 98: ...ewdriving machine Lower the machine to the ground Re tighten all nuts to a torque 440 Nm Checkthetighteningofwheelsonehourafterthejob They might get loose until they do not stay correct On new machine...

Page 99: ...rting your daily work proceed with a random check of the bolts For the correct tightening torques please refer to par 2 13 in section 2 Technical Specifications A 4 CHECK THE COUPLINGS FOR OIL LEAKS B...

Page 100: ...e Contact TEREXLIFT Service Centre if replacement manuals are needed A 6 INSPECT THE DECALS AND PLACARDS Maintaining all of safety and instructional decals and placards in good condition is mandatory...

Page 101: ...tridge by beating it some times on the ground paying attention not to damage the filtering element Do not dry clean the filtering element Check the filter box for cracks light showing through Smear th...

Page 102: ...ing using compressed air Direct a jet of compressed air toward radiator paying attention not to damage its fins Remove any loose particles of dirt with some water Cleaning using water under pressure o...

Page 103: ...gers but a piece of cardboard to detect oil leaks Check the hydraulic oil level visually through the special level C fitted into the tank When necessary add new oil through filler D Check the oil leve...

Page 104: ...ides of the profile These pads are secured to both fixed and mobile part of every section At regular intervals check that the telescopes are well greased in correspondence of the sliding pads If neces...

Page 105: ...intervention zone to avoid that mud dust or other matters can mix with the lubricant and reduce or annihilate the lubrication effect Remove any old grease with a degreaser from the telescopes before...

Page 106: ...ters can mix with the lubricant and reduce or annihilate the lubrication effect Remove any old grease with a degreaser from the telescopes before smearing them with new grease Regularlygreasethemachin...

Page 107: ...d use the table below as a reference When switched on lamps get hot Before touching a lamp with your fingers let it cool down Never touch the bulb of halogen lamps mount type H3 with your fingers this...

Page 108: ...n 10 2006 INDEX A 15 CHECK THE EFFICIENCY OF BRAKING SYSTEM AND PARKING BRAKE For any intervention on the braking system adjustment and or substitution of the brake discs address to the TEREXLIFT Tech...

Page 109: ...solid and level ground 2 Set the steering selection switch A to four wheel steer pos 3 Rotate the steering up to its stop either to the right or to the left 4 Setthesteeringselectionswitchto two wheel...

Page 110: ...e machine s forks To check the efficiency of the fork balancing system obey the instructions below Drive the machine to a flat smooth ground Move the retracted boom fully down and align the forks with...

Page 111: ...wn Checking the machine start control at every use Attempt to start the engine with the forward or reverse gear put The engine must not start If the engine starts contact the TEREXLIFT Technical Servi...

Page 112: ...utrigger at a time With the outriggers up light A on the load limiter panel must be off with the outriggers down to the ground the same light must be on Should it not be the case contact the TEREXLIFT...

Page 113: ...e parking brake at every use To check the efficiency of the microswitch on the parking brake proceed as follows sit on the driving place put the parking brake and attempt to move with the machine The...

Page 114: ...sure Use protection gloves and keep your face at a safe distance Weekly check the coolant level within pan A before starting working when coolant is cold When necessary add clean water or an antifreez...

Page 115: ...ashing the buzzer sounds an error code is shown on the display and the machine enters the alarm mode and cannot be operated The meaning of the error messages is shown in Section 2 To do a manual check...

Page 116: ...ed with the steps below Move the boom to the zero position fully retract the boom and hold the retract system over relief for approx 20 seconds Raise the boom to approx 60 and operate the retract func...

Page 117: ...ocument 57 4402 9200 1st Edition 10 2006 INDEX 4 4 TABLE B PROCEDURES B 1 CHANGE THE ENGINE OIL B CHECKTHETENSIONOFTHEALTERNATOR BELT For the engine maintenance please refer to the specific Operator h...

Page 118: ...refer to the table below 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 Always use tyres having the dimens...

Page 119: ...rewdriving machine Lower the machine to the ground Re tighten all nuts to a torque 440 Nm Checkthetighteningofwheelsonehourafterthejob They might get loose until they do not stay correct On new machin...

Page 120: ...200 1st Edition 10 2006 INDEX B 5 CHECKTHETIGHTENINGOFTHECARDAN SHAFT SCREWS Check every week that the screws of the Cardan shafts A and B are tight For the correct tightening torques please refer to...

Page 121: ...using compressed air Direct a jet of compressed air toward radiator paying attention not to damage its fins Remove any loose particles of dirt with some water Cleaning using water under pressure or s...

Page 122: ...AND IN THE POWER DIVIDER To check the oil level in the front and rear differential gears Stop the machine on a level ground and engage the parking brake Place a container of suitable size under the pl...

Page 123: ...through plug A until it is level with the hole Refit and tighten filler level plug A Recommended oil FUCHS TITAN GEAR LS 85 W 90 API GL 5 LS GL 5 A B C CHECK THE OIL LEVEL IN THE FOUR WHEEL REDUCTION...

Page 124: ...ent D Clean the filter bowl Clean the cartridge by beating it some times on the ground paying attention not to damage the filtering element Do not dry clean the filtering element Check the filter box...

Page 125: ...BATTERY TERMINALS Check the cable clips are well secured to the battery terminals To tighten the clips always use a box wrench never pliers Keep out of items which can produce sparks of naked flames o...

Page 126: ...KTHEAIRSUCTIONHOSEBETWEEN ENGINE AND FILTER Check the state of sleeves A forming the air suction line between engine and filter every month Ifyouusethemachinecontinuouslyforseveraldays check these sle...

Page 127: ...ument 57 4402 9200 1st Edition 10 2006 INDEX C 7 CHECK THE CYLINDER CHROMIUM PLATED RODS Visually check the cylinder rods for scoring every month For this operation fully extend all of the cylinders a...

Page 128: ...g mechanical parts as they could rub against such parts and get damaged Replace any worn hoses immediately before using the machine again C 9 CHECK THE ELECTRIC CABLES Every month do a random check of...

Page 129: ...stable pads located on the four sides of the profile These pads are secured to both fixed and mobile part of every section Allpadscanbeadjustedbythespecialshimsnotsupplied by TEREXLIFT Pads must compu...

Page 130: ...ut slots Fit the necessary amount of shims If the residual thickness of the pad is insufficient or near the maximum wearing limit renew the pad Tightenthescrewsfixingthepadsattherecommended torque see...

Page 131: ...OOM SECTIONS Check every month that the telescopes are well greased in correspondence of the sliding pads If necessary scrape off the old grease and brush new grease We recommend using INTERFLON greas...

Page 132: ...ry leads since they can short the terminals and burn you Beforedisconnectingthebattery setallswitches within the cab to OFF Todisconnectthebattery disconnectthenegative lead from the frame earth first...

Page 133: ...ht and extend it some centimetres Loosen the oil hoses to the cylinder of which you are checking the valve with caution To check the efficiency of the block valves of the outriggers lower them to the...

Page 134: ...action generated does not result in an uncontrolled movement of the machine TO REMOVE THE BLOCK VALVES OR THE CYLINDERS Lower the boom to the ground in a firm way since the removal of the block valve...

Page 135: ...that the amount of smoke coming out of the exhaust is normal repeat the check while accelerating the engine Do this check outdoors or use an adequate smoke extraction system In case of excess smoke st...

Page 136: ...ight For this operation use a torque wrench and tighten the screws to a torque of 18 Nm D 4 CHECK THE BACKLASH BETWEEN PINS AND BUSHINGS IN ALL JOINTS Every 6 months check the machine randomly to be s...

Page 137: ...00 1st Edition 10 2006 INDEX D 5 HAVETHEHYDRAULICSYSTEMCHECKED BY A SKILLED TECHNICIAN Every 6 months we recommend have the efficiency of the hydraulic system checked by a skilled technician In case o...

Page 138: ...king brake Unscrew wing nut A and remove cover B Unscrew wing nut C and remove the outer element D Clean the filter bowl Fit a new cartridge D smear a thin coat of grease on its seals and check it is...

Page 139: ...tering cloth is damged Cleaning and changing the cartridge Shut the engine down and engage the parking brake Pull filter A out of the housing accessible from the outside of the cab Clean the filter bo...

Page 140: ...filter canister B with the special wrench provided Renew the canister Before fitting a new canister thoroughly clean and grease both bowl and gasket Hand tighten and re open cock A The handling and d...

Page 141: ...wing nut C and remove the outer element D Loosen wing nut E and remove the inner element F Clean the filter bowl Smear the seal with grease then mount the new element and make sure it is correctly pos...

Page 142: ...r Refit and tighten drain plug C Add new oil through the filler until it is level with hole A Refit and tighten plugs A and B Recommended oil FUCHS TITAN GEAR LS 85 W 90 API GL 5 LS GL 5 To change the...

Page 143: ...nd and ensure the parkingbrakeisengagedandplugAisorientedalong the vertical axis Place a container of suitable size under the plug Unscrew plug A and drain any oil from the reduction gear Rotate the w...

Page 144: ...oil leaks Remove the drain plug and allow oil to flow out into the container Remove the inspection cover E of tank Carefully wash the tank with Diesel oil and blow a jet of compressed air Refit the dr...

Page 145: ...g brake is engaged Place a container of suitable size under the tank then allow oil to flow out until its level is under the inspection hatch E 90 litres approx Remove the inspection hatch and unscrew...

Page 146: ...o drain the antifreeze Let the engine cool down Unscrew the plug at the bottom of the radiator or disconnecttherubberhose ifnoplugispresent Allow the coolant to flow out into a special container Refit...

Page 147: ...TATE OF THE STRUCTURE Five years or 6000 hours after the first placing into operation of the machine whichever occurs first check the state of the structure paying an extreme attention to the welded s...

Page 148: ...TELELIFT 3713 SX SCHEDULED MAINTENANCE INSPECTIONS 56 4 56 Document 57 4402 9200 1st Edition 10 2006 INDEX Intentionally blank page Courtesy of Crane Market...

Page 149: ...OUBLESHOOTING 5 1 Document 57 4402 9200 1st Edition 10 2006 INDEX Section 5 TROUBLESHOOTING SECTION INDEX 5 1 Introduction page 5 About this section 5 Electrical faults 4 5 4 Hydraulic faults 11 Court...

Page 150: ...nd operating instructions printed in the Operator Manual of the machine Be sure that all necessary tools are available and ready for use Read each appropriate flow chart thoroughly Pay special attenti...

Page 151: ...following tables are given to help you find such parts on the schemes and diagrams in chapter 6 The tables should be read as follows once you have identified the problem search this problem in the pro...

Page 152: ...rrupted Electric line between relay K11 and relay K01 defective Check the battery charge and replace the battery if necessary Turn to correct position or repair if damaged Check the ground clamp conne...

Page 153: ...ed Parking brake micro switch damaged Rexroth pump solenoid valves damaged Electric connecting lines Check the relay and replace if necessary Check the starting motor and replace if necessary Check th...

Page 154: ...ontinuity and repair if necessary Check the position change the selector if damaged Check the fuse and replace if necessary Check the operation of the button on the control lever replace if necessary...

Page 155: ...chine is on wheels or stabilised No steering mode selction two wheels four wheels crab The horn doesn t work The beacon doesn t work Check the fuse and replace if necessary Check the micro switches an...

Page 156: ...icator light X1 defective Electric connecting lines Pressure switch B11 for low engine oil pressure damaged Dashboard indicator light X1 defective Check the line continuity and repair if necessary Che...

Page 157: ...tric connecting lines Hour meter damaged Alternator A1 damaged Electric connecting lines Check the line continuity and repair if necessary Check the thermometer and replace if necessary Check the tran...

Page 158: ...DEX Problem Cause Solution The display of the overload warning system does not turn on 10A fuse F 5 blown DLE display damaged Electric connecting lines Check the fuse and replace if necessary Change t...

Page 159: ...in section 2 Technical specifications Check and replace if necessary Check and replace if necessary Change the pump Change the motor Re calibrate the pump as indicated in section 2 Technical specifica...

Page 160: ...rity valve of pump If necessary change the power steering Check cylinders and their internal seals The pump doesn t deliver oil Check and replace if necessary The pump priority valve is clogged or dam...

Page 161: ...m damaged third telescope extension Extension cylinder outside the boom damaged second telescope extension Carefully check the pump and replace if necessary Carefully check the pump refer to section b...

Page 162: ...e DFE module damaged Check the valve clean or replace if necessary Check the valve clean or replace if necessary Check the valve clean or replace if necessary Check the efficiency of the internal slid...

Page 163: ...damaged Fan motor damaged Remove the valves and check for foreign matters Change the valves if broken Remove and clean the valves and check their seals replace if necessary Checkandreplacethehosesif d...

Page 164: ...TELELIFT 3713 SX TROUBLESHOOTING 5 16 Document 57 4402 9200 1st Edition 10 2006 INDEX Intentionally blank page Courtesy of Crane Market...

Page 165: ...ms 11 6 4 1 Wiring diagrams for machines with old cab 11 6 4 1 1 Wiring diagrams Component description 15 6 4 1 Fuses and relays 17 6 4 1 Engine compartment fuses and relays 18 6 4 Wiring diagrams for...

Page 166: ...ring Mechanical control with roller Electro magnetic control with winding solendoid Control with electric motor M Direct pressure control Indirect piloted pressure control Control with electromagnet a...

Page 167: ...y and two position distributor with hydraulic control Electro hydraulic single acting servo valve Distributor with mechanical control and span proportional to the action of the same control Two positi...

Page 168: ...EF LS LS L R T P Cilindro forche Forks tilt cylinder Cilindro equilibrio Forks levelling slave cylinder B 1 A 2 B 2 A 3 B 3 28 29 Cilindro sollevamento Boom lift cylinder A T G B U Leva tipo joystik M...

Page 169: ...valve for 3rd telescope extension cylinder 3rd telescope extension cylinder 4 Right outrigger cylinder 5 Right outrigger cylinder block valve 6 Left outrigger cylinder 7 Left outrigger cylinder block...

Page 170: ...6 6 INDEX TELELIFT 3713 SX SCHEMATICS Document 57 4402 9200 1st Edition 10 2006 Intentionally blank page Courtesy of Crane Market...

Page 171: ...1 SX From serial no 1 076 To serial no 14845 6 Telelift 71 SX from serial no 1 076 up to serial no 14845 TELELIFT 3713 SX SCHEMATICS 6 7 Document 57 4402 9200 1st Edition 10 2006 INDEX Courtesy of Cra...

Page 172: ...TELELIFT 71 SX From serial no 14846 To serial no xxxxx 6 Telelift 71 SX from serial no 14846 TELELIFT 3713 SX SCHEMATICS 6 8 Document 57 4402 9200 1st Edition 10 2006 INDEX Courtesy of Crane Market...

Page 173: ...ry ACCUMULATORS Thermocouple Element Ring TERMINALS AND GROUNDS Ground Terminal Ground to frame Knot Protection ground Frame ground 2 Coil COILS Mechanical coupling coil Winding A C coil Coil with dio...

Page 174: ...Thermal CONTACTS Normally open NO Normally closed NC NO limit switch NC limit switch Contactor Magneto thermal closure Thermal closure Thermal opening Exchange NC proximity NO proximity NO mechanical...

Page 175: ...N 1 H 1 N 1 SCH N 1 H 1 GR 1 CG 1 GE 1 M 1 25 N 1 GE 1 M 1 H 1 1 26 2 4 3 SCH 6 5 5 6 3 4 1 2 AF 1 5 AN 1 FN 1 5 A 1 3 5 6 4 1 2 ER 1 3 N 1 5 5 6 4 R 1 5 F 1 1 2 CF 1 CF 1 N 1 5 F 1 R 1 5 ER 1 N 1 5 M...

Page 176: ...7 8 5 6 DG 1 CG 1 3 4 2 3 1 2 C 1 N 2 5 N 2 5 2 1 2 1 4 3 4 3 5 6 5 6 3 3 5 5 6 6 4 4 2 2 1 1 6 6 4 5 4 5 2 2 3 3 1 1 3 3 5 5 6 6 4 4 2 2 1 1 C B B C A A GR 1 CG 1 N 1 N 1 N 1 F 1 5 12v 12v R 1 N 1 HN...

Page 177: ...1 G 1 DE 1 RN 1 N 1 FR 1 GN 1 R 4 FN 1 5 CE 1 5 6 N 1 MG 1 AF 1 N 1 0 1 P 2 15 19 50 30 3 58 8 7 RN 1 C 1 DG 1 N 1 M 4 1 2 3 MN 1 11 7 6 5 2 4 3 1 8 10 12 11 9 7 6 5 4 3 2 1 RN 1 RN 1 RN 1 RN 1 RN 1 R...

Page 178: ...Intentionally blank page TELELIFT 3713 SX SCHEMATICS 6 14 Document 57 4402 9200 1st Edition 10 2006 INDEX Courtesy of Crane Market...

Page 179: ...TURN SIGNAL 85 BRAKE FAILURE SENSOR 86 FUEL LEVEL FLOAT Ref Description 1 WARNINGLIGHTS GEN SET BRAKE FAILURE ENGINE OIL PRESSURE WATER TEMPERATURE 2 WARNING LIGHTS POSITION LIGHTS HIGH BEAM TURN SIG...

Page 180: ...6 WAY CONNECTOR RIGHT FRONT LIGHTS CONNECTION 93 BACK UP HORN 94 WHEEL SHAFTING SENSOR 95 3 WAY CONNECTOR WHEEL SHAFTING CONNECTION Ref Description WIRE COLOURS A LIGHT BLUE B WHITE C ORANGE G YELLOW...

Page 181: ...ay 10 F17 Power supply R road safety switch shafting sensor parking brake sensor R8 relay pickup 10 F18 Power supply fuel reserve indicator air filter clogging indicator hydraulic oil temperature indi...

Page 182: ...lashing R11 Platform power supply enabling command R1 T V solenoid valve enabling command R1 Enabling command to R16 relay R14 Engine stop with platform enabled R15 Engine stop enabled by platform key...

Page 183: ...B R1 2 0 M1 5 2 0 G1 G1 A G1 H N1 A G1 H N1 H R1 H R1 H R1 H L1 H L1 H L1 M1 5 M1 5 M1 5 M1 5 M1 5 M V1 M R1 H1 H1 H1 H1 B10 C1 C1 S1 S1 S1 L G1 B R1 B R1 N1 N1 C N1 A4 R4 R10 A4 R6 R4 R1 5 R6 B10 R10...

Page 184: ...ITTING 1 0 15 RELAY CARD A1 F24 10A X6 10 X6 1 X21 21 S17 1 9 5 10 N1 3 0 N1 1 5 M1 5 A G1 L N1 L N1 N1 N1 B R1 B R1 L G1 L G1 A1 9 1 X20 4 X20 5 S13 B R1 4 0 X4 9 X4 2 X6 4 X6 5 X6 6 X6 13 X6 12 K12...

Page 185: ...6 C R1 H V1 V N1 S G1 A B1 A B1 M V1 M V1 M V1 M V1 M V1 M V1 V N1 V N1 N1 N1 N1 N1 N1 S G1 7 0 X21 5 X29 3 H25 Y02 1 2 Y01 1 2 31 4 0 31 2 5 X12 3 X12 2 X12 1 X16 8 X16 1 K9 86 87a 87 85 30 K10 86 87...

Page 186: ...5 XH26 1 XH26 2 XH26 3 XH26 5 H26 57 59c R 31 XH26 6 XH23 1 H23 57 59c L 31 XH23 6 XH23 5 XH23 3 XH23 2 A1 5 0 L1 5 0 A1 5 0 L1 5 0 G N1 6 0 X21 14 X21 18 B12 B12a B16 H20 H24 S30 XH22 1 XH21 1 XH21...

Page 187: ...1 H G1 H G1 Z1 Z1 H B1 V B1 H G1 5 A1 L1 A1 L1 L1 A1 A1 L1 L1 L1 A1 A1 N1 5 X20 3 X19 20 X19 21 N1 6 0 X20 1 X20 2 X21 9 X22 8 X26 5 H G1 4 5 Z1 4 5 H B1 4 5 V B1 4 5 H G1 5 4 5 X11 6 X11 10 X11 9 X11...

Page 188: ...R N1 V1 S N1 G N1 B R1 B R1 B R1 B R1 B R1 N1 N1 N1 5 N1 N1 5 N1 5 N1 N1 N1 N1 5 N1 N1 N1 5 N1 N1 N1 X19 12 N1 5 5 N1 8 0 X2 2 B R1 1 5 X26 8 X26 6 X26 7 X26 12 X20 12 X26 1 X20 13 X20 14 B R1 8 0 V1...

Page 189: ...WN A B1 8 3 C L1 8 3 A N1 V N1 A N1 X26 9 V N1 A N1 8 0 S54 S53 S52 S51 S50 V N1 8 0 X26 10 S N1 9 1 C L1 H1 9 1 X7 10 X7 3 X7 11 X7 4 X7 2 K18 86 87a 87 85 30 S6b S6a X21 1 X5 4 A B1 S N1 N1 N1 B N1...

Page 190: ...B34 A XB33 A XB32 A XB31 A XB34 B XB32 B XB33 B XB31 B XB30 B XB30 A V Z1 V Z1 A B1 A B1 7 5 C L1 C L1 7 5 A N1 7 5 B1 9 1 H V1 V1 F5 10A X7 1 A N1 S2 1 7 2 8 5 6 X26 11 Y20 X21 3 X21 4 C N1 H R1 H R1...

Page 191: ...20 R V1 B G1 C N1 S3 1 7 9 5 10 R N1 R N1 N1 N1 N1 5 X18 9 X18 1 X7 13 X7 11 X7 12 X7 6 X7 7 X7 5 K19 86 87a 87 85 30 X6 2 F13 10A K22 86 87a 87 85 30 R N1 7 5 B N1 7 5 X4 3 X4 1 X4 6 53 7 2 K17 86 87...

Page 192: ...8 S30 HYDROSTOP 4 S50 DEADMAN BUTTON 7 Ref Description Sheet A1 ALTERNATOR 1 B1 BATTERY 1 B11 PRESSURE SWITCH ENGINE OIL FILTER 1 B12 FUEL GAUGE 4 B12A FUEL RESERVE 4 B13 THERMOSTAT HIGH ENGINE WATER...

Page 193: ...2 WAY 90 CONNECTOR X51 4 WAY DEUTSCH CONNECTOR X52 4 WAY DEUTSCH CONNECTOR X53 3 WAY DEUTSCH CONNECTOR X91 2 WAY 90 CONNECTOR X101 BEACON 6 X102 CAB LIGHTS 6 XB30 2 WAY DT CONNECTOR 8 XB31 2 WAY DT C...

Page 194: ...zard warning light switch 15 F17 Position light and signal function switch 10 F18 Outrigger down limit switch 10 F19 Hydraulic operation switch 10 F20 Power supply K13 relay 10 F21 Horn 15 F22 Blank f...

Page 195: ...ICS Document 57 4402 9200 1st Edition 10 2006 6 4 Engine compartment fuses and relays Ref Circuit Amp F 0 Fuse 50 F 1 Fuse 50 F Fuse 15 F Fuse 50 R 5 Relay 70 R 6 Relay 70 R 7 Relay 40 R 5 F 0 R 6 R27...

Page 196: ...MPONENTS ON THE MACHINE All references under form of a digit are referred to hydraulic components the remaining references are initials which can be found on the wiring diagram of the machine 6 5 1 El...

Page 197: ...6 INDEX TELELIFT 3713 SX SCHEMATICS Document 57 4402 9200 1st Edition 10 2006 M13 M5 M3 3B6 S6a S6b X9 X10 X11 X14 X16 X17 X18 X3 X4 X5 X6 X7 X8 M91 X101 Courtesy of Crane Market...

Page 198: ...6 4 INDEX TELELIFT 3713 SX SCHEMATICS Document 57 4402 9200 1st Edition 10 2006 F56 A1 Y0 F36 F26 F16 K03 K02 K01 B13 B14 Y00 B11 B17 B15 M1 Courtesy of Crane Market...

Page 199: ...6 5 INDEX TELELIFT 3713 SX SCHEMATICS Document 57 4402 9200 1st Edition 10 2006 B34 B33 B32 B31 B30 Y10 Courtesy of Crane Market...

Page 200: ...6 6 INDEX TELELIFT 3713 SX SCHEMATICS Document 57 4402 9200 1st Edition 10 2006 Y21 Y20 Courtesy of Crane Market...

Page 201: ...6 7 INDEX TELELIFT 3713 SX SCHEMATICS Document 57 4402 9200 1st Edition 10 2006 S51 S52 B38 EU20 Courtesy of Crane Market...

Page 202: ...6 8 INDEX TELELIFT 3713 SX SCHEMATICS Document 57 4402 9200 1st Edition 10 2006 Y01 Y02 B56 Courtesy of Crane Market...

Page 203: ...1st Edition 10 2006 6 5 Hydraulic components The numbering in the following pictures refers to the hydrauliccomponentslistedinsection Introduction paragraph Description of the machine operation in th...

Page 204: ...6 40 INDEX TELELIFT 3713 SX SCHEMATICS Document 57 4402 9200 1st Edition 10 2006 18 16 20 27 42 26 25 24 41 14 15 43 6 21 19 3 11 7 Courtesy of Crane Market...

Page 205: ...6 41 INDEX TELELIFT 3713 SX SCHEMATICS Document 57 4402 9200 1st Edition 10 2006 22 23 30 32 31 Courtesy of Crane Market...

Page 206: ...6 4 INDEX TELELIFT 3713 SX SCHEMATICS Document 57 4402 9200 1st Edition 10 2006 36 35 32 31 38 35 29 28 34 33 40 39 Courtesy of Crane Market...

Page 207: ...nt 57 4402 9200 1st Edition 10 2006 1 X 2 INPUT OUTPUT SIGNALS X 3A X 3B X 1 3 2 6 6 LOAD LIMITING SYSTEM 6 6 1 Wiring diagram lay out Ref Description 1 Control panel Extensometric sensor double bridg...

Page 208: ...DEX TELELIFT 3713 SX SCHEMATICS Document 57 4402 9200 1st Edition 10 2006 6 6 2 Wiring diagram External connections SHLD BLACK REF1 BLUE IN1 YELLOW OUT1 GREEN OUT1 RED IN1 WHITE REF1 Courtesy of Crane...

Page 209: ...TELELIFT 3713 SX REPAIR PROCEDURES 7 1 Document 57 4402 9200 1st Edition 10 2006 INDEX Section 7 REPAIR PROCEDURES SECTION INDEX 7 1 Time schedule page Courtesy of Crane Market...

Page 210: ...cylinder inside the boom 2 2 50 each change the extension cylinder kit inside the boom 1 1 30 change the block valve of the extension cylinder inside the boom 1 0 30 change the extension cylinder on t...

Page 211: ...of the main actuator operating the boom movements 2 0 30 each check the pressure of brake pump and hydrostatic steering unit 1 0 30 check the safety valves 1 0 30 change the drive pump 1 3 00 change t...

Page 212: ...the braking system 2 0 30 each change the return filter of the hydraulic oil tank 1 0 30 change the hydrostatic steering unit 1 1 30 change the beacon 1 0 20 change the battery 1 0 30 change the exhau...

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