TEREXLIFT TELELIFT 3713 Elite Instruction manual

Document 57.4400.7200 - 1st Edition 03/2005 INDEXINDEX
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TELELIFT 3713 Elite - 4017 - 4514
WORKSHOP MANUAL
Code 57.4400.7200 - 1st Edition 03/2005
Number: ....................................
Consigned to: ................................................................................................................................
DECLARATION
I, the undersigned..............................................................................................................................
declare that I have received the Workshop manual for TEREXLIFT lifts series Telelift 3713
Elite - 4017 - 4514.
Copies consigned: n°...... on paper
n°...... on CD-Rom
The undersigned is obliged to use the manual in their workshop, without disclosing 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 written
authorisation of TEREXLIFT to do so.
If business relations between the undersigned and TEREXLIFT should come to an end, the
undersigned is obliged to return the copies received without charges for TEREXLIFT.
Yours sincerely
Date ............................
For acceptance
The consignee Company stamp
and signature of the Legal representative
...........................................
Copy to return stamped and signed for acceptance by the
Legal representative of the company receiving the copies of the manual.
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Document 57.4400.7200 - 1st Edition 03/2005 INDEXINDEX
3
TELELIFT 3713 Elite - 4017 - 4514
WORKSHOP MANUAL
Code 57.4400.7200 - 1st Edition 03/2005
Number: ....................................
Consigned to: ................................................................................................................................
DECLARATION
I, the undersigned..............................................................................................................................
declare that I have received the Workshop manual for TEREXLIFT lifts series Telelift 3713
Elite - 4017 - 4514.
Copies consigned: n°...... on paper
n°...... on CD-Rom
The undersigned is obliged to use the manual in their workshop, without disclosing 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 written
authorisation of TEREXLIFT to do so.
If business relations between the undersigned and TEREXLIFT should come to an end, the
undersigned is obliged to return the copies received without charges for TEREXLIFT.
Yours sincerely
Date ............................
For acceptance
The consignee Company stamp
and signature of the Legal representative
...........................................
Courtesy of Crane.Market

Document 57.4400.7200 - 1st Edition 03/2005 INDEX
MANUAL CONTENTS
INTRODUCTION
Sect. 1 SAFETY RULES
Sect. 2 TECHNICAL SPECIFICATIONS
Sect. 3 SCHEDULED MAINTENANCE INSPECTIONS
Sect. 4 SCHEDULED MAINTENANCE PROCEDURES
Sect. 5 TROUBLESHOOTING
Sect. 6 SCHEMES
Sect. 7 REPAIR PROCEDURES
TELELIFT 3713 Elite - 4017 - 4514
GENERAL INDEX
5
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Document 57.4400.7200 - 1st Edition 03/2005 INDEX
Machine denomination Literature valid up to serial number
TELELIFT 3713 Elite from serial n. 11376 to serial n. 14856
TELELIFT 4017 up to serial n. 14866
TELELIFT 4514 up to serial n. 15124
INDEX
TELELIFT 3713 Elite - 4017 - 4514
SERIAL NUMBER IDENTIFICATION
6
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INTRODUCTION
INTRODUCTION
Important
Read, understand and obey the safety rules and operating
instructions in the Telelift 3713 Elite - 4017 - 4514
Operator's Handbook before attempting any
maintenance or repair procedure.
This manual provides the machine owner and user with
detailed information on the scheduled maintenance. It
also provided qualified service technicians with
infromation on troubleshooting and repair procedures.
Basic mechanical, hydraulic and electrical skills are
required to perform most procedures. However, several
procedures require specialized skills, as well as specific
tools and equipment.
In these instances, we strongly recommend letting service
and repair the machine at an authorized TEREXLIFT
service center.
Technical Publications
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
srl.
In pursuing a policy of constant quality improvement,
TEREXLIFT srl 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.
Contact Us
http://www.terexlift.it
© Copyright 2005 TEREXLIFT srl - All rights reserved.
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Document 57.4400.7200 - 1st Edition 03/2005 INDEX
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TELELIFT 3713 Elite - 4017 - 4514
INTRODUCTION
DESCRIPTION OF THE MACHINE OPERATION
The source of mechanical energy of this machine is a
Perkins turbo-compressed diesel engine (pos. 1), model
1104C-44T, which supplies 74.5 kW at 2300 rev/min
and with a max torque of 412 Nm at 1400 rev/min.
On the flywheel side of the engine, and connected to
this engine by a Technodrive coupler with elastic joint
and with a 1-to-1 ratio, there is Bosch-Rexroth closed-
loop pump for hydrostatic drives, model A4VG71 (pos.
2) with adjustment valve of DA type. The max
displacement of this swashplate pump is 71 cm3and
the max calibration pressure is 420 bar. This pump is
used to supply hydraulic power under form of pressure
and flow rate which is then used for moving the machine.
On the through-shaft of such drive pump there is a
Casappa open-loop gear pump (with fixed
displacement) (pos. 3) with priority valve integrated in
the housing. The displacement of this pump is 43 cm3.
Its function is to provide hydraulic power, under form of
pressure and flow rate, to the steering cylinder of the
machine (priority side) and to the telescopic boom
movement cylinder (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 (with fixed
displacement) (pos. 4) with a displacement of 25 cm3,
is installed on the PTO of the engine located to the
distribution side. This pump feeds the servo-assisted
braking system (pos. 24), the control block operating
the outriggers and the sway function (pos. 28) and the
cooling fan (pos. 34) of the heat exchanger (pos. 33)
used to cool down the diesel engine and the hydraulic
circuit.
The suction lines of the open-loop pumps (pos. 3) and
(pos. 4) are protected by an immersed filter (pos. 9),
placed inside the hydraulic fluid tank (pos. 10) whose
capacity is 120 litres.
The drive pump (pos. 2) is protected by another
cartridge-filter (pos. 8), located on the suction line of
the boost pump, such pump being integral part of the
drive pump.
The one-way valve (pos. 11) set at 2.5 bar protects the
pump housing against high pressures and guarantees
a certain circulation of the drain oil to the hydrostatic
motor reducing, in this way, the temperature.
From port “G” of the drive pump (pos. 2) low-pressure
oil is taken (25-30 bar) and used for the anti-cavitation
circuit of the automatic levelling system of the forks and
for feeding the control circuit of the electro-proportional
distributor (pos. 16) which controls the movements of
the telescopic boom.
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INTRODUCTION
The hydraulic energy produced by the drive pump (pos.
2) is converted into mechanical power by a closed-loop
hydrostatic motor, model Bosch-Rexroth A6VM80 (pos.
5) equipped with adjustment valve of DA1 type and with
flush valve for reducing the max temperatures inside
the drive circuit.
The motor is flanged to a two-speed mechanical
gearbox, model 357 (pos. 6) manufactured by Dana.
Speeds are engaged by a special oil-dynamic cylinder
located inside the gearbox, while the selection of the
first and second speed is controlled by a 4-way/3-
position solenoid valve (pos. 7) of the on/off type.
The mechanical torque at the gearbox output is
transmitted to the front axle (pos. 26) and the rear axle
(pos. 25), both model 212 manufactured by Dana,
through Cardan shafts.
The hydraulic drive (pos. 12) of “load sensing” type with
a displacement of 315 cm3, receives oil from the priority
line of the pump (pos. 3) in relation to the “load sensing”
signal sent by the hydraulic drive and connected to such
pump with function of pilot signal. In this way, the input
flow to the hydraulic drive will be exactly the one needed
for the instantaneous steering functions; any excess flow
of the pump will be available for the functions of the
telescopic boom.
The steering circuit is protected against input
overpressures by a pressure reducing valve set at 140
bar. On the two delivery lines, there are other two
reducing valves with anti-shock function set at 200 bar.
The scope of these two valves is limiting possible shocks
on the steering wheel due to overstress on the steering
cylinders. The three pressure reducing valves are
installed in the hydraulic drive (pos. 12) and cannot be
regulated from the outside.
The steering circuit is completed by the front steering
cylinder (pos. 14), the rear steering cylinder (pos.
15)[these cylinders being integral part of the front axle
(pos. 26) and the rear axle (pos. 25) respectively] and
by a 4-way/3-position solenoid valve (pos. 13) for the
selection of the three different steer modes (rear wheels
straight, co-ordinate front/rear steering and independent
front/rear steering). When the solenoid valve (pos. 13)
is not energised, the front steering cylinder is fed by the
hydraulic drive and the rear cylinder is blocked. When
one magnet or the other of the solenoid valve (pos. 13)
is energised, the chambers of the cylinders are
connected in a different manner thus causing the desired
effect on the steering mode.
The Bucher/Tecnord electro-proportional distributor
(pos. 16), with 4 modular sections, receives oil from
the secondary line of the pump (pos. 3) and feeds all of
the movements of the telescopic boom.
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INTRODUCTION
This distributor consists of an input head with 3-way
pressure compensator used as a flow regulator for the
user which works at max load (load sensing), and as a
discharge valve when the pump flow is not used for the
boom movements, and of 4 modules each one of them
controlling a specific function of the telescopic boom,
that is lifting/lowering, attachment holding plate rotation,
boom extension/retraction, attachment locking/
unlocking.
In the head there is a pressure relief valve set at 280 bar
which, acting on the line of the “load sensing” signal,
limits the maximum pressure at the inlet of the distributor
through such 3-way compensator.
On the main inlet head of the distributor, there is the
pilot line head which includes an inlet safety filter, a
pressure relief valve acting on the pilot line, and a safety
solenoid valve which, when de-excited, discharges the
input pilot pressure, thus preventing the distributor from
working. This solenoid valve is used as a “dead man”
control and is activated by the relevant button on the
joystick in the driving cab. The pilot head delivers oil at
pressure to the 4 control modules of the distributors,
such modules operating the relevant main sliders in
relation to the command signal they receive from such
joystick via the control unit.
Module 1 of the distributor controls the telescopic boom
lifting cylinder (pos. 17). This cylinder has one single-
acting compensation valve with safety function. The
control module of element 2 of the distributor is the
electro-proportional type with electrical feed-back and
integrated electronics. The 0.33-lt. accumulator prefilled
at 50 bar (pos. 18) and located on the line of the
differential chamber of the lifting cylinder (pos. 17),
allows for damping the boom swings when the same
boom is moved down.
Module 2 of the distributor controls the cylinder
operating the attachment holding plate of the telescopic
boom (pos. 19). This cylinder is equipped with a double-
acting compensation valve with safety function.
Paralleled to this cylinder we find the fork levelling
cylinder (pos. 20) (or balancing cylinder) equipped with
a special double-acting compensation valve. Inside this
valve, the one-way valves are installed in a reverse
manner with respect to the normal position to avoid the
pressurisation of the cylinder when the rotation
command of the attachment holding plate is operated.
Again inside this valve, there are other two one-way
valves set at 5 bar with anti-cavitation function. These
are used to deliver oil, sucked from the low pressure
line coming from the drive pump (pos. 2), to the
compensation circuit of the fork levelling function, when
such circuit cannot do it alone.
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INTRODUCTION
The control module of element 2 of the distributor is
the electro-proportional type with electrical feed-back
and integrated electronics. On the two control lines of
the cylinder (pos. 19), and integral to module 2, there
are two pressure relief valves set at 295 bar which
protect the automatic levelling system of the forks when
the boom is moved up and down and in case of overload
on the attachment holding plate (ex. use of the bucket).
Module 3 of the distributor controls the boom telescopes
extension cylinder (pos. 21). This cylinder is equipped
with a double-acting compensation valve with safety
function. The control module of this element of the
distributor is the electro-proportional type with electrical
feed-back and integrated electronics.
On the control line of the circular chamber of the cylinder
(pos. 21) and integral to module 3, there is a pressure
relief valve set at 150 bar which limits the load when
the boom is extended in those working zones where
the electronic overturning control system cannot detect
overload conditions with respect to the load chart of
the machine.
Module 4 of the distributor controls the attachment
locking cylinder (pos. 22). This cylinder has a double
one-way valve with hydraulic release and safety
function. The control module of this element of the
distributor is the ON/OFF electrical type with integrated
electronics.
On the feeding lines of this cylinder, there are two quick-
fit connectors (pos. 23) for the connection of the
hydraulic lines to the optional attachments which need
hydraulic power for their operation (ex. hydraulic winch
and maintenance jib, mixing bucket, etc.).
The SAFIM S6 servo-assisted braking system with pedal
(pos. 24) receives oil from the pump (pos. 4) and uses
this oil to pressurise 3 hydraulic accumulators
connected to the same system. The oil at pressure
contained in these accumulator is then used to operate
the service brakes of the two axles (pos. 25) and (pos.
26) and to release the parking brake located inside the
front axle (pos. 26).
The fill valve inside the braking system takes the flow
from the feeding line so the pressure on the line of the
accumulators reaches the calibration value of the cutout
valve set at 150 bar. When this pressure is reached, the
valve gradually releases all the flow to line B for other
uses.
The brake pedal located in the driving cab, which is an
integral part of the braking system S6, is connected to
two proportional sliders which control the two separated
lines of the service brake, one for each axle. In relation
to the stroke of these sliders, a gradual communication
between the feeding line, connected to two
accumulators which, at their turn, are connected to ports
R1 and R2 (the accumulators have 0.5-lt. capacity and
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INTRODUCTION
50bar fill pressure), and the service brake lines is
established so the flow is distributed to such lines and
the discharge line increasing, in this way, the pressure
(and as a result the braking force) on the lines of the
service brakes. When the sliders are in the rest position,
the lines of the service brakes are connected to the
discharge.
The pressure switch set at 2-10 bar, paralleled to on of
the two lines of the service brake, sends an electrical
signal when this brake is engaged.
The pressure 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 lines is
too low to guarantee the minimum braking efficiency.
The accumulator with 1.5-lt. capacity and 35bar fill
pressure is connected to port R of system S6 and is
used to unlock the parking brake of the front axle (pos.
26).
The command of the parking brake is controlled by a
special valve with lever control (pos. 27) located in the
driving cab. In relation to the position of the lever, the
release line of the parking brake is connected to the
pressure line (parking brake unlocked) or the discharge
line (parking brake locked).
The two pressure switches set at 10-20 bar send an
electrical warning signal when the parking brake is
activated (brake locked).
The Bucher electro-hydraulic modular distributor of the
ON/OFF type for open loops (pos. 28) drives the
movements of the outriggers and the sway function of
the machine. It receives oil from port B of the braking
system (pos. 24) and uses this to operate the cylinder
of the left outrigger (pos. 29), the cylinder of the right
outrigger (pos. 30) and the right and left sway cylinders
(pos. 31) and (pos. 32). These two cylinders (pos. 31)
and (pos. 32) are cross-connected, say the annular
chamber of one cylinder is connected to the annular
chamber of the other and vice versa. This connection
is consistent with the operation of the cylinder which
move out and in an opposite way one respect to the
other. All of these cylinders are equipped with double-
acting compensation valves with safety function.
On the inlet head of this control block there is a pressure
relief valve set at 220 bar. The oil flow which is not used
by the control block to operate the outriggers and the
machine sway function, is sent to the Casappa 20 cm3
hydraulic gear motor (pos. 34) for the operation of the
cooling fan of the heat exchanger (pos. 33). Inside the
motor housing, there are an anti-cavitation valve and a
pressure relief valve with by-pass function set at 140
bar.
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INTRODUCTION
The heat exchanger (pos. 33) is divided in two sectors;
one absorbs heat from the cooling circuit of the diesel
engine and the other absorbs heat from the hydraulic
circuit of the machine. The flows of pumps (pos. 3) and
(pos. 4) are conveyed in the latter. The oil cooled down
by the heat exchanger is sent back to the tank (pos.
10).
When the machine is equipped with man-platform, a
motor-driven pump (pos. 36) powered by the battery,
is installed to be used in an emergency when the main
circuit of the telescopic boom is faulty. To work correctly,
this circuit uses one-way valves (pos. 37) with different
opening pressures.
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TELELIFT 3713 Elite - 4017 - 4514
INTRODUCTION
M
X2 MH S
A
T1 PS Fa Fa1 Fe MB
T2
R
N
RF
P
B
N’
B
MA
FS
L
S
L
R
TP
25 bar
430 bar
450 bar
450 bar
Tp3
Tp2
Tp1
P1 P1
R1
T1
T1’
T2’
T2
R2
P2 P2
T
A
P
B
A
M1
X1
X2
T
G
B
U
TP
AB
E
150 bar
280 bar
1
0
2
E
1
0
2
1
0
2
E
290 bar
290 bar
1
0
2
T1
A
A
A
A
B
B
B
B
P
P
T
T
LS
Pp
Tp
Tp
FLT
Pp
RPM
G1
Ev13
MPR
A1
B1
B3
A3
B2
A2
T
P
220 bar
1
1
10
0
0
2
2
2
140 bar
R
T
N
150 bar
30 bar
X1 G
M
Ev1 Ev2
Ev3 Ev4
Ev5 Ev6
Ev14 Ev15
Ev7
Ev8
Ev9
Ev10
Ev11
Ev12
Pv1
Pv2
Pv3
Pv4
24
26
25
27
22 23
15
13
14
12
35
20
19
29 30
31
32
28
21
37
18
37
37
17
11
1
4
2
16
10
5
33
34
7
36
6
3
9
8
HYDRAULIC CIRCUIT
COLORS LEGENDA
Boom / steering, brakes, stabilizers
and chassis levelling functions lines
Low pressure and transmission
charge pressure lines
Hydrostatic transmission
high pressure lines
Hydrostatic transmission and
boom functions valve piloting lines
Boom / steering, brakes, stabilizers,
chassis levelling pump pressure lines
Boom / steering, auxiliary and
transmission pumps suction lines
Tank lines
Hydraulic scheme
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TELELIFT 3713 Elite - 4017 - 4514
SAFETY
Section 1
SAFETY INFORMATION
SECTION INDEX
1.1 Safety rules .......................................................................................... page 2
1.1-1 Personal safety ............................................................................................. 2
1.1-2 Workplace safety.......................................................................................... 2
1.2 General remarks ........................................................................................... 4
1.3 Servicemen's requisites .............................................................................. 4
1.3-1 Personal protective equipment................................................................... 5
1.4 General safety precautions ......................................................................... 5
1.4-1 Working areas............................................................................................... 5
1.4-2 Precautions during work ............................................................................. 5
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SAFETY
1.1 SAFETY RULES
1.1-1 Personal Safety
In this manual, any important information is preceded by
a SPECIAL SYMBOL.
All operators who work or service the machine must
know the exact meaning of these safety symbols.
There are six special (or safety) symbols in this manual,
always combined with keywords that class the situations
according to their danger degree.
The symbols are always followed by a text explaining the
situation taken into account, the attention to be paid to
such situation, the method and the behaviour to 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:
Draws the attention to situations that involve 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 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 or moderate injury or to situations
that involve the machine efficiency.
Draws the attention either to situations that involve
your own as well as the others’ safety and that can
result in minor or moderate injury or to situations
that involve the machine efficiency.
Draws the attention to important technical
information or practical advice that allows for a safer
and more efficient use of the machine.
Draws the attention to important environment-related
information.
Be sure to wear protective eye wear and
other protective clothing if the situation
warrants it.
Be aware of potential crushing hazards
such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved steel-
toed shoes.
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SAFETY
1.1-2 Workplace Safety
Be sure to keep sparks, flames and lighted
tobacco away from flammable and
combustible materials like battery gases
and engine fuels. Always have an approved
fire extinguisher within easy reach.
Be sure that all tools and working areas are
properly maintained and ready for use. Keep
work surfaces clean and free of debris that
could get 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 capable
of supporting and stabilizing the weight to
be lifted. Use only chains or straps that are
in good condition and of ample capacity.
Be sure that fasteners intended for one time
use (i.e., cotter pins and self-locking nuts)
are not reused. These components may fail
if they are used a second time.
Be sure to properly dispose of old oil or
other fluids. Use an approved container.
Please be environmentally safe.
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SAFETY
1.2 GENERAL REMARKS
Most accidents occurring while working, servicing 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 that may come of
operations carried out on the machine.
If you recognise hazardous situations, you can prevent
accidents!
For instance, this handbook makes use of special safety
symbols to highlight potentially hazardous situations.
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
commissioning, operation and maintenance that take
into account the available spaces and means.
If you decide to follow instructions other than those given
in this manual, you must:
•be sure that the operations you are going to carry
out are not explicitly forbidden;
•be sure that the methods are safe and in compliance
with the indications 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.
Do not hesitate to pose questions if you are in doubt!
Contact 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.
1.3 SERVICEMEN'S REQUISITES
The operators who use the machine regularly or
occasionally (e.g. for maintenance or transport) shall
have the following requisites:
health:
before and during any operation, operators shall never
take alcoholic beverages, medicines or other substances
that 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 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 familiarise with this handbook, its
enclosed graphs and diagrams, the identification and
hazard warning plates. They shall be skilled and trained
about the machine use.
It is recommended to take part in at least one technical
training course organised by TEREXLIFT Assistance
Office.
Ordinary and extraordinary maintenance of the
machineare quite complex from a technical point of
view and should be performed by an authoirsed
service centre.
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