TEREXLIFT TELELIFT 3713 Elite, TELELIFT 4514, TELELIFT 4017 Workshop Manual

WORKSHOP MANUAL

Code 57.4400.7200 - 1

Edition 03/2005

Handler with telescopic boom

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)

English

Edition

INDEX

Courtesy of Crane.Market

TELELIFT 3713 Elite - 4017 - 4514

Intentionally blank page

Document 57.4400.7200 - 1

Edition 03/2005

INDEX

Courtesy of Crane.Market

TELELIFT 3713 Elite - 4017 - 4514

WORKSHOP MANUAL

Code 57.4400.7200 - 1

Number: ....................................

Consigned to: ................................................................................................................................

Edition 03/2005

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.

Document 57.4400.7200 - 1

Edition 03/2005

INDEXINDEX

Courtesy of Crane.Market

TELELIFT 3713 Elite - 4017 - 4514

WORKSHOP MANUAL

Code 57.4400.7200 - 1

Number: ....................................

Consigned to: ................................................................................................................................

Edition 03/2005

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

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

Document 57.4400.7200 - 1

Edition 03/2005

INDEXINDEX

Courtesy of Crane.Market

TELELIFT 3713 Elite - 4017 - 4514

LIST OF REVISED PAGES

Revision Revised Issued

No. date pages Notes by

1 03-2005 Publication

Document 57.4400.7200 - 1

Edition 03/2005

INDEXINDEX

Courtesy of Crane.Market

TELELIFT 3713 Elite - 4017 - 4514

GENERAL 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

Document 57.4400.7200 - 1

Edition 03/2005

INDEX

Courtesy of Crane.Market

TELELIFT 3713 Elite - 4017 - 4514

SERIAL NUMBER IDENTIFICATION

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

Document 57.4400.7200 - 1

Edition 03/2005

INDEX

Courtesy of Crane.Market

TELELIFT 3713 Elite - 4017 - 4514

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.

INTRODUCTION

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.

http://www.terexlift.it e-mail: info@terexlift.it

Document 57.4400.7200 - 1

Edition 03/2005

INDEX

Courtesy of Crane.Market

TELELIFT 3713 Elite - 4017 - 4514

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 cm3 and 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.

INTRODUCTION

Document 57.4400.7200 - 1

Edition 03/2005

INDEX

Courtesy of Crane.Market

TELELIFT 3713 Elite - 4017 - 4514

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.

INTRODUCTION

iii

Document 57.4400.7200 - 1

Edition 03/2005

INDEX

Courtesy of Crane.Market

TELELIFT 3713 Elite - 4017 - 4514

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.

INTRODUCTION

Document 57.4400.7200 - 1

Edition 03/2005

INDEX

Courtesy of Crane.Market

TELELIFT 3713 Elite - 4017 - 4514

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

INTRODUCTION

Document 57.4400.7200 - 1

Edition 03/2005

INDEX

Courtesy of Crane.Market

TELELIFT 3713 Elite - 4017 - 4514

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 cm 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.

INTRODUCTION

Document 57.4400.7200 - 1

Edition 03/2005

INDEX

Courtesy of Crane.Market

TELELIFT 3713 Elite - 4017 - 4514

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.

INTRODUCTION

vii

Document 57.4400.7200 - 1

Edition 03/2005

INDEX

Courtesy of Crane.Market

PS Fa Fa1 Fe MB

N’

25 bar

430 bar

450 bar

Tp3

Tp2

Tp1

T1’

T2’

150 bar

280 bar

102

290 bar

FLT

RPM

Ev13

MPR

220 bar

022

140 bar

150 bar

30 bar

Ev1

Ev2

Ev3

Ev4

Ev5

Ev6

Ev14

Ev15

Ev7

Ev8

Ev9

Ev10

Ev11

Ev12

Pv1

Pv2

Pv3

Pv4

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

Document 57.4400.7200 - 1

Edition 03/2005

Hydraulic scheme

TELELIFT 3713 Elite - 4017 - 4514

INTRODUCTION

INDEX

viii

Courtesy of Crane.Market

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

Document 57.4400.7200 - 1

Edition 03/2005

INDEX

Courtesy of Crane.Market

TELELIFT 3713 Elite - 4017 - 4514

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:

SAFETY

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.

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.

Document 57.4400.7200 - 1

Edition 03/2005

INDEX

Courtesy of Crane.Market

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.

TELELIFT 3713 Elite - 4017 - 4514

SAFETY

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.

Document 57.4400.7200 - 1

Edition 03/2005

INDEX

Courtesy of Crane.Market

TELELIFT 3713 Elite - 4017 - 4514

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.

SAFETY

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.

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.

Document 57.4400.7200 - 1

Edition 03/2005

Ordinary and extraordinary maintenance of the machineare quite complex from a technical point of view and should be performed by an authoirsed service centre.

INDEX

Courtesy of Crane.Market

TELELIFT 3713 Elite - 4017 - 4514

SAFETY

1.3-1 PERSONAL PROTECTIVE EQUIPMENT

During work, but especially when maintaining or repairing the machine, operators must wear suitable protective clothing and equipment:

• Overalls or any other comfortable garments. Operators should wear neither clothes with large sleeves nor objects that can get stuck in moving parts of the machine

•Protective helmet when working under or in the vicinity of suspended load

•Protective gloves

•Working shoes

•Breathing set (or dust mask)

• Ear-protectors or equivalent equipment

• Goggles or facial screen.

Use only type-approved protective equipment in good condition.

1.4 SAFETY PRECAUTIONS

Read and understand the following safety instructions before servicing the machine. The following list contains safety rules which must absolutely be obeyed to prevent accidents and injuries.

1.4-1 WORKING AREA

• Make sure the area all around the machine is safe. Always be aware of potential risks.

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

1.4-2 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 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 3 meters from the ground), always use type- approved safety belts or fall preventing devices.

• Do not enter/leave the machine when it is running.

• Before servicing the engine, let its parts cool down.

• Do not leave the driving place when the machine is running.

• Neither stop nor carry out interventions under or between the machine wheels when engine is running. When maintenance in this area is needed, stop the engine, engage the parking brake and chock the wheels to prevent accidental movements.

• 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, ensure they are properly connected and efficient.

• Do not carry out interventions on electric components with voltage over 48V.

Document 57.4400.7200 - 1

Edition 03/2005

INDEX

Courtesy of Crane.Market

TELELIFT 3713 Elite - 4017 - 4514

• Do not connect wet plugs or sockets.

• Signs and stickers shall never be removed, hidden or become unreadable.

• Except for maintenance purposes, do not remove safety devices, covers, guards,. 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.

• Aleays stop the engine and disconnect the batteries before maintenance or service.

• 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.

• Before carrying out operations on hydraulic lines under pressure (hydraulic oil, compressed air) and/ or before disconnecting hydraulic components, ensure the relevant line has been previously depressurised and does not contain any hot fluid.

SAFETY

Treatment and disposal of used oils is subject to federal, national and local laws and regulations. Collect and deliver these wastes to authorised centres.

• Use the assistance of a second person to handle loads weighing 30 to 50 kg.

• For loads over 50 kg, the use of special hoisting equipment in good condition and equipped as per enforced regulations is mandatory.

Any intervention on the hydraulic or pneumatic circuit must be carried out by authorised personnel. Before any operation on lines under pressure, release any residual pressure from the circuit. Do not use your fingers to check 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 unsuitable places.

• Do not empty catalytic mufflers or other vessels containing burning materials without taking the necessary precautions.

• Carefully handle all flammable or dangerous substances.

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

• Never give orders to several people at a ime. Instructions and signs must be given by one person only.

•Always pay the due attention to the instructions given by the foreman.

• Never distract the operator during working phases or crucial manoeuvres.

• Do not call an operator suddenly, if unnecessary.

• Do not frighten an operator or throw objects by no means.

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

Document 57.4400.7200 - 1

Edition 03/2005

INDEX

Courtesy of Crane.Market

TELELIFT 3713 Elite - 4017 - 4514

TECHNICAL SPECIFICATIONS

Section 2

TECHNICAL SPECIFICATIONS

SECTION INDEX

2.1 Main dimensions ................................................................................. page 2

2.2 Tyres .............................................................................................................. 2

2.3 Limit of use ................................................................................................... 3

2.4 Weight ........................................................................................................... 3

2.5 Speed ............................................................................................................ 3

2.6 Payload and reach ....................................................................................... 3

2.7 Forks (floating type) ..................................................................................... 4

2.8 Diesel engine ................................................................................................ 4

2.9 Electrical system .......................................................................................... 4

2.10 Machine sound levels .................................................................................. 4

2.11 Vibration levels ............................................................................................. 5

2.12 Refuelling ...................................................................................................... 5

2.13 Tightening torques ....................................................................................... 6

2.14 Drill diameters for threads .............................................................................. 8

2.15 Standard tightening torques for fitting seals ................................................... 9

2.16 Locking material .......................................................................................... 11

2.17 Hoisting instructions .................................................................................... 12

2.18 Advice to renew flexible hoses ................................................................... 13

2.19 Lists of recommended spare parts ............................................................ 14

2.20 Machine paint colour ................................................................................... 18

2.21 Checking the cylinder movement times .................................................... 19

2.22 Hydraulic settings ........................................................................................ 21

2.23 Calibrating the DLE load limiter .................................................................. 31

2.24 Checking the TECNORD control unit ......................................................... 34

2.25 DLE system ................................................................................................... 41

Document 57.4400.7200 - 1

Edition 03/2005

INDEX

Courtesy of Crane.Market

TELELIFT 3713 Elite - 4017 - 4514

TECHNICAL SPECIFICATIONS

2.1 MAIN DIMENSIONS

TELELIFT 3713Elite 3713T Elite 4017 4514

A Overall height mm 2550 2550 2550 2630

B Height to the steering wheel mm 1920 1920 1920 1980

C Overall width mm 2330 2330 2330 2330

D Cab width mm 850 850 850 850

E Track mm 1920 1920 1920 1920

F Wheel-base mm 2850 2850 2850 2850

G Length to the front tyres mm 3910 3910 3910 3910

H Length to the attachment holding plate mm 5610 5610 5610 6290

I Ground clearance mm 460 460 460 460

J Max width with extended outriggers mm 2930 2930 2930 2930

• Internal steering radius mm 1300 1300 1300 1300

• External steering radius mm 3990 3990 3990 3990

2.2 TYRES

ALL TELELIFT Standard Opzionali 3713 Elite

- Dimensions (front and rear) 400/70-20 400/80-24 18-19.5 405/70-24

-P.R. (or load index) 14 pr 153B 16 14 pr / 151 D

- Rim 13x20 13x24 13x19.5 13x24

- Wheel disc 8 holes DIN 70361

-Pressure bar/Psi 4/58 4.25/61.6 4.5/65.2 4.25/61.6

Document 57.4400.7200 - 1

Edition 03/2005

Opz. 4017-4514

INDEX

Courtesy of Crane.Market

TELELIFT 3713 Elite - 4017 - 4514

TECHNICAL SPECIFICATIONS

2.3 LIMIT OF USE

TELELIFT 3713Elite 3713T Elite 4017 4514

• Angle of approach (with/without outriggers) 39° 39° 39° 39°

• Departure angle 45° 45° 45° 45°

• Min/max ambient temperature °C -20°/+40° -20°/+40° -20°/+40° -20°/+40°

2.4 WEIGHT

TELELIFT 3713Elite 3713T Elite 4017 4514

•Weight in working order kg 9500 9500 11900 10900 lbs

2.5 SPEED

TELELIFT 3713Elite 3713T Elite 4017 4514

-Working speed (*) km/h 8 8 8 8

-Travel speed (*) km/h 37 37 37 35

- Max. slope with full load % 54 54 54 50

(*) = either forward or reverse motion.

2.6 PAYLOAD AND REACH

TELELIFT 3713Elite 3713T Elite 4017 4514

- Max lifting height:

with outriggers mm 12640 12640 12640 16700

- Max lifting height:

without outriggers mm 12470 12470 12470 16600

- Reach at max height without outriggers mm 1290 1290 1290 1320

- Max reach forward with outriggers mm 8740 8740 8740 12700

- Attachment holding plate rotation 145° 145° 145° 145°

- Maximum payload with outriggers kg 3700 3700 3700 3500

- Payload at max height with outriggers kg 2500 2500 2500 2200

- Payload at max reach with outriggers kg 700 700 700 100

Document 57.4400.7200 - 1

Edition 03/2005

INDEX

Courtesy of Crane.Market

TELELIFT 3713 Elite - 4017 - 4514

TECHNICAL SPECIFICATIONS

2.7 FORKS (floating type)

TELELIFT 3713Elite 3713T Elite 4017 4514

- Dimensions mm 1200x130x50 1200x130x50 1200x130x50 1200x130x50 ft

-Weight kg 70 70 70 70

lbs

- Fork holding frame - class FEM III FEM III FEM III FEM III

2.8 DIESEL ENGINE

TELELIFT 3713Elite 3713T Elite 4017 4514

- Make PERKINS PERKINS PERKINS PERKINS

- Model/Type 1004.42 1104C-44T 1104C-44T 1104C-44T

- Features: Diesel Diesel Diesel Diesel

4 cylinders in line 4 cylinders in line 4 cylinders in line 4 cylinders in line

4 strokes 4 strokes 4 strokes 4 strokes

direct injection direct injection direct injection direct injection

- Bore x Stroke mm 103 x 127 105 x 127 105 x 127 105 x 127 ft

-Total displacement cc 4232 4400 4400 4400

- Power at 2300 giri/min kW 63 74,4 74,4 74,4

2.9 ELECTRICAL SYTEM

TELELIFT 3713Elite 3713T Elite 4017 4514

-Voltage V 12 12 12 12

- Starter (power) kW 3 3 - -

- Battery Ah 92 92 100 100

2.10 MACHINE SOUND LEVELS

TELELIFT 3713Elite 3713T Elite 4017 4514

- Guaranteed sound power level

(in accordance with the Directive 2000/14/CE) dB Lwa = 109 Lwa = 109 Lwa = … Lwa = …

- Measured sound pressure level

(in accordance with the Directive 98/37/CE) dB Lpa = 78 Lpa = 78 Lpa = 84 Lpa = 84

Document 57.4400.7200 - 1

Edition 03/2005

INDEX

Courtesy of Crane.Market

TELELIFT 3713 Elite - 4017 - 4514

TECHNICAL SPECIFICATIONS

2.11 VIBRATION LEVELS

TELELIFT 3713Elite 3713T Elite 4017 4514

- Mean assessed vibration level transmitted to arms m/s

- Mean assessed vibration level transmitted to body m/s

Values calculated in accordance with standard prEN13059

This is a Class A device. In a residential environment, such device can cause radio disturbance. In such cases, the operator is required to take suitable measures.

< 2.5 < 2.5 < 2.5 < 2.5

< 0.5 < 0.5 < 0.5 < 0.5

2.12 REFUELLING

TELELIFT 3713Elite 3713T Elite 4017 4514

- Diesel engine l 11,5 11,5 11,5 11,5

- Engine cooling system l 15 15 15 15

- Fuel tank l 135 135 135 135

- Hydraulic system tank l 150 150 150 150

- Gearbox l 1,5 1,5 1,5 1,5

- Differential gears l 8,7 8,7 8,7 8,7

- Wheel reduction gears l 0,75 0,75 0,75 0,75

Products:

Engine oil: SHELL RIMULA SAE 15W-40 (API CH-4/ CG-4/ CF-4/CF, ACEA E3, MB 228.3)

Power divider-Differential gears-Reduction gears: FUCHS TITAN GEAR LS 85 W-90 (API GL-5 LS / GL-5)

Hydraulic system and brakes: SHELL TELLUS T 46 (DENISON HF-1 DIN 51524 part. 2 e 3)

Document 57.4400.7200 - 1

Edition 03/2005

INDEX

Courtesy of Crane.Market

TELELIFT 3713 Elite - 4017 - 4514

TECHNICAL SPECIFICATIONS

2.13 TIGHTENING TORQUES

Thread Pitch Wrench measure Tightening torques

diameter mm Material class

UNI UNI UNI Normal Galvanized Normal Galvanized Normal Galvanized

mm mm

5931/32 5933÷36 5923÷30

4 0.7 7 3 2.5 2 3.2 2.8 4.4 3.9 5.3 4.8

5 0.8 8 4 3 2.5 6.1 5.5 8.7 7.8 10.3 9.3

61 10 5 4 3 10.6 9.5 14.8 13.3 17.8 16.0

8 1.25 13 6 5 4 25.1 22.5 35.4 31.8 42.5 30.2

11365426.5 23.8 37.3 33.5 44.7 40.3

10 1.5 17 8 6 5 51.1 46.0 71.9 64.7 86.3 77.6

1.25 17 8 6 5 53.4 48.1 75.1 67.5 90.2 81.1

12 1.75 19 10 8 6 86.5 77.8 121.4 109.2 145.9 131.3

1.25 19 10 8 6 92.4 83.2 129.5 116.6 156.1 140.5

8.8

Nm Nm Nm Nm Nm Nm

10.9

12.9

14 2 22 12 10 6 137.7 123.9 193.8 174.4 232.6 209.3

1.5 22 12 10 6 145.9 131.3 206.1 185.5 246.9 222.0

16 2 24 14 10 8 209.1 188.2 293.8 264.4 353.0 317.7

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 10 408.1 367.3 573.4 516.1 687.7 618.9

1.5 30 17 12 10 439.7 395.8 619.3 557.4 742.8 662.5

22 2.5 32 17 - 12 542.3 488.5 763.2 686.9 915.3 823.7

1.5 32 17 - 12 582.6 524.3 819.3 737.4 983.6 885.3

24 3 36 19 - 12 705.1 634.5 990.8 891.7 1193.3 1074.4

23619-12 745.3 671.3 1051.0 945.9 1255.1 1129.5

27 3 41 19 - - 1036.0 927.5 1448.9 1304.0 1734.6 1561.2

24119--1091.8 982.6 1530.6 1377.5 1836.7 1653.0

30 3.5 46 22 - - 1307.9 1258.1 1989.3 1772.4 2357.1 2121.4

24622--1510.2 1359.1 2122.4 1910.2 2540.8 2286.7

33 3.5 50 24 - - 2000.0 1800.0 2800.0 2520.0 3400.0 3060.0

25024--1610.0 1450.0 2300.0 2070.0 2690.0 2420.0

36 4 55 27 - - 2600.0 2340.0 3700.0 3330.0 4300.0 3870.0

35527--2800.0 2520.0 3900.0 3510.0 4600.0 4140.0

39 4 60 27 - - 3400.0 3060.0 4800.0 4320.0 5600.0 5040.0

36027--3600.0 3240.0 5100.0 4590.0 5900.0 5310.0

Document 57.4400.7200 - 1

Edition 03/2005

INDEX

Courtesy of Crane.Market

TELELIFT 3713 Elite - 4017 - 4514

TECHNICAL SPECIFICATIONS

Thread Pitch Standard nuts Low nuts

diameter

Nm Nm Nm Nm

4 0.7 5.5 3.5

5 0.8 5.5 3.5

61 9.5 13.0 6.0 8.0

8 1.25 23.0 32.0 14.0 20.0

1 25.0 35.0 16.0 22.0

10 1.5 46.0 64.0 29.0 40.0

1.25 49.0 68.0 31.0 42.0

12 1.75 80.0 110.0 50.0 69.0

1.25 88.0 125.0 55.0 78.0

14 2 125.0 180.0 78.0 110.0

1.5 140.0 195.0 88.0 120.0

16 2 195.0 275.0 120.0 170.0

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

1.5 570.0 800.0 360.0 500.0

24 3 660.0 930.0 410.0 580.0

2720.0 1000.0 450.0 630.0

27 3 980.0 1400.0 610.0 880.0

2 1050.0 1500.0 660.0 940.0

30 3.5 1350.0 1850.0 850.0 1160.0

2 1450.0 2050.0 910.0 1280.0

33 3.5 1650.0 2310.0 1050.0 1470.0

2 1980.0 2770.0 1270.0 1780.0

36 4 2120.0 2970.0 1360.0 1900.0

3 2550.0 3570.0 1630.0 2280.0

39 4 2730.0 3820.0 1750.0 2450.0

3 3250.0 4550.0 2080.0 2910.0

Document 57.4400.7200 - 1

Edition 03/2005

INDEX

Courtesy of Crane.Market

TELELIFT 3713 Elite - 4017 - 4514

TECHNICAL SPECIFICATIONS

2.14 DRILL DIAMETERS FOR THREADS

Thread DRILL DIAMETER DRILL BIT

x pitch LIMITS DIAMETER

max min

M 4 x 0.7 3.42 3.24 3.30

x 0.5 3.60 3.46 3.50

M 5 x 0.8 4.33 4.13 4.20

x 0.5 4.60 4.46 4.50

M 6 x 1 5.15 4.92 5.00

x 0.75 5.38 5.19 5.20

M 8 x 1.25 6.91 6.65 6.80

x 1 7.15 6.92 7.00

M 10 x 1.5 8.87 8.38 8.50

x 1.25 9.38 9.19 9.20

M 12 x 1.75 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 20 x 2.5 17.74 17.29 17.50

x 1.5 18.68 18.38 18.50

M 22 x 2.5 19.74 19.29 19.50

x 1.5 20.68 20.38 20.50

M 24 x 3 21.25 20.75 21.00

x 2 22.21 21.83 22.00

M 27 x 3 24.25 23.75 24.00

x 2 25.21 24.83 25.00

M 30 x 3.5 26.77 26.21 26.50

x 3 27.25 26.75 27.00

M 33 x 3.5 27.77 29.21 29.50

x 2 31.21 30.83 31.00

M 36 x 4 32.27 31.65 32.00

x 3 33.25 32.75 33.00

M 39 x 4 35.27 34.67 35.00

x 3 36.25 35.75 36.00

Document 57.4400.7200 - 1

Edition 03/2005

INDEX

Courtesy of Crane.Market

+ 178 hidden pages

TEREXLIFT TELELIFT 3713 Elite, TELELIFT 4514, TELELIFT 4017 Workshop Manual

Specifications and Main Features

Frequently Asked Questions

User Manual