Terex Telelift 2506 Gladiator Handler Service Manual

WORKSHOP MANUAL Cod. 57.4400.6400 - 2 nd Edition 06/2007 INDEX English Edition Handler with telescopic boom TELELIFT 2306 - 2506 - 3007 GLADIATOR AGRILIFT 357 - 359

Document 57.4400.6400 - 2 nd Edition 06/2007 INDEX 5 TELELIFT Series CONTENTS MANUAL CONTENTS Sect. A GENERAL INFORMATION Sect. B SAFETY REGULATIONS Sect. C TECHNICAL OPERATION DATA Sect. D CHECKS AND ADJUSTMENTS Sect. E DISMANTLING AND REASSEMBLY Sect. F TROUBLESHOOTING Sect. G CARRARO AXLE ASSEMBLY/DISMANTLING (valid for Telelift 2306 - Gladiator) Sect. G DANA AXLE ASSEMBLY/DISMANTLING (valid for Telelift 2506 - 3007) Sect. H PERKINS ENGINE MAINTENANCE (valid for Telelift 2306 - Gladiator) Sect. H DEUTZ ENGINE MAINTENANCE (valid for Telelift 2506 - 3007) Sect. I REPAIR INSTRUCTIONS - REXROTH PUMP (valid for Telelift 2306 - 2506 - 3007 - Gladiator) Sect. L REPAIR INSTRUCTIONS - REXROTH MOTOR (valid for Telelift 2306 - 2506 - 3007 - Gladiator) Sect. M COMPACT PLUS TRANSMISSION (valid for Agrilift 357 - 359)

Document 57.4400.6400 - 2 nd Edition 06/2007 INDEX 6 Date Previous denomination Present denomination Notes TELELIFT Series MACHINE CORRESPONDENCE

Document 57.4400.6400 - 1 st Edition 05/2004 INDEX A 1 TELELIFT Series GENERAL INFORMATION Section A GENERAL INFORMATION SECTION INDEX A.01 Introduction ......................................................................................... page 2 A.02 Symbols used in the manual ....................................................................... 3 A.03 Abbreviations ................................................................................................ 4 A.04 Units of measure .......................................................................................... 5 A.05 Minimum workshop equipment .................................................................. 6 A.06 Special tools and equipment ...................................................................... 7 A.07 Bolt and nut tightening torques .................................................................. 11 A.08 Drill diameters for threads .......................................................................... 13 A.09 Fitting tightening torques ............................................................................ 14 A.10 Threadlockers, thread sealants and gaskets ............................................ 16 A.11 Hoisting instructions .................................................................................... 17 A.12 Weight list of the main parts ....................................................................... 18 A.13 Advice to renew flexible hoses ................................................................... 19 A.14 Repair interventions, welds and weld materials ....................................... 21 A.15 Weld material ................................................................................................ 23 A.16 Checks with liquid penetrants .................................................................... 24 A.17 Checks with magnetoscope ....................................................................... 25 A.18 Refilling and product specifications ........................................................... 26 A.19 Machine paint coulours ............................................................................... 26 A.20 Lists of recommended spare parts ............................................................ 27

Document 57.4400.6400 - 1 st Edition 05/2004 INDEX A 2 TELELIFT Series GENERAL INFORMATION A.01 INTRODUCTION This manual has been prepared to provide information about the routine and extraordinary maintenance of the main units of the machine in a safe and proper way. STRICTLY COMPLY WITH THE INSTRUCTIONS GIVEN IN THIS MANUAL! READ AND UNDERSTAND THIS MANUAL BEFORE CARRYING OUT ANY INTERVENTION ON THE MACHINE. If you are unsure about anything after the reading of this manual, address to TEREXLIFT Assistance Service: addresses, phone and fax numbers are printed in the cover and in the title-page of this manual. Keep this manual in the workshop at all times and read it before carrying out any extraordinary maintenance job.

Document 57.4400.6400 - 1 st Edition 05/2004 INDEX A 3 TELELIFT Series GENERAL INFORMATION A.02 SYMBOLS USED IN THE MANUAL In this manual, any important information starts with a SPECIAL SYMBOL. Symbols are also used to direct the reader's attention to special technical information about the tools to use, the tightening torques, etc. There are six safety symbols in this manual, always combined with keywords that class the situations according to their degree of dangerousness. 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. If necessary, it stresses prohibitions or provides instructions to prevent dangers. Sometimes, it can be followed by illustrations. The safety symbols are the following: DANGER Draws the attention to situations that involve your own as well as the others’ safety and that can result in serious or lethal injury. ELECTRICAL DANGER Draws the attention to electrical risks that involve your own as well as the others’ safety and that can result in serious injury or lethal injury. CAUTION 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 affect the machine efficiency. ATTENTION 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 affect the machine efficiency. IMPORTANT Draws the attention to important technical information or practical advice that allows for a safer and more efficient use of the machine. PROTECT THE ENVIRONMENT Draws the attention to important environment-related information. Indicates the number of people needed for the job Time expected to do the intervention (except in case of troubles) Special tools needed for the job Weight of the unit to be handled Tightening torque of bolts and screws Inspection needed

Document 57.4400.6400 - 1 st Edition 05/2004 INDEX A 4 TELELIFT Series GENERAL INFORMATION A.03 ABBREVIATIONS Abbreviation Definition Tab. Table Pag. Page Sect. Section Dwg. Drawing Ref. Reference CLS Concrete Mach. Machine Fig. Figure Ph. Photo T.O. Technical Office T.A.S. Technical Assistance Service

Document 57.4400.6400 - 1 st Edition 05/2004 INDEX A 5 TELELIFT Series GENERAL INFORMATION A.04 UNITS OF MEASURE 1 FORCE The unit of measure of force is the Newton (N) For the conversion: 1 N = 0.1019 kg 1 kg = 9.81 N 2 POWER The unit of measure of power is the kilowatt (kW). Other units of measure used are: CV Horsepower HP Horsepower For the conversion: 1 kW = 1.36 CV 1 kW = 1.34 HP 1 CV = 0.736 kW 1 CV = 0.986 HP 1 HP = 0.746 kW 1 HP = 1.014 CV 3 TORQUE The unit of measure of power is the Newton metre (Nm). For the conversion: 1 Nm = 0.1019 kgm 1 kgm = 9.81 Nm 1 kgm = 10 Nm NOTE: For simplicity, the Nm unit is converted according to the ratio 10 Nm = 1 kgm 4 SPECIFIC CONSUMPTION The specific consumption is expressed in g/kWh (grams per kilowatt-hour). Another unit of measure used is: g/HPh (grams per horsepower- hour) For the conversion: 1 g/kWh = 0.736 g/CVh 1 g/CVh = 1.36 g/kWh 5 PRESSURE The unit of measure of pressure is the kPa (kilopascal). Other units of measure used are: kg/cm 2 kilogram per square centimetre Atm Technical atmosphere psi Pound per square inch For the conversion: 1 kg/cm 2 = 1 Atm 1 kg/cm 2 = 98.1 kPa 1 kg/cm 2 = 0.981 bar 1 kg/cm 2 = 1 bar 1 kg/cm 2 = 14.22 psi 1 bar = 100 kPa 1 bar = 1.02 kg/cm 2 1 bar = 14.51 psi 1 psi = 6.9 kPa 1 psi = 0.069 bar 1 psi = 0.0703 kg/cm 2 1 kPa = 0.145 psi 1 kPa = 0.0102 kg/cm 2 1 kPa = 0.01 bar NOTE: For simplicity, the bar unit is converted according to the ratio 1 bar = 1 kg/cm 2 6 CONVERSION OF SOME METRIC UNITS OF MEASURE INTO IMPERIAL UNITS OF MEASURE 0,1 mm = 3.937 mils 1 mm = 0.039 inch 1 m = 3.281 ft 1 km = 0.621 miles 1 cm 3 = 0.061 cu. in. 1 g = 0.035 oz. 1 kg = 2.205 lbs. 1 t = 1.102 short ton 1 t = 0.9842 long ton 0°C = 32°F Note: in case of differences of temperature 1°C = 1.8°F

Document 57.4400.6400 - 1 st Edition 05/2004 INDEX A 6 TELELIFT Series GENERAL INFORMATION A.05 WORKSHOP EQUIPMENT IMPORTANT The list below indicates the minimum equipment necessary for servicing the vehicle. Standard tools • 6 to 41 mm box wrench set • 6 to 41 mm socket wrench set • 2 to 10 mm Allen wrench set • External circlip pliers - ø 10÷60 mm • Internal circlip pliers - ø 20÷200 mm • Two-leg pullers - ø 25÷200 mm • Three-leg pullers - ø 50÷400 mm • American cutters • Scissors • Screwdriver set • Hammer set • Mallets with plastic plugs • Combination pliers • Wire nippers • Nylon collar pliers • Wire cutter • Wire strippers • Shears • Cutting nippers • Hand-saw • Cutter • Slotted screw driver set - ø 2.5 ÷ 10 mm • Crosshead screw driver set - ø 2.5 ÷ 10 mm • Adjustable self-locking pliers • Ring nut spanner • Wrench set for hydraulic cylinders • Drift bolt set • Chisel set • Punch • Funnel • Funnel with flexible extension • Calibrated measuring beaker • Crowbar • Fluid collecting tanks • Pliers for internal cylinder seals Fittings for plugging disconnected pipes • 1/4" gas male plug • 3/8" gas male plug • 1/2" gas male plug • 1" gas male plug • 1" 1/4 gas male plug • 1" 1/2 gas male plug • 1/4" gas female plug • 3/8" gas female plug • 1/2" gas female plug • 1" gas female plug • 1" 1/4 gas female plug • 1" 1/2 gas female plug Sealing material • Teflon tape • Loctite sealant • Loctite threadlocker Equipment and instrumentation • Measure instruments: metre, gauge, micrometres • Compressor with compressed air system • Hydraulic circuit test bench for pressures up to 400 bar • Pressure gauges 0-60 bar / 0-240 bar / 0-600 bar • Ammeter • Digital tester • Hourmeter • Hydrometer for checking the battery charge • Thermometer for oil temperature check • Lamp/indicator for checking hydraulic circuit leaks • Painting system • Steam cleaner • Forklift and/or pallet lift • Stackable wooden planks and/or pallets • Electric welding machine • Cylinder and blowpipe • Hoisting means with 5000 kg payload • Textile bridles • Two-/three-leg chains with hooks • Pneumatic screwdriver • Water level • Bench drilling machine • Portable electric drill • Set of helical bits • Set of screw taps and threaders • Battery charger • Adjustable stands Consumable material • Oils • Greases • Rags for cleaning Personal protection equipment • Goggles • Gloves • Ear-protectors • Shoes • Overall

Document 57.4400.6400 - 1 st Edition 05/2004 INDEX A 7 TELELIFT Series GENERAL INFORMATION A.06 SPECIAL TOOLS AND EQUIPMENT PART# DESCRIPTION Pressure gauge for checking the hydraulic oil low pressure - 0÷60 bar Pressure gauge for checking the hydraulic oil medium pressure 0÷240 bar Pressure gauge for checking the hydraulic oil high pressure 0÷600 bar Amperometric detector Electronic hourmeter Tester for electric values

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Terex Telelift 2506 Gladiator Handler Service Manual

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