Terex TH 19-55 Service Manual 57.4400.9201 – PDF DOWNLOAD

Description

Terex TH 19-55 Service Manual 57.4400.9201 – PDF DOWNLOAD

Language : English
Pages : 152
Downloadable : Yes
File Type : PDF

Table of Contents:

Terex TH 19-55 Service Manual 57.4400.9201 – PDF DOWNLOAD

Introduction iii
Important iii
Machine Identification iv
Description v
Description of the machine operation v
TH 19-55 hydraulic schematic vii
Section 1 Rev. Safety Rules ix
1.1 Safety rules x
1.1-1 Personal Safety x
1.1-2 Workplace Safety xi
1.2 General remarks xii
1.3 Servicemen’s requisites xii
1.3-1 Personal Protective equipment xiii
1.4 General safety precautions xiii
1.4-1 Working area xiii
1.4-2 Precautions during work xiii
Section 2 Rev. Technical Specification 1
2.1 Main dimensions 1
2.2 Tyres 1
2.3 Limit of use 2
2.4 Weight 2
2.5 Speed 2
2.6 Payload and reach 2
2.7 Forks (floating type) 3
2.8 Diesel engine 3
2.9 Hydraulic system 3
2.10 Electrical system 3
2.11 Machine sound levels 4
2.12 Vibration levels 4
2.13 Refilling 4
2.14 Tightening torques 5
2.15 Hoisting instructions 6
2.16 Advice to renew flexible hoses 7
2.17 Lists of recommended spare parts 8
2.18 Machine paint colour 9
2.19 Checking the cylinder movement times 10
2.20 Hydraulic settings 11
1. Preliminary operations 11
2. Calibrating the boom main valve 11
2.1 Calibrating the main valve pressure control valve 11
3. Setting the hydromatik pump hydrostatic transmission 12
3.1 Calibration of the maximum pressure 13
4. Calibrating the power steering 13
5. Negative brake pressure 13
6. Service brake pressure 13
Section 3 Rev. Maintenance Inspections 1
3.1 Introduction 1
3.2 About this section 2
3.3 Maintenance table 3
3.4 Maintenance inspection report 6
Section 4 Rev. Maintenance Procedures 1
4.1 Introduction 1
4.2 About this section 2
4.3 Table A procedures 3
A-1 Check the oil level within reduction gears, power divider
and differential gears 3
A-2 Check the tightening of the wheel bolts and the tyre pressure 5
A-3 Check the tightening of all bolts and nuts 6
A-4 Check the couplings for oil leaks 6
A-5 Inspect the Operator’s manual 7
A-6 Inspect the decals and plates 7
A-7 Check the engine oil level 8
A-8 Clean the air suction filter 9
A-9 Check and clean the radiator 10
A-10 Check the hydraulic oil level in the tank 11
A-11 Check the greasing of the boom section pads 12
A-12 Grease the forks 13
A-13 Grease all joints of the boom, the rear axle shaft joint,
the transmission shafts, the front and rear axles
and any equipment of the machine 14
A-14 Check the efficiency of the lighting electric system 15
A-15 Check the efficiency of braking system and parking brake 16
A-16 Check the efficiency of the steering selection system 18
A-17 Check the efficiency of the fork balancing system 19
A-18 Make sure the safety devices installed are in efficient working order 19
A-19 Check the engine coolant level 20
4.4 Table B procedures 21
B-1 Check the machine is in efficient working order 21
B-2 Check the tension of the alternator belt 21
B-3 Check the tyre inflation 22
B-4 Check the tightening of the wheel nuts 23
B-5 Check the tightening of the cardan shaft screws 24
4.5 Table C procedures 25
C-1 Change the engine oil and relevant filter 25
C-2 Check the oil level in the differential gears and power divider 26
C-3 Check the oil level in the four wheel reduction gears 27
C-4 Check and clean the engine air filter 27
C-5 Check the clamping of the cableheads to the battery terminals 28
C-6 Check the air suction hose between engine and filter 28
C-7 Check the cylinder chromium-plated rods 29
C-8 Check the hydraulic lines 29
C-9 Check the electric cables 30
C-10 Check the wear of the sliding pads of the boom sections 31
C-11 Adjust the play of the sliding pads of the boom sections 32
C-12 Grease the sliding parts of the boom sections 33
C-13 Check the level of the battery electrolyte 34
C-14 Check the efficiency of the block valves 35
4.6 Table D procedures 37
D-1 Visually check the smoke quantity evacuated from
the engine exhaust 37
D-2 Check the tightening of the engine fixing screws 37
D-3 Check the tightening of the cab fixing screws 38
D-4 Check the backlash between pins and bushings in all joints 38
D-5 Change the hydraulic oil filter 39
D-6 Change the hydraulic oil filter in the tank 40
D-7 Have the hydraulic system checked by a skilled technician 41
D-8 Change the main cartridge of the engine air filter 42
D-9 Clean the cab air filter 43
D-10 Change engine oil, oil filter and fuel filter 44
4.7 Table E procedures 45
E-1 Change the safety element of engine air filter 45
E-2 Change the oil in power divider and differential gears 46
E-3 Change the oil in the four wheel reduction gears 47
E-4 Change the hydraulic oil 48
4.8 Table F procedures 49
F-1 Change the engine coolant 49
4.9 Table G procedures 50
G-1 The machine structure 50
Section 5 Rev. Problems-Causes-Solutions 1
5.1 Introduction 1
5.2 About this section 2
5.3 Problems-Causes-Solutions 3
5.3.1 Hydraulic faults 3
5.3.2 Electrical faults 8
Section 6 Rev. Schemes 1
6.1 Hydraulic symbols 1
6.2 Hydraulic schemes 3
6.2.1 TH 19-55 3
6.3 Electrical symbols 4
6.4 Wiring diagrams 6
6.4.1 Wiring diagrams – Component description 11
6.4.2 Fuses and relays 12
6.5 Position of the electrical and hydraulical components on the machine 13
6.5.1 Hydraulical components 13
Section 7 Rev. Repair Procedures 1
7.1 Time schedule 1
001 – Cylinder disassembly, Boom raising cylinder 5
002 – Cylinder disassembly, Fork balance cylinder 9
003 – Removing the engine from the machine 11
004 – Hydrostatic pump disassembly 17
005 – Disassembling the hydraulic motor 19
006 – Cylinder disassembly, Boom extension cylinder 21
007 – Water-oil cooler disassembly 23
008 – Main valve disassembly 25
009 – Renewing the slide pads of the telescopic boom 27
010 – Renewing the flexible hoses inside the boom 31
011 – Cylinder disassembly, Attachment rotation cylinder 33

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