Terex LCRTF TX 51-19M Service Manual 57.4400.0100_020510 – PDF DOWNLOAD

Description

Terex Light Capability Rough Terrain Forklift (LCRTF) TX 51-19M Service Manual 57.4400.0100_020510 – PDF DOWNLOAD

Language : English
Pages : 588
Downloadable : Yes
File Type : PDF

Table of Contents:

Terex Light Capability Rough Terrain Forklift (LCRTF) TX 51-19M Service Manual 57.4400.0100_020510 – PDF DOWNLOAD

Section 1 – Introduction
1 0 Introduction 3
1 1 Symbols 4
Section 2 – Safety Rules
2 0 Safety Rules 7
2 1 General 7
2 2 Operators Maintenance Staff
Responsibilities 7
2 3 Clothing 7
2 4 Personal Equipment 8
2 5 Safety Precautions 8
2 6 Getting Ready to Work 8
2 7 During Work or Maintenance 8
Section 3 – General Information and
Specification
3 0 Machine References 13
3 1 Machine Position 13
3 2 Labels and Warning Decals 14
3 3 Explanation of the Different Symbols 19
3 4 Machine Model and Type 20
3 5 Manufacturer 20
3 6 Machine Identification 20
3 7 Chassis Serial Number 21
3 8 Identification Plates 21
3 9 Allowed Use 21
3 10 Improper Use 21
3 11 Applicable Standards 22
3 12 List of Main Components 22
3 13 Description of Main Components 23
3 14 Optional Accessories 23
3 15 Technical Data and Performance 24
Section 4 – Controls and Instruments
4 0 Preoparation, Inspection and
Adjustments 29
4 1 Adjusting the Seat 29
4 2 Fastening the Seat Belts 30
4 3 Adjusting the Rear View Mirrors 30
4 4 Controls and Operations 32
4 5 Controls and Instruments 33
4 6 Control Description 35
4 7 Control Lever 43
4 8 Operating the Control Lever 44
4 9 Tilting the Forks Forward and
Rearward 45
4 10 Side Shifting the Forks 46
4 11 Rotating the Forks 47
4 12 Quick-Coupling the Fork 48
Section 5 – Pre-operation Inspection
and Adjustment
5 0 Pre-operation Inspection and
Adjustment 51
5 1 Pre-Operation Inspection and
Check List 51
5 2 Starting the Engine 51
5 3 Jump-Starting the Engine 52
5 4 Battery Disconnect Switch 52
5 5 Stopping / Parking Machine 52
5 6 Refueling the Machine 53
Section 6 – Lubrication
6 0 Lubrication 57
6 1 Lubricant Specification 57
6 2 Lubricant Chart 58
Section 7 – Preventive Maintenance
7 0 Preventive Maintenance 63
7 1 Using the Suggested Schedule
Check Sheet 63
7 2 50 Hours or Weekly 65
7 3 250 Hours or Monthly 66
7 4 500 Hours or Quarterly 67
7 5 1000 Hours or Semi-Annually 68
7 6 2000 Hours or Two Years 69
7 7 3000 Hours or Three Years 70
Section 8 – 50 Hours or Weekly
Maintenance
8 0 50 Hours Or Weekly Maintenance 73
8 1 Check Engine Oil 73
8 2 Engine Coolant Level 73
8 3 Drain Engine Fuel Pre-Filter 74
8 4 Check Hydraulic Reservoir Oil 74
8 5 Check Brake Oil Reservoir Level 74
8 6 Lube Boom Pads 74
8 7 Lube Drive Shaft 75
8 8 Lube Axle King Pins 75
8 9 Lube Axle Rear Pivot Pin 75
8 10 Lube Cylinder 75
8 11 Lube Fork Attachment 76
8 12 Lube Boom Pivot 76
8 13 Check Tire Inflation 76
8 14 Check Tire Wheel Nuts 76
8 15 Check Drive Shaft Bolt 77
Section 9 – 250 Hours or Monthly
Maintenance
9 0 250 Hours Or Monthly Maintenance 81
9 1 Engine and Hydraulic Oil Sampling 81
9 2 Check Engine Coolant Concentration 81
9 3 Check Engine Air Filter 82
9 4 Check Engine Drive Belts 82
9 5 Check Axle Wheel Ends 83
9 6 Check Axle Differential 83
9 7 Check Battery 83
Section 10 – 500 Hours or Quarterly
Maintenance
10 0 500 Hours or Quarterly Maintenance 87
10 1 Change Engine Oil 87
10 2 Change Engine Oil Filter 88
10 3 Change Engine Air Filter 88
10 4 Change Engine Fuel Filter 89
10 5 Check Engine Glow Plug 89
10 6 Change Hydraulic Reservoir Filter 90
Section 11 – 1000 Hours or Semi-Annually
Maintenance
11 0 1000 Hours or Semi-Annually
Maintenance 93
11 1 Check Engine Valve Tip Clearance 93
11 2 Check Electrical Alternator 93
11 3 Check Electrical Starter 93
11 4 Check Electrical System 94
11 5 Check Hydraulic Hoses and Fitting 94
11 6 Change Hydraulic, Reservoir Oil Filter,
Cleaning Hydraulic Magnet 94
11 7 Change Axle Wheel End Oil 95
11 8 Change Axle Differential Oil 95
11 9 Check Accumulator Pre-charge
Pressure 95
Section 12 – 2000 Hours or Two Years
Maintenance
12 0 2000 Hours or Two Years 99
12 1 Change Engine Coolant 99
Section 13 – 3000 Hours or Three Years
Maintenance
13 0 3000 Hours or Three Years 103
13 1 Check Atomisers (Fuel Injector) 103
Section 14 – Routine Maintenance
14 0 Routine Maintenance 107
14 1 Replacing the Attachments 107
14 2 Slider Pad Adjustment 108
14 3 Changing Slider Pads 108
14 4 Attachment Removal 110
14 5 Parking Brake Adjustment 111
14 6 Bleeding Brake System 112
14 7 Proximity Switch Adjustment 113
14 8 Drive Shaft 113
14 9 Fuel Tank 115
14 10 Oil Tank 115
14 11 Radiator 117
Section 15 – Hydraulic Boom
15 0 Boom Introduction 123
15 1 Boom Removal / Installation 123
15 2 Tilt Cylinder Replacement 126
15 3 Boom Disassembly 127
15 4 Boom Assembly 128
15 5 Fork Cylinder Disassembly 129
15 6 Attachment Locking Cylinder
Disassembly / Assembly 130
15 7 Boom Hoist Cylinder Disassy / Assy 132
15 8 Boom Extend Cylinder Disassy / Assy 135
Section 16 – Carrara Axles
16 0 Front Alxe Removel / Installation 139
16 1 Rear Axle Removel / Installation 142
16 2 Carrara Front Axle 146
16 3 Carrara Rear Axle 176
Section 17 – Troubleshooting
17 0 Troubleshooting Guide 205
17 1 General Troubleshooting 205
17 2 Hydraulic Troubleshooting 206
17 3 Electrical Troubleshooting 211
Section 18-Hydraulic System
18 0 Hydraulic System 225
18 1 Hyd Drive Pump Removal / Assy 225
18 2 Cylinder Holding Valve Removal / Assy 226
18 3 Motor Removel / Assembly 226
18 4 Rexroth Pump (A4vG) 227
18 5 Rexroth Motor (A6Vm107) 271
18 6 Rexroth Operating Manual 313
Section 19 – Engine
19 0 Engine Introduction 331
19 1 Engine Removel / Assembly 331
19 2 Perkins User Handbook 336
19 3 Perkins 700 Series WorkShop 379
Section 20- Tables and Enclosures
20 0 Torque Wrench Settings 537
20 1 Pressure Setting 539
20 2 Special Tool List 541
Section 21- 3B6 Technologies LMI System
21 0 3B6 Load Moment Indicator Manual 551

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