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Terex Genie GTH-4020 ER, Operator'S Manual

The Terex Genie GTH-4020 ER Operator's Manual is a comprehensive guide designed to assist users in operating and maintaining their equipment with ease and efficiency. This manual can be downloaded for free from our website, ensuring a hassle-free experience while accessing this valuable resource.

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Part No. 57.0009.0404          GTH-4518ER - GTH-4020ER - GTH-6025ER                                           175

Operator’s Manual

First Edition - Third Printing

Diagrams and Schemes

   WIRING DIAGRAM 13/13

DRIVER’S SEAT LINE

WINDER

CAN OPEN LINE

TERMINAL RESISTANCE

ARM3 CONTROL UNIT

20

18

16

14

12

10

8

6

4

2

19

17

21

11

15

13

7

9

1

3

5

22

23

24

29

28

+

V

P

51

46

40

34

44

30

25

21

7

5

12

1

3

27

56

50

31

33

36

45

4

6

8

14

24

26

2

42

W

D

O

B

U

Z

Z

E

R

P

L

A

T

F

O

R

M

 O

V

E

R

L

O

A

D

P

L

A

T

F

O

R

M

 O

V

E

R

L

O

A

D

O

P

T

IO

N

A

L

 S

O

L

. 

V

A

LV

E

 1

O

P

T

IO

N

A

L

 S

O

L

. 

V

A

LV

E

 2

C

H

A

N

 H

W

D

O

G

N

D

P

L

A

T

F

O

R

M

 C

O

N

N

E

C

T

 K

E

Y

E

N

G

IN

E

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T

A

R

T

 B

U

T

T

O

N

J

O

Y

S

T

IC

K

 P

O

W

E

R

 S

U

P

P

LY

W

E

IG

H

T

 4

 A

C

C

E

S

S

. 

D

E

C

O

D

.

W

E

IG

H

T

 2

 A

C

C

E

S

S

. 

D

E

C

O

D

.

E

X

T

E

N

S

IO

N

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O

N

T

R

O

L

R

E

D

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N

D

IC

A

T

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R

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IG

H

T

G

N

D

C

H

A

N

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W

D

O

W

D

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N

D

S

IG

N

- 

M

IC

R

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S

W

IT

C

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IP

P

E

D

D

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A

D

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A

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T

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N

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IG

H

T

 1

 A

C

C

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S

S

. 

D

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M

E

R

G

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T

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N

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N

T

R

O

L

ARM3 CONTROL UNIT

P

U

S

H

B

U

T

T

O

N

 -

 2

n

d

 F

U

N

C

T

IO

N

PRE-INSTALLATION

FOR OPTIONAL

VALVES

KEY

UP

in/out

up/down

rotation

IGNITION

MOTORDRIVEN

PUMP

BASKET

ROTATION

MICRO1

MICRO2

MUSHROOM

BUTTON

BUZZER

X194s

C1 A2 A1

platform

rotation

platform

rotation up

platform

rotation

C3

C8

B1

+

1

2

V

+

1

2

V

p

la

tf

o

rm

 r

o

ta

tio

n

p

la

tf

o

rm

 r

o

ta

tio

n

 u

p

p

la

tf

o

rm

 r

o

ta

tio

n

B2

a

c

c

e

s

s

o

ry

B7 C7

C

H

A

N

 H

C

H

A

N

 L

A3

ground

C5

B5

B6

A5

7A

A6

C6

B8

c

e

ll 

2

c

e

ll 

1

+

g

ro

u

n

d

s

ig

s

ig

s

ig

s

ig

g

ro

u

n

d

+

CLIO

PUSHBUTTON PANEL SYSTEM

PLATFORM SYSTEM

LOAD CELL

PLATFORM

alarm warning light

1

2

3

4

5

C

-N

1

C

-N

1

M

-V

1

V

1

.5

L

1

.5

R

1

.5

X134

11

27

26

42

33

29

28

31

30

36

34

40

51

46

45

44

50

56

A192

6

X192

1

3

2

5

4

14

8

7

12

24

21

25

A

1

.5

X134

10

X134

9

X134

8

X189

9

X189

8

CA2 B1

CA2 A1

C

A

3

 B

1

C

A

3

 A

1

C

A

3

 V

0

.3

5

C

A

3

 B

0

.3

5

C

A

4

 B

1

C

A

4

 B

1

C

A

4

 A

1

C

A

4

 A

1

A

-N

1

A

-N

1

C

A

1

 V

1

CA1 V1

CA1 B1

C

A

1

 B

1

C

/N

1

C

/N

1

C

-N

1

.5

C

-N

1

A

-V

1

A

-V

1

H

/R

1

H

/R

1

B

/R

1

B

/R

1

M

-B

1

M

-B

1

C

-L

1

C

-L

1

C

A

5

 B

1

H

-B

1

H

-B

1

C

-R

1

C

-R

1

M

1

L

-R

1

L

-R

1

L

-R

1

L

-R

1

L

-R

1

M

-N

1

M

-N

1

B

-G

1

B

-G

1

H

-V

1

H

-V

1

Z

1

Z

1

Z

-N

1

Z

-N

1

S

-G

1

S

-G

1

CA5 A1

C

A

5

 A

1

N

1

.5

N

1

.5

N1

N

1

N

1

N

1

N

1

N

1

N

1

G

-N

1

G

-N

1

H

-N

1

H

-N

1

L

1

L

1

M-V1

M

-V

1

M

-V

1

M

-V

1

R

-V

1

R

-V

1

B

-N

1

B

-N

1

C/N1

9.3

A-N1

9.5

C-N1.5

2.5

M1

9.3

X195

7

X195

6

X195

1

X195

2

X195

3

X195

4

X189

2

X189

1

X189

4

X189

7

X189

6

X189

3

X189

5

X195

5

X193

B

X193

A

4

3

2

X196

1

24

23

22

21

20

19

18

17

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

X194

1

N1.5

9.5

CA03 B0.35

9.5

CA03 V0.35

9.5

Sal4

Sal5

Sal2

Sal3

R193

120 ohm

X196

Summary of Contents for Genie GTH-4020 ER

Page 1: ... GTH 4518 ER First Edition Third Printing Part No 57 0009 0404 Serial number range From s n 18004 To s n 20111 GTH 4020 ER From s n 19127 To s n 20117 With Maintenance Information GTH 6025 ER From s n 13309 To s n 19308 ...

Page 2: ...machine at all times For any further information please call Terexlift Contents Introduction Page 3 Machine Identification Page 5 Symbols Used On The Machine Page 7 Labels And Plates Applied On The Machine Page 9 Safety Precautions Page 15 Description Of The Main Components Page 23 Controls And Instruments Page 25 Inspections Page 55 Operating Instructions Page 61 Transporting The Machine Page 75 ...

Page 3: ... or death DANGER Red indicates a hazardous situationwhich ifnotavoided will result in death or serious injury WARNING Orange indicatesahazardous situationwhich ifnotavoided couldresultindeathorserious injury CAUTION Yellow indicatesahazardous situationwhich ifnotavoided could result in minor or moderate injury NOTICE Blue indicates a property damage message PROTECT THE ENVIRONMENT Green used to dr...

Page 4: ...4 GTH 4518ER GTH 4020ER GTH 6025ER Part No 57 0009 0404 Operator s Manual First Edition Third Printing Intentionally blank page ...

Page 5: ...chinery Roll over protectivestructures Laboratorytests and performance requirements EN 13059 2002 Safety of Industrial trucks Test methods for measuring vibration MACHINE IDENTIFICATION PLATES The following data plates are applied on the machine Machine data plate Theidentificationplatecontainsthemainidentification data of the machine like model serial number and year of manufacture On machines de...

Page 6: ...de member IDENTIFICATION PLATES OF THE MAIN PARTS The plates of the main components not directly manufactured by TEREXLIFT srl for instance engines pumps etc are located where originally applied by the manufacturers HOW TO READ YOUR SERIAL NUMBER Chassis serial number The chassis serial number is punched on the front right part of the chassis side member Machine data plate On machines destined for...

Page 7: ...y Retract Outrigger Extend Outrigger Raise Outrigger Lower Outrigger Right Machine Sway Left Machine Sway Turret Rotation Unlock Fuel Level Glow Plugs Preheatinh Service Engine Coolant Temperature Battery Charge Engine Oil Pressure Brake Pressure Hydraulic Oil Filter Air Filter Not Active Water in Fuel Hydraulic Oil Level General Warning Shift on Fly Comando luci retronebbia Emergency Pump Hazard ...

Page 8: ...Maintain required clearance Electrocution Hazard No people under load Falling Object Hazard Read the operator s manual Burn Hazard Burn Hazard Explosion Burn Hazard No smoking No open flame Allow system to cool Allow surfaces to cool Crush Hazard Keep away from moving parts Crush Hazard Keep clear of moving parts Allow compartment access Crush Hazard Keep clear of moving outriggers Tip over Hazard...

Page 9: ...ER 9 Operator s Manual First Edition Third Printing Labels And Plates Applied On The Machine 8 10 18 9 13 1 6 11 18 B 5 15 5 14 7 25 3 9 13 C A 32 16 28 4 14 13 2 26 15 25 22 4 3 5 14 34 29 12 3 26 19 5 14 13 9 27 25 20 25 33 19 30 24 31 21 3 9 14 14 33 ...

Page 10: ...GTH 4518 ER GTH4020 ER Tyre inflat P 8bar 116psi GTH 6025 ER 4 4 09 4618 0918 Falling Object Hazard 3 5 09 4618 0919 Crush Hazard 4 6 09 4616 0041 09 4618 0260 Sound power level 103 db for GTH 4518ER and GTH 4020ER Sound power level 105 db for GTH 6025ER 1 7 09 4618 0920 Compartment Access 1 8 Kg 4000 Kg 4500 Kg 6000 09 4616 0040 09 4618 0373 09 4618 0757 Max Capacity Kg 4000 GTH 4020 ER Kg 4500 G...

Page 11: ...n posizione di riposo gli organi di comando del braccio posizionare la leva marcia avanti indietro in folle inserire il freno a mano e arrestare il motore Norme per l utilizzo di macchine dotate di stabilizzatori È vietato utilizzare gli stabilizzatori se il carico è già sollevato gli stabilizzatori servono solamente ad aumentare la stabilità della macchina l uso scorretto degli stabilizzatori può...

Page 12: ...Cosmetic Genie GTH 6025 ER 2 2 2 2 2 2 20 09 4618 0923 Burn Hazard 2 21 09 4618 0924 Burn Explosion Hazard 1 22 09 4618 0925 Crush Hazard 1 23 09 4618 0926 No Riders 1 24 09 4618 0927 Burn Hazard 1 25 09 4618 0916 Lift Point 6 26 09 4618 0917 Diesel Fuel Cap 1 27 09 4618 0928 Hydraulic Oil 2 GTH 4518 ER 09 4618 0923 09 4618 0925 09 4618 0926 09 4618 0927 09 4618 0916 09 4618 0924 09 4618 0917 09 4...

Page 13: ...5 Lmi Control F26 Optional F27 Work Lights Ref Circuit Ref Circuit Ref Circuit K1 High Beam K9 Transmission Disconnected K17 Optional K2 Low Beam K10 Transmission Disconnected K18 Outriggers K3 Horn K11 Start Up Enabling Command K19 Overload Warning System K4 Speed Switch Power Supply K12 Optional K20 High Boom K5 Optional K13 Optional K21 Tilt Ext Exchange Movements K6 Optional K14 Outriggers K22...

Page 14: ... NO E SER E OMO OG ONE F R TO N T M E N T PESO M SS E NT M FRONT E E GHT PO S M ESS E NT HS ST O N ST O PESO M E E NTER OR PESO M SS E POST M RE R E E GHT PO S M ESS E RR ERE HS ST H N ST O PESO M E E POSTER OR PESO TOT E TOT E GHT PO S TOT GES MTGE HT N ST O PESO TOT M TR O MOTORE TERM O ENG NE SER N N MOTE R THERM E F R NR ESE MOTOR NO E SER E MOTOR TERM O MODELLO TYPE DƒSIGNATION MODELL MODELO ...

Page 15: ...aulic oil leaks can penetrate or burn the skin Always operate the machine in a well ventilated area to avoid carbon monoxide poisoning Do not lower the boom if the area underneath is not clear of personnel or obstructions SAFETY DEVICES Several safety devices have been fitted to the machine They must never be tampered with or removed Regularly check the efficiency of such devices In case of faults...

Page 16: ...re safe say in compliance with the rules and provisions 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 Not observing the instructions and safety rules in this manual may result in death or serious injury Do not operate the machine unless Yo...

Page 17: ...hs and diagrams the identification and hazard warning plates They shall be skilled and trained about the machine use The operator shall have a licence or a driving licence when provided for by the laws enforced in the country where the machine works Please ask the competent bodies In Italy the operator must be at least 18 year old Requisites of the SERVICEMEN Thepersonnelchargedwiththemachinemaint...

Page 18: ...distance from the telescopic boom and the lifted load Electrical hazards Keep away from the machine in case of contact with energized power lines Personnel on the ground must never touch or operate the machine until energized power lines are shut off DANGER Do not at any time use the machine during a storm Use only type approved working clothing in good condition Personal PROTECTIVE EQUIPMENT Unde...

Page 19: ...loamy peaty pasty soil rippable soft ground non cohesive well com pact soil sand gravel 2 0 0 2 rippable soil solid 1 0 0 1 semi solid 2 0 0 2 hard 4 0 0 4 Rocks concrete heavy traffic paved roads above 10 0 above 1 0 Table 1 WARNING Make sure the machine wheels and stabilisers rests on a firm ground to prevent hazardous unstable conditions If the ground is not firm enough position some supporting...

Page 20: ...s 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 1 5 meters from the ground always use approved fall restraint or fall arrest devices Do not enter leave the machine while it is running Do not leave the driving place when the machine ...

Page 21: ...working do not give instructions or signs to several people at the same time Instructions and signs must be given by one person only Always pay 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 any means After work never leave ...

Page 22: ...ence of fuel oil or batteries Carefully handle all flammable or dangerous substances Do not tamper with fire extinguishers or pressure accumulators DAMAGED COMPONENT hazards Do not use battery chargers or batteries with a voltage above 12V to start the engine Do not use the machine as a ground for welding PERSONAL INJURY hazards Do not operate the machine in case of hydraulic oil or air leak Air o...

Page 23: ...ds and fork locking during transfer 8 Collapsible forks for palletised loads 9 Attachment holding frame 10 4th boom section 11 3rd boom section 12 2nd boom section 13 1st boom section 14 Left hand side tool compartment 15 Access step 16 Front axle 17 Front left stabilizer 18 Front right stabilizer 19 Engine compartment Part No 57 0009 0404 GTH 4518ER GTH 4020ER GTH 6025ER 23 Operator s Manual Firs...

Page 24: ...24 GTH 4518ER GTH 4020ER GTH 6025ER Part No 57 0009 0404 Operator s Manual First Edition Third Printing Intentionally blank page ...

Page 25: ...20 Ignition switch 21 Cab Road Platform switch 22 Emergency stop switch 23 Load limiter disable selector 24 Inclinometer 25 Throttle pedal 26 Service brake pedal 27 Multipurpose joystick right 28 Cab heater control cock 29 Fuse and relay box 30 Manual potentiometric accelerator 31 Warning light Shift on fly system enabled 32 Multipurpose joystick left 33 Parking brake 34 Optional switches dashboar...

Page 26: ...on de selection 60 Button 2 front right stabilizer selection de selection 61 Button 3 rear left stabilizer selection de selection 62 Button 4 rear right stabilizer selection de selection 63 Warning lights and luminous indicators 64 Function button A automatic machine levelling 65 Function button B not active 66 Function button C not active 67 Function button D stabilizer lifting lowering flush wit...

Page 27: ... the reverse gear 1 2 0 Controls And Instruments 20 _ Ignition Switch Three position switch No circuit under voltage key can be removed and engine is stopped Circuits under voltage for engine start up Board controls and instruments are on Wait until the warning light 6 2 signalling the glow plugs preheating goes off before proceeding with the engine starting Engine start up when released key sprin...

Page 28: ...indscreen Wiper Horn Lights Horn function When sliding the lever along its axis horn switches on independently from other pre set functions Windscreen washer function Push the second stage of the lever along its axis to direct a jet of water onto the cab windscreen Windscreen wiper function To operate the windscreen wiper rotate the lever tip to one of the four positions I Intermittence not activa...

Page 29: ...brake efficiency Accelerator control 25 _ Throttle Pedal Itspressurecontrolstheenginerpmandthemachine speed It is fitted with an adjustable stop in the lower part 30 _ Manual Potentiometric Accelerator Turning the regulator 30 clockwise lets you increase the engine speed Turning the regulator counter clockwise lets you decrease the engine speed The manual gas control can only be used with man plat...

Page 30: ...It is located on the left side of the dashboard and has two positions with automatic return to centre Whenthebuttonisheldpresseddown theemergency pump is activated Releasing the button stops the pump Theactivationoftheemergencypumpshouldbedone with the simultaneous operation of the cab controls or the main valve manual controls Correct operation sequence Turn the ignition key 20 to position I Shif...

Page 31: ...ravelling The yellow activation pushbutton 1 is located at the backofthejoystickhandleandshallbepresseddown only when the warning light 31 is lit This warning light flashes to warn of any errors or problems In such case gear won t be shifted When the warning light 31 is lit with a solid light pressing the button lets you shift from one gear to another from 1st speed to 2nd speed and from 2nd speed...

Page 32: ...and the platform controls are activated The green indicator light A comes on NOTICE Before switching the controls from the cab to the platform rotate the ignition switch to position I Steering Mode Selection 7 _ Steering Mode Selector The three position switch for the selection of the steering mode is located on the dashboard to the right 1 Crab steering 0 Two wheel steering 2 Four wheel steering ...

Page 33: ... switch off heated air Turn the cock counter clockwise to switch on the cab heater Adjust the flow of heated air in the cab operating the A C fan switch 16 17 _ Differential Lock Switch The button is located on the right side of the dashboard and has two stable positions 0 Axle differential unlocked 1 Axle differential locked The locked condition is signalled by indicator light 77 The differential...

Page 34: ... circuit 1 Attachments hydraulic circuit Switching The selector has a block to keep the switch pressed Before switching the selector to another position unlock control B at the top of the selector Mixing Bucket Switch OPTIONAL Two position switch The pressure of this button enables the movement of the internal mixer of the bucket 0 Mixer OFF 1 Mixer ON The selector has a block to keep the switch p...

Page 35: ...ltipurpose Display When the machine is started the graphic display shows Engine rpm Hour meter speed Hydraulic oil temperature Battery voltage Service next service intervals Additionally the function buttons MODE 1 and MODE 2 let you access to and scroll through the menus and sub menus with the following functions Language selection Italian English Service password protected function reserved to a...

Page 36: ...en 11 and 15 volt corresponding to the green section of the scale on the right of the display If the voltage displayed is less than 11 Volt the alternator charge could be insufficient or the battery could be discharged If the voltage is above 15 Volt the alternator voltage is above the normal working voltage In both cases you should stop the machine and find and rectify the problem In the central ...

Page 37: ...s displayed Quitting the menu Select EXIT using button MODE 2 Press button MODE 1 to quit and display the home page C 105 60 VOLT 15 11 SELEZIONA LINGUA SERVICE VISUALIZZA ERRORI ESCI C 105 60 VOLT 15 11 C 105 60 VOLT 15 11 SELEZIONA LINGUA SERVICE VISUALIZZA ERRORI ESCI ITALIANO INGLESE ESCI C 105 60 VOLT 15 11 SELEZIONA LINGUA SERVICE VISUALIZZA ERRORI ESCI C 105 60 VOLT 15 11 SELEZIONA LINGUA S...

Page 38: ...quit the sub menu the EXIT command lets you quit the menu without changing any settings By quitting the sub menu you will go back to the SERVICE window of the main menu Password protected service sub menu reserved to authorised service centres Access to this sub menu is reserved to authorised service centres and is therefore password protected If you have entered the SERVICE menu accidentally pres...

Page 39: ...quit the sub menu select EXIT using button MODE 2 and then press button MODE 1 to confirm By quitting the sub menu you will go back to the EXIT window of the main menu C 105 60 VOLT 15 11 SELEZIONA LINGUA SERVICE VISUALIZZA ERRORI ESCI C 105 60 VOLT 15 11 ESCI C 105 60 VOLT 15 11 ESCI Part No 57 0009 0404 GTH 4518ER GTH 4020ER GTH 6025ER 39 Operator s Manual First Edition Third Printing ...

Page 40: ...ogged When this lamp sets to on immediately change the oil filter on the return line to the tank 6 8 Warning light air filter restricted When this red light comes on clean or change the air filter cartridges see Maintenance section 6 9 Warning light not active 6 10 Warning light water in fuel This yellow light comes on to alert to the presence of water in fuel 6 11 Warning light low hydraulic oil ...

Page 41: ...urntable aligned This green light comes on to warn that the turntable is in line with the longitudinal axis In this condition the locking pin can be driven in 77 Warning light differential lock This red light comes on to warn that the differential lock has been activated 78 Warning light second speed engaged This green flashing light comes on to warn that the second speed has been engaged 79 Warni...

Page 42: ...orward backward to the right or to the left The right joystick has two additional buttons 2 and 3 at the top for the activation of further functions Pushbutton 1 lets you use the mechanical Shift on fly system Seize the control lever correctly and move it gently The motion speed of the actuators depends on the lever position a small motion results in a slow motion of the actuators vice versa a ful...

Page 43: ...o C D Attachment coupling release To activate the function hold button 3 pressed down and move the joystick to C or D The following controls do not need you to press the intentional control button 4 for their operation Shift on fly To change mechanical gear press the yellow button 1 when the relevant warning light on the dashboard is lit with a solid light If during operation button 4 is released ...

Page 44: ... Turntable rotation to activate the function shift the joystick to C or D If during operation button 4 is released for more than 0 5 seconds the movement stops To restart the movement re select the function Controls And Instruments 44 GTH 4518ER GTH 4020ER GTH 6025ER Part No 57 0009 0404 Operator s Manual First Edition Third Printing ...

Page 45: ...machine To lift or lower the boom Set thecontrol lever to central position and press button 4 Smoothly shift the lever to position B to lift the boom shift the lever to position A to lower the boom Controls And Instruments Part No 57 0009 0404 GTH 4518ER GTH 4020ER GTH 6025ER 45 Operator s Manual First Edition Third Printing ...

Page 46: ...To extend or retract the boom telescopes Set the control lever to central position and press button 4 Press button 2 to A to move out the boom telescope press the same button to B to move in the boom telescope Controls And Instruments 46 GTH 4518ER GTH 4020ER GTH 6025ER Part No 57 0009 0404 Operator s Manual First Edition Third Printing ...

Page 47: ...itch forward back the attachment holding frame Set the control lever to central position and press button 4 Smoothly shift the lever to position D to pitch the holding plate forward shift the lever to position C to pitch the plate back Controls And Instruments Part No 57 0009 0404 GTH 4518ER GTH 4020ER GTH 6025ER 47 Operator s Manual First Edition Third Printing ...

Page 48: ... Set the control lever to central position and press button 4 Press button 3 to select the attachment locking function and hold it pressed until the end of the motion Smoothly shift the lever to position C to lock the attachment shift the lever to position D to unlock the attachment 48 GTH 4518ER GTH 4020ER GTH 6025ER Part No 57 0009 0404 Operator s Manual First Edition Third Printing ...

Page 49: ...s been removed To rotate the turntable Shift the control lever to central position and press button 4 Smoothly shift the lever to direction D to rotate the turntable clockwise shift the lever to direction C to rotate the turntable counter clockwise Part No 57 0009 0404 GTH 4518ER GTH 4020ER GTH 6025ER 49 Operator s Manual First Edition Third Printing ...

Page 50: ...tabilized machine lower all the stabilizers to the ground and press button A During operation the machine will level automatically Checkthatthemachineislevelontheinclinometer 24 The air bubble must be right in the middle of the instrument NOTICE Operatetheswaycontrolonlywhentheturntable is locked in central position and the boom is at max 10 50 GTH 4518ER GTH 4020ER GTH 6025ER Part No 57 0009 0404...

Page 51: ...lizer Stabilizers can be moved one at a time or all at the same time by repeating for each of them the same operating sequence Indicator lights 5 6 7 8 show the selected stabilizer 5 Front left stabilizer 6 Front right stabilizer 7 Rear left stabilizer 8 Rear right stabilizer Pressing or releasing buttons 9 10 11 12 lets you move the selected stabilizer 9 Stabilizer in 10 Stabilizer out 11 Stabili...

Page 52: ...elected stabilizer comes on Hold button 11 pressed down to raise the stabilizer pad Hold button 9 pressed down to retract the stabilizer De select the stabilizer by pressing the relevant button 1 2 3 4 and check that the indicator light of the de selected stabilizer goes off NOTICE Correct sequence to lower the stabilizers Extend the stabilizer to end of stroke Lower the stabilizer pad and make su...

Page 53: ...n fly control The yellow Shift on fly pushbutton 1 lets you shift from one gear to another when the machine is travelling Use this button only when the warning light 31 is lit with a solid light WhenthewarninglightisOFF thetravellingspeedis beyondtheadmissiblespeedrangeand bypressing the button gear won t be shifted If the warning light flashes there are errors or problems Try to modulate the mach...

Page 54: ...pped with the emergency pump In order to operate the emergency pump with the manual controls follow the instructions below Open the rear hatch to access to the main valve Fit the control levers supplied to the elements of the main valve Activate the emergency pump by holding button Z pressed down If the button is released the pump stops Shift the lever of the main valve to the position correspondi...

Page 55: ...before the operator performs the function tests The pre operation inspection also serves to determine if routine maintenance procedures are required Only routine maintenance items specified in this manual may be performed by the operator Refer to the list on the next page and check each of the items If damage or any unauthorized variation from factory delivered condition is discovered the machine ...

Page 56: ...steering system braking system boom telescopes sliding pads clean glasses lights and rear view mirrors engine and relevant components horn lights machine ignition control nuts bolts and other fasteners Check the entire machine for cracks on welds or structural components dents or damage to the machine Make sure that all structural and other critical components are present and the relevant fastener...

Page 57: ...ration inspection before going on to the next section 3 Always perform function tests prior to use 4 Inspect the workplace 5 Only use the machine as it was intended Test the Control Levers always pressing button 4 7 Using the right control lever momentarily raise and lower the boom tilt the forks up and tilt the forks down Result All functions should operate smoothly 8 Using the right lever and th...

Page 58: ... in reverse then come to an abrupt stop The back up alarm should sound when the transmission control lever is in reverse 23 Move the transmission control lever to neutral 24 Pull the parking brake lever upward Result The parking brake indicator light should come on indicating the parking brake is on 25 Move the transmission control lever forward then in reverse Result The machine should not move 2...

Page 59: ... and operating the machine Be aware of and avoid the following hazardous situations drop offs or holes bumps floor obstructions or debris sloped surfaces unstable or slippery surfaces overhead obstructions and high voltage conductors hazardous locations inadequate surface support to withstand all load forces imposed by the machine wind and weather conditions the presence of unauthorized personnel ...

Page 60: ...60 GTH 4518ER GTH 4020ER GTH 6025ER Part No 57 0009 0404 Operator s Manual First Edition Third Printing Intentionally blank page ...

Page 61: ...er Optional attachments WARNING Before using the machine inspect the job site and check for possible hazardous conditions Make sure that there are no holes moving banks or debris that may cause you to lose the control of the machine DANGER Pay the greatest attention when working close to electric lines Check their position and ensure that no part of the machine operates at less than 6 meters from ...

Page 62: ...completely Rotate handle 3 to open the upper section of the door and lock it against the special catch CAUTION The upper section of the door must be secured to the rear part of the driving cab or latched to the lower section of the same door To unlock the door latched in open position Press button 4 to unlock the door from the catch Once released re close the upper section of the door by means of ...

Page 63: ...e backrest angle Operate lever D press your back firmly against the backrest and put the backrest at the angle you wish then release the lever Adjusting the armrest height Raise armrest E and turn wheel F to put the armrest at the height you want CAUTION The seat is for one person only Don t adjust the seat when the machine is moving FASTENING THE SEAT BELTS Sit correctly in the driving seat then ...

Page 64: ...lly rotate the joint it is fitted with SWITCHING ON THE CAB INTERIOR LAMP The cab ceiling fitting A has a three position switch B which lets you switch on the interior light press the bottom of the switch to switch on the interior light switch off the light press the switch to the central position to switch off the light switch on the interior light when the door is opened press the top of the swi...

Page 65: ...ine through the battery of another machine make sure that the two vehicles cannot collide to prevent formation of sparks Batteries give off a flammable gas and sparks may burn it and cause an explosion Do not smoke when checking the electrolyte level Keep any metal object like buckles watch straps etc clear of the battery positive terminal These elements can short between the terminal and nearby m...

Page 66: ...e Please refer to the engine use and maintenance manual The machine is supplied with oil SAE 15W 40 To start the engine from cold proceed as follows Set the forward back speed lever to neutral position Turn the ignition switch to the glow plugs preheating position the relevant warning light 46 goes on Step down on the gas pedal and start the engine by turning the ignition switch Release the switch...

Page 67: ... a smooth stop by easing up the gas pedal and stepping down on the brake pedal Set the forward back speed lever to neutral position Engage the parking brake and ensure its indicator light switches on Release the service brake pedal Rest the attachment coupled to the boom flat on the ground Rotate the ignition key to 0 and remove the key Leave the driving cab and lock the cab door WARNING Always fa...

Page 68: ...the same boom pos 2 and compared with the load chart The tag 3 located at the top of each load chart indicates the type of attachment used Theloadchartsillustratedinthismanualaregiven only as a mere example To define the payload limits refer to the load charts applied within the cab of your machine Operating Instructions WARNING The load charts applied on the cab windscreen refer to a stationary m...

Page 69: ...um allowed load the buzzer emits a continuous sound and the machine motions are stopped but for those allowing to return the load within safety limits ENTER The display of the limiting device is divided into four areas LT area operating modes 1 Front operation with stabilizers 2 Side operation with stabilizers 3 Front operation without stabilizers 4 Side operation without stabilizers LED s area Th...

Page 70: ...hmentusedisof mechanical type proceed with the manual search and selection Press INDEX until the letter corresponding to the used attachment is displayed in the F window Press ENTER to confirm The machine is ready to use DANGER Beforeusingthemachine makesurethatthefirst green LED is ON and that the operating mode shown in window E and the attachment shown in window F are those actually used The mo...

Page 71: ...ct spacing L o c k t h e s c r e w s r e tightening the nut WARNING The centre of gravity of the load must always be halfway between the forks Ensure you exactly know the weight of the load before handling it When extending the boom do not exceed the payload limit Refer to the payload limits given in the load chart applied on the cab windscreen or in the quick user s guide Space the forks as wide ...

Page 72: ...e load 20 30 cm from the ground Suit the machine speed to the ground conditions to avoid dangerous jumps side skids of the vehicle and possible load falls When driving on slopes or ramps hold the load uphill DANGER Do not drive on slopes sideways this wrong manoeuvre is one of the main reasons for accidents due to vehicle overturning Unloading phase Drive to the unloading point with straight wheel...

Page 73: ...r Pitch the attachment holding frame forward and lower the boom to release the attachment upper lock Move back with the machine and drive to the new attachment to be coupled Hold the frame pitched forward and hook the upper lock of the new attachment Retract and raise the attachment some centimetres It will centre automatically on the quick coupling frame Operate the attachment locking joystick an...

Page 74: ...me 2 Fully extend the stabilizers 3 Completly lower the stabilizers and sway the machine checktheoperationontheinclinometer 24 in the cab 4 Unlock the rotation of the counter frame turntable 5 Level the platform floor The platform floor cannot be levelled once the controls have been switched from the driving cabin to the platform Before starting using the platform make sure the floor is level 6 Tu...

Page 75: ...screws 31 on the two sides of the front differential casing as follows Loosen the four counter nuts fixing screws 31 then move the nuts backwards by approx 8 mm Tighten screws 31 so as to fasten them onto the pressure plate Using a wrench tighten the screws 31 in an alternate sequence by 1 4 turn a time so as to compress the Belleville washers and disengage the braking disks Tighten max by one tur...

Page 76: ...ow the steps below Ensure ramps are correctly positioned Retraact the boom to transfer position Carefully drive the machine onto the transporting vehicle Put the parking brake and rest the attachment flat on the vehicle platform Ensure the overall dimensions do not exceed the allowed limits Shut the engine down and close the driving cab of the machine Secure the machine to the vehicle platform by ...

Page 77: ...ts by blowing some compressed air Lubricate the machine thoroughly Do a walk around inspection and replace any worn or damaged part Re paint any worn or damaged part Remove the battery smear its terminals with vaseline and store it in a dry place Battery can be used for other purposes Otherwise periodically check its charge level Refuel the tank to prevent internal oxidation Store the machine in a...

Page 78: ...rewashingtheengine protecttheairintakefilter to prevent water from entering the circuit NOTICE If the machine shall be used in a marine or equivalent environment protect it against salt deposits with an adequate treatment against saltiness to prevent rust formation MACHINE DISPOSAL PROTECT THE ENVIRONMENT Attheendofthemachinelife callinaspecialised firm to dispose of it in compliance with the loca...

Page 79: ...orking hours INTRODUCTION A thorough and regular maintenance keeps the machine in a safe and efficient working condition For this reason it is advisable to wash grease and servicethemachineproperly especiallyafterhaving worked under particular conditions muddy or dusty environments heavy operations etc Always ensure all machine components are in good condition Check for oil leaks or loosening of g...

Page 80: ...se Pour exhausted oil into cans and deliver them to specialised firms for disposal Oil leaks In case of accidental oil leaks cover with sand or type approvedgranulate Thenscrapeoffanddispose of it as chemical waste Maintenance First aid Eyes In case of accidental contact with the eyes wash with fresh water If the irritation persists seek medical advice Intake In case of oil intake do not induce vo...

Page 81: ...parts and the pivot pin of the telescopic boom Every 10 working hours or daily 1 Check the engine oil level 2 Clean the air suction filter 3 Clean the air suction pre filter 4 Remove the dust from the filter by squeezing the special rubber element on the same filter 5 Check the engine coolant level 6 Clean the radiator if necessary 7 Check the hydraulic oil level within the reservoir 8 Make sure t...

Page 82: ...r mechanical components 12 Check the wear of the sliding pads of the boom sections 13 Adjust the clearance of the sliding pads of the boom sections Maintenance 14 Adjust the parking brake 15 Check the level of the battery electrolyte Every 3 working months 1 Check the efficiency of the block valves Every 500 working hours or every two months Jobs to be done in addition to those above 1 Visually ch...

Page 83: ...F 1 DIN 51524 part 2 3 First change Subsequent changes 1000 6 month Turntable rotation reduction gear Oil level check 250 monthly SHELL OMALA 150 DN 51 517 3 CLP ISO 12295 1 TYPE CKC US STEEL 224 DAVID BROWN 51 53 101 First change Subsequent changes 1000 6 month Every 2000 working hours or yearly Jobs to be done in addition to those above 1 Change the engine coolant Every 6000 hours or 5 years and...

Page 84: ...al WARNING When raising a component for maintenance purposes secure it in a safe way before any maintenance intervention WARNING Any intervention on the hydraulic circuit must be carried out by skilled personnel The hydraulic circuit of this machine is fitted with pressure accumulators You and others could be seriously injured if accumulators are not completely depressurised For this purpose shut ...

Page 85: ...rdens and hold the bonnet in raised position To open the bonnet Shut the engine down and put the parking brake Turn the key to unlock and open the bonnet CAUTION Take all precautions when approachingtheenginecompartment Somepartsoftheenginemaybevery hot Always use protective gloves Part No 57 0009 0404 GTH 4518ER GTH 4020ER GTH 6025ER 85 Operator s Manual First Edition Third Printing ...

Page 86: ... outer element 2 Changing the inner element See step 1 for removing the outer element Remove the inner element D Clean the filter bowl Smear the seal with grease then fit the new element and make sure it is correctly positioned To refit the outer element and the cover see step 1 NOTICE The inner element should be replaced every two times the outer element is replaced SERVICE INTERVAL Running in __...

Page 87: ...ement Refit cover B and lock it with the special clamps Make sure that the rubber element D is oriented downwards NOTICE As soon as the indicator light 6 8 switches on replace the outer element 2 Changing the cyclone pre filter Daily clean the cyclone pre filter Shut the engine down and engage the parking brake Loosen wing nut E and remove cover F Remove the dust container and empty it Refit the d...

Page 88: ...llow the coolant to flow out into a special container Once the coolant has been drained refit plug C and pour fresh mixture 50 water and 50 antifreeze in the radiator This proportion will provide protection down to 38 C Daily clean the radiator grille using a brush with hard bristles or compressed air at a max pressure of 6 bar SERVICE INTERVAL Running in __________________________ None Ordinary__...

Page 89: ... Release the pressure from the hydraulic circuit 3 Place a container of suitable size under the drain plug C placed in the lower part of the reservoir and collect any oil leaks 4 Remove the drain plug C and allow oil to flow out into the container 5 Refit the drain plug C 6 Add new oil by making sure that it matches the recommended type until it is level with A PROTECT THE ENVIRONMENT Handling and...

Page 90: ...ilter cover NOTICE The hydraulic oil filter cartridge shall be replaced as soon as the warning light 6 7 comes on see par Controls and instruments NOTICE Hydraulic oil filter canisters cannot be cleaned or washed and refitted They must be replaced with new ones of the type recommended by the manufacturer PROTECT THE ENVIRONMENT The handling and disposing of used oils may be ruled by local or natio...

Page 91: ...g brake Pull filter A out of the housing accessible from the outside of the cab Clean the filter bowl Clean the filter cartridge by beating it against a piece of wood Replace the cartridge if damaged NOTICE Paper filters must never be cleaned using compressed air or washed with water and or solvents Part No 57 0009 0404 GTH 4518ER GTH 4020ER GTH 6025ER 91 Operator s Manual First Edition Third Prin...

Page 92: ...ine on a level ground and ensure the parking brake is engaged and plug finds on the horizontal axis Clean the plug all around then remove it and check if oil is level with the hole If necessary add new oil through hole until it is level Refit the plug To change the oil Stop the machine and ensure the plug is oriented along the vertical axis Place a container of suitable size under the reduction ge...

Page 93: ...o change the oil Place a container of suitable size under the drain plug Remove the plug Remove the drain plug and empty the power divider gearbox Refit and tighten the drain plug Pour in new oil through the filler placed at the top of the reduction gear of the power divider Stop when oil is level with hole Refit and tighten plug SERVICE INTERVAL Running in _________ Within the first 10 hours Ordi...

Page 94: ...the oil in the turntable rotation reduction gear Stop the machine on a level ground and engage the parking brake Place a container of suitable size under drain plug C Remove drain plug C and let oil flow out of the reduction gear Unscrew the filling plug B Clean level plug A all around Loosen level plug A Refit and tighten drain plug C Pour new oil through the hole of plug B until it starts flowin...

Page 95: ... shown in the following figures the symbol represents the points to be greased by a pump the symbol represents the points to be greased by a brush SERVICE INTERVAL Running in __________________________ None Ordinary__________________ Every 10 hours CAUTION Use only PTFE INTERFLON FIN GREASE LS 2 to lubricate the sliding parts of the telescopic section Observe the following schedule After the first...

Page 96: ...6 pr Rim 14x22 5 14x19 5 Wheel disc 10 holes DIN 70361 Pressure bar Psi 8 116 5 5 80 RIGHT WAY WRONG WAY OKAY WRONG BRAKES Foranyinterventiononthebrakingsystem adjustment and or substitution of the brake discs address to the TEREXLIFT Technical Assistance Service or the nearest TEREXLIFT authorised workshop On new machines and when a wheel has been disassembled or replaced check the nut torque of ...

Page 97: ...teering selection switch to two wheel steer pos 0 5 Rotate the steering up to its stop turn in the same direction as above 6 Reset the steering selection switch to four wheel steer pos 2 7 Rotatethesteering tothesideoppositetopoint 3 so that the rear axle reaches its stop 8 Resetthesteeringselectionswitchto two wheel steer pos 0 9 Rotate the steering to the same side as in point 7 so that the fron...

Page 98: ...new the pad Tighten the screws fixing the pads at the recommended torque see below Use a dynamometric wrench Tightening torques of the pad screws in relation to the screw diameter Screws M10 Nm 30 Screws M14 Nm 50 Tightening torques higher than those recom mended can cause the break of the pad or of the locking threaded bush CAUTION Pads must compulsorily be replaced if the residual thickness of t...

Page 99: ...bile part C of the machine controlled by the sensor as close as possible to it Near the sensor to the component until the LED indicator D lights up 3 Further near the sensor by 1 2 mm Smoothly tighten the sensor fixing nut and the relevant lock nut The machine is fitted with the following proximity switches E N 1 turntable unlocking cylinder sensor F N 1 turntable rotation locking sensor G N 1 tur...

Page 100: ...imum tension value of 25 Nm 4 Check that all chains have been equally tensioned If not repeat the operation described above 5 Lockthechaintensionersbymeansofacounter nut and locknut SERVICE INTERVAL Running in __________________________ None Ordinary_________________ Every 500 hours 100 GTH 4518ER GTH 4020ER GTH 6025ER Part No 57 0009 0404 Operator s Manual First Edition Third Printing ...

Page 101: ...ystem does not enter the alarm mode contact the TEREXLIFT Technical Service SAFETY PUSHBUTTON on JOYSTICKS Both joysticks are equipped with a safety system deadman system The red pushbutton must be held pressed down until theendofthemanoeuvreoperatedusingthejoystick If the button is released the manoeuvre stops Do this check in the two positions with the turntable longitudinal and rotated 90 Check...

Page 102: ...efficient order stop the engine press the on off button for some seconds and check that the pump works regularly EMERGENCY STOP PUSHBUTTON 22 Set on the dashboard to the right of the steering wheel Pressing down this button stops the engine of the machine Before starting work again find and rectify the relevant causes then reset the button to neutral position turning it clockwise Checking the emer...

Page 103: ... installed in the stabilisers Lower or raise all the stabilisers The display of the MIDAC moment limiter will change the scale of the admissible payloads accordingly Should that not be the case contact the TEREXLIFT Technical Service WARNING If a limit switch is faulty or a lever is deformed immediately replace the part Stabiliser strain gauge every 40 hours or whenever an anomalous capacity is no...

Page 104: ...tion cylinder Block valve on machine sway cylinders Block valve on the turntable anti rotation pin DANGER Always use the lock ring of the lift cylinder see picture below when carrying out maintenance on the lift cylinder block valve or in general any operation in the area under the boom I Lift and extend the boom II Unscrew the two screws on the frame pos A to release the ring III Put the ring on ...

Page 105: ...the action generated does not result in an uncontrolled movement of the machine Checking the block valves every 3 months The piloted blocking valves allow to held the load in position in case of burst of a flexible hose To check the efficiency of a valve proceed as follows Load a weight near the maximum payload onto the boom Raise the load some centimetres above the ground max 10 cm To check the v...

Page 106: ...e engine Attempt to move with the machine The machine must not move Should that not be the case contact the TEREXLIFT Technical Service Maintenance Boom strain gauge 2 at every use To verify the efficiency of the strain gauge on the boom Visually check the wire for damage If the wire is damaged address to GENIE Technical Service Ifthestraingaugeisdefectiveoritswireisbroken the display will show an...

Page 107: ...ine whichever occurs first check the state of the structure paying an extreme attention to the welded supporting joints and the pins of both boom and platform if present WARNING After the first 5 years repeat this check every 2 years Part No 57 0009 0404 GTH 4518ER GTH 4020ER GTH 6025ER 107 Operator s Manual First Edition Third Printing ...

Page 108: ...gles and protective gloves and handle the battery with caution to prevent spillage Keep metal objects watch straps rings necklaces clear of the battery leads since they can short the terminals and burn you Before disconnecting the battery set all switches within the cab to OFF To disconnect the battery disconnect the negative lead from the frame earth first To connect the battery connect the posit...

Page 109: ...UPPLY 7 5 F10 LIGHTS SWITCH HAZARD WARNING LIGHTS 7 5 F11 BEACON 7 5 F12 CONTROL UNIT 10 F13 REAR WORK LIGHT SWITCH 10 F14 CONTROL UNIT 10 F15 HIGH BEAM 10 F16 ECO WARNING 15 F17 POSITION LIGHTS 10 F18 BACK UP LAMP 10 F19 CONTROL UNIT 10 F20 CONTROL UNIT 10 F21 HORN 15 F22 CONTROL UNIT 15 F23 CAB LIGHTS 10 F24 PROP SOLENOID VALVE 10 F25 CONTROL UNIT 10 F26 PARKING BRAKE SENSOR MICROSWITCH POWER 10...

Page 110: ...uses for an emergency Never try to repair or short blown fuses Make sure the contacts of fuses and fuse sockets ensure a good electric connection and are not oxidised Engine compartment fuses and relays Ref Circuit Amp FG1 IGNITION BOARD 40 FG2 AUX CIRCUIT 50 FG3 IGNITION 30 FG4 OPTIONAL 5 K110 IGNITION K160 OIL WATER RADIATOR FAN UNDER CONSTRUCTION 110 GTH 4518ER GTH 4020ER GTH 6025ER Part No 57 ...

Page 111: ...SHELL TELLUS T46 DENISON HF 1 DIN51524 part 2 3 NOTICE Never mix different oils this may result in troubles and component breaks Oils for hydraulic system Arctic climates Temperatures below 10 C Use SHELL Tellus T22 Mild climates Temperatures from 15 C to 45 C Use SHELL Tellus T46 Tropical climates Temperatures above 30 C Use SHELL Tellus T68 Part Product Capacity L GTH 4518 ER Capacity L GTH 4020...

Page 112: ...r 50 antifreeze At the delivery the machine is refilled with TEREX PRO COOL by VALVOLINE The use of this product guarantees protection to the circuit for 3 years or 7000 hours without having to add any dry coolant additive NOTICE Use an antifreeze mixture in the proportions recommended by the manufacturer in relation to the ambient temperature of the jobsite Lithium based Vanguard LIKO grease type...

Page 113: ...ompartment and replace if necessary The starter does not run Forward reverse gear selector not in neutral position Emergency button ON Fuse blown Battery down Set the switch to 0 Reset the button Check fuse FG3 and replace if necesary Recharge or replace the battery The starter runs but the engine does not start No fuel Fuel filter clogged Fuel hose empty fuel used up Refuel Change the filter See ...

Page 114: ...lector turned to ROAD Turn to JOBSITE MACHINE IN ALARM red LED on the IDR display lit Alarm of the moment limiter Retract or raise the boom whitin safe limits see Load Charts Faults and Troubleshooting DANGER WARNING CAUTION NOTICE PROTECT THE ENVIRONMENT In case of faults not listed in this chapter address to the TEREXLIFT Technical Assistance your nearest authorised workshop or dealer ...

Page 115: ...OT locked 1014 Stabiliser on the ground 1015 Manoeuvre not admitted for angle above 10 degrees 1016 Verticality command blocked as max extension has been reached 1017 Verticality command blocked as max extension has been reached 1018 Command not permitted in ROAD configuration 1019 Command not permitted in PLATFORM configuration 1020 Turntable NOT unlocked 1021 Horizontality command blocked as max...

Page 116: ... from the high chamber pressure transducer of the compensation cylinder below the minimum value 21 Signal from the high chamber pressure transducer of the compensation cylinder above the maximum value 22 Error in the feedback of the watchdog relay 30 The 2 readings of the signal of deployed stabilisers are not congruent 31 The 2 readings of the signal of stabilisers on ground are not congruent 32 ...

Page 117: ...ntrol 105 Error on the output control 106 Error on the 5V check 110 Lower cell reading at minimum 111 Upper cell reading at minimum 112 Congruency error of the load read by the 2 cells detected by CLIOA 115 Can Bus does not receive message 2 116 Can Bus does not receive message 3 119 Congruency error of the load read by the 2 cells detected by Midac 120 Can Bus does not receive from ACT1A 121 Can ...

Page 118: ...1 3 No CanBus 3 message from CLS 1161 1 No CanBus 2 message from ClioA 1161 2 No CanBus 3 message from ClioA 1171 1 No CanBus 2 message from ClioB 1171 2 No CanBus 3 message from ClioB 1200 Error or fault detected on ARM board Boom 1201 1 No CanBus 1 message from ARM Boom 1201 2 No CanBus 2 message from ARM Boom 1201 3 No CanBus 3 message from ARM Boom 1201 4 No CanBus 4 message from ARM Boom 1201...

Page 119: ...ror or fault detected on Rotation driver 1331 No CanBus message 1340 Error or fault detected on Aux circuit driver 1341 No CanBus message 1089 Error or fault detected on Lifting Bucher board 1090 Error or fault detected on Extension Bucher board 1091 Error or fault detected on Fork Bucher board 1092 Error or fault detected on Rotation Bucher board 1093 Error or fault detected on Aux Circuit Bucher...

Page 120: ...01 0 0 017 110 0 061 1388 3 105 157 2 149 611 4 302 0 1 018 105 3 062 1388 4 106 157 18 150 703 14 303 0 2 019 105 4 063 251 2 107 677 3 151 94 18 304 0 3 020 105 0 064 651 5 108 677 4 152 94 1 305 0 4 021 1080 4 065 655 5 109 103 16 153 630 31 306 0 5 022 111 3 066 653 5 110 167 16 154 157 1 307 0 6 023 111 4 067 656 5 111 167 18 155 1075 3 308 0 7 024 111 18 068 652 5 112 167 1 156 1075 4 309 1 ...

Page 121: ...r Shorted to High Source 145 110 4 Amber Engine Coolant Temperature Coolant Temperature Sensor Circuit Voltage Below Normal or Shorted to Low Source 146 110 16 Amber Engine Coolant Temperature Coolant Temperature High Data Valid but Above Normal Operational Range Moderately Severe Level 147 91 1 Red Accelerator Pedal Position Accelerator Pedal or Lever Position Sensor Circuit Abnormal Frequency Pu...

Page 122: ...Ambient Air Temperature Sensor Circuit Voltage Below Normal or Shorted to Low Source 261 174 16 Amber Fuel Temperature Engine Fuel Temperature Data Valid but Above Normal Operational Range Moderately Severe Level 263 174 3 Amber Fuel Temperature Engine Fuel Temperature Sensor 1 Circuit Voltage Above Normal or Shorted to High Source 265 174 4 Amber Fuel Temperature Engine Fuel Temperature Sensor 1 ...

Page 123: ...l or Shorted to Low Source 341 630 2 Amber Calibration Memory Engine Control Module data lost Data Erratic Intermittent or Incorrect 342 630 13 Red Calibration Memory Electronic Calibration Code Incompatibility Out of Calibration 343 629 12 Amber Controller 1 Engine Control Module Warning internal hardware failure Bad Intelligent Device or Component 351 629 12 Amber Controller 1 Injector Power Sup...

Page 124: ...age Auxiliary Input Output 3 Circuit Voltage Above Normal or Shorted to High Source 551 558 4 Amber Accelerator Pedal Low Idle Switch Accelerator Pedal or Lever Idle Validation Circuit Voltage Below Normal or Shorted to Low Source 553 157 16 Amber Injector Metering Rail 1 Pressure Injector Metering Rail 1 Pressure High Data Valid but Above Normal Operational Range Moderately Severe Level 554 157 2...

Page 125: ...nder 2 Mechanical System Not Responding Properly or Out of Adjustment 1142 653 7 Amber Injector Cylinder 03 Injector Cylinder 3 Mechanical System Not Responding Properly or Out of Adjustment 1143 654 7 Amber Injector Cylinder 04 Injector Cylinder 4 Mechanical System Not Responding Properly or Out of Adjustment 1144 655 7 Amber Injector Cylinder 05 Injector Cylinder 5 Mechanical System Not Respondi...

Page 126: ... Circuit Error Condition Exists 2321 190 2 None Engine Speed Engine Speed Position Sensor 1 Data Erratic Intermittent or Incorrect 2322 723 2 None Engine Speed Sensor 2 Engine Speed Position Sensor 2 Data Erratic Intermittent or Incorrect 2345 103 10 Amber Turbocharger 1 Speed Turbocharger speed invalid rate of change detected Abnormal Rate of Change 2346 2789 15 None System Diagnostic Code 1 Turb...

Page 127: ... Engine Coolant Temperature Engine Coolant Temperature High Data Valid but Above Normal Operational Range Least Severe Level 2964 105 15 None Intake Manifold 1 Temperature Intake Manifold Temperature High Data Valid but Above Normal Operational Range Least Severe Level 2973 102 2 Amber Boost Pressure Intake Manifold Pressure Sensor Circuit Data Erratic Intermittent or Incorrect Faults and Troubles...

Page 128: ... M 14 x 1 5 28000 56000 78800 94500 71 7 143 202 242 M 16 x 2 35200 70300 98900 119000 102 205 288 346 M 16 x 1 5 37400 74800 105000 126000 107 214 302 362 M 18 x 2 5 43000 86000 121000 145000 142 283 398 478 M 18 x 1 5 48400 96800 136000 163000 154 308 434 520 M 20 x 2 5 54900 110000 154000 185000 200 400 562 674 M 20 x 1 5 60900 122000 171000 206000 216 431 607 728 M 22 x 2 5 67900 136000 191000...

Page 129: ...section DANGER WARNING CAUTION NOTICE PROTECT THE ENVIRONMENT When replacing interchangeable attachments keep any person clear of the working area DANGER WARNING CAUTION NOTICE PROTECT THE ENVIRONMENT Mounting optional attachments and especially theextensionjib canchangethecentreofgravity of the machine Before handling a load check its weight and compare it with the values on the load charts The w...

Page 130: ... etc Safety Strictly obey the general safety precautions given in section Safety Operation To load unload the material operate the rotation lever of the attachment holding plate DANGER WARNING CAUTION NOTICE PROTECT THE ENVIRONMENT When using a shovel load the material only when the boom is completely retracted and push against the heap with straight wheels Maintenance Visually check the shovel fo...

Page 131: ...plate Maintenance Visually check the bucket for damage before using it Wash thoroughly with water after use or in case of prolonged inactivity to prevent the mix or residues from hardening Check for oil leaks from hoses and connectors Carefully protect the quick connectors once disconnected to prevent impurities from entering the circuit DANGER WARNING CAUTION NOTICE PROTECT THE ENVIRONMENT Before...

Page 132: ...otheforksusingthechainsprovided To unload the concrete Manual Version manually operate the gate opening lever Hydraulic Version operate the attachment locking lever after connecting the feeding lines of the new attachment to the quick couplings Maintenance Visually check the skip for damage before using it Wash with water after use or in case of prolonged inactivity to prevent the mix or residues ...

Page 133: ...otheforksusingthechainsprovided To unload the concrete Manual Version manually operate the gate opening lever Hydraulic Version operate the attachment locking lever after connecting the feeding lines of the new attachment to the quick couplings Maintenance Visually check the skip for damage before using it Wash with water after use or in case of prolonged inactivity to prevent the mix or residues ...

Page 134: ...ce with all pertinent regulations To handle the load raise and rotate the telescopic boom of the handler Maintenance Visually check the hook for damage before using it Check the safety catch is in good working order DANGER WARNING CAUTION NOTICE PROTECT THE ENVIRONMENT The fixed hook has been designed to support the load declared beside The max payload correspondstothenominalcapacityratingofthe ha...

Page 135: ...ads Avoid abrupt acceleration or deceleration Avoid load oscillations and especially do not move the load from the vertical pull line Do not pull crosswise and do not tow Operation To change the working height operate the rotation lever of the attachment holding plate Maintenance Visually check the jib for damage before using it Check the safety catch is in good working order Daily grease the join...

Page 136: ...cillations and especially do not move the load from the vertical pull line Do not pull crosswise and do not tow Operation To change the working height operate the rotation lever of the attachment holding plate Maintenance Visually check the jib for damage before using it Check the safety catch is in good working order Daily grease the joints using the greasing gun DANGER WARNING CAUTION NOTICE Mak...

Page 137: ...xtending the boom Operation Fork the hook and hold it in position All loads must be bridled with special textile slings or chains in compliance with all pertinent regulations To handle the load raise and rotate the telescopic boom of the handler Maintenance Visually check the hook for damage before using it Check the safety catch is in good working order DANGER WARNING CAUTION NOTICE Make sure thi...

Page 138: ...boom Operation Fork the hook and hold it in position All loads must be bridled with special textile slings or chains in compliance with all pertinent regulations To handle the load raise and rotate the telescopic boom of the handler Maintenance Visually check the hook for damage before using it Check the safety catch is in good working order DANGER WARNING CAUTION NOTICE Make sure this attachment ...

Page 139: ... with the chains with shackles supplied Safety Strictly obey the general safety precautions given in section Safety Operation Fork the basket from the rear side being careful that the door that can be opened is at the front Secure the basket to the forks using the chains supplied Maintenance Visually check the attachment for damage before using it Part No 57 0009 0404 GTH 4518ER GTH 4020ER GTH 602...

Page 140: ...140 GTH 4518ER GTH 4020ER GTH 6025ER Part No 57 0009 0404 Operator s Manual First Edition Third Printing Intentionally blank page 1RYHPEHU 7 7 7 7 7 7 3DUW 1R LY 7KLV SDJH LQWHQWLRQDOO OHIW EODQN ...

Page 141: ... mm External steering radius mm 3025 2135 2430 780 1950 3030 5280 6485 440 5015 2425 3845 7900 5260 3025 2135 2430 780 1950 3030 5280 7250 440 5015 2425 4825 8660 6020 3150 2230 2470 780 2020 3500 6090 8400 540 5040 3280 5120 9600 6310 2750 4850 LIMITS OF USE P Obstruction angle P Departure angle Min max ambient temperature C 20 20 20 40 20 20 20 40 21 5 21 5 20 40 Weight Weight in working order k...

Page 142: ...I 1200x120x50 70 FEM III 1200x150x60 70 FEM III Diesel engine Make Model Type Features Total displacement cc Power kW Torque N m DEUTZ TCD2012L042V Diesel 4 cylinders in line 4 strokes direct injection 4000 88 2400rpm 420 1600rpm DEUTZ TCD2012L042V Diesel 4 cylinders in line 4 strokes direct injection 4000 88 2400rpm 420 1600rpm CUMMINS QSB4 5 Diesel 4 cylinders in line 4 strokes direct injection ...

Page 143: ...D E 18 0 6 m 1500 kg 1000 kg 2000 kg 3000 kg 4000 kg 750 kg 4500 kg 90 0 180 09 4618 0968 GTH 4518 ER 0 180 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 0 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 0 10 20 30 40 60 50 70 15 16 78 4 4 750 kg A B C D E 2000 kg 500 kg 1000 kg 3000 kg 1500 kg 4000 kg 250 kg 14 99 m 16 98 m 0 6 m 18 0 kg 09 4618 0969 GTH 4518 ER 90 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 0 1 1 2 3 4...

Page 144: ...40 14 53 m 18 47 m 1000 kg 4500 kg 3500 kg 2500 kg 1500 kg 750 kg 09 4618 0971 GTH 4518 ER 0 180 0 kg 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 0 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 10 20 30 60 50 70 15 16 78 4 4 A B C D E 18 0 40 250 kg 750 kg 500 kg 2000 kg 1250 kg 4000 kg 3000 kg 14 53 m 17 20 m 09 4618 0972 GTH 4518 ER 90 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 0 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14...

Page 145: ... 50 40 30 20 78 750 kg 18 21 m 21 55 m A B C D E 900 kg 600 kg 09 4618 0974 GTH 4518 ER 0 180 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 0 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 2 18 19 20 21 22 40 30 20 10 0 60 50 70 78 18 19 m 21 17 m 0 kg 450 kg 900 kg 600 kg 250 kg A B C D E 4 4 09 4618 0975 GTH 4518 ER 90 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 0 1 1 2 3 4 5 6 7 8 9 10 1...

Page 146: ...0 E D C B A 78 3000 kg 2000 kg 1000 kg 2500 kg 1500 kg 750 kg 14 42 m 16 79 m 09 4618 0977 GTH 4518 ER 0 180 40 30 20 10 0 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 0 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 60 50 70 78 E D C B A 2 14 42 m 16 52 m 3000 kg 1500 kg 500 kg 0 kg 250 kg 1000 kg 2000 kg 09 4618 0978 GTH 4518 ER 90 40 30 20 10 0 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 0 1 1 2 3 4 5 6 7 8 9 ...

Page 147: ...0 40 60 50 70 78 A B C D E 18 62 m 16 55 m 1000 kg 500 kg 750 kg 200 kg 1300 kg 09 4618 0980 GTH 4518 ER 90 0 180 2P 1000 REM 5500 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 17 19 0 20 30 78 0 kg 10 40 50 70 60 D C B A 16 56 m 18 62 m E 120 kg 500 kg 1000 kg 750 kg 300 kg 09 4618 0981 GTH 4518 ER 90 0 180 2P 300F 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16...

Page 148: ... 2P 300 RNE 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 0 10 20 30 40 60 50 70 78 A B C D 17 120 kg E 300 kg 19 16 55 m 18 68 m 09 4618 0983 GTH 4518 ER 90 0 180 2P 500 REM 4400 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 0 10 20 30 40 60 50 70 78 A B C D 0 kg 16 55 m 17 120 kg 500 kg 300 kg 19 18 73 m E ...

Page 149: ...42 m 250 kg 4000 kg 2000 kg 3000 kg 1000 kg 500 kg 90 0 180 09 4618 0951 GTH 4020 ER 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 0 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 0 10 20 30 60 50 70 15 16 78 4 4 750 kg A B C D E 1500 kg 250 kg 18 19 20 2 17 18 40 3 0 0 0 k g 19 39 m 0 6 m 2000 kg 500 kg 0 kg 1000 kg 4 0 0 0 k g 17 42 m 0 180 09 4618 0952 GTH 4020 ER 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 0 1 1 2 3...

Page 150: ...1500 kg 500 kg 19 87 m 16 97 m 4000 kg 2000 kg 1000 kg 250 kg 4 4 09 4618 0954 GTH 4020 ER 0 180 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 0 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 0 kg 10 20 30 60 50 70 78 4 4 A B C D E 0 40 250 kg 1000 kg 2500 kg 3500 kg 1500 kg 500 kg 0 kg 19 62 m 16 97 m 17 18 19 20 09 4618 0955 GTH 4020 ER 90 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 0 1 1 2 3 4 5 6 7 8 ...

Page 151: ...13 14 15 16 17 18 19 20 2 3000 kg 1500 kg 750 kg 250 kg 16 86 m 19 19 m 09 4618 0957 GTH 4020 ER 0 180 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 78 1500 kg 500 kg 0 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 2 4 4 0 10 20 40 30 50 60 70 E D C B A 0 kg 2500 kg 1000 kg 250 kg 16 86 m 18 94 m 09 4618 0958 GTH 4020 ER 90 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 0 1 1 2 3 4 5 6 7 8...

Page 152: ...50 70 A B C D E 120 kg 17 89 m 21 01 m 300 kg 90 0 180 09 4618 0960 GTH 4020 ER 2P 300 REN 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 0 10 78 17 18 18 20 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 20 30 40 60 50 70 A B C D E 120 kg 300 kg 0 kg 19 07 m 21 08 m 90 0 180 09 4618 0961 GTH 4020 ER 2P 500 REM 4400 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 0 1 2 3 4 5 6 7 8 9 10 11 12 13 ...

Page 153: ...5 16 17 18 19 20 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 0 10 78 20 30 40 60 50 70 A B C D E 1000 kg 750 kg 750 kg 750 kg 750 kg 750 kg 18 88 m 21 06 m 90 0 180 09 4618 0963 GTH 4020 ER 3P 1300 REM 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 0 10 78 20 30 40 60 50 70 A B C D 20 750 kg 1300 kg 250 kg 0 kg 1000 kg 50...

Page 154: ... 78 400 kg 750 kg 0 kg E D C B A 900 kg 250 kg 20 33 m 23 83 m 600 kg 09 4618 0965 GTH 4020 ER 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 0 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 2 18 19 20 21 22 23 24 20 21 10 0 4 4 70 60 50 40 30 20 78 250 kg 600 kg 20 33 m 23 58 m E D C B A 0 kg 400 kg 900 kg 0 180 09 4618 0966 GTH 4020 ER 90 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 0 1 1 2...

Page 155: ... 8 9 10 11 12 13 14 15 16 17 18 2 19 20 21 22 23 24 25 0 20 30 40 50 70 78 A B C D E 60 4 4 10 0 kg 24 84 m 21 46 m 500 kg 1500 kg 3000 kg 5000 kg 250 kg 1000 kg 2000 kg 4000 kg 6000 kg 0 6 m 09 4618 1075 GTH 6025 ER 0 180 5000 kg 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 0 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 15 16 5 5 18 19 20 2 17 18 19 20 21 22 23 24 25 21 22 0 20 30 40 50 70 A B C D E 60 10 2...

Page 156: ...H 6025 ER 0 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 2 19 20 21 22 23 24 25 0 20 30 40 50 70 78 A B C D E 60 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 250 kg 5000 kg 3000 kg 1500 kg 750 kg 5 5 10 24 77 m 21 00 m 2000 kg 1000 kg 4000 kg 500 kg 6000 kg 0 180 09 4618 1078 GTH 6025 ER 90 09 4618 1079 GTH 6025 ER 0 180 09 4618 1080 GTH 6025 ER 90 ...

Page 157: ...4020ER GTH 6025ER 157 Operator s Manual First Edition Third Printing Load Charts Load Chart with 900 KG JIB GTH 6025 ER 09 4618 1081 GTH 6025 ER 0 180 09 4618 1082 GTH 6025 ER 90 09 4618 1083 GTH 6025 ER 0 180 09 4618 1084 GTH 6025 ER 90 ...

Page 158: ...JIB GTH 6025 ER 09 4618 1085 GTH 6025 ER 0 180 09 4618 1086 GTH 6025 ER 90 09 4618 1087 GTH 6025 ER 0 180 09 4618 1088 GTH 6025 ER 90 158 GTH 4518ER GTH 4020ER GTH 6025ER Part No 57 0009 0404 Operator s Manual First Edition Third Printing ...

Page 159: ...025 ER 90 0 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 2 19 20 21 22 23 24 25 0 20 30 50 70 78 A B C D E 60 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 5 5 24 15 m 21 13 m 250 kg 40 10 2 0 0 0 k g 500 kg 0 kg 1500 kg 750 kg 1000 kg Part No 57 0009 0404 GTH 4518ER GTH 4020ER GTH 6025ER 159 Operator s Manual First Edition Third Printing ...

Page 160: ...160 GTH 4518ER GTH 4020ER GTH 6025ER Part No 57 0009 0404 Operator s Manual First Edition Third Printing Intentionally blank page 1RYHPEHU 7 7 7 7 7 7 3DUW 1R LY 7KLV SDJH LQWHQWLRQDOO OHIW EODQN ...

Page 161: ...A6 B0 35 2 1 CA6 V0 35 2 1 37 28 13 14 C N1 2 1 Z B1 B V1 B V1 B V1 X64 19 H L1 N1 X218 1 X218 2 B218 X219 1 X219 2 Y219 R217 86 87a 87 85 30 N1 N50 N70 R25 R25 R50 N50 3 1 R50 3 1 N1 N1 N1 N4 A4 H V1 M6 R6 S B1 N1 N1 CA3 B0 35 A117 X119 A X119 B R119 A126 A158 35 34 33 32 27 25 24 22 21 19 18 16 12 11 9 8 5 3 X145 1 P145 R112 86 87 85 30 B4 2 1 M1 7 1 M N1 2 1 B R0 5 4 1 CA6 V0 35 7 1 CA6 B0 35 7...

Page 162: ... CARD ECO MULTIPURPOSE INSTRUMENT ELECTRONIC CONTROL PANEL IGNITION RELAY AUX CIRCUITS RELAY MOTOMETER GROUND Ground Pedal NC contact Power supply re reading bridge Power supply re reading bridge CHAN L CHAN H Power supply VP Power supply VP Ground Rexroth control unit box ground AIR FILTER HYDR OILFILTER CLOGGING SENSOR HYDR OIL LEVEL SENSOR CAB BUS LINE TERMINAL ALTERNATOR STARTING MOTOR ...

Page 163: ...IT DIAGNOSTIC SYSTEM TEACHING REXROTH CONTROL UNIT DIAGNOSTIC SYSTEM OPTIONAL GLOW PLUGS CUMMINS ENGINE DIAGNOSTIC CUMMINS CONTROL UNIT REXROTH CONTROL UNIT 1 2 3 4 5 X143 4 N1 N1 N1 N1 H R1 7 2 A G1 10 1 B N1 B N1 7 3 A G1 A G1 10 1 A R1 A R1 7 3 H R1 7 1 B N1 7 3 A R1 7 3 H B1 9 4 V1 L R1 L R1 3 1 L R1 L R1 V Z1 X138 21 A138 H R1 H R1 1 5 C N1 5 C2 5 C2 5 C2 5 C4 Sal59 C N1 5 C N1 M N0 5 S0 5 S0...

Page 164: ...164 GTH 4518ER GTH 4020ER GTH 6025ER Part No 57 0009 0404 Operator s Manual First Edition Third Printing Diagrams and Schemes GTH 4018 ER 6 gth 4020 er Wiring diagram 2 13 UNDER CONSTRUCTION ...

Page 165: ...UNIT 12V GROUND FROM LINDE SIG EMERGENCY PUMP SOLENOID VALVE 2nd SPEED SOLENOID VALVE 1st SPEED PRESS SWITCH BRAKING PROP CONTROL PRESS SWITCH LOWACCUMULATOR PRESSURE SOLENOID VALVE FLOW CHANGE SOLENOID VALVE REVERSE GEAR SOLENOID VALVE FORWARD GEAR 1 2 3 4 5 L G1 A N1 A N1 11 1 V B1 C B1 C B1 X33 13 V B1 X33 12 A133 V B1 C B1 C B1 V B1 B L1 L R1 L R1 2 5 L G1 A G1 N1 N1 N1 29 31 15 49 16 8 X162 1...

Page 166: ...H R1 H R1 H R1 B R1 5 B N1 5 A N1 5 G R1 5 G R1 5 G R1 5 G R1 5 A B1 A B1 A B1 L B1 L B1 L B1 L B1 L B1 R G1 5 R G1 5 R G1 A B1 L B1 B R1 5 H R1 R G1 M B1 5 G1 V1 C L1 G M1 L R1 B N1 5 G R1 5 Z1 5 A1 L R1 L B1 G1 G1 C L1 L1 L R1 L B1 G N1 G N1 C L1 B R1 L1 G N1 V1 H1 N1 5 G1 V1 5 H1 5 N1 5 N1 N1 N1 N1 N1 R N1 R N1 R N1 R N1 R N1 R N1 R N1 R N1 N1 N1 5 N1 N1 5 N1 5 N1 5 N1 C N1 Z1 X140 8 X140 1 X14...

Page 167: ...1 M193 X193 2 M185 X139 9 12 3 5 1 7 13 11 2 8 6 10 9 R0 5 1 5 M B1 5 4 5 A B1 4 5 R V1 4 5 M B1 4 5 A1 4 5 L1 4 5 H R1 4 5 C B1 8 1 R1 L N1 5 L N1 5 L N1 5 C B1 A1 A1 A1 A1 A1 L1 L1 L1 L1 L1 Z B1 Z B1 Z B1 Z B1 Z B1 H R1 H R1 H R1 H R1 R1 R1 R1 R0 5 N1 H G1 5 H G1 5 L1 A1 C R1 C R1 G L1 G L1 B V1 B V1 Z N1 Z N1 Z N1 Z N1 Z N1 Z N1 M B1 H G1 H G1 H G1 H R1 H R1 R V1 A B1 M B1 5 X139 3 X140 6 X139 ...

Page 168: ...R N1 H G1 H G1 5 N1 H G1 X141 18 N1 5 5 5 C1 5 A G1 5 X356 9 X356 10 E356 E184 X104 10 R N1 4 5 N1 5 5 L0 5 1 5 N1 8 1 R N1 8 1 N1 N1 N1 N1 N1 H R1 5 L C1 5 L C1 5 L C1 5 L C1 5 L0 5 L0 5 R N1 R N1 R N1 R N1 R N1 R N1 C1 5 C1 5 C1 5 M B1 5 M B1 5 A G1 5 A G1 5 A G1 5 A G1 5 A G1 5 R1 5 R1 5 R1 G V1 5 G V1 5 G V1 5 N1 5 N1 N1 5 R1 G V1 5 X181 4 X181 3 X181 1 X140 12 X140 11 X139 4 X139 5 X139 8 X14...

Page 169: ...5 B L1 C L1 C L1 4 5 H N1 H N1 9 4 B N1 G R1 X138 42 L B1 G E J E D C B X136 A D C B X137 A X137 F H R1 2 5 B N1 2 5 A R1 A R1 2 5 B N1 A R1 2 1 H R1 2 1 B N1 2 1 S B1 8 1 B N1 9 1 X17 17 M1 M1 9 1 M1 1 2 N1 N1 4 5 N1 12 4 N1 4 2 A46 CA4 B0 35 11 1 CA4 V0 35 11 1 B L1 9 1 A V1 11 5 B L1 11 1 CA6 V0 35 1 5 CA6 B0 35 1 5 C N1 2 5 CA6 V0 35 CA6 B0 35 C N1 Z B1 Z B1 Z B1 Z B1 A B1 A B1 A B1 A B1 B L1 ...

Page 170: ...EER SOLENOID VALVE REAR LH STABILISER DOWN SOLENOID VALVE REAR LH STABILISER UP SOLENOID VALVE FRONT LH STABILISER DOWN SOLENOID VALVE FRONT LH STABILISER UP 1 2 3 4 5 A N1 N1 N1 9 1 N1 9 2 N1 10 2 N1 3 4 N1 9 5 N1 S173 B C D F A E R N1 9 5 V N1 9 2 R N1 A R1 9 1 C N1 9 1 L N1 9 1 A N1 9 1 A N1 9 1 V B1 9 1 A N1 3 5 N1 6 5 R N1 6 5 S B1 7 2 S B1 1 3 A V1 2 5 C B1 5 5 R N1 R N1 A R1 S B1 A V1 S B1 ...

Page 171: ...N1 5 10 1 N1 5 5 5 X1111 1 X1111 2 S1111 S N1 S N1 10 1 M B1 30 X126 9 34 N1 5 10 1 L1 X64 32 S101 N1 N1 8 1 N1 11 1 N1 10 1 N1 8 2 S198 S197 N1 N1 8 5 S177 S178 A N1 B L1 CA02 V0 35 CA03 B0 35 CA02 V0 35 CA02 B0 35 S193 X176 1 X176 4 X176 2 X176 3 C B1 C B1 X140 4 V N1 8 2 R N1 8 3 CA03 B0 35 13 1 CA03 V0 35 13 1 CA18 V0 35 12 1 CA18 B0 35 12 1 31 10 1 M1 C N1 M1 13 1 C N1 13 1 M0 5 1 5 G R0 5 1 ...

Page 172: ... B1 9 5 M B1 A G1 A G1 2 5 A G1 A G1 2 5 A G1 N2 5 N2 5 N2 5 12 2 N1 5 9 5 X162 8 X33 11 X50 19 X33 1 A G1 X187 3 X187 8 N1 5 N1 5 9 2 A G1 X187 9 N1 5 N1 11 1 N1 9 3 N1 X50 21 M B1 A V1 A V1 A G1 X50 22 B216 C B B215 X215 A B A X60 C Y60 N1 12 1 N1 8 5 X162 9 A V1 11 1 V Z1 11 1 S N1 9 5 C2 5 2 5 C2 5 2 5 S N1 S N1 S N1 S N1 S N1 S N1 S N1 S N1 N1 5 N1 5 N1 5 H N1 H N1 H N1 H N1 H N1 H N1 H N1 L ...

Page 173: ... RIGHT STABILISER IN SOLENOID VALVE FRONT LEFT STABILISER IN SOLENOID VALVE REAR RIGHT STABILISER OUT SOLENOID VALVE REAR LEFT STABILISER OUT SOLENOID VALVE FRONT RIGHT STABILISER OUT SOLENOID VALVE FRONT LEFT STABILISER OUT JOINT CAN BUS PLUG 1 2 3 4 5 A N1 A N1 3 5 A V1 12 2 A V1 12 1 X187 5 X30 1 B30 X30 2 B31 X31 2 X31 1 N1 N1 9 2 Sal13 N1 10 2 A V1 A V1 A V1 X44 1 B44 X44 2 X45 1 B45 X45 2 Sa...

Page 174: ...A18 B0 35 9 5 X157 5 X157 4 CA18 V0 35 9 5 CA6 B0 35 11 5 CA6 V0 35 11 5 CA3 B0 35 CA3 V0 35 CA5 B0 35 CA5 V0 35 CA1 B0 35 CA1 V0 35 CA1 B0 35 CA1 V0 35 CA1 B0 35 CA1 V0 35 A V1 CA3 B0 35 CA3 V0 35 B V1 B V1 B V1 B V1 M N1 B R1 B R1 B R1 B R1 M N1 M N1 M N1 M V1 M V1 CA10 V0 35 CA10 B0 35 CA10 V0 35 CA10 B0 35 CA18 V0 35 CA18 B0 35 CA16 V0 35 CA16 B0 35 CA17 V0 35 CA17 B0 35 CA15 V0 35 CA15 B0 35 ...

Page 175: ...ion platform rotation up platform rotation C3 C8 B1 12V 12V platform rotation platform rotation up platform rotation B2 accessory B7 C7 CHAN H CHAN L A3 ground C5 B5 B6 A5 7A A6 C6 B8 cell 2 cell 1 ground sig sig sig sig ground CLIO PUSHBUTTON PANEL SYSTEM PLATFORM SYSTEM LOAD CELL PLATFORM alarm warning light 1 2 3 4 5 C N1 C N1 M V1 V1 5 L1 5 R1 5 X134 11 27 26 42 33 29 28 31 30 36 34 40 51 46 4...

Page 176: ...gram a c system optional AIR CONDITIONING SWITCH PRESSURE SWITCH TO CAB LINE HEATING A C SYSTEM FANS AND PRESSURE SWITCH COMPRESSOR RELAY PRESSURE SWITCH A C SYSTEM FAN RELAY COMPRESSOR 15 SERVICES REF DESCRIPTION HEATING COMPRESSOR COMPRESSOR FUSE FAN FUSE COMPRESSOR RELAY AIR CONDITIONING RELAY AIR CONDITIONING SWITCH PRESSURE SWITCH ...

Page 177: ...ram remote control optional CAN BUS HEAD A138 CONTROL UNIT CHAN H CHAN L GND POWER SUPPLY GND 50 START remote control power supply REMOTE CONTROL X4 BATTERY CHARGER X2 SERIAL CONN REMOTE CONTROL OPERATION SIGNAL X1 TERMINAL BOARD REMOTE CONTROL POWER SUPPLY BATTERY CHARGER SERIAL CONNECTOR TERMINAL BOARD REF DESCRIPTION CAN BUS CONNECTOR ...

Page 178: ...178 GTH 4518ER GTH 4020ER GTH 6025ER Part No 57 0009 0404 Operator s Manual First Edition Third Printing Diagrams and Schemes gth 6025 er hydraulic diagram 1 2 ...

Page 179: ...Part No 57 0009 0404 GTH 4518ER GTH 4020ER GTH 6025ER 179 Operator s Manual First Edition Third Printing Diagrams and Schemes gth 6025 er hydraulic diagram 2 2 ...

Page 180: ...ouble overcenter safety valve piloting ratio 4 1 cracking pressure 350 bar Single overcenter safety valve piloting ratio 4 1 cracking pressure 350 bar capacity 0 5 Litri precharge pressure 40 bar Hydraulically piloted double check valve piloting ratio 4 1 Hydraulically piloted double check valve piloting ratio 4 1 Turret rotation hydraulic motor Turret rotation hydraulic motor double overcenter sa...

Page 181: ...ont axle levelling cylinder left Rear axle steering cylinder Front axle Rear axle Steering modes selector valve 4 ways 3 positions Chassis leveling selector valve 4 ways 3 positions Front axle pivoting lockout valves 2 ways 2 positions Rear axle pivoting lockout valves 2 ways 2 positions Rear axle lockout cylinders control valve orifice dia 0 5 mm cracking pressure 0 5 bar Double overcenter safety...

Page 182: ...182 GTH 4518ER GTH 4020ER GTH 6025ER Part No 57 0009 0404 Operator s Manual First Edition Third Printing Intentionally blank page 1RYHPEHU 7 7 7 7 7 7 3DUW 1R LY 7KLV SDJH LQWHQWLRQDOO OHIW EODQN ...

Page 183: ...alidation and processing Seller s obligation and liability under this warranty is expressly limited to at Seller s sole option repairing or replacing with new or remanufactured parts or components any part which appears to Seller upon inspection to have been defective in material or workmanship Such parts shall be provided at no cost to the owner FOB Seller s parts facility If requested by Seller ...

Page 184: ...ices and Wear Parts maintenance services and wear parts are excluded from warranty claims Maintenance services and wear parts not covered include but are not limited to such items as seals gaskets hoses glass clutch and brake linings wire rope exterior coatings proper tightening of bolts nuts and fittings adding or replacing of fluids breathers belts nozzles adjustments of any kind services suppli...

Page 185: ...ER OBLIGATIONS OR LIABILITY ON SELLER S PART THERE ARE NO WARRANTIES THAT EXTEND BEYOND THE LIMITED WARRANTY CONTAINED HEREIN Seller neither assumes nor authorizes any other person to assume for seller any other liability in connection with the sale of seller s equipment This warranty shall not apply to any of seller s equipment or any part thereof which has been subject to misuse alteration abuse...

Page 186: ...186 GTH 4518ER GTH 4020ER GTH 6025ER Part No 57 0009 0404 Operator s Manual First Edition Third Printing Intentionally blank page 1RYHPEHU 7 7 7 7 7 7 3DUW 1R LY 7KLV SDJH LQWHQWLRQDOO OHIW EODQN ...

Page 187: ...__________________________ ___________________________ ___________________________ ___________________________ ___________________________ Client s Copy WARRANTY HANDING OVER CERTIFICATE Warranty is subject to delivery according to the regulation and the submission of this certificate to TEREXLIFT s r l Model ___________________ Serial Number ___________________ Delivery date ___________________ D...

Page 188: ......

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