Terex Gyro 4020, Service Manual

Page 1: ...INDEX Handler with telescopic boom Gyro 4020 From serial n 12888 Gyro 4518 From serial n 12508 SERVICE MANUAL Code 57 4402 8200 1st Edition 03 2007 English Edition...

Page 2: ...Document 57 4402 8200 1st Edition 03 2007 INDEX GYRO 4020 4518 Intentionally blank page...

Page 3: ...in any way to unauthorised workshops and third parties in general and not to photocopy or reproduce this manual or parts of the same in any way without the prior written authorisation of TEREXLIFT to...

Page 4: ......

Page 5: ...without disclosing the informa tion in the same in any way to unauthorised workshops and third parties in general and not to photocopy or reproduce this manual or parts of the same in any way without...

Page 6: ...n 03 2007 INDEX Revision Revised pages Notes Issued by No Date 1 03 2007 Publication 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 GYRO 4...

Page 7: ...AL CONTENTS INTRODUCTION Sect 1 SAFETY RULES Sect 2 TECHNICAL SPECIFICATIONS Sect 3 SCHEDULED MAINTENANCE INSPECTIONS Sect 4 SCHEDULED MAINTENANCE PROCEDURES Sect 5 TROUBLESHOOTING Sect 6 SCHEMES Sect...

Page 8: ...Document 57 4402 8200 1st Edition 03 2007 INDEX Machine denomination Literature valid up to serial number Gyro 4020 12888 Gyro 4518 12508 TELELIFT 4013 SERIAL NUMBER IDENTIFICATION 6...

Page 9: ...rform most procedures However several procedures require specialized skills as well as specific tools and equipment Intheseinstances westronglyrecommendlettingservice and repair the machine at an auth...

Page 10: ...the machine On the through shaft of such drive pump there is a Bosch Rexroth variable displacement piston pump with swashplate suitable for open lopp circuits model A10VO45DFR 3 equipped with flow and...

Page 11: ...the drain oil to the hydrostatic motor reducing in this way the temperature From port X of the drive pump 2 low pressure oil is taken 25 30 bar This oil is first conveyed to the undercarriage through...

Page 12: ...e steering cylinders The three pressure reducing valves are installed in the hydraulic drive 7 and cannot be regulated from the outside The steering circuit is completed by the front steering cylinder...

Page 13: ...ingle acting compensation valve 13 with safety function The control module of element 2 of the main valve is the electro proportional type with electrical feed back and integrated electronics The 1 5...

Page 14: ...ck function and through port n 3 of the hydraulic rotary joint 9 for the operation of the outriggers and the frame levelling On the feeding lines of this cylinder and close to the terminal part of the...

Page 15: ...then used to operate the service brakes of the two axles 57 58 and to release the parking brake located inside the rear axle 58 The fill valve inside the braking system takes the flow from the feeding...

Page 16: ...motor housing there are an anti cavitation valve and a pressure relief valve with by pass function set to 140 bar as well as a solenoid valve which once electrically energised directly sends the oil...

Page 17: ...ary joint 9 is fed by the simultaneous operation of the 4th element of the electro proportional main valve 8 and of the electric divider 22 The solenoid valve n 1 of block 70 controls the cylinder 71...

Page 18: ...om the SAFIM braking system 35 through port 5 of the hydraulic rotary joint 9 is connected to the service brake ports of the front axle 57 On the contrary when valve 69 is energised a condition corres...

Page 19: ...DEX xi GYRO 4020 4518 INTRODUCTION circuit As already mentioned the undercarriage levelling function is possible through the simultaneous energisation of the two spools of the solenoid valve 59 and th...

Page 20: ...selector valve 3 ways 2 positions Front axle steering cylinder Front axle levelling cylinder right Rear axle pivoting cylinder right Rear axle pivoting cylinder left Front axle levelling cylinder left...

Page 21: ...rcenter safety valve piloting ratio 7 6 1 cracking pressure 350 bar Double overcenter safety valve piloting ratio 4 1 cracking pressure 350 bar Single overcenter safety valve piloting ratio 4 1 cracki...

Page 22: ...Intentionally blank page Document 57 4402 8200 1st Edition 03 2007 INDEX GYRO 4020 4518 INTRODUCTION xiv...

Page 23: ...SAFETY INFORMATION SECTION INDEX 1 1 Safety rules page 2 1 1 1 Personal safety 2 1 1 2 Workplace safety 3 1 2 General remarks 4 1 3 Servicemen s requisites 4 1 3 1 Personal protective equipment 5 1 4...

Page 24: ...ions that involve your own as well as the others safety and that can result in serious or lethal injury Draws the attention to situations that involve your own as well as the others safety and that ca...

Page 25: ...at could get into machine components and cause damage Be sure that your workshop or work area is properly ventilated and well lit Be sure any forklift overhead crane or other lifting or supporting dev...

Page 26: ...in doubt Contact GENIE the assistance service is at your disposal Addresses phone and fax numbers are given in the cover and in the title page of this manual 1 3 SERVICEMEN S REQUISITES The operators...

Page 27: ...movements and represent a danger for personnel 1 4 2 PRECAUTIONS DURING WORK Do not walk or stop under raised loads or machine parts supported by hydraulic cylinders or ropes only Keep the machine han...

Page 28: ...rs to check for pressure leaks Fine jets of air oil or fuel can injure you Neither smoke nor use open flames if there is a risk of fire or close to fuel oil or batteries Do not leave fuel cans or bott...

Page 29: ...levels 5 2 12 Refuelling 6 2 13 Tightening torques 7 2 14 Drill diameters for threads 9 2 15 Standard tightening torques for fitting seals 10 2 16 Locking material 12 2 17 Hoisting instructions 13 2 1...

Page 30: ...m 2430 2430 D Cab width mm 910 910 E Track mm 1950 1950 F Wheel base mm 3030 3030 G Length to the front tyres mm 5280 5280 H Length to the attachment holding plate mm 7085 6485 I Ground clearance mm 4...

Page 31: ...10 holes DIN 70361 Pressure bar Psi 6 87 6 87 2 3 LIMIT OF USE Gyro 4020 Gyro 4518 Angle of approach 20 20 Departure angle 20 20 Min max ambient temperature C 20 46 20 46 2 4 WEIGHT Gyro 4020 Gyro 45...

Page 32: ...load at max front reach with outriggers kg 250 750 Payload at max side reach with outriggers kg 250 750 TELELIFT 3512 4010 2 7 FORKS floating type Gyro 4020 Gyro 4518 Dimensions mm 1200x130x50 1200x13...

Page 33: ...20 Gyro 4518 Guaranteed sound power level in accordance with the Directive 2000 14 CE dB Lwa Measured sound pressure level in accordance with the Directive 98 37 CE dB Lpa 2 11 VIBRATION LEVELS Gyro 4...

Page 34: ...gears l 0 6 0 6 Turret rotation reduction gear l 2 8 2 8 Products Engine oil SHELL RIMULA SAE 15W 40 API CH 4 CG 4 CF 4 CF ACEA E3 MB 228 3 Gearbox Differential gears Reduction gears but for turntabl...

Page 35: ...8 3 196 5 308 1 277 3 369 3 332 4 18 2 5 27 14 12 8 288 7 259 8 406 1 365 5 487 7 436 9 1 5 27 14 12 8 314 2 282 8 442 8 398 5 530 6 477 5 20 2 5 30 17 12 10 408 1 367 3 573 4 516 1 687 7 618 9 1 5 30...

Page 36: ...0 275 0 120 0 170 0 1 5 210 0 295 0 130 0 185 0 18 2 5 270 0 390 0 170 0 245 0 1 5 305 0 425 0 190 0 265 0 20 2 5 305 0 540 0 190 0 340 0 1 5 425 0 600 0 260 0 375 0 22 2 5 510 0 720 0 320 0 450 0 1 5...

Page 37: ...0 M 12 x 1 75 10 44 10 10 10 20 x 1 5 10 68 10 38 10 50 M 14 x 2 12 21 11 83 12 00 x 1 5 12 68 12 38 12 50 M 16 x 2 14 21 13 84 14 00 x 1 5 14 68 14 38 14 50 M 18 x 2 5 15 74 15 29 15 50 x 1 5 16 68 1...

Page 38: ...1 11 16 12 190 1 5 8 12 225 1 7 8 12 270 2 12 245 2 1 4 12 360 FRONT O LOK Parker SEALS Thread TIGHTENING diameter TORQUES 0 10 FRONT O LOK Parker SEALS inc mm Nm 9 16 18 25 11 16 16 40 13 16 16 55 1...

Page 39: ...G 1 8 M20x1 5 L 42 245 G 1 4 M12x1 5 S 6 50 G 1 4 M14x1 5 S 8 50 G 3 8 M16x1 5 S 10 80 G 3 8 M18x1 5 S 12 80 G 1 2 M22x1 5 S 16 105 G 3 4 M27x2 S 20 220 G 1 M33x2 S 25 370 G 1 1 4 M42x2 S 30 500 G 1...

Page 40: ...llent Loctite 573 Formed in place gasket 150 0 2 Slow Excellent Loctite 574 Formed in place gasket 150 0 5 Rapid Excellent Loctite 510 Formed in place gasket 200 0 2 Moderate Excellent Loctite 5699 Fo...

Page 41: ...or other hoisting accessories suitable to the weight of the part to be handled For ropes refer to the following table STRANDED ROPES Rope diameter Max admissible load mm kg 10 1000 11 2 1400 12 5 1600...

Page 42: ...personal protection equipment e g goggles gloves facial screen etc Wrap up the end of the pipe to be disconnected with some rags and slowly loosen the pipe connector so that air comes out as slow as...

Page 43: ...Plug 1 639981 Seals kit 4 54 0702 0027 Sliding guide 12 638337 Seals kit 4 695971 Sliding guide 12 54 0200 0000 Bushing 26 54 0702 0024 Sliding guide 2 695970 Sliding guide 4 695959 Sliding guide 2 6...

Page 44: ...cal components Code Description Q ty 04 4240 0041 Solenoid 4 07 0728 0007 Solenoid 2 56 0016 0043 Control lever 1 07 0741 0011 Pushbutton 1 07 0741 0010 Cap 1 56 0021 0051 Linde control unit 1 56 0010...

Page 45: ...ntact 1 07 0709 0442 Security switch 1 56 0013 0015 Sensor 1 56 0012 0016 Micro switch 2 56 0012 0010 Micro switch 2 56 0012 0021 Sensor 2 07 0709 0730 Sensor 2 56 0005 0000 Fuse 1 07 0703 0069 Fuse 3...

Page 46: ...0702 0027 Sliding guide 12 638337 Seals kit 4 695971 Sliding guide 12 54 0200 0000 Bushing 26 54 0702 0024 Bushing guide 2 695970 Sliding guide 4 695959 Sliding guide 2 695957 Sliding guide 2 695959 S...

Page 47: ...0016 0043 Control lever 1 07 0741 0011 Pushbutton 1 07 0741 0010 Cap 1 56 0021 0051 Linde control unit 1 56 0010 0032 Right front light 1 56 0009 0001 Horn 1 56 0013 0004 Sensor 4 56 0010 0030 Left r...

Page 48: ...0015 Sensor 1 56 0012 0016 Micro switch 2 56 0012 0010 Micro switch 2 56 0012 0021 Sensor 2 07 0709 0730 Sensor 2 56 0005 0000 Fuse 1 07 0703 0069 Fuse 30A 1 07 0703 0192 Relay 2 07 0703 0535 Relay 1...

Page 49: ...518 TECHNICAL SPECIFICATIONS 2 20 MACHINE PAINT COLOUR STANDARD machines GREY RAL 7012 WHITE RAL 1013 MAT BLACK RAL 9005 from June 2004 for cylinders AUSA machines ORANGE RAL 2004 GENIE machines BLUE...

Page 50: ...TIMES BOOM EXTENSION RETRACTION ATTACHMENT DUMPING Lift Lower Extend Retract Roll back Dump Gyro 4020 Time s up down Max engine speed 17 11 Min engine speed 44 30 Gyro 4518 Time s up down Max engine...

Page 51: ...gine speed 4 6 3 6 Min engine speed 4 6 6 3 Gyro 4518 Time s up down Max engine speed 4 6 3 6 Min engine speed 4 6 6 3 Gyro 4020 Time s up down Max engine speed 5 7 5 Min engine speed 6 8 11 7 Gyro 45...

Page 52: ...Max engine speed 4 5 5 9 Min engine speed 8 6 3 Gyro 4518 Time s out in Max engine speed 4 5 5 9 Min engine speed 8 6 3 Gyro 4020 Time s out in Max engine speed 5 4 6 8 Min engine speed 13 4 9 Gyro 4...

Page 53: ...BLE ROTATION Gyro 4020 Time s 360 Max engine speed 58 Min engine speed 70 Gyro 4518 Time s 360 Max engine speed 58 Min engine speed 70 Gyro 4020 Time s left to right right to left Max engine speed 5 5...

Page 54: ...e 0 60bar pressure gauge from the mini socket ref A and fit a 0 400bar pressure gauge before lifting the boom to end of stroke Calibrate the max pressure valve ref C encl 1 to 330 bar If it is not pos...

Page 55: ...engine run at max speed and check that the high pressure value is 445 bar 5 CALIBRATING THE BRAKING SYSTEM PRESSURE encl 3 Connect a 0 250 bar pressure gauge to position L encl 5 Depress the foot bra...

Page 56: ...bar pressure gauge to both of them Operate the turntable rotation in one direction and verify that the value displayed on the pressure gauge is 150 bar Operate the turntable rotation in the opposite d...

Page 57: ...Document 57 4402 8200 1st Edition 03 2007 INDEX 2 29 GYRO 4020 4518 TECHNICAL SPECIFICATIONS HYDRAULIC SYSTEM LIFTING Encl 1 C A W...

Page 58: ...Document 57 4402 8200 1st Edition 03 2007 INDEX GYRO 4020 4518 TECHNICAL SPECIFICATIONS 2 30 HYDRAULIC SYSTEM FORK BALANCE Encl 2 E F...

Page 59: ...Document 57 4402 8200 1st Edition 03 2007 INDEX 2 31 GYRO 4020 4518 TECHNICAL SPECIFICATIONS HYDRAULIC SYSTEM TRANSMISSION Encl 3 1 7 7 1 2 2 12 H G...

Page 60: ...Document 57 4402 8200 1st Edition 03 2007 INDEX GYRO 4020 4518 TECHNICAL SPECIFICATIONS 2 32 SUCTION SYSTEM HYDRAULIC PUMPS Encl 4 B D...

Page 61: ...Document 57 4402 8200 1st Edition 03 2007 INDEX 2 33 GYRO 4020 4518 TECHNICAL SPECIFICATIONS HYDRAULIC SYSTEM SERVICE BRAKE Encl 5 P C 5 5 6 6 T L M...

Page 62: ...Document 57 4402 8200 1st Edition 03 2007 INDEX GYRO 4020 4518 TECHNICAL SPECIFICATIONS 2 34 HYDRAULIC SYSTEM POWER STEERING Encl 6 9 8 9 8 O P N...

Page 63: ...Document 57 4402 8200 1st Edition 03 2007 INDEX 2 35 GYRO 4020 4518 TECHNICAL SPECIFICATIONS HYDRAULIC SYSTEM Turntable ROTATION Encl 7 R R Q Q...

Page 64: ...l times until displaying page 60 BASKET EMPTY and then press ENTER and INDEX In this way the tare weight value is sent to the platform 8 Press key several times until displaying page 61 BASKET AC and...

Page 65: ...on 5 Go back to the driving place and turn the dashboard to the ON position and A If the date of the software is the one shown in the picture to the side turn the road jobsite platform selector to the...

Page 66: ...n press ENTER and INDEX to confirm 5 Press key several times until displaying page 58 LEVELLING and using a spirit level make sure that the machine is level with the two axes then press ENTER and INDE...

Page 67: ...shall receive and display information from the engine controller via Can and from the sensors or contacts positioned on the machine In the case of a faults a buzzer starts sounding There is a 128x64 m...

Page 68: ...ved to authorised repair shops Display of the diesel engine errors Central unit multipurpose display When the machine is turned on the display ref E will appear as shown in the picture above The black...

Page 69: ...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 part ref H of the display starting fr...

Page 70: ...D to gain access and scroll through menus and sub menus Press the two buttons MODE 1 and MODE 2 simultaneously to access to the menu Press button MODE 1 to confirm any selection made D C 105 60 VOLT 1...

Page 71: ...GUA SERVICE VISUALIZZA ERRORI ESCI C 105 60 VOLT 15 11 SELEZIONA LINGUA SERVICE VISUALIZZA ERRORI ESCI C 105 60 VOLT 15 11 SERVICE ENGINE RPM 0 0 4 50 h Language selection sub menu Select SELECT LANGU...

Page 72: ...check that the text Service Reset appears The service can be reset only after verifying that the scheduled service operations have have been carried out Press the ESC button to quit the menu without c...

Page 73: ...0 errors To view the errors list you can enter the CONFIGURATION menu and select the item VIEW ERRORS If a second error triggers before the operator presses button MODE 1 or button MODE 2 the system s...

Page 74: ...gauge ohm 10 Warning light L7 Change fault alarm 11 Warning light L10 Red generic 12 GND 13 NC 14 NC 15 NC 16 Hydraulic oil temperature ohm 17 NC 18 12V Batteria 19 Warning light L9 Hydraulic oil leve...

Page 75: ...nits connected WINSCOPE is a programme which lets you display the state of the machine and modify some parameters relevant to the speed of some movements of the machine boom Configuring the machine in...

Page 76: ...lect the PEAK USB CAN at address 0FFh node Once the existing network has been selected press the right button of the mouse and select the Properties menu If you have selected the PEAK USB CAN at addre...

Page 77: ...empirically evaluated and vary from a machine model to the other they can changed at any times and for each machine if necessary Installing WINSCOPE This programme lets you carry out a number of adju...

Page 78: ...the OK button to close the window Select the Hardware Configuration item from the Utils menu A window like the one to the side will appear Type the values shown in the picture and press the OK button...

Page 79: ...ers you shall type in 3b6 in the User Name field and 4482 in the Password field and then confirm by pressing the OK button In order to change the machine parameters you shall turn on the electronic co...

Page 80: ...ts and outputs of the main electronic board as well as other features You find the IN OUT description with the PIN number and a small flag showing if IN OUT is active or not Additionally there is a sm...

Page 81: ...57 4402 8200 1st Edition 03 2007 INDEX 2 53 GYRO 4020 4518 TECHNICAL SPECIFICATIONS The Chassis sub menu is similar to the one shown below This window displays information on the switches and the sta...

Page 82: ...Document 57 4402 8200 1st Edition 03 2007 INDEX GYRO 4020 4518 TECHNICAL SPECIFICATIONS 2 54 The Engine sub menu displays the main parameters of the diesel engine of the machine...

Page 83: ...Document 57 4402 8200 1st Edition 03 2007 INDEX 2 55 GYRO 4020 4518 TECHNICAL SPECIFICATIONS The Movements sub menu indicates the position of the lift and the speed and position of the boom cursor...

Page 84: ...1st Edition 03 2007 INDEX GYRO 4020 4518 TECHNICAL SPECIFICATIONS 2 56 The last four sub menus are relevant to the Rotax ACT ASA and CLIO units they show the actual values and the CAN messages exchan...

Page 85: ...menu is the SPEED menu and has 3 sub menus as shown in the picture below From these menus you can adjust the speed of each single movement from any control position All of them are independent Adjust...

Page 86: ...Document 57 4402 8200 1st Edition 03 2007 INDEX GYRO 4020 4518 TECHNICAL SPECIFICATIONS 2 58 Platform Speed menu Radio Remote Control Speed menu...

Page 87: ...w each of them representing a double function of the boom As the 5 menus are quite similar we propose one single example for all of them The value entered in the Ramp field is R the acceleration time...

Page 88: ...alarms the warnings the flags of the control mode and the saving parameters field The latter is quite important as after having set the speed and time of the response you shall save the parameters to...

Page 89: ...e platform calibration the last two show the output values of the load cell for the first two channels The DOWNLOAD BLACKBOX sub menu lets you display the events which have occurred on the machine on...

Page 90: ...hines The main features are as follows 1 Total management via CANBUS control units 2 Boom movement management from driving place 3 Boom movement management from platform 4 Boom movement management fro...

Page 91: ...Document 57 4402 8200 1st Edition 03 2007 INDEX 2 63 GYRO 4020 4518 TECHNICAL SPECIFICATIONS Layout With the platform installed 9 10 6 8 15 16 17 4 1 5 3 2 11 14 7 12 13 18 20 19...

Page 92: ...slave boards they have no programmable logics but are equipped with micro switches and manage the CAN I O Their outside aspect is similar to the one of the HEAD but they have a resin coating as they...

Page 93: ...of the front carriage ARM C1 Front carriage ACT ACT ARM C2 Rear carriage Analog transducers on stabi lisers transmits the ARM the extension condition ACT ACT Analog transducers on stabi lisers transm...

Page 94: ...Intentionally blank page Document 57 4402 8200 1st Edition 03 2007 INDEX GYRO 4020 4518 TECHNICAL SPECIFICATIONS 2 66...

Page 95: ...under such working conditions 2 White reference with vertical black stripes Safety zone 3 Black reference with vertical white stripes Alarm zone load lifted above 90 of the max admissible load 4 Black...

Page 96: ...E LOAD in the current machine configuration Graphic symbol underneath MAX Reading in tons with one decimal 10 WORK RADIUS measures the distance from the slewring centre to the projection of the load a...

Page 97: ...s the displays shows again the main readings ACT MAX R Pressing the ENTER key displays the previous page once again 12 BOOM LENGTH Graphic symbol underneath L Reading in Metres with one decimal 13 BOO...

Page 98: ...bar 8 WEIGHT OF THE LIFTED LOAD ACT 9 MAX ADMISSIBLE LOAD MAX 10 WORK RADIUS R 11 WORK CONFIGURATION LT I 12 BOOM LENGTH 13 BOOM ANGLE For the reading of the HEIGHT above the ground H press the ENTER...

Page 99: ...m the panel The setting of the Operating Mode LT is automatic and selected by external micro switches In the main page the one usually displayed the Chart of the selected equipment I and the Operating...

Page 100: ...essories with automatic recognition If the accessory is preset for the automatic recognition you have only to install the accessory and plug the connector in the relevant socket at the top of the boom...