Terex Gyro 4020, Gyro 4518 Service Manual

INDEX

Handler with telescopic boom

Gyro 4020 (From serial n. 12888)

Gyro 4518 (From serial n. 12508)

SERVICE MANUAL

Code 57.4402.8200 - 1

Edition 03/2007

English

Edition

Document 57.4402.8200 - 1

Edition 03/2007

INDEX

GYRO 4020 - 4518

Intentionally blank page

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GYRO 4020 - 4518

SERVICE MANUAL

Code 57.4402.8200 - 1

Edition 03/2007

Number: ....................................

Consigned to: ................................................................................................................................

DECLARATION

I, the undersigned..........................................................................................................................

declare I have received the Service Manual for TEREX handlers of the Gyro 4020 - 4518

series.

Copies consigned: n° ...... on paper

n° ......

on CD-Rom The undersigned is obliged to use the manual in their workshop, without disclosing the information 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 the prior written authorisation of TEREXLIFT to do so. If business relations between the undersigned and TEREXLIFT should come to an end, the undersigned is obliged to return the copies received without charges for TEREXLIFT. Yours sincerely

Date ............................

For acceptance

The consignee Company stamp and signature of the Legal representative

........................................... ...........................................

Copy to return stamped and signed for acceptance by the

Legal representative of the company receiving the copies of the manual.

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INDEX

SERVICE MANUAL

Code 57.4402.8200 - 1

Edition 03/2007

Number: ....................................

Consigned to: ................................................................................................................................

DECLARATION

I, the undersigned..........................................................................................................................

declare I have received the Service Manual for TEREX handlers of the Gyro 4020 - 4518

series.

Copies consigned: n° ...... on paper

n° ......

Date ............................

For acceptance

The consignee Company stamp and signature of the Legal representative

........................................... ...........................................

GYRO 4020 - 4518

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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 4020 - 4518

LIST OF REVISED PAGES

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INDEX

MANUAL 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. 7 REPAIR PROCEDURES

GYRO 4020 - 4518

GENERAL INDEX

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INDEX

Machine denomination Literature valid up to serial number

Gyro 4020 12888

Gyro 4518 12508

TELELIFT 4013

SERIAL NUMBER IDENTIFICATION

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INTRODUCTION

Important

Read, understand and obey the safety rules and operating instructions in the Gyro 4020 and Gyro 4518 Operator's Handbook before attempting any maintenance or repair procedure. This manual provides the machine owner and user with detailed information on the scheduled maintenance. It also

provided qualied service technicians with infromation on

troubleshooting and repair procedures. Basic mechanical, hydraulic and electrical skills are required to perform most procedures. However, several

procedures require specialized skills, as well as specic

tools and equipment. In these instances, we strongly recommend letting service and repair the machine at an authorized TEREXLIFT service center.

Technical Publications

No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means without prior written permission from TEREXLIFT srl. In pursuing a policy of constant quality improvement, TEREXLIFT srl reserves the right to make changes at any time and without undertaking to give prior notice; therefore,

also this publication may be subject to modications.

http://www.terexlift.com e-mail: info@terexlift.it

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INTRODUCTION

DESCRIPTION OF THE MACHINE OPERATION

The oil-pressure system of this machine consists of two macro sections, namely turntable and undercarriage, corresponding to the machine's main parts. From an oilpressure point of view, these two sections are connected with one another by the 13-way hydraulic rotary joint (9). The source of mechanical energy of this machine is a Deutz turbo-compressed diesel engine (1), model BF4M2012, which supplies 74.9 kW at 2300 rev/min and with a max torque of 390 Nm at 1500 rev/min.

On the ywheel side of the engine, and connected to

this engine by a Technodrive coupler with elastic joint and with a 1-to-1 ratio, there is a Linde closed-loop pump for hydrostatic drives, model HPV 75-02RE112V (2) with electroproportional adjustment valves. The max displacement of this swashplate pump is 75 cm3 and the max calibration pressure is 445 bar. This pump is used to supply hydraulic power under form

of pressure and ow rate which is then used for moving

the machine. This pump is used to supply hydraulic power under form

of pressure and ow rate which is then used for moving

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 ow and pressure control valve. The displacement of this pump is 45 cm3. The function of this pump, through the “load sensing” priority valve (6) is to provide hydraulic power, under form of pressure and

ow rate to the steering cylinder of the machine (priority

side of the valve) and to the telescopic boom and slewing turntable circuits (secondary side of the valve). This "load sensing" pump is adjusted through an adequate piloting line which provides the pump a pressure signal corresponding to the max load of all the users fed by this pump. Between pump (3) and priority valve (6), a one-way valve (5) is placed to avoid that oil at pressure, produced by the power-driven emergency pump (48), may escape from pump (3) when this is stopped. The assembly of the two pumps involves they have a rotation velocity equal to the speed of the diesel engine.

A third Casappa xed displacement gear pump suitable

for open loop circuits (4) with a displacement of 25 cm3, is installed on the PTO of the engine located on the distribution side. This pump feeds the servo-assisted braking system (35) and the hydraulic motor (42) of the heat exchanger fan (43) used to cool down the diesel engine and the hydraulic circuit.

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The circuit of pump (4) is protected by a pressure relief valve 33) calibrated to 160 bar. The suction lines of the open-loop pumps (3-4) and the power-driven emergency pump (48) are not protected by

lters and are conveyed to a single port on the hydraulic

uid tank (32).

Between this port and the suction lines of the aforesaid pumps, there is a gate valve (31) that allows to perform important maintenance interventions on the oil-pressure circuit of the machine without emptying the oil tank. This tank has a capacity of 230 litres. On the contrary, the drive pump (2) is protected by a special lter (45), placed on the discharge line of pumps (3-4). This lter puries the oil from the open circuits of the machine (boom-turntable control circuit and service and parking brake feeding circuit) and allows to have an additional oil port for the drive suction line with a minimum pressure of 0.5 bar.

This construction feature of the lter guarantees signicant advantages in terms of absence of cavitation

in the drive suction line, especially when the machine is started from cold. The one-way valve (34) set to 1.5 bar protects the pump housing against high pressures and guarantees a certain circulation of 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 rst conveyed to the

undercarriage through port 11 of the hydraulic rotary joint (9), and then used for the two-speed mechanical gearbox circuit (51), for the adjustment of the hydrostatic drive motor (50) and for the differential anti-slip circuit through the mechanism placed inside the front axle (57). The hydraulic energy produced by the drive pump (2) and conveyed to the undercarriage through ports n.1 and n.2 of the hydraulic rotary joint (9), is converted into mechanical power by a closed-loop hydrostatic motor, model Linde HMV 75-02E112V (50) equipped with an

electroproportional adjustment valve and with a ush

valve for reducing the max temperatures inside the drive circuit. In addition to the high-pressure connections with pump (2) throughj ports n. 1 and n. 2 of the hydraulic rotary joint (9), the motor (50) is hydraulically connected to the turntable through port n.12 of the aforesaid joint from

which it receives the ow from the drain circuit of the

drive pump (2), through port n. 7, to which it conveys

all the drain ow, and through port n. 11, from which it

takes the low pressure needed for its adjustment. The electroproportional valves of pump (2) and motor (50) are controlled by a dedicated electronic control unit (Linde) which is connected to the remaining control devices of the machine through the digital network.

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The motor is anged to a two-speed mechanical

gearbox, model 357 (51) manufactured by Dana. Speeds are engaged by a special oil-dynamic cylinder (52) located inside the gearbox, while the selection of

the rst and second speed is controlled by a 4-way/3-

position solenoid valve (53) of the on/off type. The mechanical torque at the gearbox output is transmitted to the front axle (57) and the rear axle (58), both model 212HY manufactured by Dana, through Cardan shafts. The hydraulic drive (7) of “load sensing” type with a displacement of 315 cm3, receives oil from the priority valve (6) in relation to the “load sensing” signal sent by the hydraulic drive and connected to such valve with

function of pilot signal. In this way, the input ow to the

hydraulic drive will be exactly the one needed for the

instantaneous steering functions; any excess ow of the

valve will be available for the functions of the telescopic boom asn other auxiliary functions. The steering circuit is protected against input overpressures by a pressure reducing valve set to 140 bar. On the two delivery lines, there are other two reducing valves with anti-shock function set to 200 bar. The scope of these two valves is limiting possible shocks on the steering wheel due to overstress on the 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 (55), the rear steering cylinder (56) (these cylinders being integral part of the front axle (57) and the rear axle (58) respectively) and by a 4-way/3position solenoid valve (54) for the selection of the three different steer modes (rear wheels straight, co-ordinate front/rear steering and independent front/rear steering). When the solenoid valve (54) is not energised, the front steering cylinder is fed by the hydraulic drive and the rear cylinder is blocked. When one magnet or the other of the solenoid valve (54) is energised, the chambers of the cylinders are connected in a different manner thus causing the desired effect on the steering mode. The connection of the steering circuit between the section integral of the turntable and the one integral of the undercarriage is done through ports n.8 and n. 9 of the hydraulic rotary joint (9). The Bucher/Tecnord electro-proportional distributor (8), with 5 modular sections, receives oil from the secondary line of the priority valve (6) and feeds all of the movements of the telescopic boom and the turntable

and provides an oil ow to the auxiliary lines for the

secondary functions such as turntable lock, outriggers and frame levelling. This main valve consists of an input head with 3-way

pressure compensator used as a ow regulator for the

user which works at max load (load sensing), and as a

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discharge valve when the pump ow is not used for the

boom movements, and of 5 modules.

Four of these modules control specic functions of the

telescopic boom (lifting/lowering, attachment holding frame rotation, extension/retraction, attachment lock/

unlock) and the fth module controls the rotation of the

turntable of the machine. In the head there is a pressure relief valve set to 300 bar which, acting on the line of the “load sensing” signal, limits the maximum pressure at the inlet of the main valve through such 3-way compensator. On the main inlet head of the main valve, there is the pilot

line head which includes an inlet safety lter, a pressure

relief valve acting on the pilot line, and a safety solenoid valve which, when de-excited, discharges the input pilot pressure, thus preventing the main valve from working. This solenoid valve is used as a “dead man” control and is activated by the relevant button on the joysticks in the driving cab. The pilot head delivers oil at pressure to the 5 pilot modules of the main valve. These modules operate the relevant main sliders in relation to the command signal they receive from the joysticks via the control unit. Module 1 of the main valve controls the telescopic boom lifting cylinder (12). This cylinder has one singleacting 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-lt. accumulator prelled at 35 bar (14) and located on the line of the differential chamber of the lifting cylinder (12), allows for damping the boom swings when the same boom is moved down. Module 2 of the main valve controls the boom telescopes extension cylinder (15). This cylinder is equipped with a double-acting compensation valve (16) with safety function. The control module of this element of the main valve is the electro-proportional type with electrical feed-back and integrated electronics. Module 3 of the main valve controls the cylinder operating the attachment holding plate of the telescopic boom (17). This cylinder is equipped with a doubleacting compensation valve (18) with safety function.

Paralleled to this cylinder we nd the fork levelling

cylinder (19) (or balancing cylinder) equipped with a special double-acting compensation valve (20). Inside this valve, the one-way valves are installed in a reverse manner with respect to the normal position to avoid the pressurisation of the cylinder when the rotation command of the attachment holding plate is operated. Again inside this valve, there are other two one-way valves set to 5 bar with anti-cavitation function (21). These valves are used to deliver oil, sucked from the low pressure line coming from the pressure relief valve (11), to the fork levelling compensation circuit, when such

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circuit cannot do it alone. The control module of element 3 of the main valve is the electro-proportional type with electrical feed-back and integrated electronics. On the two control lines of the cylinder (17), and integral to module 3, there are two pressure relief valves set to 320 bar which protect the automatic levelling system of the forks when the boom is moved up and down and in case of overload on the attachment holding plate (ex. use of the bucket). Module 4 of the main valve controls the attachment locking cylinder (23). This cylinder has a double oneway valve with hydraulic release, acting as safety valve (24). The pilot module of element n. 4 of the main valve is the electroproportional type with integrated electric and electronic feedback. On one of the two hydraulic control lines of this section of the main valve, there is a 3-way/2-position electric divider with on/off control (22). When this divider is not energised, the oil at pressure coming from the module of the main valve, is sent to the attachment locking cylinder. On the contrary, when the divider (22) is energised, the oil at pressure from element n.4 of the main valve (8), is made available for the auxiliary feeding line of the turntable lock/unlock 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 end trunk, there are two quick-t

connectors (25) for the connection of the hydraulic lines of any optional equipment needing a hydraulic power for their operation (e.g. hydraulic winch and jib, mixing bucket, etc.). Module n. 5 of the main valve controls the hydraulic slewing motor of the turntable (26), equipped with brake with internal mechanical block and external hydraulic release. The mechanical torque produced by this motor is transmitted to the turntable through an epicyclic reduction gear with two stages and a slewring with internal toothing. The feeding line of this motor is equipped with a doubleacting compensation valve (27), used also as safety and anti-cavitation valve. The pilot module of this element of the main valve is of electroproportional type with integrated electric and electronic feedback. Inside this module of the main valve, there is a two-way pressure compensator which keeps the proportionality of the slewing control of the turntable as the loads on this table and the pressure entering the main valve modules change. The pressure of the main valve is adjusted by the three-way compensator placed on the inlet head. The main valve (8) is equipped with a pilot line of the “load sensing” type which, through the exchange valve (10), is connected to the priority valve (6), which, at

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its turn, receives an analog pressure signal from the hydraulic drive (7). The exchange valve (10) is then connected to the "load sensing" port of pump (3), thus guaranteeing the adaptation of the pump adjustment to the maximum load on the various users served by this pump under any conditions. The pressure relief valve (11) calibrated to 30 bar is placed upstream of the pressure inlet port of the main valve (8). This valve is used to deliver low-pressure oil (30 bar) to the anti-cavitation circuits of automatic fork levelling system and to feed the pilot line of the same main valve (8). The block cylinder of the slewing turntable (28) is equipped with a double one-way valve (29) with hydraulic release, acting as safety valve, and is controlled by the 4-way/3-position solenoid valve of the on/off type (30). As already mentioned, the turntable lock/unlock is possible through the simultaneous energisation of module n.4 of the main valve (8), the electric divider (22) and the solenoid valve (30). The SAFIM S6 servo-assisted braking system with pedal (35) receives oil from the pump (4) and uses this oil to pressurise 3 hydraulic accumulators (36-37) connected to the same system. The oil at pressure contained in these accumulator is 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 ll valve inside the braking system takes the ow

from the feeding line so the pressure on the line of the accumulators reaches the calibration value of the cutout valve set to 140 bar. When this pressure is reached, the

valve gradually releases all the ow to line B for other

uses. The brake pedal located in the driving cab, which is an integral part of the braking system S6, is connected to two proportional sliders which control the two separated lines of the service brake, one for each axle. Such lines connect the part of circuit in the turntable with the one in the undercarriage through ports n. 5 and n. 6 of the hydraulic rotary joint (9). In relation to the stroke of these sliders, a gradual communication between the feeding line, connected to two accumulators (36) which, at their turn, are connected to ports R1 and R2

(the accumulators have 0.5-lt. capacity and 50 bar ll

pressure), and the service brake lines is established so

the ow is distributed to such lines and the discharge

line increasing, in this way, the pressure (and as a result the braking force) on the lines of the service brakes. When the sliders are in the rest position, the lines of the service brakes are connected to the discharge. The pressure switch (38) set to 2-10 bar, paralleled to on of the two lines of the service brake, sends an electrical signal when this brake is engaged.

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The pressure switch (39) set to 70 bar and connected to port F, sends an electrical warning signal when the pressure inside the feeding circuit of the brake lines is

too low to guarantee the minimum braking efciency.

The accumulator (37) with 0.5-lt. capacity and 50 bar

ll pressure is connected to port R of system S6 and is

used to unlock the parking brake of the rear axle (58). The connection of the part of this circuit placed in the turntable to the one of the undercarriage is done through port n. 13 of the hydraulic rotary joint (9). The command of the parking brake is controlled by a special valve with lever control (40) located in the driving cab. In relation to the position of the lever, the release line of the parking brake is connected to the pressure line (parking brake unlocked) or the discharge line (parking brake locked). The two pressure switches (41) set to 10-20 bar send an electrical warning signal when the parking brake is activated (brake locked). The oil which is not used by the SAFIM S6 servo-assisted braking system with pedal, is sent to the Casappa hydraulic geared motor (42) with a displacement of 20 cm3, for the operation of the cooling fan of the heat exchanger (43). Inside the 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 entering to the motor, to the drain. The function of this solenoid valve, suitably controlled by a thermostatic circuit, is to avoid an operation of the cooling fan of the heat exchnager when the oil is cold. This allows reaching the ideal working temperature of the hydraulic oil faster. The heat exchanger (43) is divided in two sectors; one absorbs heat from the cooling circuit of the diesel engine and the other absorbs heat from the hydraulic circuit of the machine. The ows of pumps (3-4) and the partial ow of the drain circuit of the hydrostatic transmission are conveyed to this second sector. The oil cooled down by the heat exchanger is sent back to tank (32). A one-way valve (44) with an opening pressure of 5 bar is installed parallel to heat exchanger (43) to protect the same exchanger. In all the cases in which the pressure drop in the exchanger exceeds 5 bar (starts from cold, partial obstruction of the heat exchanger, etc.), valve (44) opens so that a part of the ow to the exchanger can be conveyed through this valve by reducing the maximum pressure inside the exchanger (43). On the drain line from the drive motor (50), passing through port n.7 of the hydraulic rotary joint (9), there are two one-way valves (46-47) with an opening pressure of

0.5 bar and 1.5 bar, respectively.

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The function of these valves is to avoid a pressure of the drain line of motor (50) above 1.5 bar which is the admissible limit for the seals placed on the motor shaft. This circuit allows for the partial passage through the heat exchanger (43) of the ow from the pump drain circuit (2) and the drive motor (50) to keep within the

pressure limits mentioned above. Any excess ow will

pass through valve (47) to directly reach the tank (32). Ports n.4 and n.10 of the hydraulic rotary joint (9) are used to connect some drain lines between undercarriage and turntable. In particular, port n.10 is the one which can guarantee the lowest counter-pressure values on the drain, being directly connected to tank (32). The motor-driven pump (48), supplied with power by the battery, is used as emergency feeding pump in the event of a failure of the primary control circuit of the telescopic boom. Just downstream of the motor-driven pump (48) there is a one-way valve (49) which avoids that oil at pressure, produced by the main pump (3), may escape through pump (48) when this is stopped. The movements of the front outriggers are controlled by four 4-way/3-position solenoid valves of the o/off type, installed on the oil-pressure block (70). This block, through port 3 of the hydraulic rotary 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) operating the front left stabilising foot. This cylinder is equipped with a double-acting compensation valve(72) used also as safety valve. On the rod side of this cylinder, there is a pressure gauge (73) calibrated to 50 bar which detects when the outrigger is lowered to the ground. The solenoid valve n. 2 of block(70) controls the extension cylinder (74) of the front left outrigger. This cylinder is equipped with a double one-way valve with hydraulic release, acting as a safety valve (75). The solenoid valve n. 3 of block (70) controls the extension cylinder (76) of the front right outrigger. This cylinder is equipped with a double one-way valve with hydraulic release, acting as a safety valve (77). The solenoid valve n. 4 of block (70) controls the cylinder (78) operating the front right stabilising foot. This cylinder is equipped with a double-acting compensation valve (79) used also as safety valve. On the rod side of this cylinder, there is a pressure gauge (80) calibrated to 50 bar which detects when the outrigger is lowered to the ground. The movements of the rear outriggers are controlled by four solenoid valves installed on the oil-pressure block (81). This block, through port 3 of the hydraulic rotary 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).

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The solenoid valve n. 1 of block (81) controls the cylinder (82) operating the rear left stabilising foot. This cylinder is equipped with a double-acting compensation valve (83) used also as safety valve. On the rod side of this cylinder, there is a pressure gauge (84) calibrated to 50 bar which detects when the outrigger is lowered to the ground. The solenoid valve n. 2 of block (81) controls the extension cylinder (85) of the rear left outrigger. This cylinder is equipped with a double one-way valve with hydraulic release, acting as a safety valve (86). The solenoid valve n. 3 of block (81) controls the extension cylinder (87) of the rear right outrigger. This cylinder is equipped with a double one-way valve with hydraulic release, acting as a safety valve (88). The solenoid valve n. 4 of block (81) controls the cylinder (89) operating the rear right stabilising foot. This cylinder is equipped with a double-acting compensation valve (90) used also as safety valve. On the rod side of this cylinder, there is a pressure gauge (91) calibrated to 50 bar which detects when the outrigger is lowered to the ground. The differential anti-slip circuit is controlled by the 3way/2-position solenoid valve (69). When this valve is not energised, the service brake control line of the front axle (57), coming from 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 corresponding to the anti-slip control "ON", the service brake ports of the front axle (57) are connected to the 25-30bar low-pressure line and help the action of the differential anti-slip system. The oscillation of the front axle (57) is controlled by two cylinders (60-63) equipped with block solenoid valves (61-62). The movement of cylinders (60-63), and thus the front axle oscillation (57), is only possible when solenoid valves (61-62) are energised. The frame levelling is controlled by a 4-way/3-position ON/OFF solenoid valve (59) which feeds in a crossed manner the cylinders (60-63). This solenoid valve, through port 3 of the hydraulic rotary joint (9), is activated by the simultaneous operation of the 4th element of the electro-proportional main valve (8) and of the electric divider (22). The oscillation of the rear axle (58) is controlled by two cylinders (65-68) equipped with block solenoid valves (66-67). The movement of cylinders (65-68), and thus the rear axle oscillation (58), is only possible when solenoid valves (66-67) are energised. The ow control valve (64) allows for the free passage of the oil coming from the drive drain circuit during the lling of the cylinders (65-68) (air venting) and avoids pressure peaks in the circuit of such cylinders when high oscillation speed conditions of the rear axle produce potentially dangerous overpressures in the drive drain

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circuit. As already mentioned, the undercarriage levelling function is possible through the simultaneous energisation of the two spools of the solenoid valve (59) and the spools of the solenoid valves (61-62-66-67).

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xii

Gyro 4020 - 4518 carrier hydraulic scheme

6065

1 2

Double overcenter safety valve

piloting ratio: 11 1

cracking pressure: 200 350 bar

Front left outrigger

foot cylinder

Rear left outrigger

foot cylinder

Rear right outrigger

foot cylinder

Front right outrigger

foot cylinder

Front left outrigger

telescope cylinder

Rear left outrigger

telescope cylinder

Rear right outrigger

telescope cylinder

Front right outrigger

telescope cylinder

Hydraulically piloted

double check valve

piloting ratio: 41/

Hydraulically piloted

double check valve

piloting ratio: 41/

Hydraulically piloted

double check valve

piloting ratio: 41/

Rear outriggers

selector valves block

Front outriggers

selector valves block

Hydraulically piloted

double check valve

piloting ratio: 41/

Pressure

switch

activating

pressure

50 bar

Pressure

switch

activating

pressure

50 bar

Differential lock

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)

Rear axle

steering cylinder

Front axle

Rear axle

Steering modes

selector valve

4 ways / 3 positions

Mechanical gear

speeds selector valve

4 ways / 3 positions

2 speeds mechanical gear

14 bar

Mechanical gear

speeds shifting

actuator

Chassis leveling

selector valve

4 ways / 3 positions

13 ways hydraulic rotating collector

Rear axle pivoting cylinders

control valve

orifice dia.: 0.5 mm

cracking pressure: 0.5 bar

Hydrostatic transmission motor

max displacement: 75 ccrev

Double overcenter safety valve

piloting ratio: 11 1

cracking pressure: 200 350 bar

Double overcenter safety valve

piloting ratio: 111

cracking pressure: 200 350 bar

Double overcenter safety valve

piloting ratio: 111

cracking pressure: 200 350 bar

HYDRAULIC CIRCUIT

COLORS LEGENDA

Boom teering, brakes, auxiliaries

and chassis levelling functions lines

/ s

Low pressure lines

Boom functions valve piloting lines

Boom teering, brakes, auxiliaries,

chassis levelling pump pressure lines

/ s

Boom teering, auxiliary pumps

suction lines

/ s

Tank lines

Pressure

switch

activating

pressure

50 bar

Rear axle pivoting

lockout valves

2 ways/2 positions

Front axle pivoting

lockout valves

2 ways/2 positions

Pressure

switch

activating

pressure

50 bar

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INDEX

xiii

GYRO 4020 - 4518

INTRODUCTION

Gyro 4020 - 4518 turntable hydraulic scheme

B A

320 bar

300 bar

140 bar

200 bar

Unlocking

pressure

15/50 bar

FLT

RPM

Ev13

Pv1

Pv2

Pv3

Pv5

Pv4

N’

T1’

T2’

capacity:

0.5 Litri

precharge

pressure

50 bar

capacity:

0.5 Litri

precharge

pressure

50 bar

Pressure

switch

activating

pressure

70 bar

Pressure

switch

activating

pressure

2-10 bar

Pressure

switch

activating

pressure

10 bar-20

Pressure

switch

activating

pressure

10 bar-20

Hydraulically powered

service/emergency brakes

pedal pump

140 bar

30 bar

Parking brake handle

selector valve

Hydrostatic transmission pump

max displacement 75 cc/rev

25 bar

19 bar

445 bar

Hydrostatic transmission

boost pressure test port

Pressure reducing valve

setting pressure: 30 bar

Shuttle

valve

Priority

valve

Hydrostatic transmission

high pressure test port

0.9

Boom functions pump

withpressure/flow control

max displacement: 45 cc/rev

Anticavitation valves

cracking pressure

5 bar

Forks levelling

slave cylinder

Boom telescoping cylinder

Forks tilt cylinder

Boom lift

cylinder

Double overcenter safety valve

piloting ratio: 41

cracking pressure: 350 bar

Double overcenter safety valve

piloting ratio: 7.61

cracking pressure: 350 bar

Double overcenter safety valve

piloting ratio: 4/1

cracking pressure: 350 bar

Single overcenter safety valve

piloting ratio: 4/1

cracking pressure: 350 bar

capacity:

1,5 Litri

precharge

pressure

35 bar

Hydraulically piloted

double check valve

piloting ratio: 41/

Hydraulically piloted

double check valve

piloting ratio: 41/

Turret rotation

hydraulic motor

Turret rotation hydraulic motor

double overcenter safety valve

piloting ratio: 3/1

cracking pressure: 150 bar

13 ways hydraulic rotating collector

Turret rotation

lock cylinder

Forks attachment

quick coupling cylinder

Quick coupling

hydraulic ports

140 bar

Heat

exchanger

Oil tank

capacity

230 liters

Diesel engine

Auxiliary gear pump

brakes stabilizers chassis levelling

displacement: 25 cc/rev

/ /

Check valve

cracking pressure:

1.5 bar

Check valve

cracking pressure:

0 bar

Check valve

cracking pressure:

5 bar

Check valve

cracking pressure:

0.5 bar

Check valve

cracking pressure:

1.5 bar

Check valve

cracking pressure:

0.5 bar

Return filter

with suction line

pressurized at 0,5 bar

Pressure relief valve

cracking pressure: 160 bar

Heat exchanger fan

hydraulic motor

displacement 20 cc/rev

Boom functions hydraulic

circuit test port

Boom functions

main valve

Steering rotating actuator

displacement: 315 ccrev/

Turret rotation lock/unlock

selector valve

4 ways / 3 positions

Auxiliary functions

selector valve

3 ways / 2 positions

Emergency electrical

motor driven pump set

2,6 cc/rev

Shutoff valve

HYDRAULIC CIRCUIT

COLORS LEGENDA

Boom teering, brakes, auxiliaries

and chassis levelling functions lines

/ s

Low pressure lines

Boom functions valve piloting lines

Boom teering, brakes, auxiliaries,

chassis levelling pump pressure lines

/ s

Boom teering, auxiliary pumps

suction lines

/ s

Tank lines

Intentionally blank page

Document 57.4402.8200 - 1

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INDEX

GYRO 4020 - 4518

INTRODUCTION

xiv

INDEX

GYRO 4020 - 4518

SAFETY

Document 57.4402.8200 - 1

Edition 03/2007

Section 1

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 ...........................................................................................

1.3 Servicemen's requisites

............................................................................. 4

1.3-1 Personal protective equipment

.................................................................. 5

1.4 General safety precautions

........................................................................ 5

1.4-1 Working areas

.............................................................................................. 5

1.4-2 Precautions during work

............................................................................ 5

INDEX

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SAFETY

Document 57.4402.8200 - 1

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1.1 SAFETY RULES

1.1-1

Personal Safety

In this manual, any important information is preceded by a SPECIAL SYMBOL. All operators who work or service the machine must know the exact meaning of these safety symbols.

There are six special (or safety) symbols in this manual, always combined with keywords that class the situations according to their danger degree. The symbols are always followed by a text explaining the situation taken into account, the attention to be paid to such situation, the method and the behaviour to be adopted. When necessary, it stresses prohibitions or supplies instructions to prevent dangers. Sometimes, it can be followed by illustrations.

We list below the special (or safety) symbols according to the relative seriousness of the hazard situation:

Draws the attention to situations that involve your own as well as the others’ safety and that can result in serious or lethal injury.

Draws the attention either to situations that involve your own as well as the others’ safety and that can result in minor or moderate injury or to situations

that involve the machine efciency.

Draws the attention either to situations that involve your own as well as the others’ safety and that can result in minor or moderate injury or to situations

that involve the machine efciency.

Draws the attention to important technical information or practical advice that allows for a safer and more

efcient use of the machine.

Draws the attention to important environment-related information.

Be sure to wear protective eye wear and other protective clothing if the situation warrants it.

Be aware of potential crushing hazards such as moving parts, free swinging or unsecured components when lifting or placing loads. Always wear approved steel-toed shoes.

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SAFETY

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1.1-2 Workplace Safety

Be sure to keep sparks, flames and

lighted tobacco away from ammable and

combustible materials like battery gases and engine fuels. Always have an approved

re extinguisher within easy reach.

Be sure that all tools and working areas are properly maintained and ready for use. Keep work surfaces clean and free of debris that 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 device is fully capable of supporting and stabilizing the weight to be lifted. Use only chains or straps that are in good condition and of ample capacity.

Be sure that fasteners intended for one time use (i.e., cotter pins and self-locking nuts) are not reused. These components may fail if they are used a second time.

Be sure to properly dispose of old oil or other

uids. Use an approved container. Please

be environmentally safe.

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SAFETY

Document 57.4402.8200 - 1

Edition 03/2007

1.2 GENERAL REMARKS

Most accidents occurring while working, servicing or maintaining operation machines, are caused by not complying with the basic safety precautions. Therefore, it is necessary to pay steady attention to the potential hazards and the effects that may come of operations carried out on the machine.

If you recognise hazardous situations, you can prevent accidents!

For instance, this handbook makes use of special safety symbols to highlight potentially hazardous situations.

The instructions given in this handbook are the ones established by GENIE. They do not exclude other safe and most convenient ways for the machine commissioning, operation and maintenance that take into account the available spaces and means.

If you decide to follow instructions other than those given in this manual, you must:

• be sure that the operations you are going to carry out are not explicitly forbidden;

• be sure that the methods are safe and in compliance with the indications given in this section;

• be sure that the methods cannot damage the machine directly or indirectly or make it unsafe;

• contact GENIE Assistance Service for any suggestion and the necessary written permission.

Do not hesitate to pose questions if you are 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 who use the machine regularly or occasionally (e.g. for maintenance or transport) shall have the following requisites:

health:

before and during any operation, operators shall never take alcoholic beverages, medicines or other substances that may alter their psycho-physical conditions and, consequently, their working abilities.

physical:

good eyesight, acute hearing, good co-ordination and ability to carry out all required operations in a safe way, according to the instructions of this manual.

mental:

ability to understand and apply the rules, regulations and safety precautions. They shall be careful and sensible for their own as well as for the others’ safety and shall desire to carry out the work correctly and in a responsible way.

emotional:

they shall keep calm and always be able to evaluate their own physical and mental conditions.

training:

they shall read and familiarise with this handbook, its

enclosed graphs and diagrams, the identication and

hazard warning plates. They shall be skilled and trained about the machine use.

It is recommended to take part in at least one technical training course organised by GENIE Assistance

Ofce.

Ordinary and extraordinary maintenance of the machineare quite complex from a technical point of view and should be performed by an authoirsed service centre.

INDEX

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SAFETY

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1.3-1 PERSONAL PROTECTIVE EQUIPMENT

During work, but especially when maintaining or repairing the machine, operators must wear suitable protective clothing and equipment:

• Overalls or any other comfortable garments. Operators should wear neither clothes with large sleeves nor objects that can get stuck in moving parts of the machine

• Protective helmet when working under or in the

vicinity of suspended load

• Protective gloves

• Working shoes

• Breathing set (or dust mask)

• Ear-protectors or equivalent equipment

• Goggles or facial screen.

Use only type-approved protective equipment in good condition.

1.4 SAFETY PRECAUTIONS

Read and understand the following safety instructions before servicing the machine. The following list contains safety rules which must absolutely be obeyed to prevent accidents and injuries.

1.4-1 WORKING AREA

• Make sure the area all around the machine is safe. Always be aware of potential risks.

• During work, keep the working area in order. Never leave objects scattered: they could hinder the machine 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 handholds and access steps 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 3 meters from the ground), always use type- approved safety belts or fall preventing devices.

• Do not enter/leave the machine when it is running.

• Before servicing the engine, let its parts cool down.

• Do not leave the driving place when the machine is running.

• Neither stop nor carry out interventions under or between the machine wheels when engine is running. When maintenance in this area is needed, stop the engine, engage the parking brake and chock the wheels to prevent accidental movements.

• Do not carry out maintenance or repair works without

a sufcient lighting.

• When using the machine lights, the beam should be oriented in order not to blind the personnel at work.

• Before applying voltage to electric cables or components, ensure they are properly connected

and efcient.

• Do not carry out interventions on electric components with voltage over 48V.

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SAFETY

Document 57.4402.8200 - 1

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• Do not connect wet plugs or sockets.

• Signs and stickers shall never be removed, hidden or become unreadable.

• Except for maintenance purposes, do not remove safety devices, covers, guards,. Should their removal be necessary, stop the engine, remove them with

the greatest care and always remember to ret them

before starting the engine and using the machine again.

• Aleays stop the engine and disconnect the batteries before maintenance or service.

• Do not lubricate, clean or adjust moving parts.

• Do not carry out operations manually when specic

tools are provided for this purpose.

• Absolutely avoid to use tools in bad conditions or in an improper way.

• Before carrying out operations on hydraulic lines under pressure (hydraulic oil, compressed air) and/or before disconnecting hydraulic components, ensure the relevant line has been previously depressurised

and does not contain any hot uid.

Any intervention on the hydraulic or pneumatic circuit must be carried out by authorised personnel. Before any operation on lines under pressure, release any residual pressure from the circuit.

Do not use your ngers to check for pressure leaks.

Fine jets of air, oil or fuel can injure you.

• Neither smoke nor use open ames if there is a risk of re or close to fuel, oil or batteries.

• Do not leave fuel cans or bottles in unsuitable places.

• Do not empty catalytic mufers or other vessels

containing burning materials without taking the necessary precautions.

• Carefully handle all flammable or dangerous substances.

• After any maintenance or repair work, make sure that no tool, cloth or other object has been left within compartments with moving parts or in which suction and cooling air circulates.

•

Never give orders to several people at a ime. Instructions and signs must be given by one person only.

• Always pay the 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 no means.

• After work, never leave the machine under potentially dangerous conditions.

Treatment and disposal of used oils is subject to federal, national and local laws and regulations. Collect and deliver these wastes to authorised centres.

• Use the assistance of a second person to handle loads weighing 30 to 50 kg.

• For loads over 50 kg, the use of special hoisting equipment in good condition and equipped as per

enforced regulations is mandatory.

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INDEX

GYRO 4020 - 4518

TECHNICAL SPECIFICATIONS

Section 2

TECHNICAL SPECIFICATIONS

SECTION INDEX

2.1 Main dimensions .................................................................................page 2

2.2 Tyres

............................................................................................................. 3

2.3 Limit of use

.................................................................................................. 3

2.4 Weight

........................................................................................................... 3

2.5 Speed

............................................................................................................ 3

2.6 Payload and reach

....................................................................................... 4

2.7 Forks(oatingtype)

.................................................................................... 4

2.8 Diesel engine

............................................................................................... 4

2.9 Electrical system

......................................................................................... 4

2.10 Machine sound levels

................................................................................. 5

2.11 Vibration levels

............................................................................................ 5

2.12 Refuelling

..................................................................................................... 6

2.13 Tightening torques

...................................................................................... 7

2.14 Drill diameters for threads

.......................................................................... 9

2.15 Standardtighteningtorquesforttingseals

............................................ 10

2.16 Locking material

.......................................................................................... 12

2.17 Hoisting instructions

................................................................................... 13

2.18 Advicetorenewexiblehoses

.................................................................. 14

2.19 Lists of recommended spare parts

............................................................ 15

2.20 Machine paint colour

................................................................................... 21

2.21 Checking the cylinder movement times

.................................................... 22

2.22 Hydraulic calibrations

................................................................................. 26

2.23 Setting the platform

..................................................................................... 36

2.24 Setting the overload warning system

........................................................ 38

2.25 Ecomatrice panel

......................................................................................... 39

2.26 Controlling and setting the machine with Winscope

............................... 47

2.27 MIDAC system ..............................................................................................

Document 57.4402.8200 - 1

Edition 03/2007

INDEX

GYRO 4020 - 4518

TECHNICAL SPECIFICATIONS

2.1 MAIN DIMENSIONS

Gyro 4020 Gyro 4518

A Overall height mm 3020 3020 B Height to the steering wheel mm 2135 2135 C Overall width mm 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 440 440

L Max width with extended outriggers mm 5015 5015 M Rear reach from the rotation centre mm 2425 2425 N Front reach from the rotation centre mm 4445 3485 O Length to the forks mm 8500 7900

E C

N M

+ 70 hidden pages

Terex Gyro 4020, Gyro 4518 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual