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PN 57.0009.0419

1. SCHEMES 2 3 4 5 m SETTING EMERGENCY LIGHTS FORWARD REVERSE LEVER ANO PROGRAMMING LMI DISPLAY LMI BYPASS KEY AUXILIARY HYDRAULIC SWITCH P33 e 33 p a pX 2 LMI DISPLAY zd CALIBRATION JUMPER A SAR CALIBRATION 51 1 55 Pad wA 1 gt 1 4 j gt iba ERF 1259 gt S2 a 1 15 52 2 4 5 1 Q 19 55555 save QE 1 9 J 4 4 2 6 1 1 S8 dh dg pde 18116 54 E si TE 45 X33 c mE z o lt als Al 4i La A RI we 11 5 5 us e E nN 18 u 9 8 3 4 5 2 0 25 3 8 7 5 1 U x 1 xn U 1 X21 U m 9 1 T 1 U X26 X26 X26 X26 X26 X26 X26 X26 x5 x5 x5 5 X LU aa 2 ale 15 M 31 M a ad 4 B RI 31 gt 5
2. SCHEMES 6 4 2 3007 AGRI 730 1 2 3 4 3 MAIN GAUGES CLUSTER ENGINE IGNITION KEY ET EMERGENCY STOP ala 2 2 5 gs z 5 m gu ums S2 Wr zl ad xl E oe a od Vg Fg Tg Tg 1i 18 ag 22 2629 29 if af j 4 of spoleto ds bebo o oso d d Y 51 DIESES e xz r z Z BN 2 51 31 LA n a gt 21 23 IND T 2 UN 11 33 L MVI a H5 ar ii d 8 2 1 1 7 3 9 1 20 x x x x x 30 15 43 Cu ad H F20 21 F18 WA 21 10 ts al AX D5 D6 E 415 415 877 l 2 p 23 2 71 1 15 F8 T 2 RELAY CARD 6 A 10 X2 X2 21 e l p EVI si 2 a E Es gt 2 1 6 8 2 5 n 3 n 3 t Ane q X15 xt X103 X15 E L2 R6 Ld el s 8 sl n PREHEATING mFG2 STARTER Eg GLOW ANG 60A 40A RELAY 5 a RELAY 5 K02 amp E 2 _ 5 1 1 1 1 61 XOA XWA xu
3. 4 25 5 El eh 2 E 2 lL ATTACHMENT UNLOCK SOLENOID VALVE m y 2 a 5 E 5 5 2 9 3 9 e 5 4 elu Z S2 2 1 2 EI e 3l ATTACHMENT LOCK SOLENOID VALVE 5 gt s 3 X E Y L C e 2 B a ws 1 5 5 H abpug lt lc 2 cles sH 8 E 5 z JA ee eee ee 4 e Xa gt TELESCOPING IN SOLENOID VALVE 5 e 5 o TN E amp 9 dz se H i 5 EE Que Ele 2 lt wo amp 22 TELESCOPING OUT SOLENOID VALVE E lt 1 5 lt ens N e CETERI Srp Sl nl Erw FORK UP SOLENOID VALVE a e ee ty ml lt X Sz al FORK DOWN SOLENOID VALVE yayims yeas 2j lt 21 uH X t b ain ies 2l x snonujuo o Lom 2 d UE AS P ue emm uis snoad m Ham g Ans sanoa Heo z BOOM DOWN SOLENOID V
4. SCHEMES 1 e 3 4 3 AIR CONDITION SWITCH CABIN FAN SWITCH HEATING FAN WORK LIGHT WORK FLASHING CABIN CABIN ROOF CABIN REAR SWITCH SPOTLIGHT BEACON INTERIOR WINDSCREEN WINDOW LIGHT WIPER WIPER 45 015 45 o E A Tm z m 5 z 5 5 1 TLT 2 P J J 5 1 510 59 1 4 1 m M M yo 6 4 5 3 oS 1 ML gt a E2 ae a a E E un 4 5 15 Ig d dsdi bi 1 M dM n 2 5 5 Lu n o 25 25 5 31 05 61 m 55 E A Az Aghj A 1 Tis x uletele 1 F11 F13 F15 25A 10A P Kh 15 15 15 25 RELAY CARD enie A TEREX COMPANY Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 11 April 2008 Section 6 Schemes SCHEMES AUXILIARY BOOM FUNCTIONS BOOM FUNCTIONS CONTROL CIRCUIT INTERFACE CONNECTOR
5. SCHEMES 1 3 4 5 ROAD LIGHTS SELECTOR LEVER WINDSCREEN WINDSCREEN ROAD LIGHTS SWITCH STOP LIGHT WIPER MOTOR WASHER PUMP PRESSURE SWITCH 25 35 ul 51 0 MI 1 274 M 1 x57 lt 07 w 30050 mio 5 5 EN 5 lt VN 55 1 1 z e Un rz kn E P z lt 25 4 wa al 2 sf al 5 E 1 gt a 3 S i lt d 5 ds sizininisisi 8 xn Xn X21 X2 1 KZ X21 7 X21 X5 XS 5 un 2 S S 2 gt zx 3 4 lt 25 ARI 33 5 51 21 23 Z M w z 5 9 2 5 5 xt x xt F19 F6 FI F17 F16 10 SA SA 10 10 b mel nl i im m 415 415 415 Qr Qm 30 30 30 Fa F3 to p 13 RELAYS CARD 4 9 3 1 4 n x x x 5 15 e hd 15 x x lt a 5 5 5 5 1 1717 16 11 125 16 3 21 9 12 LE XI XII XP X27 X27 xn X27 z 3 5 S gt gt 5 Fa x p 454 1 3 54 140273
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8. ZY spod oinejp u Buyjdnoo yoinb 59104 4eq 066 eunssaid 1 27 ones Bunojd NE panem xoous nuv eAejs S404 T suonisod 20 pig Buueejs v 3 yf a T 7 axe I I NC bd S104 juos 08 einsseud 1 pod 338 fs 124 2 9 8 2 1 eunsseud S a yoyms ensseud Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 April 2008 Section 6 Schemes 6 3 ELECTRICAL SYMBOLS
9. ACTUATORS Emergency controls Pushbutton control Rotary control Pedal control Proximity control Lever control Timed control Mechanical manual control Key control RESISTANCES Resistance Resistor Potentiometer Variable resistance SIGNALS Intermittent lamp Whistle Lamp Buzzer Siren Bell Horn FUSES AND RELAYS Horizontal fuse Relay ACCUMULATORS Battery Thermocouple Element TERMINALS AND GROUNDS Ring Ground Terminal Ground to frame Knot Protection ground Frame ground 2 COILS Coil Mechanical coupling coil Document 57 0009 0419 SCHEMES DYNAMIC APPLICATIONS Motor Generator As_3p_motor ELECTRONIC PARTS Rectifier Light emitting diode Diode Condenser PUSHBUTTONS Manual NC contact TEREX COMPANY Winding l H A Manual NO contact A C coil q NC mushroom head pushbutton Coil with diode NO mushroom head pushbutton es 7 NC level Winding with diode p N NO level CONNECTORS Connector Pushbutton with NC return STATIC APPLICATIONS C Pushbutton with NO return Auto transformer 4 NC tie rod Transformer E J E N NO tie rod Genie Section 6 Schemes April
10. 2 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 Section 6 Schemes April 2008 SCHEMES HYDRAULIC SCHEMES GTH 2506 AGRI 625 6 2 6 2 1 soul yue seuj uonong Buno id pue peo eunsseJd pue ensseJd seul saul ainsseid uiu uoissiusueJ 9nejsoJp H seul eunsseud VQON3931 SYO109 2 9 8 Ds eunsseud Bupjoejo uaeJos uonons 4 goinus 1z A31 99 96 jueuieoe dsip 9 xX onejsoJpAH M 99 20 oneisoJp 1561 ohejsoJp H nay 72 uewede dsip uy woog 1 uoissiusuen SIN i z od 158 eunsseud 52 eunsse1d
11. G Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 27 Section 2 Technical Specification April 2008 TECHNICAL SPECIFICATION GTH 3007 AGRI 730 DIAGRAM 1250 kg at 3 00 metres 6 89 m 3 00 m 28 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 2 Technical Specification TECHNICAL SPECIFICATION DIAGNOSTIC FUNCTION IN CALIBRATION MODE FUNCTION DISPLAY A B Display of the value read by the ADC converter cell channel 1 A This diagnosis function allows you to check proper reading of the load cell As you move the boom you can see the LEDs of the load bar progressively go on off valid if calibration has already been done Position the machine for a calibration without load If the function A is setted by a progressive boom extension the LEDs of the load bar progressively have to go off If function A is activated and the LED is completely ON or OFF there could be a problem with the connection or in the cell thereof if it is partly lit but there is no movement in the boom make sure the cell is fixed Digital Inputs display this function allows you to see if the following signals are properly delivered to the DLE device according to the lighted LEDs of the load bar LED3 lit when the load limiter disconnect key is turned LED4 ON if the interlock relay is active machine safe without alar
12. Section 2 Technical Specification April 2008 TECHNICAL SPECIFICATION Thread Pitch Standard nuts Low nuts diameter amp 4 0 7 5 5 3 5 5 0 8 5 5 3 5 6 1 9 5 13 0 6 0 8 0 8 1 25 23 0 32 0 14 0 20 0 1 25 0 35 0 16 0 22 0 10 1 5 46 0 64 0 29 0 40 0 1 25 49 0 68 0 31 0 42 0 12 1 75 80 0 110 0 50 0 69 0 1 25 88 0 125 0 55 0 78 0 14 2 125 0 180 0 78 0 110 0 1 5 140 0 195 0 88 0 120 0 16 2 195 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 5 570 0 800 0 360 0 500 0 24 3 660 0 930 0 410 0 580 0 2 720 0 1000 0 450 0 630 0 27 3 980 0 1400 0 610 0 880 0 2 1050 0 1500 0 660 0 940 0 30 3 5 1350 0 1850 0 850 0 1160 0 2 1450 0 2050 0 910 0 1280 0 33 3 5 1650 0 2310 0 1050 0 1470 0 2 1980 0 2770 0 1270 0 1780 0 36 4 2120 0 2970 0 1360 0 1900 0 3 2550 0 3570 0 1630 0 2280 0 39 4 2730 0 3820 0 1750 0 2450 0 3 3250 0 4550 0 2080 0 2910 0 6 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 2 Technical Specification ee ee TECHNICAL SPECIFICATION 2 15 DRILL DIAMETERS FOR THREADS Thread DRILL DIAMETER DRILL BIT x pitch LIMITS DIAMETER max min M 4x 0 7 3 42 3 24 3 30 x 0 5 3 60 3 46 3 50 M5x0 8
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14. Ref Description FG1 FUSE 50 Gams rc FG2 GLOW PLUGS FUSE 40A STARTER ENABLING SWITCH K01 GLOW PLUGS PREHEATING A TEREX COMPANY 22 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 6 Schemes SCHEMES 65 POSITION OF ELECTRICAL AND HYDRAULICAL COMPONENTS ON THE MACHINE 6 5 1 Hydraulical components SS SSS 10 MOTORE DEUTZ 25 MOTORE DEUTZ Genie Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 23 Section 6 Schemes April 2008 SCHEMES Genie A TEREX COMPANY 24 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 6 Schemes SCHEMES Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 25 Section 6 Schemes April 2008 SCHEMES Legend of the hydraulic components Pos Description 1 Diesel engine 3 radiator unlock control 17 23 24 Deutzengine expansion tank 25 Ca 26 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 7 Repair Procedures eas Repair Procedures 7 1 TIME SCHEDULE
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16. 04 yn 5904 910 4 eie I 1 1 T suonisod skem p 10199 95 Buueejs O X 2 Buueejs l axe Je y I 1 j bd GOL Ps 10014 vii GTH 2506 3007 AGRI 625 730 2 1 08 eunsseud 1 April 2008 GTH 2506 AGRI 625 hydraulic schematic Buneiado jeped l pod 453 at 9 45 1eq 69 82 41 1 591 jInoJro S enssejd LS yams ainssaid G yesq 5 Document 57 0009 0419 Description April 2008 DESCRIPTION DESCRIPTION OF THE MACHINE OPERATION GTH 3007 AGR 730 The mechanical energy source of this machine is a 1 Deutz diesel engine model TD2011 LO4W Tier 3 which supplies a 68 kW at 2600 rev min 68 Hp with a max torque of 210 Nm 155 lb ft at 1700 rev min On the flywheel side of
17. PROTECT THE T gt Ge ENVIRONMEN The handling and disposing of used oils can be ruled by local or national regulations Address to authorised centres Document 57 0009 0419 Section 4 Maintenance Procedures April 2008 TABLE A A 11 CHECK THE GREASING OF THE BOOM SECTION PADS boom section is fitted with adjustable pads located on the four sides of the profile These pads are secured to both fixed and mobile part of every section At regular intervals check that the telescopes are well greased in correspondence of the sliding pads see the red strip in the image below If necessary scrape off the old grease and brush new grease We recommend using Grease INTERFLON FIN GREASE LS 2 Avoid mixing greases of different type or features and do not use greases of lower quality Before injecting grease into the greasers thoroughly clean them to avoid that mud dust or other matters can mix with the lubricant and reduce or annihilate the lubrication effect Remove any old grease with a degreaser from the telescopes before smearing them with new grease 12 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 4 Maintenance Procedures eae TABLE A A 12 GREASE THE FORKS Before use grease thoroughly clean the intervention zone to avoid that mud dust or other matters can mix with the lubricant and re
18. to the maximum height B e If the oil is below this level remove the pluh C and add new oil in the engine using a gradueted cup 8 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 4 Maintenance Procedures A 8 CLEAN THE AIR SUCTION FILTER Clean the engine air filter every 10 hours Stop the engine and engage the parking brake Unlock the clamps A and remove the cap B Extract the filtering cartridge C Clean the inside of the filter Dry clean the cartridge max pressure 6 bar Check for cracks in the filtering element Fit the cartridge correclty Refit cap B locking it with clamps A As soon as the warning lamp on the cab dashboard switches on replace the filtering elements C and D Stop the engine and engage the parking brake Unlock the clamps A and remove the cap B Extract the filtering cartridges C and D Check for cracks in the filtering element Fit the new cartridges C and D correclty Refit cap B locking it with clamps A Document 57 0009 0419 TABLE A Genie A TEREX COMPAT GTH 2506 3007 AGRI 625 730 9 Section 4 Maintenance Procedures April 2008 TABLE A A 9 CHECK AND CLEAN THE RADIATOR 4a DANGER When using a steam washer always wear protective clothes Hot steam may cause serious injury Stop the engine and engage the parking brake Open the panel of the radiator C C
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20. 1 strain cage e Thoroughly clean whole tightening system especially 2 washer 10 the ground and unpainted area A of rear axle 3 clamping screw M10x40 cl 10 9 2 ASSEMBLY a 5 gt Apply the strain cage B with its resinated side facing the axle and holding the cable s toward the machine Tighten the two screws C with a torque wrench at 70 Nm e the position of the screws with paint in order to wheelside make possible loosening visible to the eye machine sid output extensometer rope m SS l E pe RH A resin side view ground and unpainted area for strain cage support rear axle plane M 5 22 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 2 Technical Specification TECHNICAL SPECIFICATION 3B6 Displa 1 p y 2 WHITE VB 3 GREEN CUTOFF 4 5 YELLOW OUTRIGGERS 6 PINK SPARE 7 y v v vyv y w v v v 8 RED SPARE 4 15 18 19 20 21 22 23 16 9 10 17 111 13 4 5 12 6 5 Fay a SF d 2 E CONN DESCRIPTION CODE AMP CONNECTOR 23 C MV 770680 1 FEMALE DEUTSCH CO
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22. lt lt S 21 4 C Vv1 gt 3 Z A 21 BETE 23 ZN 21 HAN E 2 51 11 G L1 33 L z a ge aa Te 8 Te Te 50 15 42 we 11 F20 gt F18 10A 21 10 at 03 04 05 06 AA 415 j 415 21 23 15 Z 21 F8 2 23 wa RELAY CARD 1 6 n 10 x2 X2 B RIS 5 ES G ES ES 2 1 1 ls 10 12 5 12 A 1 3 n Y 5 5 1 X15 5 5 X103 X15 xt 5 5 8 n i ih z lt Es Ed ES L2 R6 e 2 gt E PREHEATING STARTER GLOW PLUGS 60A 40A RELAY s s RELAY K02 K01 E E z s z els ele p 835 86 ww R36 fes Bp E 5 YB BIA m Q8 YR X34 X12A XGA g ig 27 Fd lt 2 31 21 Ng S lt S PRO a lt Ms SF xe A S Se Ss eos Ss Sue ak er S SS e NU S e 4 gy Ke gt SS lt lt S o s 55 e gt amp S lt V Document 57 0009 0419 enie A TEREX COMPANY GTH 2506 3007 AGRI 625 730 Section 6 Schemes April 2008
23. Front aiterenial goarwihreaucion gear 1 70 44 Frentwneetreauctongears Rear wheel Products Engine oil SHELL RIMULA SAE 15W 40 API CH 4 CG 4 CF 4 CF ACEA E3 MB 228 3 Power divider Differential gears Reduction gears TRACTORENAULT THFI 208 LF SAE 80W API GL 4 FORD M2C 86B Massey Ferguson M1135 Hydraulic system and brakes SHELL TELLUS T 46 DENISON HF 1 DIN 51524 part 2 e 3 4 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 2 Technical Specification TECHNICAL SPECIFICATION 2 14 TIGHTENING TORQUES Thread Pitch Wrench measure Tightening torques diameter mm Material class wr gt gt S P s Crs 88 10 9 429 UNI UNI UNI Normali Zincate Normali Zincate Normali Zincate mm mm 5931 32 5933236 5923 30 Nm Nm Nm Nm Nm Nm 4 0 7 7 3 2 5 2 3 2 2 8 4 4 3 9 5 3 4 8 5 0 8 8 4 3 2 5 6 1 5 5 8 7 7 8 10 3 9 3 6 1 10 5 4 3 10 6 9 5 14 8 13 3 17 8 16 0 8 1 25 13 6 5 4 25 1 22 5 35 4 31 8 42 5 30 2 1 13 6 5 4 26 5 23 8 37 3 33 5 44 7 40 3 10 1 5 17 8 6 5 51 1 46 0 71 9 64 7 86 3 77 6 1 25 17 8 6 5 53 4 48 1 75 1 67 5 90 2 81 1 12 1 75 19 10 8 6 86 5 77 8 121 4 109 2 145 9 131 3 1 25 19 10 8 6 92 4 83 2 129 5 116 6 156 1 140 5 14 2 22 12 10 6 137 7 123 9 193 8 174 4 232 6 209 3 1
24. Ki 16 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 4 Maintenance Procedures Check that air flows out of valve B As soon as oil without air bubbles starts flowing out of this valve close the same e Checkthatthe fluid in tank E reaches the recommended level Close the tap of the compressor Disconnect the hose from mini socket TP5 e Test the efficiency of the braking system In order to bleed the service brake circuit WITHOUT A COMPRESSOR for this operation two service technicians are needed one in the driving place and the other near the drain valve B 1 Fill tank D with oil 2 With the machine stopped step down on the brake pedal 5 6 times 3 Hold the pedal pressed down and slowly unscrew valve B Close the valve as soon as oil mixed with air starts flowing out 4 Ease up the brake pedal 5 Repeat steps 2 3 and 4 until oil without air bubbles starts flowing out of the valve 6 Testthe efficiency of the braking system Oil level Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 TABLE A TO BLEED THE CIRCUIT OF THE PARKING BRAKE DO THE FOLLOWING e Start the diesel engine Press pushbutton C to unlock the parking brake Slowly unscrew valve A and close the same as soon as oil mixed with air starts flowing out Repeat until oil without air bubbles starts flowing out of the valve Test the efficiency of the
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27. I eni a 7 7 A 2 amp lt E amp al S amp 5 e eo lt amp Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 31 12 April 2008 Section 6 Schemes eee 6 4 1 1 General wiring diagram GTH 2506 AGRI 625 PART LEGEND SCHEMES Item Description Sh Description Air filter clogged switch 13 Power air condition compressor plug Seat switch Engine oil pressure transducer Tecnord line plug Steering unit plug Optional Back Up horn Transmission reverse mode solenoid valve Fuel level gauge 1 Hydraulic oil temperature switch 5 43 2 Parking brake low pressure switch 2 Transmission forward mode solenoid valve Engine stop solenoid Rear wheels aligned sensor Auxiliary hydraulic circuit solenoid valve Load cell Hydraulic oil temperature switch Parking brake solenoid valve Four wheels steering solenoid valve Hydraulic oil filter clogged switch Crub steering solenoid valve Buzzer Air conditioning pressure switch 24 Air conditioning temperature control thermostat 24 Plug in Connector 11 way Relay card Plug in Connector Seat switch Plug in Connector Coolant thermistor Coolant thermistor Plug in Connector 3 way Air conditionig motor Air conditioning compressor pressure switch Air conditionig te
28. inflation 0 8 Cartridge of the engine air filter B4 Tightening of the wheel D 9 Air filter in the cab nuts 0 10 Engine oil and filter and fuel B 5 Tightening of the cardan shaft filter Screws Genie Every 1000 working hours Safety element of engine air filter E 2 Oil of the differential casing and the power divider Olilinthefourwheelreduction gears E 4 Change the hydraulic oil GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 3 Maintenance Inspections M MAINTENANCE INSPECTIONS Model Every 2000 working hours F 1 Change the engine coolant Serial number Date YN R LL At6000 working hours Hour meter 6 1 Checking the state of the structure Machine owner Inspected by Inspector signature Inspector title Inspector company Instructions Make copies of this page to use for each inspection Selectthe appropriate checklist s forthe type of inspection to be performed Every 10 hours A Every 50 hours A B Every 250 hours A B C Every 500 hours A B C D Every 1000 hours A B C D E Every 2000 hours At 6000 hours G Place a check in the appropriate box after each inspection procedure is completed Use the maintenance tables in this section and the step by step procedures in section 4 to learn how to perform thes
29. 36 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 2 Technical Specification eee TECHNICAL SPECIFICATION DLE MONITORING WITH 3B6 WINSCOPE PARAMETERS Displaying the parameters 386 WinScope v1 10 19 File Parametri Stato Window Ukils P Parametri Unit 14 iul x 00 Cicella uoto 10 Celle MaxDelta 01 CicellaCarico 11 5panFarche 02 ClcellaMin 12 SpanNavicella 03 ClcellaMax 13 DeltaSpanGomme 04 C2cellaVuoto 14 5 05 C2cellaCarico 15 OffSet1 06 C2cellaMin 16 palsteresiS blocco 07 C2cellaMax 17 paHitardoS blocco 08 Filter 09 paCellaUnica Or E A ea V Re dc tris IE te Mk oo Te lt 15 53 Connection OK Simulation of the variables load calculated in relation to the calibration value of the analog signal read and converted into bits 386 WinScope v1 10 19 File Parametri Stato Window Utils Help E 00 msgAlarm 0 10 Clswl 01 742 11 Clade 02 AUadc 719 12 ClactMom C 03 Aladc 639 13 CladcFiliro 718 04 CurM odo 0 14 C2swl 185 05 PCorder E 0 15 C2ade 639 06 Cicur ccCeVuoto gt 755 16 185 07 391 17 C2adcFiltro 638 5 0 18 CurSwl 10 344 19 100 TU MN NUN gt gt 1557 Connection 2 Genie Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 37
30. Clean the filter cartridge and replace in case of da mage Paper filters must never be cleaned using compressed air or washed with water and or solvents Genie Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 43 Section 4 Maintenance Procedures April 2008 TABLE D D 10 CHANGE ENGINE OIL OIL FILTER AND FUEL FILTER EVERY 500 HOURS OR EVERY YEAR WHICHEVER OCCURS FIRST Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin Drain the crankcase while the oil is warm This allows waste particles that are suspended in the oil to drain As the oil cools the waste particles will settle to the bottom of the crankcase and cannot be drained through hole A Park the machine on a level surface Unscrew plug B engine filling plug Place a collecting tray under plug A and with an appropriate wrench unscrew this plug and allow the oil to drain into the tray If the engine has two drain plugs allow the oil to drain off from both Once oil has been drained clean plug A with care and refit it If necessary replace the plug gasket Unscrew filter C with an appropriate tool Remove it from its seat Check the filter surface and the filter housing base are clean Apply a thin film of clean engine oil to the seal of the filter Install the filter by hand Remove dipstick D engine level check F
31. By stepping down on the pedal the machine does not brake Brake pump damaged Front axle brakes defective Check the pump operation and bleed the system if necessary Check the operation of the brake disks of the front axle When the engine is stopped the lifting cylinder does not support the boom Block valves damaged or dirty Cylinder seal defective Check the efficiency of the valves replace if necessary Replace the seal When the engine is stopped the cylinder does not support the forks Block valves damaged or dirty Cylinder seal defective Check the efficiency of the valves replace if necessary Replace the seal When the engine is stopped and the boom is high the extension cylinder moves in Block valves damaged or dirty Cylinder seal defective Check the efficiency of the valves replace if necessary Replace the seal When the load is lifted the fork cannot be levelled Seals of the levelling cylinder worn out Shockproof valves of the main valve dirty or maladjusted One way valves of the levelling cylinder dirty or damaged Dismantle the cylinder and replace the seals Remove the valves dry clean or replace if damaged and recalibrate Remove the valves dry clean or replace if damaged and replace in their seats GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 5 Problems Causes Solutions Dp a CUERO 25
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33. 18 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 7 Repair Procedures TABLE 005 Procedure Disassembling the hydraulic motor table 005 GTH 2506 3007 AGRI 625 730 Bridge crane or swing hoist payload Standard tools 500 kg Operation PROTECT THE Before disconnecting the hydraulic piping place containers of suitable size underneath to prevent oil spillage Carefully clean the area around the piping to be disconnected plug all disconnected parts with connectors clothes or adhesive tape to prevent dustor impurities fromentering the circuit They can cause serious damage 1 Remove the central covers of the machine by driving out all the bolts with two 13mm wrenches N Using a 36mm wrench and a 17mm wrench disconnect the hydraulic hoses Disconnect the two delivery hoses with a 19 mm wrench Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 19 Section 7 Repair Procedures April 2008 TABLE 005 Procedure Disassembling the hydraulic motor 4 Remove the four locking screws of the motor with a 24mm wrench E 5 Pull out the motor from the power divider fitted to the front axle 6 Protect the engine compartment to prevent the entrance of impurities Genie 20 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 7 Repair Procedures TABLE 006 Procedure Cylinder disas
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35. Clean the filter bowl Mount the new safety element and make sure it is correctly positioned Tighten wingnut Refit the outer element C Close cover B and lock in place with fasteners A AWARNING The inner element should be replaced every second time the outer element is replaced Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 45 Section 4 Maintenance Procedures April 2008 TABLE E E 2 CHANGE THE OILIN POWER DIVIDER AND DIFFERENTIAL GEARS To change the oil level in the power divider Stop the machine on a level ground and engage the parking brake PROTECT THE ENVIRONMEN 2 Place a container of suitable size under the plug Remove the level plug A and the filler Remove the drain plug B and allow oil to flow out from the power divider Refit and tighten the drain plug B Add new oil through the filler until it is level with hole A Refit and tighten filler level plug Recommended oil FUCHS TITAN GEAR LS 85 W 90 API GL 5 LS GL 5 46 GTH 2506 3007 AGRI 625 730 To change the oil level in the front and rear differential gears Stop the machine on a level ground and engage the parking brake ae Ge ENVIRONMEN Place a container of suitable size under the plug PROTECT THE Loosen the drain plug B and the level plug A and allow oil to flow out from the differential gears Refit and tig
36. PROBLEMS CAUSES SOLUTIONS Problems Causes Solutions When the max load is applied forks move down Seals rod and liner of the fork tilting cylinder worn out Leakage in the cylinder block valve Dismantle the cylinder and check and replace any defective parts Check the leakage remove the valve and rectify or replace The fork tilting is not efficient The seals of the fork levelling cylinder are damaged Leakage in the cylinder block valve Line from main valve to block valve defective Safety valves of the main valve maladjusted or damaged Fit a new kit of seals and check the tightness of the cylinder Check the valve operation if necessary clean or change the valve Checkthe hydraulic line carefully and replace any defective pipelines Check the efficiency of the safety valve fitted to the ports of the main valve If necessary proceed with the calibration or replacement The boom extension is not efficient The seals of the internal boom extension cylinder are damaged Cylinder rod damaged Leakage in the cylinder block valve Hydraulic line defective Main valve damaged Fit a new kit of seals and check the tightness of the cylinder Check the rod condition Checkthe valve operation if neces sary clean or replace the valve Checkthe hydraulic line carefully and replace any defective pipelines Check the efficiency of the main valve and replace if necessar
37. Rise with caution by tilting the cooler forward to prevent damage to the fixed fan of the engine 24 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 7 Repair Procedures Procedure Main valve disassembly table 008 GTH 2506 3007 AGRI 625 730 P Standard tools PROTECT THE Before disconnecting the hydraulic piping place containers of suitable size underneath to prevent oil spillage Carefully clean the area around the piping to be disconnected plug all disconnected parts with connectors clothes or adhesive tape to prevent dust or impurities from entering the circuit They can cause serious damage 4a DANGER Before disconnecting the hydraulic piping ensure the line is notunder pressure Release the pressure if necessary by operating the control levers with the engine stopped In any case disconnect the hydraulic piping with extreme caution and always wear suitable 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 possible Genie TABLE 008 Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 25 Section 7 Repair Procedures April 2008 TABLE 008 Procedure Main valve disassembly Before disconnecting any flexible hoses label t
38. SERIAL NUMBER ENGINE TYPE YEAR OF MANUFACTURER Document 57 0009 0419 April 2008 Description DESCRIPTION OF THE MACHINE OPERATION GTH 2506 AGR 625 The mechanical energy source of this machine is a 1 Deutz diesel engine model D2011 104 Tier 3 which supplies a 50 kW at 2600 rev min 68 Hp with a max torque of 210 Nm 155 lb ft at 1700 rev min On the flywheel side of the engine and connected to the same by Technodrive coupler complete with elastic joint and with 1 to 1 ratio there is Bosch Rexroth closedloop pump for hydrostatic drives model A4VG56 2 with adjustment valve of DA type The max displacement of this swashplate pump is 56 cm3 rev and the max calibration pressure is 430 bar 6235 psi This pump is usedto supply hydraulic power underform of pressure and flow rate which is then used for moving the machine On the through shaft of such drive pump there is a Casappa open loop gear pump with fixed displacement 3 with priority valve integrated in the housing The displacement of this pump is 27 cm rev Its function is to provide hydraulic power under form of pressure and flow rate to the steering circuit of the machine primary branch of the priority valve and to the circuit for the telescopic boom movements secondary branch of the priority valve The assembly of the two pumps involves they have a rotation velocity equal to the speed of the diesel engine The
39. spaying ape see WCE E g rj gn guts 3 spaus ino4 pis E 18 7 Cm b 1 BUMPS qe on DT CE 10 7 SIND 5 155 e SA SIA eee jueuuBmje sjaaym 100 1 I Hm PNA 1908 05 qe 110 si LAW 5 gt ESSE RUN Ud jun NI E SN 5 prouajos 5 sjaaym snoy 100 Q A 18 A 18 N pg WH RH ao a ai al yd ol ly ya i at ea aac a PTS 4 4 AES E E 11414 A A enie G GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 Section 6 Schemes April 2008 SCHEMES 1 e 3 4 5 ROAD LIGHTS SELECTOR LEVER WINDSCREEN WINDSCREEN ROAD LIGHTS SWITCH STOP LIGHT WIPER MOTOR WASHER PUMP PRESSURE SWITCH 25 o si in m 518 uio 52 V EN lt 1 M22 x182 XS X57 1 x51 S57 amp
40. Max eingine speed ATTACHMENT DUMPING GTH 2506 AGRI 625 Time s roll back dump Max engine speed GTH 3007 AGRI 730 Time s roll back dump Max engine speed Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 17 Section 2 Technical Specification April 2008 TECHNICAL SPECIFICATION 2 23 HYDRAULIC SETTINGS 1 PRELIMINARY OPERATIONS Check that the engine idle is set at 950 rpm and that the engine maximum speed is set at 2600 rpm Warm up the hydraulic oil to 60 C by keeping one of the elements of the boom main valve to full stroke under pressure To reach this temperature in a faster way cover the oil core of the radiator with a carton in the case of a wateroil combined cooler or the oil radiator if the machine is equipped with a separate oil radiator 2 CALIBRATING THE BOOM MAIN VALVE In front of machine find the mini socket TP1 see image 1 on the internal left side of the chassis and fit a 0 400 bar manometer IMAGE 1 2 2 1 CALIBRATING THE MAIN VALVE PRESSURE CONTROL VALVE Remove the central protective cover of the machine and using a 13 mm spanner unscrew the locknut of the pressure relief valve A of the main valve see image 2 Using joystick with the engine running at max speed lift completely the boom and set the valve A to 280 bar To check the safety
41. Section 2 Technical Specification April 2008 TECHNICAL SPECIFICATION LIST OF THE DLE PARAMETERS Value saved in analog channel 1 calibration with unloaded machine best setting around 700 Value saved in analog channel 1 calibration with loaded machine best setting around 300 2 C1cellaMin Min admissible value for analog channel 1 reading if actual value is E below alarm 2 value set at 10 roughly 3 Max admissible value for analog channel 1 reading if actual value is above alarm 2 value set at 1010 4 C2cellaVuoto Value save in analog channel 2 calibration with unloaded machine setting around 700 C2cellaMin Min admissible value for analog channel 2 reading if actual value is above alarm 3 value set at about10 C2cellaMax Max admissible value for analog channel 2 reading if actual value is above alarm 3 value set at about 1010 Number of filter samples with mobile mean Load cell reading Max 5 paCellaUnica Sets to 1 automatically during the machine selection when the DLE is used in single channel mode Celle_MaxDelta Max admissible delta between readings of analog channels 1 and 2 expressed as a default 10 current 20 1 SpanForche Limiter intervention percentage in case of work with stabilised machine and forks Default 100 as per calibration 12 SpanNavicella Limiter intervention percentage in case of work with stabilised machine and platform changed by the
42. T URL ft GTH 3007 AGRI 730 850 acs 5 Heswsrsemgwer 5 mesbwa 7 7 E mea 80 om o 478 7 1 K erous aerenca rema steering em Ememaseengrdus _________ o TEREX COMPANY Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 1 Section 2 Technical Specification April 2008 TECHNICAL SPECIFICATION 2 2 TYRES SSS ef ee Wheel disk 8 holes DIN 70631 8 holes DIN 70631 2 3 LIMIT OF USE Ta 05 jommeeage 2 4 WEIGHT Weight with forks 4450 5900 2 5 SPEED iY GrHcanor AGRETGO __ __ Towing capacity at dynamometer max oaa 4mo Towing at dynamometer win tors ka 300 5 wane ann 270 jewssewewg natal 2 6 PAYLOAD AND REACH Lifting height max 5790 6900 Forward reach max 3900 Reach at maximum height 605 Lifting capacity max 3000 Lift capacity at max height 2500 Lift capacity at max reach 1
43. G 1 4 M12x1 5 S 6 50 G1 400 190 G1 4 M14x1 5 S 8 50 M33x2 400 150 3 8 16 1 5 5 10 80 G 1 1 4 600 240 3 8 M18x1 5 S 12 80 M42x2 600 260 G 1 2 M22x1 5 S 16 105 G 1 1 2 800 300 G 3 4 M27x2 S 20 220 M48x2 800 350 G1 M33x2 S 25 370 G 1 1 4 M42x2 S 30 500 G 1 1 2 M48x2 S 38 600 A A Male face Mechanical seal or copper washer B Male face Soft seal with O ring Genie Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 9 Section 2 Technical Specification TECHNICAL SPECIFICATION 2 17 LOCKING MATERIAL April 2008 THREAD LOCKERS Product APPLICATION Characteristics Locking Resistance Temp C Thread speed Loctite 290 Thread locking to 150 M 12 Rapid Medium Loctite 222 Thread locking to 150 M 20 Moderate Low Loctite 243 Thread locking to 150 M 20 Rapid Medium Loctite 262 Thread locking to 150 M 20 Moderate High Loctite 270 Thread locking to 150 M 20 Moderate Very high Loctite 277 Thread locking to 150 M 36 Slow High Loctite 272 Thread locking to 200 M 36 Slow High THREAD SEALANT For hermetic sealing Not suitable for thermoplastic materials Product APPLICATION Characteristics Locking Disassembly max Thread speed difficulty max type Loctite 511 Fitting sealant 150 M80 Con Cyl Rapid Low Loctite 542 Fitting sealant 150 M36 Con Cyl Rapid Moderate Loctite 545 Fitting sealant 150
44. GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 2 Technical Specification ER TECHNICAL SPECIFICATION o Cod Description 07 0728 0007 07 0709 0417 07 0701 0200 07 4529 0012 07 4529 0027 teerin electrovalve solenol Axals cylinders seals kit Transmission pump seals kit Service pump seals kit Break pump seals kit 635965 Fork movement cylinder seals kit 07 4529 0091 Lift cylinder seals kit 639993 Extension cylinder seals kit 07 0705 0085 Fork movement cylinder valve seals kit 639992 Fork balance cylinder seals kit 07 0700 0028 07 0738 0002 07 0701 0007 07 0701 0209 56 0016 0090 56 0016 0089 07 0741 0010 07 0741 0011 04 4239 0004 Hydraulic oil return filter restriction indicator Cardan spider Transmission pump electrovalve coil Transmission pump electrovalve Speed switch Diesel engine ignition switch White cap Push button cap Fork balance cylinder valve 07 0703 0080 5A Fuse 07 0703 0148 10A Fuse 634973 15A Fuse 07 0703 0071 25A Fuse 56 0005 0001 50A Big fuse 56 0005 0000 40A Big fuse 56 0021 0104 56 0013 0001 07 0723 0042 09 0803 0513 09 0803 0514 07 4645 0032 09 4670 0003 07 0723 0446 07 0723 0037 56 0017 0044 56 0017 0048 56 0017 0037 56 0017 0035 56 0017 0049 56 0017 0046 56 0012 0053 56 0017 0054 56 0017 0055 56 0017 0047 56 0017 0051 56 0017 0052 54 0702 0013 54 0702 0000 54 0702 0001 Fuses and relays label Fuel livel indicator Mirror
45. Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the appropriate Operator s Manual on your machine will result in death or serious injury Many of the hazards identified in the Operator s Manual are also safety hazards when maintenace and repair procedures are performed Do Not Perform Maintenace Unless You are trained and qualified to perform maintenace on this machine You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulations You have the appropriate tools lifting equipment and a suitable workshop GTH 2506 3007 AGRI 625 730 xi Section 1 Safety Rules April 2008 SAFETY RULES 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 b
46. carefully clean the area all around Blow some compressed air to remove any impurity For an easier renewal of the hoses whose run is not clearly visible proceed as follows remove the brackets A which secure the hoses to the second boom telescope disconnect the hose to be replaced from both sides attach a cord to the side of the hose which reaches the boom tip B disconnect the hose from the rear side of the boom C remove the hose pulling the cord until it comes out completely D disconnect the cord and reconnect the same to the end of the new flexible hose making sure the hose has been previously plugged to prevent dirt from entering the circuit proceed in reverse order and re assemble the hose GTH 2506 3007 AGRI 625 730 31 Section 7 Repair Procedures April 2008 TABLE 010 Procedure Renewing the flexible hoses inside the boom AGRI 625 730 32 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 7 Repair procedures SS SSS TABLE 010 Procedure Renewing the flexible hoses inside the boom Consigli peril montaggio di tubi flessibili TEREX COMPANY Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 33 Section 7 Repair Procedures April 2008 TABLE 010 Procedure Renewing the flexible hoses inside the boom AGRI 625 730 Intentionally blank page 34 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 7 R
47. of the congruence with the current state of the limiter The alarm triggers even in the absence of malfunctions if the load limiter cutout key is used Action The relay or the cable can be shorted check Alarm code Description Action The limiter s outputs do not deactivate Switch off and on the machine and run a complete test of the outputs If the alarm persists replace the DLE 5 8 Block Relay check error at start When the instrument is started the re reading of the block output is always OFF except when the two outputs of the DLE are connected in series 5 DLE output OV or low voltage 12V re reading 8 DLE output 12V ow voltage or OV re reading The alarm triggers even in the absence of malfunctions if the load limiter cutout key is used when the instrument is started The relay or the cable can be shorted check The limiter s outputs do not deactivate Switch off and on the machine and run a complete test of the outputs If the alarm persists replace the DLE Alarm code Description Action A RAM data error Checks that the parameters load in the RAM at start up remain unaltered Switch off and on the limiter Alarm code Description Action B Outrigger congruence Check that the signal of stabilised machine is congruent between the two inputs used for reading during operation Display until the system is turned off Operations check wiring power cable DLE connector If the alarm
48. with two 17 mm wrenches 10 Knock out and extract the pin using a plug of soft material aluminium copper wood etc 11 Secure the cylinder to the bridge crane with a textile bridle then slightly raise the boom to set the cylinder free 12 Remove the cylinder using the bridge crane 36 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419
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50. 11 Adjust the play of the sliding pads of the boom sections C 12 Grease the sliding parts of the boom sections C 13 Check the level of the battery electrolyte C 14 Check the efficiency of the block valves xviii 20 21 21 21 22 23 24 25 25 26 27 27 28 28 29 29 30 31 Genie GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 TABLE OF CONTENTS 4 6 Table D procedures 37 D 1 Visually check the smoke quantity evacuated from the engine exhaust 37 D 2 Check the tightening of the engine fixing screws 37 D 3 Check the tightening of the cab fixing screws 38 D 4 Check the backlash between pins and bushings in all joints 38 D 5 Change the hydraulic oil filter 39 D 6 Change the hydraulic oil filter in the tank 40 D 7 Have the hydraulic system checked by a skilled technician 41 D 8 Change the main cartridge of the engine air filter 42 D 9 Clean the cab air filter 43 D 10 Change engine oil oil filter and fuel filter 44 4 7 Table E procedures 45 E 1 Change the safety element of engine air filter 45 E 2 Change the oil in power divider and differential gears 46 E 3 Change the oil in the four wheel reduction gears 47 E 4 Change the hydraulic oil 48 4 8 Table F procedures 49 F 1 Change the engine coolant 49 4 9 Table G procedures 50 G 1 The machine structure 50 Section5 Rev Problems Causes Solutions 4 5 1 Introduction 1 5 2 About this section 2 5 3 Problems Causes Solutions 3 5 3 1 Hydraulic faults 3 5 3
51. 2008 SCHEMES CONTACTS Thermal m d Normally open NO _ Normally closed NC D NO limit switch lt r NC limit switch Contactor Da Magneto thermal closure a Magneto thermal opening 7 Thermal closure N Thermal opening Exchange gt NC proximity gt NO proximity d NO mechanical p NC mechanical Selector by Selector2 6 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 6 Schemes SCHEMES 6 4 ELECTRICAL SCHEMES 6 4 1 GTH 2506 AGRI 625 1 2 3 4 9 MAIN GAUGES CLUSTER ENGINE IGNITION KEY Oh 21 EMERGENCY STOP as 5 zs e F102 20A AA A 2 S24 _ 2 al aA 5 1 7 8 5 6 16 1 21 25 28 TN Lokal 1215 8 1722775 17420 221 2627 29 m d al af sh af bs bdo bebo bos osos 29 Se gt SF SS 52 2
52. 25 Al SEE S 2 2 5 2 2 pall 3 SES lt A lt gt lt 5 bs 5 6 3 2 15 17 120 18 16 0 xn Xn xn XB KONO X21 5 XS xs X 4 4 5 4 2 55155 5 lt 5 25 21 33 5 21 23 __ i ps E To To T Le F19 F6 FT FIT F16 10A 5 5 10A 10A 4 l s xl 15 15 15 amr 30 F3 F2 5 i t 13 RELAYS CARD E ida bis di 1 5 5 81 T 15 P MV T 15 HIS 15 cu 2 5 z 5 5 E gt 5 gt in Malin an ind in Ms Uh 2 E zx 2 2 2 5 5 5 5 5 ET 5 z x 5 1 2 44575 1 2 3 qe N 123456 1 2 7516 1 1 E x56 xs xs X dd ud cast aa X5s fa al fal al a 1 IDs x 1 m 1 8 5 B55 Saas Lo 8 E L J B39 E54 E53 M E7 M 62 35 31 Eu x 71 a xe ae 3 51 A m SS SS 9 Y VS eg VS eo 9 ov e S ex lt lt lt lt amp p lt lt S _________________ __ _ 10 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 6 Schemes
53. AGRI 625 730 e After work never leave the machine under potentially dangerous conditions PROTECT THE ENVIRONMENT Treatment and disposal of used oils is subject to federal national and local laws and regulations Collect and deliver these wastes to authorised centres e 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 Document 57 0009 0419 April 2008 REEL Table of Contents Rev Introduction iii Important iii Machine Identification iv Description v Description of the machine operation V Section 1 Rev Safety Rules xi 1 1 Safety rules xii 1 1 1 Personal safety xii 1 1 2 Workplace safety xiii 1 2 General remarks xiv 1 8 Servicemen s requisites xiv 1 3 1 Personal protective equipment XV 1 4 General safety precautions 1 4 1 Working area XV 1 4 2 Precautions during work XV Section2 Rev Technical Specifications 1 2 1 Main dimensions 1 2 2 Tyres 2 2 3 Limit of use 2 2 4 Weight 2 2 5 Speed 2 2 6 Payload and reach 2 2 7 Forks floating type 3 2 8 Diesel engine 3 2 9 Hydraulic system 3 2 10 Electrical system 3 2 11 Machine sound levels 4 2 12 Vibration levels 4 2 13 Refuelling 4 2 14 Tightening torques 5 2 15 Drill diameters for threads 7 2 16 Standard tightening torques for fitting seals 8 2 17 Locking material 10 2 18 Hoisting instruc
54. Broken or damaged wiring Negative brake pressure switch Check the efficiency or replace Check the efficiency or replace Check the efficiency or replace Reconnect or replace the wiring Check the efficiency or replace No steer selection F5 fuse blown Steer selector damaged Coils of the steer selection solenoid valve damaged Broken or damaged wiring Change the fuse Check the efficiency or replace the selector if necessary Check the coils replace if necessary Reconnect or replace the wiring Hydraulic oil thermometer defective Indicator damaged Temperature sensor defective Broken or damaged wiring Change the part Check or replace the sensor Reconnect or replace the wiring The parking brake lamp does not come on Dashboard instrument damaged Broken or damaged wiring Change Reconnect or replace the wiring The fuel gauge does not work Dashboard instrument damaged Fuel sensor defective Broken or damaged wiring Change Check and replace the sensor if necessary Reconnect or replace the wiring Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 Section 5 Problems Causes Solutions PROBLEMS CAUSES SOLUTIONS April 2008 Problems Causes Solutions The engine coolant thermometer Indicator defective does not work emperature sensor defective Broken or damaged wiring Change the part Check and replace the sensor if nec
55. FUSE Rear wheels aligned sensor Plug in Connector Auxiliary hydraulic circuit solenoid valve Plug in Connector Back up horn 10A FUSE Flashing beacon light Plug in Connector 5 way In Out relay card ht 4 5 10A FUSE Road light 10A FUSE Emergency stop 1 Plug in Connector Trasmission reverse mode solenoid valve Plug in Connector Windscreen rear cabin 10A FUSE Windscreen washer motor Plug in Connector Fuel level gauge 10A FUSE ECO Multipurpose Instruments 20A FUSE Fan Plug in Connector Fuel level Plug in Connector Rear right road light 60A FUSE Maxi fuse electric system power Plug in Connector Rear wheels aligned sensor Plug in Connector Load cell Plug in Connector Parking brake solenoid valve Plug in Connector 21 way In Out relay card Relay hig beam Plug in Connector Four wheels steering solenoid valve Plug in Connector Crab steering solenoid valve Plug in Connector Front right road light Plug in Connector Front left road light Relay securuty low pressure switch parking brake Plug in Connector Road light switch Relay trasmission reverse mode Relay trasmission forward mode Plug in Connector Forward reverse switch Plug in Connector Emergency switch Relay starter enabling switch Plug in Connector 12 way In Out relay card Timer 2 Preheating glow plugs 4 3 1 Relay start engine 1 in Conne
56. GTH 2506 3007 AGRI 625 730 m Section 4 Maintenance Procedures April 2008 TABLE A A 15 CHECK THE EFFICIENCY OF BRAKING SYSTEM AND PARKING BRAKE For any intervention on the braking system adjustment and or substitution of the brake discs address to the GENIE Technical Service Centre or the nearest GENIE authorised workshop The malfunctioning of the braking system may depend on the presence of air in the hydraulic circuit The braking system is equipped with two purge valves A and B to eliminate any air from the circuit The first valve is used to purge the service brake circuit B the second valve is used to purge the negative parking brake circuit A Both valves can be easily reached through the slot located on the front part of the chassis TO BLEED THE CIRCUIT OF THE SERVICE BRAKE DO THE FOLLOWING Make sure that compressor F contains a sufficient quantity of oil so you can proceed with the circuit bleeding Connect the flexible hose of the compressor to the mini socket TP5 placed in the frontal part of machine the mini sockets come out from a gap in the central carter Connect the compressor to an air source and pressurise the system e Unscrew valve B to help air flow out of the braking circuit Open the cap of the feeding tank D CUP 90 Open the tap of the compressor F which has been previously connected to mini socket TP5
57. Job Operators Expected needed time h 1 30 1 00 1 00 1 00 1 00 1 00 1 00 2 30 change the ignition key change the speed switch change the light and horn switch change the joystick change the fork locking releasing pushbutton change the fork locking releasing red pushbuttons change the brake pump change the boom lifting cylinder change the boom lifting cylinder kit complete overhaul 1 30 change the block valve of the boom lifting cylinder 0 30 change the cylinder inside the boom 2 30 change the extension cylinder kit inside the boom 1 30 change the block valve of the extension cylinder inside the boom change the fork pitching cylinder change the fork pitching cylinder kit change the valve of the fork pitching cylinder change the attachment locking cylinder change the attachment locking cylinder kit change the block valve of the attachment locking cylinder change the fork compensation cylinder change the fork compensation cylinder kit change the valve of the fork compensation cylinder check the one way valves of the fork compensation cylinder 1 00 change the boom internal line for the boom extension 1 00 change the boom internal line for the fork pitching 2 00 change the boom internal line for the fork locking 2 00 change the boom slide pads 2 30 check the transmission pump pressures 0 30 each check the pressure of the main actuator operating the boom movements 0 30 each check the pressure of brake pump
58. MAINTENANCE INSPECTIONS 3 4 MAINTENANCE INSPECTION REPORT Model Serial number Date Hour meter Machine owner Inspected by Inspector signature Inspector title Inspector company Instructions Make copies of this page to use for each inspection Selectthe appropriate checklist s for the type of inspection to be performed Every 10 hours A Every 50 hours A B Every 250 hours A B C Every 500 hours A B C D Every 1000 hours A B C D E Every 2000 hours A B C D E F At 6000 hours G Place a check in the appropriate box after each inspection procedure is completed Use the maintenance tables in this section and the step by step procedures in section 4 to learn how to perform these inspection f any inspection receives an tag and remove the machine from service repair and re inspect it After repair place a check in the box Legend Y yes acceptable N no remove from service R repaired Table A Within me first f 0 Working hours Every 250 working hours iol x C 1 Engine oil and relevant filter ide 02 Oil level in the differentia gears and reducer SS eS 6 3 Oil level in the four reduction T gears 4 Check the couplings for oil leaks C4 Cartridge of he engine a
59. amp SE E SS Sj SU lt 5 lt NS lt SS lt S enie 8 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 Section 6 Schemes April 2008 SCHEMES CONTINUOUS FLOW ENABLING SWITCH PARKING BRAKE SWITCH STEERING MODES SELECTOR ROAD JOBSITE MODES SWITCH OPERATOR ON SEAT SWITCH CONTROL CIRCUIT INTERFACE CONNECTOR BOOM FUNCTIONS STEERING MODES UNIT hh 3 N A 2 A 07 e 8 g va lt or ESSA mn Ig p Ig 1 F 7 S8 amp Im gt gt o mE 12 4 IH 4 1a A m a La 4E IN IM vem 23 p 10 V 53 ry e S NUS 1 gt T gt 11 95 5 ro g eed ZD 4225 punous 5 Ayddng yeubis yessanay Mon ga SNOIASIg peojJaAQ l 4 E L ddns samog puouray lt lt g STAY 8 punog 5 12 4 ES PS ON D xir
60. and the parking brake unlock circuit Description The hydraulic energy produced by the drive pump 2 is converted into mechanical power by a closed loop hydrostatic motor model Bosch Rexroth A6VM107 5 equipped with adjustment valve of DA1 type and with flush valve 36 for reducing the max temperatures inside the drive circuit The max displacement of this bent axis motor is 107 cm rev The motor is directly flanged to the front steering axle 26 The mechanical torque produced by the drive motor is transmitted to the rear axle 27 through a Cardan shaft The hydraulic drive 12 of load sensing type with a displacement of 125 cm rev receives oil fromthe priority line of pump 3 in relation to the load sensing signal sent by the hydraulic drive and connected to such pump with function of pilot signal In this way the input flow to the hydraulic drive is exactly the one needed for the instantaneous steering functions any excess flow of the pump is available for operating the different movements of the telescopic boom The steering circuit is protected againstinput overpressures by a pressure reducing valve set at 170 bar 2465 psi On the two delivery lines to the steering cylinders there are other two pressure reducing valves with anti shock function set at 225 bar 3262 psi These two valves are intended to limit possible shocks on the steering wheel due to overstress caused by the wheels onthe steering cylinders These p
61. brake is engaged and plug A finds on the horizontal axis Cleanthe plug all around then remove it with a 12mm hex head wrench and check if oil is level with the hole f necessary add new oil through hole A until it is level Refit the plug PROTECT THE ENVIRONMEN Place a container of suitable size under the plug for oil leaks To check the oil level in the front and rear differential gears Stop the machine on a level ground and engage the parking brake Using a 10m hex head wrench unscrew plug A and check if oil is level with the hole f necessary add new oil through the hole of the level plug until it comes out Refit and tighten plug A PROTECT THE Ge ENVIRONMEN Place a container of suitable size under the plug for oil leaks To check the oil level in the power divider Stop the machine on a level ground and engage the parking brake Using a 10m hex head wrench unscrew plug A and check if oil is level with the hole f necessary add new oil through hole A until it is level Refit the plug PROTECT THE ENVIRONMEN Place a container of suitable size under the plug for oil leaks 26 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 n Section 4 Maintenance Procedures TABLE C C 3 CHECK THE OIL LEVEL IN THE FOUR C 4 CHECK AND CLEAN THE ENGI
62. braking system BE Once the circuit has been bled make sure the brake circuit is in efficient working order CHECKING THE BRAKE OIL LEVEL The oil within the braking circuit must be at about 2 cm from the tank plug E Section 4 Maintenance Procedures April 2008 TABLE A A 16 CHECK THE EFFICIENCY OF THE STEERING SELECTION SYSTEM During operation the alignment of the front and rear axles of the machine can be subject to variations This can depend on an oil blow by from the steering control circuit or on a steering of both axles when front and rear wheels are not perfectly aligned To fix this problem rather than checking the alignment visually follow the procedure below 1 Move to a solid and level ground 2 Set the steering selection switch A to four wheel steer pos 2 3 Rotate the steering up to its stop either to the right or to the left 4 Setthesteeringselection 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 Rotate the steering to the side opposite to point 3 So that the rear axle reaches its stop 8 Reset the steering selection switch to two wheel iil Q 2 steer pos O 9 Rotate the steering to the same side as in point 7 so that the front axle reaches its stop 10 R
63. its parts cool down e not leave the driving place when the machine is running e 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 e Donotcarry out maintenance or repair works without a sufficient lighting e When using the machine lights the beam should be oriented in order not to blind the personnel at work e Before applying voltage to electric cables com ponents ensure they are properly connected and efficient e Donotcarry out interventions on electric components with voltage over 48V e Do not connect wet plugs or sockets Section 1 Safety Rules April 2008 SAFETY RULES e 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 refit them before starting the engine and using the machine again e Aleays stop the engine and disconnect the batteries before maintenance or service e not lubricate clean or adjust moving parts e Do not carry out operations manually when specific tools are provided for this purpose e Absolutely avoid to use tools in bad conditions or in an improper way e Before carry
64. months check the machine randomly to be sure the machine chassis are tight the backlash between pins and relevant bushings on the For this operation use a torque wrench and tighten the joints is not too high screws to a torque of 188 Nm If you have to change some parts please refer to the spare parts catalogue enclosed with the technical literature of the machine 38 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 4 Maintenance Procedures D 5 CHANGE THE HYDRAULIC OIL FILTER To change the hydraulic oil filter element proceed as follows 1 Stop the machine on a level ground and engage the parking brake 2 Place a container of suitable size under the filter to collect any oil leaks 3 Remove the filter cover B per accedere alla cartuccia A 4 Change the filter element then before fitting a new one thoroughly clean and grease both seat and gasket 5 Refit and tighten the filter cover PROTECT THE oe Ge ENVIRONMEN Handling and disposing of used oils may be ruled by local or national regulations Address to authorised waste centres 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 Flow rate I 1 MPS 150 Filtering 10 u code 09 4604 0001 When changing the oil drain it when it is still hot and the polluting substanc
65. persists change the DLE digital input reading malfunction Alarm code Description Action A D C reading control error If the analog digital converter works fine after special rereading of the DLE board Switch off and on the limiter If the alarm continues replace DLE 30 Genie GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 2 Technical Specification TECHNICAL SPECIFICATION PC CONNECTION WINSCOPE Ns 4 If you want to check save the system parameters variables you have to open the relevant windows check the values contained in these Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 31 Section 2 Technical Specification April 2008 TECHNICAL SPECIFICATION SAVING OR UPLOADING SETTINGS WITH WINSCOPE When you launch the program the first time you have to configure some options to guarantee a correct dialogue with the hardware the machine in use Turn on the board to connect the PC and the unit aboard the machine From the Utils menu select Prj Selection Type in the correct path of file CFG IT or look for the same in the Windows folders suing the Browse function The file must not necessarily be in the path shown in the following example as it is at the user s discretion It contains the menus and the name of the parameters corresponding to the hardware and there
66. pump see sec 2 Check the operation and replace the valve if necessary Change the oil filter The boom does not move Low pressure Hydraulic pump damaged Load sensing valve damaged The valve of the main valve leaks Pilots main valve Set the max pressure of the main valve to 270 bar Replace the pump Check the efficiency of the valve replace if necessary Dismantle the valve check and eliminate any foreign matters Check the operating pilots Wrong wheel shafting Leakage in the steering cylinders Leakage in the steer selection solenoid valve Check and replace the seals if necessary Check the efficiency of the solenoid valve The steering wheel is hard low force in the cylinders Low pressure Priority valve damaged Check the pressure in case reset 170 bar Check the efficiency of the valve replace if necessary Low booster supply Pump damaged Motor damaged Change the pump Change the motor The machine drive is not enough Hydraulic oil filter restricted Low hydraulic oil level Clean the oil filter Replenish the tank up to the recommended level Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 Section 5 Problems Causes Solutions i PROBLEMS CAUSES SOLUTIONS April 2008 Problems Causes Solutions The oil in the tank is contaminated Drain the oil clean tank and pipes empty the pumps and add new oil
67. relevant procedure during calibration 1 7 10 1 C2cellaCarico Value save in analog channel 2 calibration with loaded machine best ER When the platform is selected the limiter uses this 96 default 11096 load increase of 1096 instead of the SpanForche datum current value 125 DeltaSpanGomme Limiter intervention percentage in case of work with non stabilised machine changed by the relevant procedure during calibration value that adds to the calibration with forks and outriggers SpanForche 14 OffSetO Command given to the digital potentiometer for cell 1 value from 0 to 255 to set the reading scale during calibration with unloaded machine to a certain pre set value about 900 bit ADC C1cellaVuoto about 700 15 OffSet1 Command given to the digital potentiometer for cell 2 value from 0 to 255 to set the reading scale during calibration with unloaded machine to a certain pre set value about 200 bit ADC C2cellaVuoto about 300 palsteresiSblocco Load for the reset of the movements once the block condition has been rectified default 5 95 paRitardoSblocco Value expressed in tenths of second corresponding to the time that must elapse between the block condition and the movement reset default 10 1 second 38 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 2 Technical Specification TECHNICAL SPECIFICATION 20 C1NavicellaVuot
68. t block any manoeuvres so the calibration can be done We recommend keeping the load of known weight in the range of action of the machine The calibration of the machine should be done after a few minutes of use in other words with the machine warm Enter the calibration mode Within 5 seconds from when the instrument is activated even if the display is still off you should press the keys on the front panel in the right sequence tasti da utilizzare ed il relativo significato riportato di seguito Press to enter number 0 Press to enter number 1 Press to confirm the sequence entered The access code currently used is 1001 Therefore you should enter the following sequence 0 1 CONFIRM If the sequence is correct the confirmation of the instrument functioning in the calibration mode is given by the LED near lighting with a fixed light The display shows a number that ISN T blinking starting from 0 TEREX TECHNICAL SPECIFICATION 4 cierre H 55 0016 0022 DESCRIPTION OF THE CONTROLS Calibration selection button Display Stability indicator with LED bar Green light power OK Yellow light calibration mode Calibration confirmation button Botton used during calibration only Buzzer ON OFF pushbutton Red light overload pre alarm alarm
69. the rear top pads for wear clean the sliding guides of the boom thoroughly and lubricate with the special INTERFLON FIN GREASE LS 2 grease When moving out the second telescope the boom tends to move right and left Sliding blocks worn out Check the play and replace any worn parts or place shims GTH 2506 3007 AGRI 625 730 When moving out the second Grease is insufficient or Check that the grease smeared telescope the boom tends to inadequate on the boom is INTERFLON FIN jump GREASE LS2 smear the boom again with grease Genie Document 57 0009 0419 April 2008 Section 5 Problems Causes Solutions PROBLEMS CAUSES SOLUTIONS Problems Causes Solutions Foreign matters on the sliding blocks and the relevant surfaces of the boom Check and eliminate any foreign matters Low traction Drive pump defective Check the pressure values of the drive pump and re calibrate if necessary If the overfeeding pressure drops down replace the pump and clean the pump motor couplings Genie Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 Section 5 Problems Causes Solutions gU es PROBLEMS CAUSES SOLUTIONS 5 3 2 Electrical faults April 2008 Problems Causes Solutions No power to dashboard Battery switch off Battery down 60A fuse blown Dashboard damaged Broken or damaged wiring Turn on the switch Check
70. the tension of the alternator belt B 3 Check the tyre inflation B 4 Check the tightening of the wheel nuts B 5 Check the tightening of the cardan shaft screws Every 250 working hours or monthly C 1 Change the engine oil and relevant filter after first 250 working hours C 2 Check the oil level in the front and rear differential gears C 3 Check the oil level in the four wheel reduction gears 4 Check the main filtering element of the engine air filter Replace if necessary C 5 Check the clamping of the cableheads to the battery terminals C 6 Check the air suction hose between engine and filter Replace if necessary C 7 Check the cylinder chromium plated rods C 8 Check the hydraulic lines are not worn because of rubbing against the frame or other mechanical components C 9 Check the electric cables do not rub against the frame or other mechanical components C 10 Check the wear of the sliding pads of the boom sections C 11 Adjust the play of the sliding pads of the boom sections C 12 Remove any grease from the boom then re grease the sliding parts of the boom sections C 13 Check the level of the battery electrolyte C 14 Check the efficiency of the block valves every 250 working hours or every 3 working months 4 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 3 Maintenance Inspections MAINTENANCE INSPE
71. to confirm the LOADED calibration of the machine and check that the alarm triggers The audible alarm will sound to confirm the command has been executed Move the boom fully in while holding the same in the horizontal position Press to proceed to the next point 3 GTH 3007 AGRI 730 Place a load on the forks with a weight of 1250 kg extend the boom while holding it horizontal till reaching the overturning moment corresponding to 3 00 metres overturning distance distance from the front part of the wheels to the centre of the load calculated to 60 cm from forks see image X Press to confirm the LOADED calibration of the machine and check that the alarm triggers The audible alarm will sound to confirm the command has been executed Move the boom fully in while holding the same in the horizontal position Press to proceed to the next point 3 F Press to exit calibration and to SAVE the changes made the audible alarm sounds and the LED s come on to confirm that data have been saved The limiter is no longer in the calibration mode The LED is not lit fixed any more You should turn the machine off and then on again to eliminate any alarm messages Test machine strictly respect the values shown on the load diagram 26 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 2 Technical Specification TECHNICAL SPECIFICATION GTH 2506 AGRI 625 DIAGRAM 2500 kg at 1 10 metres
72. to the storage container after use NOTICE Contact TEREXLIFT Service Centre if replacement manuals are needed Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 7 TABLE A A 6 INSPECT THE DECALS AND PLATES Maintaining all of safety and instructional decals and placards in good condition is mandatory for safe machi ne operation Decals alert operators and personnel to the many possible hazards associated with using this machine Anillegible decal will fair to alert personnel of a procedure or hazard and could result in unsafe operating conditions refer to the labels and warning plates applied on the machine section in the Operator Manual and use the decal list and illustrations to determine that all decals and placards are in place inspect all decals for legibility and damage Replace any damaged or illegible decal immediately MORI Contact TEREXLIFT Service Centre if replacement decals are needed Section 4 Maintenance Procedures April 2008 SSS SSS TABLE A A 7 CHECK THE ENGINE OIL LEVEL Pull out the rod A again and ensure the oil comes to the maximum level B Tocheck the engine oil leve proceed as follows Refit the plug Stop the machine on a level ground stop the engine and ensure the parking brake is engaged e Pull out the rod ofthe level A and ensure the oil comes oX9
73. 07 AGRI 625 730 Document 57 0009 0419 April 2008 Section 7 Repair Procedures TABLE 003 Procedure Removing the engine from the machine 12 Disconnect the flexible hose of the silencer loosening the clamps with a 13 mm wrench 13 Remove the manifold with a 17 mm wrench 14 Disconnect all the electrical wires connected to the engine and namely oil pressure bulb electrical stop water temperature bulb the three alternator connections starter motor ground between chassis and engine the two coils of the transmission pump solenoid valve 15 Disconnect the radiator tremove the clamps fixing the sleeves to the radiator DDocument 57 0009 0419 GTH 2506 3007 AGRI 625 730 13 Section 7 Repair Procedures April 2008 TABLE 003 Procedure Removing the engine from the machine AGRI 625 730 16 Disconnect the hydraulic pipes of the radiator 9 PROTECT THE ENVIRONMEN Before disconnecting the hydraulic piping place containers of suitable size underneath to prevent oil spillage Plug all disconnected parts to prevent dust and impurities from entering the circuit They can cause serious damage disconnect the two drain lines of the hydraulic pump with a 36mm wrench disconnect the suction line of the hydraulic pump with a 50mm wrench disconnect the low pressure line duct with a 19mm wrench disconnect the four flanges which connect the dri
74. 09 0419 April 2008 Section 7 Repair Procedures Procedure Cylinder disassembly Boom raising cylinder TABLE 001 12 Remove the screw which fixes the rod pin to the boom using two 19 mm wrenches 13 Knock out and extract the pin using a plug of soft material aluminium copper wood etc 14 Put two wooden plugs each 100mm high on the oil cylinder to support the raising cylinder 15 Lower the boom until the cylinder rests on the supporting plugs previously positioned 16 Untie the sling fixing the cylinder to the boom then raise the boom with the bridge crane to go on working 17 Remove the screw which fixes the bottom side pin of the cylinder using two 19 mm wrenches Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 AGRI 625 730 Section 7 Repair Procedures April 2008 _ Ps H esl TABLE 001 Procedure Cylinder disassembly Table 001 GTH 2506 3007 Boom raising cylinder AGRI 625 730 18 Knock out the pin using a plug of soft material aluminium copper wood etc and extract it through the hole on the frame 19 Lower the boom onto the adjustable stand to remove the slinging chains 20 Sling the cylinder with a textile bridle and remove it from the machine using the bridge crane To reassemble the cylinder repeat the steps above in reversed order Remember to set the cir
75. 1 CES si z E z z B15 33 z E ol o x E x ES ale Pale Te Vx B 4 15 15 gt gt eee F10 F12 F9 10 5A 10 10 02 101 NN sl ull Ste T red 5 ls FN 15 15 L m Ies Lj 155 K p K5 K6777 aas F14 H 0 13 lt RELAY CARD 16 10 v 15 ZERA e di 15 pe L B1 15 HINT 51 15 15 p BRIS 15 LN 15 211 E z 5 En 5 5 e E 5 5 FAN 5 mL n COMPRESSOR jw 2 1 RELAY r RELAY 126 In 2 1 3 28 29 13 X27 5 X27 X27 X27 X27 X27 K100 K101 T im BE N N a a 72 N g 11 pt 4 4 E EH 5 5 a a 2 5 5 a 1 1 Xs 1 1 1993 105 FAR PUA B50 B51 45 8105 B104 B41 A ERY e iconoimonnc PA EA PRA H7 ERA 53 7 5 EIGN 840 5 ICOMPRESSOR Bub B47 M106 M196 L j Y36 18 XR Xs e 6 X196 4 806 31 lt lt lt s 2 lt 5 gt P 2 c lt lt 55 553 Se Se Se SA X 5 SUO 56 GE aA SF EE SE 49 ES SSS SF SS a SF lt SE SE SK oS QS amp es S lt lt 0 M ES 9 VAY SS SS lt AFS lt CSN amp v
76. 1 Section 5 Problems Causes Solutions April 2008 _ EES PROBLEMS CAUSES SOLUTIONS 5 2 ABOUT THIS SECTION The tables on the following pages should be used to find and rectify problems that can occur when using the machine Prepare adequate tools and especially a voltmeter and a pressure gauge to carry out the checks explained on next pages The initials of the electrical and hydraulic parts indicated in the following tables are given to help you find such parts on the schemes and diagrams in chapter 6 The tables should be read as follows once you have identified the problem search this problem in the problems column analyse the possible causes explained inthe causes column proceed with the check or replacement according to the instructions provided in the solutions column check that the machine runs well if the problem cannot be eliminated check again all indications in the causes column and proceed accordingly For any further information contact the GENIE Service Centre 2 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 5 Problems Causes Solutions E 5 3 PROBLEMS CAUSES SOLUTIONS 5 3 1 Hydraulic faults PROBLEMS CAUSES SOLUTIONS Problems Causes Solutions The machine does not move nei ther forwards nor in reverse Low pressure of the drive pump DA valve damaged Hydraulic oil filter restricted Re calibrate the
77. 1 56 0016 0069 Joystick 1 56 0021 0081 Main valve movement control box 1 04 4210 0005 Pressure control minisocket 1 56 0012 0035 Negative breake pressure switch on main valve 1 07 0741 0052 Main valve seals kit 1 02 4102 0012 Mechanic lock fork pin 1 09 0803 0406 Rope with eyes 1 2 24 MACHINE PAINT COLOUR GENIE machine BLU GENIE WHITE RAL 9002 GREY GENIE RAL 9010 BLACK RAL 9500 RAL 9016 RAL 1013 TEREX RED RAL 3002 RAL 2002 RAL 3020 YELLOW RAL 1003 RAL 1018 Sal 7030 RAL 1007 7038 RAL 1021 RAL 7032 TEREX RAL 1016 BU RAL 1028 RAL 5003 ORANGE RAL 5010 RAL 2009 RAL 2011 RAL 2004 GREEN RAL 6029 SUNBELT GREEN 16 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 2 Technical Specification puc meee TECHNICAL SPECIFICATION 2 22 CHECKING THE CYLINDER MOVEMENT TIMES To check the engine speed the area easy to reach is the shaft of the CASAPPA pump Min engine speed 950 rpm Max engine speed 2600 rpm The check of the movement times of the cylinders shall be done with the hydraulic oil at a temperature of 60 and with max engine speed BOOM LIFTING LOWERING GTH 2506 AGRI 625 Max engine speed GTH 3007 AGRI 730 Max eingine speed BOOM EXTENSION RETRACTION Extend Qj GTH 2506 AGRI 625 Max engine speed GTH 3007 AGRI 730
78. 1 11 16 12 190 7 8 14 80 215 245 1 1 16 12 110 1 3 16 12 115 1 5 16 12 160 1 7 16 12 130 180 37 COUNTER SUNK CONICAL SEALS JIC 1 5 8 12 225 eee 1718 12 270 TORQUES 0 10 2 12 245 TET aeo CONICAL inc mm Nm 7 16 20 10 1 15 1 2 20 M12x1 5 20 9 16 18 M14x1 5 28 M16x1 5 62 3 4 16 M18x1 5 62 7 8 14 M22x1 5 80 1 1 16 12 M27x2 110 1 3 16 12 141 1 5 16 12 M33x2 160 1 5 8 12 M42x2 225 1 7 8 12 M48x2 270 2 1 4 12 10 1 360 Genie 8 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 2 Technical Specification aa X TECHNICAL SPECIFICATION SEALS WITH GRIP RING FITTING ASSEMBLY Thread TIGHTENING Thread TIGHTENING diameter TORQUE diameter TORQUE 0 10 0 10 SEALS JOINTS WITH A B Fitting Pipeo GRIP RING inc mm Series mm Nm inc mm Nm Nm G 1 8 M10x1 LL 4 10 G 1 8 M10x1 25 12 G 1 8 M10x1 LL 6 10 M12x1 5 30 18 G 1 8 M10x1 L 6 25 G 1 4 40 18 G 1 4 M12x1 5 L 8 50 M14x1 5 50 20 G1 4 M14x1 5 L 10 50 M16x1 5 60 35 G 1 8 M20x1 5 L 12 130 M18x1 5 80 50 G 1 8 M20x1 5 L 15 190 G 3 8 95 40 G 1 8 M20x1 5 L 18 245 M20x1 5 140 60 G 1 8 M20x1 5 L 22 130 G 1 2 M22x1 5 140 75 G 1 8 M20x1 5 L 28 190 M26x1 5 220 85 G 1 8 M20x1 5 L 35 245 G 3 4 250 110 G 1 e M20x1 5 L 42 245 M27x2 250 100
79. 2 Electrical faults 8 Section 6 Rev Schemes 1 61 Hydraulic symbols 1 6 2 Hydraulic schemes 3 6 2 1 GTH 2506 AGRI 625 3 6 2 2 GTH 3007 AGRI 730 4 6 3 Electrical symbols 5 6 4 Electrical schemes 7 6 4 4 GTH 2506 AGRI 625 7 6411 General wiring diagram GTH 2506 AGRI 625 13 6 4 1 2 Fuses and relays GTH 2506 AGRI 625 14 6 4 2 GTH 3007 AGRI 730 15 64 2 1 General wiring diagram GTH 3007 AGRI 730 21 6 4 2 2 Fuses and relays GTH 3007 AGRI 730 22 6 5 Position of electrical and hydraulical components on the machine 23 6 5 1 Hydraulical components 23 Section 7 Rev Repair Procedures 1 7 1 Time schedule 1 001 Cylinder disassembly Boom raising cylinder 5 002 Cylinder disassembly Fork balance cylinder 9 003 Removing the engine from the machine 11 004 Hydraulic pumps disassembly 17 005 Disassembling the hydraulic motor 19 006 Cylinder disassembly Boom extension cylinder 21 007 Water oil cooler disassembly 23 008 Main valve disassembly 25 Genie Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 Xix April 2008 EER TABLE OF CONTENTS 009 Renewing the slide pads of the telescopic boom 27 010 Renewing the flexible hoses inside the boom 31 011 Cylinder disassembly Attachment rotation cylinder 35 Genie 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 2 Technical Specification Technical Specification 2 1 MAIN DIMENSIONS GTH 2506 AGRI 625 m e
80. 250 EN Im M Attachment holding plate rotation 128 Eu E 2 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 2 Technical Specification TECHNICAL SPECIFICATION _ Floor loading kPa 506 292 2 7 FORKS floating type NE emasos AGRITOO wees 2 8 DIESEL ENGINE CL we Totatdslacenen Vera ine combustionsystem __ _rerectinjcton Direct jection Maxpoweroupurazeionm WW oe ase Waray aspiretou Turbocnargea 14 Max torque output rpm Cylinder s number Max Load With Forks 2 9 HYDRAULIC SYSTEM 2 _ 0 GTH 2506 AGRI 625 GTH 3007 AGRI 730 mese 2 10 ELECTRICAL SYSTEM GTH 2506 3007 AGRI 625 730 Voltage pm EN REN Genie Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 3 Section 2 Technical Specification April 2008 TECHNICAL SPECIFICATION 2 11 MACHINE SOUNDS LEVELS Not applicable 2 12 VIBRATION LEVELS GTH 2506 3007 AGRI 625 730 Values calculated in accordance with standard prEN13059 This is a Class A device In a residential environ ment such device can cause radio disturbance In such cases the operator is required to take suitable measures 2 13 REFUELLING e memaesra
81. 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 4 Maintenance Procedures A 14 CHECK THEEFFICIENCY OF THELIGHTING ELECTRIC SYSTEM Check every day that the electrical system powering the lights of the machine is in efficient working order Use the assistance of a second technician to check that the front lights position lights low and high beams and turn signals and the rear lights position lights stop tail lights and turn signals are in excellent state of repair Also check beacon located on the cab roof If one lamp or more must be replaced use the table below as a reference TABLE A When switched on lamps get hot Before touching a lamp with your fingers let it cool down NOTICE Never touch the bulb of halogen lamps with your fingers this may damage the lamp use of a clean cloth or a paper tissue If you touch it accidentally thoroughly clean with a paper tissue and some ethyl alcohol Use Voltage Mount type Power e Front low high beam 12V P45t 45 40 W Front position lights 12V BA 9s 3 W Side tail turn signals 12V BA 15s 21 W e Stop lights and rear position lights 12V BAY 15d 21 5 W Beacon Work lights OPTIONAL 12V H3 55W Dashboard indicators and cab lighting 12V W 2x4 6d 1 2 W e Interior lamp 12V SV 8 5 8 5W License plate lights 12V BA 15s 5W Back up lamps 12V BA 15s 21W Document 57 0009 0419
82. 3 Section 6 Schemes April 2008 plI p T SCHEMES 6 4 1 2 Fuses and relays GTH 2506 AGRI 625 CABIN FUSES AND RELAYS A 8C 888888 CO Ref Description AMP F01 WARNING 10A umm F02 HIGH BEAM 15A F03 LOW BEAM 15A 218 Gr FDA HORN 15 E POSITION LIGHTS 27 So ee F07 1 R REAR POSITION LIGHTS SA F08 POWER SUPPLY OPT 10A oo oo mum F09 2 HYDRAULIC CIRCUIT 10A ro F10 INSTRUMENT 5A GEB gt F11 HEATING 25A COO IOO F12 GEAR SELECTOR 10A F13 WORK LIGHT 15A F14 REAR AXLE SENSOR 10A oo eme ame F15 FLASHING BEACON 10A F16 STOP LIGHT 10A B A F17 HAZARD WARNING LIGHT 10A F18 EMERGENCY STOP 10A F19 WIPER 10A F20 INSTRUMENT PANEL 10A OO OO OO J ENGINE COMPARTMENT FUSES AND RELAYS Ref Description FG1 MAIN FUSE 50A cm re FG2 GLOW PLUGS FUSE 40A K02 STARTER ENABLING SWITCH K01 GLOW PLUGS PREHEATING A TEREX COMPANY 14 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 6 Schemes
83. 4 33 4 13 4 20 x 0 5 4 60 4 46 4 50 6 1 5 15 4 92 5 00 0 75 5 38 5 19 5 20 8 1 25 6 91 6 65 6 80 x1 7 15 6 92 7 00 M 10x 1 5 8 87 8 38 8 50 x 1 25 9 38 9 19 9 20 M 12 x 1 75 10 44 10 10 10 20 x1 5 10 68 10 38 10 50 M 14x2 12 21 11 83 12 00 1 5 12 68 12 38 12 50 M 16x2 14 21 13 84 14 00 1 5 14 68 14 38 14 50 M 18x 2 5 15 74 15 29 15 50 x1 5 16 68 16 38 16 50 M 20 x 2 5 17 74 17 29 17 50 x1 5 18 68 18 38 18 50 M 22 x 2 5 19 74 19 29 19 50 1 5 20 68 20 38 20 50 24 x 3 21 25 20 75 21 00 x2 22 21 21 83 22 00 27 24 25 23 75 24 00 2 25 21 24 83 25 00 30x 3 5 26 77 26 21 26 50 x3 27 25 26 75 27 00 M 33x 3 5 27 77 29 21 29 50 x2 31 21 30 83 31 00 M 36 x 4 32 27 31 65 32 00 x3 33 25 32 75 33 00 M 39 x 4 35 27 34 67 35 00 x3 36 25 35 75 36 00 Genie Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 7 Section 2 Technical Specification April 2008 eee a a TECHNICAL SPECIFICATION 2 16 STANDARD TIGHTENING TORQUES FOR FITTING SEALS 60 CONICAL SEALS FRONT O LOK Parker SEALS Thread TIGHTENING _ Thread TIGHTENING 00 diameter TORQUES 0 10 diameter TORQUES 0 10 60 CONICAL FRONT O LOK SEALS Parker SEALS inc mm Nm ine mm Nm G 1 8 15 9 16 18 25 1 4 M10x1 20 11 16 16 40 9 16 18 25 13 16 16 55 11 16 16 40 1 14 80 13 16 16 55 1 3 16 12 115 3 4 16 62 1 7 16 12 130 j 44 80
84. 5 22 12 10 6 145 9 131 3 206 1 185 5 246 9 222 0 16 2 24 14 10 8 209 1 188 2 293 8 264 4 353 0 317 7 1 5 24 14 10 8 218 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 4 516 687 7 618 9 1 5 30 17 12 10 439 7 395 8 619 3 557 4 742 8 662 5 22 2 5 32 17 12 542 3 488 5 763 2 686 9 915 3 823 7 1 5 32 17 12 582 6 524 3 819 3 737 4 983 6 885 3 24 3 36 19 12 705 1 6345 990 8 891 7 1193 3 1074 4 2 36 19 12 745 3 671 3 1051 0 945 9 1255 1 1129 5 27 3 41 19 1036 0 927 1448 9 1304 0 1734 6 1561 2 2 41 19 1091 8 982 6 1530 6 1377 5 1836 7 1653 0 30 3 5 46 22 1307 9 1258 1 1989 3 1772 4 2357 1 2121 4 2 46 22 1510 2 1359 1 2122 4 1910 2 2540 8 2286 7 33 3 5 50 24 2000 0 1800 0 2800 0 2520 0 3400 0 3060 0 2 50 24 1610 0 1450 0 2300 0 2070 0 2690 0 2420 0 36 4 55 27 2600 0 2340 0 3700 0 3330 0 4300 0 3870 0 3 55 27 2800 0 2520 0 3900 0 3510 0 4600 0 4140 0 39 4 60 27 3400 0 3060 0 4800 0 4320 0 5600 0 5040 0 3 60 27 3600 0 3240 0 5100 0 4590 0 5900 0 5310 0 Genie Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 5
85. 625 730 1 Section 3 Maintenance Inspections April 2008 E MAINTENANCE INSPECTIONS 3 2 ABOUT THIS SECTION Intervention times Maintenance interventions have been divided into 7 different groups in relation to the time at which they must be carried out say daily weekly monthly every 2 months every 6 months yearly and every 5 years afterwards every 2 years For ease of use the service intervals have been grouped in different tables as explained below Inspection Table Daly Weekly A B Monthly A B C Every six months A B C D Yearly A B C D E Every 2 years A B C D E F Every 5 years afterwards every 2 years G Maintenance table The maintenance table contains general information on the type of intervention to be carried out at a certain interval For the explanation of the maintenance jobs to be done please refer to chapter 4 Maintenance Procedures Maintenance inspection report The maintenance report summarises all ofthe interventions to be carried at a given interval and lets the maintenance technician note the result of the check or intervention carried out This card can be photocopied to be used at the different service intervals and to keep a trace of all interventions carried out Genie 2 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 3 Maintenance Inspections S MAINTENANCE INSPECTIONS 3 8 MAINTENANCE TABLE TABLE A During the first 10
86. 7476 292374 16 1 x ps xd d X x EGI ESI bd duds as Vos a s fal ap sp 1 1 8 855 L j L E 1 1 B39 53 3a C dM 602 Lh 35 31 5 x X x a ae 51 S 23 SS Ss ws S x AY AS SS gt ALY XS CONV Se sso ke 2 lt lt lt amp amp amp S 18 enie GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 6 Schemes SCHEMES 1 e 3 4 5 AIR CONDITION SWITCH CABIN FAN SWITCH HEATING FAN WORK LIGHT WORK FLASHING CABIN CABIN ROOF CABIN REAR SWITCH SPOTLIGHT BEACON INTERIOR WINDSCREEN WINDOW LIGHT WIPER WIPER 45 BI l z e E 5 25 a 192 13 z 5 a xn 5 b Ts 19 E1 Vee 4 Ss mue 2 Sis E B 2 55 b im E
87. 8 Microswitch stop light 45 REMARK Two colorwires are indicated through a 520 LMI bypass key 24 combination of the aforesaid initials as follows 24 Start up panel M G V YELLOW GREEN crosswise colouring 557 Road light switch 4a G V YELLOW GREEN lengthswise colouring 58 Forward reverse switch 22 59 Warning switch 21 Document 57 0009 0419 enie A TEREX COMPANY GTH 2506 3007 AGRI 625 730 21 Section 6 Schemes April 2008 e SCHEMES 6 4 2 2 Fuses and relays GTH 3007 AGRI 730 CABIN FUSES AND RELAYS A 8 Ref Description AMP F01 HAZARD WARNING LIGHT 10A rn Em F02 BEAM 15A F03 LOW BEAM 15A ao Cora aa FOL 15 Gp Gad 205 ROAD JOBSITE 10A F06 R FRONT amp L REAR POSITION LIGHTS 5A 2 eae F07 L FRONT amp R REAR POSITION LIGHTS SA F08 POWER SUPPLY OPT 10A C E ans F09 2 HYDRAULIC CIRCUIT 10A ros F10 INSTRUMENT SA 00 amp Ca F11 HEATING 25A OO F12 GEAR SELECTOR 10A OO OO F13 WORK LIGHT 15A 1 F14 REAR AXLE SENSOR 10A gt 00 F15 FLASHING BEACON 10 F16 STOP LIGHT 10A 75 F17 EXTERNAL LIGHT 10A F18 EMERGENCY STOP 10A F19 WIPER 10A OO F20 INSTRUMENT PANEL 10A ENGINE COMPARTMENT FUSES AND RELAYS
88. ALVE X ene 22 SOLENOID VALVE X c Section 6 Schemes SCHEMES Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 55 20 April 2008 6 4 2 1 General wiring diagram GTH 3007 AGRI 730 Section 6 Schemes r M A SCHEMES 1 3 4 5 PART LEGEND Item Description Sh Description Sh A400 Rpm sensor gear box control unit 55 136 Continuous flow knob 64 B6 Air filter clogged switch 13 137 Joystick control boom functions 63 B10 Seat switch 3 2 57 First second mecchanical gear switch 54 835 Engine oil pressure transducer 12 Power air condition compressor plug 23 839 Back Up horn mm X28 Tecnord line plug 32 62 B40 Fuel level gauge 21 X61 Steering unit plug Optional 31 B41 Hydraulic oil temperature switch 25 Y4 Transmission reverse mode solenoid valve 15 B45 Parking brake low pressure switch 24 v Transmission forward mode solenoid valve 15 B46 Rear wheels aligned sensor 25 YB Additional fuel solenoid valve 12 B47 Load cell 25 Engin
89. CTIONS TABLE D Every 500 working hours or every six months D 1 Visually check the smoke quantity evacuated from the engine exhaust D 2 Check the tightening of the engine fixing screws D 3 Check the tightening of the cab fixing screws D 4 Check the backlash between pins and bushings in all joints D 5 Change the hydraulic oil filter cartridge in the comeback suction transmission pump line D 6 Change the hydraulic oil filter cartridge in the tank D 7 Have the hydraulic system checked by a skilled technician D 8 Change the main cartridge of the engine air filter D 9 Clean the air filter in the cab Replace if necessary D 10 Change the engine oil and the filter and fuel filter every 500 working hours or once an year TABLE Every 1000 working hours or yearly E 1 Change the safety element of engine air filter E 2 Change the oil in the forward and rear differential gears and in the power divider E 3 Change the oil in the four wheel reduction gears E 4 Change the hydraulic oil Every 2000 working hours or every two years F 1 Change the engine coolant TABLE G At 6000 hours or 5 years and subsequenily every 2 years G 1 Check that the structure is intact paying a special attention to the welded supporting joints and the boom pins Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 5 Section 3 Maintenance Inspections
90. Front left rear right mud guard Front right rear left mud guard Accelerator cable Thermal engine antivibrant element Cab roof wiper blade Frontal window wiper blade Break road jobsite work light switch Air conditioning continous oil lock unlock attachment switch Lights cab fan switch Manual transmission switch 3 steering ways switch Break switch cover Road jobsite switch cover Cab fan switch cover Lights switch cover Continous flow switch cover Work lights switch cover Manual transmission switch cover 1 boom section front superior slide pad 1 boom section front inferiore slide pad 274 boom section rear superior 1 boom section front side slide pad Document 57 0009 0419 gt N S Ss SB Ss Ss Ss Ss Ss Ss Ss Ss Ss Ses se ses os PONMNNM HHHnNND H HSH SH GTH 2506 3007 AGRI 625 730 15 Section 2 Technical Specification April 2008 Se TECHNICAL SPECIFICATION Cod Description Q t 54 0702 0002 2 boom section rear side slide pa 2 54 0702 0005 2 boom section rear inferior slide pad 2 04 4210 0019 Quick coupling female 1 2 Faster 2 04 4210 0018 Quick coupling male 1 2 Faster 2 09 4604 0047 Return hydraulic oil filter 1 05 4309 0001 Break pump 1 56 0016 0085 Handle joystick 1 07 0741 0023 Extension boom joystick push button 1 07 0741 0060 Distributor pressure control valve 1 07 0741 0061 Pressure relief valve on distributor
91. Genie A TEREX COMPANY Serial number range GTH 2506 From serlal 48957 AGRI 625 From serlal n 19057 GTH 3007 From serial n 19051 AGRI 730 From serial n 19241 Part No 57 0009 0419 April 2008 Service Manual April 2008 Intentionally blank ii GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Introduction Introduction Important information Read understand and obey the safety rules and operating instructions in the GTH 2506 and AGRI 625 Operator s Manual code 57 0009 0413 and GTH 3007 e AGRI 730 Operator s Manual code 57 0009 0445 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 qualified servicetechnicians 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 specific 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 retrieval system ortransmitted in any form orby any means without prior written permission from TEREXLIFT srl In pursuing a policy of constant quality improvement TEREXLIFT srl rese
92. Jd uoissiuisue pue eunsse1d SUONOUN saul eunsseid onejsojp H eunsseJd uedo 3931 30105 54152 We ensseJd speeds 2 xoqueab ugalos uonong 9 gt goinus 81 59 96 3ueuieoe dsip 5 Jojenjoe 4ojoojes speeds ixoqieeb Jeq 06 e jasaiq 99 08 jueuie2e dsip onejsoJp H suonisod skem speeds jeolueyooyy amp 1 20 pg 3ueujeoe dsip anea yum suogouny woog x 94 4 Hod eunsseud dL uoissiusuen ainssaid Burjoejo o t
93. M36 Moderate Low Loctite 565 Fitting sealant 150 M80 Con Cyl Instantaneous Low Loctite 572 Fitting sealant 150 M80 Con Cyl Moderate Low Loctite 577 Fitting sealant 150 M80 Rapid Moderate GASKETS Total sealing in 24 72 hours Product APPLICATION Characteristics Formation Resistance max Play time to fluids C max mm Loctite 518 Formed in place gasket 150 0 5 Moderate Excellent Loctite 509 Formed in place gasket 150 0 2 Moderate Excellent 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 Formed in place gasket 200 6 0 Rapid Excellent Loctite 5999 Formed in place gasket 200 6 0 Instantaneous Excellent Loctite 5910 Formed in place gasket 200 6 0 Rapid Excellent Loctite 5900 Formed in place gasket 200 6 0 Instantaneous Excellent Loctite 5920 Formed in place gasket 250 M 36 Slow Good 10 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 2 Technical Specification 2 18 HOISTING INSTRUCTIONS 44 DANGER All parts weighing more than 25 kg MUST COMPULSORILY be handled with suitable hoisting means In the Disassembly and Assembly section there is a clear indication of the weight of the part to handle while chapter A 12 contains a summary table with the weight of the single components Before removing parts of the machine make sur
94. N x S AT PR CONDITIONING PA B7 BH X ES ES COMPRESSOR 06 The Y36 846 BAT i Js s Pa z 2 z 15 31 ris et a s e ct lt y x 31 5 S SS NS S S S s 57 S gt 599 55 ss s No gt S SS ES SSF SE SE SE RE EEF SE SS QS SS S v ee QUO SAY 5 v Y lt S SE S lt lt lt 5 LW LS 5 AS 59 S SS SS lt Su lt AS ES S lt lt VO S lt S lt 3 S 16 enie A TEREX COMPANY GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 SCHEMES 17 CONTINUOUS FLOW ENABLING SWITCH Section 6 Schemes PARKING BRAKE SWITCH SELECTOR STEERING MODES ROAD JOBSITE MODES SWITCH A TEREX COMPANY G OPERATOR ON SEAT SWITCH GTH 2506 3007 AGRI 625 730 BOOM FUNCTIONS CONTROL CIRCUIT INTERFACE CONNECTOR STEERING MODES UNIT April 2008 9 A 10 TAG 57 7 8 lt 55 IN no no 5 TA 8 TS Du gt 25 city swe 518 Dus mae ood EL ag x ex DA DW g
95. NE AIR WHEEL REDUCTION GEARS To check the oil level in the wheel reduction gears 2 Stop machine on level ground and ensure the parking brake is engaged and plug A 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 A until it is level Refit the plug PROTECT THE ENVIRONMEN Place a container of suitable size under the plug for oil leaks FILTER To clean the engine air filter Stop the engine and engage the parking brake Unlatch the fasteners A and remove cover B Pull out the filter cartridge C Clean the filter bowl Dry clean the cartridge at max 6 bar pressure and direct the air jet from inside to outside Check the filter element for cracks by introducing a lamp inside Refit the cartridge and make sure it is properly posi tioned Close cover B and lock in place with fasteners A As soon as the warning lamp on the cab dashboard switches on replace the outer element Document 57 0009 0419 A TEREX COMP GTH 2506 3007 AGRI 625 730 ls 27 Section 4 Maintenance Procedures April 2008 TABLE C C 5 CHECK THE CLAMPING OF THE CABLEHEADS TO THE BATTERY TERMINALS Check the cable clips are well secured to the battery terminals To tighten the clips always use a box wrench never pliers Aa DANGER Keep out of ite
96. NNECTOR SUPER SEAL MALE MV 282107 1 1 TP SUPER SEAL FEMALE b 5 5 4 X2 4 4 4 4 12759 949794 woe fe 3 Load cell FUSES AND RELAYS BOARD b VB VB MB VB gt gt EM WHITE REF1 18 GND 12V in work condition OV in overload condition Pin7 GND feedback 12V Pin 9 positive Pin10 boom retracted with forks in horizontal position without load 1 1 1 4 mV boom extended with forks in horizontal position without load 0 1 0 4 mV Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 23 Section 2 Technical Specification April 2008 rr ey TECHNICAL SPECIFICATION CONNECTOR X1 FOR CHECKS WITH TESTER Electrical power to control unit DLE 1 12V 2 GND Overload signal 12 generated by the DLE Pin 18 12 V normal conditions 0 V alarm overload Pin 7 re reading overload signal Electrical power to load cell equal to 5 V Channel 1 Pin 16 positive Pin 17 negative Load cell signal in range 0 1 2 5 mV Channel 1 Pin 10 positive Pin 9 negative Machine without load on the forks with boom horizontal and not extended Pin 9 e 10 11 1 2 1 3 1 4 mV Machine without load on the forks with boom hori zontal and fully extended Pin 9 e 10 0 1 0 2 0 3 0 4 mV 24 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 2 Technical Specification CALIBRATING THE DLE SYSTEM During the calibration mode the limiter device doesn
97. The digit on display 2 shows the selected attachment The user can choose among 0 Generic The system recognises the attachment fitted to the machine automatically PANY Document 57 0009 0419 GTH 2506 3007 AG RI 625 730 25 Section 2 Technical Specification April 2008 TECHNICAL SPECIFICATION DISPLAY FUNCTION 0 The LED bar indicates the type of machine in use 0 LED on GTH 2506 3007 AGRI 625 730 To select the machine to be calibrated press eb to increase the number of LED s lit or press to reduce the number of LED s lit If you are doing the first calibration press to reset the system and load the default parameters of the selected machine If you are re calibrating the instrument directly jump to point 1 Press to proceed to the next point 1 1 Lower the stabilisers to the ground fully retract the boom holding it slightly above the horizontal with respect to the ground DON T lift loads Press to confirm the EMPTY calibration of the machine The audible alarm will sound to confirm the command has been executed Press to proceed to the next point 2 2 GTH 2506 AGRI 625 Place a load on the forks with a weight of 2500 kg extend the boom while holding it horizontal till reaching the overturning moment corresponding to 1 10 metres overturning distance distance from the front part of the wheels to the centre of the load calculated to 60 cm from forks see image X Press
98. X if the value is e Run the engine at maximum speed and check the greater loosen the valve high pressure value on the manometer TP2 if this value is less than 430 bar increase the pressure to 430 bar by means of the pressure cut off valve E N B To gain access to valve X remove the protection cap see annex 1 Remove the manometers and do an attempt 5 NEGATIVE PARKING BRAKE PRESSURE e Fit a 0 60 manometer to the mini socket e Start engine and unlock the parking brake using botton S located inside the cab e Check on manometer a pressure of about 25 bar consequential from boost of the transmission pump amp 6 SERVICE BRAKE PRESSURE e Fita 0 25 bar manometer to mini socket TP5 e Step on the brake pump pedal e pressure is about 80 bar consequentely from the exerted force on the pedal 20 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 2 Technical Specification IN TECHNICAL SPECIFICATION POWER STEERING SYSTEM annex 1 SAVY AANA PFA bg 2 Document 57 0009 0419 2506 3007 AGRI 625 730 21 Section 2 Technical Specification April 2008 eee eae TECHNICAL SPECIFICATION 2 24 DLE SYSTEM To avoid damaging strain cage and to get maximum results proceed as follows INSTALLATION OF THE EXTENSIMETRIC CELL 1 PREPARATION
99. afety function 18 Slider 2 of Genie Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 Description April 2008 DESCRIPTION the main valve controls the attachment holding frame cylinder 19 of the telescopic boom This cylinder is equipped with a double acting compensation valve 21 serving also as a Safety valve Parallel to this cylinder there is the fork levelling compensation cylinder 20 also called balancing cylinder which is equipped with a special double acting compensation valve 30 Inside this valve the one way valves are mounted reversed manner with respect tothe normal position to avoid the pressurisation of the cylinder when the rotation control of the attachment holding frame is activated Again inside this valve there are other two one way valves set at 5 bar 72 psi serving as anti cavitation check valves 6 These valves deliver oil taken from the low pressure line of the transmission pump 2 to the fork levelling compensation circuit when needed The two pressure relief valves 7 set at 300 bar 4351 psi which protect the automatic fork levelling circuit during the boom lifting lowering phases and in case of overload on the attachment holding frame for instance in the case of use of the bucket are installed in the two control lines of cylinder 19 and they are integral to module 2 Slider 3 of the main valve controls the extension cylinder 22 of the telescopic boom which operates th
100. air to remove any impurity N V R M 3 For an easier renewal of the hoses whose run is not clearly visible proceed as follows Before disconnecting a hydraulic pipe place e disconnect the hose to be replaced from both containers of suitable size underneath to prevent aids P oil spillage e tie a cord to end of the hose e remove the hose pulling the cord until it comes out completely e untie the cord and tie it to the new hose make sure Plug all disconnected parts to prevent dust or the hose has a cork to avoid dust and impurity in impurities from entering the circuit They can cause the circuit serious damage e pullthe cord from the other side to refit the hose until reaching the connecting point to the line 4a DANGER Before disconnecting the hydraulic pipe check that there is no residual pressure In case eliminate the pressure operating the control levers with the engine stopped In any case disconnect the hydraulic pipe with extreme caution and always wear suitable 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 possible Useful advice for mounting flexible hoses SI NO SI NO NO noc SI 12 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 2 Technical Specif
101. and hydrostatic steering unit 1 00 change the drive pump 2 30 ee 1 00 2 00 1 30 0 30 1 00 1 30 0 30 2 00 1 30 1 00 Documento 57 0009 0418 GTH 2506 3007 AGRI 625 730 1 Section 7 Repair Procedures April 2008 _ a UOO REPAIR PROCEDURES Job Operators Expected needed time h 2 00 5 00 2 00 2 30 2 00 0 30 1 30 0 30 1 00 0 30 2 30 2 30 1 00 1 30 4 00 each 1 00 each 0 30 0 30 1 00 1 00 0 30 1 00 0 30 each 1 00 2 30 each 3 00 2 00 2 00 2 00 1 00 0 30 1 00 each 0 30 2 00 0 30 0 30 0 30 change the drive motor change motor pump transmission piping tests change main valve drive pump change main valve and calibrating tests change main valve spools and tests change relays and fuses change the windscreen wiper motor change electrovalves change the gas pedal complete with cord change the manual throttle pedal complete with cord change the front axle shaft change the rear axle shaft change a cardan joint change the axle shaft hub change the boom change the boom anchoring pin change the attachment locking cylinder pins change a cab pushbutton change and test the main valve pressure relief valve change and test the main valve safety valve change the one way valve change the maxi fuses and search for troubles bleed the brake circuit
102. ank A 11 Check the greasing of the boom section pads A 12 Grease the forks A 13 Grease all joints of the boom the rear axle shaft joint the transmission shafts the front and rear axles and any equipment of the machine A 14 Check the efficiency of the lighting electric system A 15 Check the efficiency of braking system and parking brake A 16 Check the efficiency of the steering selection system A 17 Check the efficiency of the fork balancing system orm 010 10 11 12 13 14 15 16 18 19 A 18 Make sure the safety devices installed in efficient working order19 A 19 Check the engine coolant level 4 4 Table B procedures B 1 Check the machine is in efficient working order B 2 Check the tension of the alternator belt B 3 Check the tyre inflation B 4 Check the tightening of the wheel nuts B 5 Check the tightening of the cardan shaft screws 4 5 Table C procedures C 1 Change the engine oil and relevant filter C 2 Check the oil level in the differential gears and power divider Check the oil level in the four wheel reduction gears C 4 Check and clean the engine air filter C 5 Check the clamping of the cableheads to the battery terminals C 6 Check the air suction hose between engine and filter C 7 Check the cylinder chromium plated rods C 8 Check the hydraulic lines C 9 Check the electric cable C 10 Check the wear of the sliding pads of the boom sections C
103. ctor LMI setting jumper calibration in Connector Calibration SAR Plug in Connector Steering unit bridge Timer enabling antioverload system switch Plug in Connector Steering unit Relay fans air conditionig Relay air conditionig compressor Plug in Connector 3 way In Out relay card Plug in Connector Brake accumulator only for the italian market Windsceen cabin roof Starter engine Heating fan Windscreen washer pump Air conditioning Windscreen washer motor LMI setting Air conditioning fan motor 9 34 Continuous flow enabling switch 35 33 Road jobsite switch Auxiliary hydraulic switch Svitch light Merk spotlight switch Fan switch Air condition switch 1 Steering selector 34 1 Emergency stop Microswitch stop light LMI bypass ke Start up panel Road light switch Forward reverse switch Warning switch Continuous flow knob 137 Joystick control boom functions 3 COLOR WIRE LEGEND LIGHT BLUE WHITE ORANGE YELLOW GREY BLUE BROWN BLACK RED PINK GREEN PURPLE lt gt REMARK Two colorwires are indicated through combination of the aforesaid initials as follows G V YELLOW GREEN crosswise colouring G V YELLOW GREEN lengthswise colouring Document 57 0009 0419 enie A TEREX COMPANY GTH 2506 3007 AGRI 625 730 1
104. cuit under pressure before releasing the bridge crane 8 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 7 Repair Procedures TABLE 002 Procedure Cylinder disassembly table 002 GTH 2506 3007 AGRI 625 730 Bridge crane payload 500 kg Standard tools Textile bridles or chains with hooks Adjustable stands Fork balance cylinder Operation 1 Release the attachment 2 Remove the screw fixing the rod pin with two 13 mm wrenches 3 Knock out and extract the pin using a plug of soft material aluminium copper wood etc Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 9 Section 7 Repair procedures April 2008 EE TABLE 002 Procedure Cylinder disassembly Tabe 002 506 3007 Fork balance cylinder AGRI 625 730 4 Fix the cylinder with a textile bridle connected to the bridge crane to support its weight 5 Place a container of suitable size under the hydraulic piping before disconnecting gt PROTECT THE Used oils must be handled and disposed of according to local regulations Address to legally authorised centres 6 With a 24 mm wrench disconnect two hydraulic hoses from the blocking valve then plug the disconnected connectors to prevent dust and impurities from entering the circuit 7 Drive out the lower pin 8 Unscrew and extract the screw fixing the pin with two 13 mm wrenches 9 Knock out the p
105. d check if oil is level with the hole f necessary top up through hole A until oil comes out Refit the plug PROTECT THE Place a container of suitable size under the plug for oil leaks Genie 4 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 4 Maintenance Procedures A 2 CHECK THE TIGHTENING OF THE WHEEL BOLTS If you have to check the tightening of the wheel bolts or replace a wheel proceed as follows Raise the machine using a hydraulic jack Remove the wheel rolling it on the ground Line up the wheel with the axle and fit the 8 nuts Tighten the nuts following the alternate sequence shown in the picture with a pneumatic screwdriving machine lower the machine to the ground Re tighten all nuts to a torque 440 Nm Check the tightening of wheels one hour after the job They might get loose until they do not stay correct On new machines and when a wheel has been disassembled or replaced check the nut torque of the wheels every 2 hours until they stay correct Always use tyres having the dimensions indicated in the vehicle registration card TABLE A Remove the tyre plug A Connect the hose of the manometer Check the tyre pressure by manometer If the pressure is wrong bring it to the right value see the chart GTH 2506 GTH 3007 AGRI 625 AGRI 730 Dimensi
106. der to perform maintenance interventions on the machine s hydraulic system without having to drain oil off the tank built in the same circuit The filter 34 placed in the line returning to pump 3 purifies mostoil coming from the hydraulic circuit operating the telescopic boom before this oil returns to the tank In addition to purify the oil coming from the main open loop circuit ofthe machine telescopic boom operating circuit this filter can deliver oil at a minimum pressure of 0 5 bar to the suction line of the drive pump 2 This construction feature of the filter guarantees important advantages in terms of absence of cavitation in the transmission suction line especially when the machine is started from cold The one way valve 11 set at 2 5 bar 36 psi 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 of the drive pump 2 low pressure oil is taken 25 30 bar to feed the anti cavitation circuit of the automatic fork levelling system the pilot circuit of the main valve of the telescopic boom 16 and the parking brake unlock circuit The hydraulic energy produced by the drive pump 2 is converted into mechanical power by a closed loop viii GTH 2506 3007 AGRI 625 730 hydrostatic motor model Bosch Rexroth A6VM107 5 equipped with adjustment valve of DA1 type and with flush valve 36 for r
107. ding points of the pads To this end use INTERFLON FIN GREASE LS2 16 Retract the telescope into the fixed section and refit the pin of the extension cylinder 17 With a thickness gauge ensure the play between the boom sections is correct in both positions i e with the boom fully extended and fully retracted 30 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 7 Repair Procedures Procedure Renewing the flexible hoses inside the boom How to renew flexible hoses PROTECT THE Before disconnecting the hydraulic piping place containers of suitable size underneath to prevent oil spillage Plug all disconnected parts to prevent dust or impurities from entering the circuit They can cause serious damage 4 DANGER Before disconnecting the hydraulic piping ensure there is no pressure in the line In case release the pressure by operating the control levers with the engine stopped In any case disconnect the hydraulic piping with extreme caution and always wear suitable 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 possible Document 57 0009 0419 Genie TABLE 010 Table 0 1 0 GTH 2506 3007 AGRI 625 730 Before disconnecting or refitting a flexible hose
108. disassemble and reassemble a wheel disassemble thermal engine dismantle the hydraulic oil tank dismantle the fuel tank change the oil cooler change the fork pivot pin support change the engine bonnet change the cartridge of the air filter check the seals of the steering cylinder change the return filter of the hydraulic oil tank change the hydrostatic steering unit change the battery change the muffler change the mud guard supports CN WS Se SW De SS DS Ce 2 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 7 Repair Procedures 5 REPAIR PROCEDURES Job Operators Expected needed time h change the mud guards 1 0 30 change the steering wheel 1 0 30 Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 3 Section 7 Repair Procedures April 2008 ELIIT F Intentionally blank page 4 GTH 2506 3007 AGRI 625 730 Documento 57 0009 0418 April 2008 Section 7 Repair Procedures TABLE 001 Procedure Cylinder disassembly table 001 GTH 2506 3007 AGRI 625 730 Bridge crane payload 5000 kg Standard tools Textile bridles or chains with hooks Adjustable stands Boom raising cylinder Operation 1 Release the attachment 2 Anchor the attachment holding frame to the hooks of the slin
109. duce or annihilate the lubrication effect Smear pin A with grease to help the forks slide on it Recommended grease graphitized grease tipo GR NG 3 Genie Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 13 Section 4 Maintenance Procedures April 2008 TABLE 13 GREASE ALL JOINTS OF THE BOOM THE REAR AXLE SHAFT JOINT THE TRANSMISSION SHAFTS THE FRONT AND REAR AXLES AND ANY EQUIPMENT OF THE MACHINE Before injecting grease into the greasers thoroughly clean them to avoid that mud dust or other matters can mix with the lubricant and reduce or annihilate the lubrication effect Remove any old grease with a degreaser from the telescopes before smearing them with new grease Regularly grease the machine to grantit efficient conditions and a long life By means of a pump inject grease into the special greasers As the fresh grease comes out stop the operation The greasing points are shown in the following figures A symbol by a pump represents the points to be greased thesymbol BN representsthe pointsto be greased by a brush GTH 3007 AGRI 730 14 GTH
110. dures April 2008 TABLE B B 3 CHECK THE TYRE INFLATION 44 DANGER Over inflated or overheated tyres can burst Do not flame cut or weld the wheel rims For any repair work call in a qualified technician For the tyre inflation or substitution please refer to the table below GTH 2506 AGRI 625 GTH 3007 AGRI 730 Dimensions front and rear 12 16 5 405 70 20 Load index 10 pr 14 pr Rim 9 75x16 5 13x20 Wheel disc 8 holes DIN 70361 8 holes DIN 70361 Pressure bar 4 5 5 5 On new machines and when a wheel has been disas sembled or replaced check the nut torque of the wheels every 2 hours until they stay correct Always use tyres having the dimensions indicated in the vehicle registration card 22 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 4 Maintenance Procedures TABLE B B 4 CHECK THE TIGHTENING OF THE WHEEL NUTS If you have to check the tightening of the wheel bolts or replace a wheel proceed as follows 1 Raise the machine using a hydraulic jack Remove the wheel rolling it on the ground Line up the wheel with the axle and fit the 8 nuts Tighten the nuts following the alternate sequence shown inthe picture A with a pneumatic screwdriving machine Lower the machine to the ground Re tighten all nuts to a torque 400 Nm Checkthe tightening of wheels one hour after the job They might get loose until they do not stay correct O
111. e inspection f any inspection receives tag and remove the machine from service repair and re inspect it After repair place a check in the box Legend Y yes acceptable no remove from service repaired Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 7 Section 3 Maintenance Inspections April 2008 ERE LLLI __________________________________________________________________________ Intentionally blank page 8 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 4 Maintenance Procedures 4 1 INTRODUCTION A Maintenance inspections shall be completed by a trained and qualified person on the maintenance of this machine Scheduled maintenance must be carried out at the intervals indicated in the MAINTENANCE REPORT Failure to properly complete each inspection when required may cause death serious injury or substantial machine damage Rimuovere immediatamente una macchina danneggiata dal servizio Immediately tag and remove from service a damaged or malfunctioning machine Unless otherwise specified perform each procedure with the machine in the following configuration machine parked on a flat level surface boom in the stowed position key switch in the OFF position with the key removed Genie Maintenance Procedures Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 1 Section 4 Maintenance Procedures A
112. e minimum thickness must never be less than 9 mm 60 30 4 Ifthe thickness reaches the minimum value re new the pads before adjusting the residual play 100 with some shims 70 1 15 5 Remove the fixing screws from the pads and position as many shims as necessary to reach the normal thickness value 10 Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 27 25 12 Section 7 Repair Procedures April 2008 TABLE 009 Procedure Renewing the slide pads of the telescopic boom AGRI 625 730 6 Refit the fixing screws torque 30 35 Nm after pouring some Loctite 495 on their threads 7 After shimming fully extend the boom carefully clean the sliding rails of the pads then smear with a thin coat of grease INTERFLON FIN GREASE LS2 Thickness 20 mm Thickness 15 mm New pad thickness 15 mm Max wearing thickness 6 mm Torque 30 35 Nm LLL A gt Minimum thickness 9 mm Genie 28 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 7 Repair Procedures TABLE 009 Procedure Renewing the slide pads of the telescopic boom RENEWING THE PADS To renew the pads of the fixed section proceed as follows 8 Stopthe machine extend the telescope andlower the nose to the ground for an easier removal of the bottom pads Hold it in h
113. e movement of the second boom telescope and is equipped with a single acting compensation valve 31 used as well as safety valve Slider 4 of the main valve controls the attachment locking cylinder 23 This cylinder has a double one way valve 35 with hydraulic release and safety function On the feeding lines of this cylinder there are two quick fit connectors 24 forthe connection of the hydraulic lines to those optional attachments necessitating hydraulic power for their operation ex hydraulic winch and maintenance jib mixing bucket etc The head has been designed to group in a single element some valves of the lowpressure circuit fed through port G of pump 2 In particular the selection solenoid valve 29 operates the parking brake and the relevant valve controlling the flow rate of the calibrated throttle with 0 5mm diameter The pressure reducing valve with screw adjustment 38 set at 32 bar 464 psi allows a maximum pressure to move the sliders the negative emergency brake and the feeding line of the balancing cylinder The safety pressure switch 28 set at 20 bar 290 psi is collocated on one of the hydraulic ports of the feeding line of the parking brake This pressure switch prevents the machine from moving when the pressure of the parking brake line is too low to guarantee the complete release of this brake The circuit of the service brake is operated by a SAFIM 27 20 pump 25 which takes hydraulic oi
114. e stop solenoid 14 850 Hydraulic oil temperature switch 23 Y36 Auxiliary hydraulic circuit solenoid valve 24 851 Hydraulic oil filter clogged switch 23 Yag Parking brake solenoid valve 34 B55 Buzzer Y51 Four wheels steering solenoid valve 34 858 Rpm sensor gear box 52 Y52 Crub steering solenoid valve 31 859 Microswitch first second gear ingaged 52 Y56 First gear solenoid valve 51 B104 Air conditioning pressure switch 24 Y57 Second gear solenoid valve 52 8105 Air conditioning temperature control thermostat 24 x Plug in Connector 11 way Relay card B10A Coolant thermistor 12 x10 Plug in Connector Seat switch B104A Air conditioning compressor pressure switch 23 X10A Plug in Connector Coolant thermistor B105A Air conditionig temperature switch 21 X103 Plug in Connector 3 way Air conditionig motor B Work spotlight mi X106 Plug in Connector Air conditionig fan motor Flashing beacon 54 Plug in Connector Heating fan B Cabin celling light 5 xu Plug in Connector Windscreen washer pump E35 Work spotligth 45 X12A Plug in Connector Trasmission forward mode solenoid valve E37 Rear left road light 43 XBp Plug in Connector Air conditioning compressor 8 License plate light 15 Xs Plug in Connector Air conditioning compressor EA2 Rear right road light 8 Xi Plug in Connector 2 way Power from battery E53 Front right road light 42 X5 Plug in Connector 15 way Power to engine E54 Front left road light 12 XI81 Plug in Connector Stop l
115. e that e fixing bolts have been removed all hydraulic and electrical parts have been disconnected e the part to be removed is not blocked STRANDED ROPES e Useropes 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 14 2200 16 2800 18 3600 20 4400 22 4 5600 30 10000 40 18000 50 28000 60 40000 The value ofthe admissible load has been considered as equal to 1 6 the rope breaking load Genie TECHNICAL SPECIFICATION Attach the load to the natural seat of the hook Attaching a load to an end can cause the load to fall down during raising and result in serious injury 100 88 79 71 41 Do not attach a heavy load to ropes forming a wide suspension angle The total capacity of the ropes reduces proportionally to the angle as shown in the following chart kg 2000 1000 1 500 4 30 60 90 120 150 Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 11 Section 2 Technical Specification April 2008 TECHNICAL SPECIFICATION 2 19 ADVICE TO RENEW FLEXIBLE HOSES 1 Before disconnecting or refitting a flexible hose carefully clean the area all around R E C H E 2 Blow some compressed
116. e under the drain plug placed in the lower part of the reservoir and collect any oil leaks Remove the drain plug D and allow oil to flow out into the container Remove the inspection cover C of tank Carefully wash the tank with Diesel oil and blow a jet of compressed air Refit the drain plug D and the inspection cover C new oil through hole B by making sure that it matches the recommended type indicated until it is level with A Recommended oil SHELL TELLUS T22 temperatures below 10 C SHELL TELLUS T46 temperatures from 15 C to 45 C SHELL TELLUS T68 temperatures above 30 C 7 PROTECT THE ENVIRONMEN Handling and disposing of used oils might be ruled by local or national regulations Address to authorised waste centres Genie 48 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 4 Maintenance Procedures TABLE F 4 8 TABLE F PROCEDURES F 1 CHANGE THE ENGINE COOLANT 44 DANGER When the coolant is hot the cooling system is under pressure With warm engine loosen the radiator plug slowly and carefully without removing it to drain the pressure Use protection gloves and keep your face at a safe distance To drain the antifreeze Let the engine cool down Relieve the internal pressure from the circuit by loosening plug A Remove plug A Place a collecting tray und
117. eadman device button PREALLARME LIMITATORE it is ON when the machine 1 4 is in pre alarm condition the yellow overload led of the 3 display is ON In this moment this function is always ON ALLARME LIMITATORE it is on when the machine is in overload condition ABILITAZIONE POTENZIOMETRO push the button oil on the second hydraulic line Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 43 Section 2 Technical Specification April 2008 TECHNICAL SPECIFICATION POTENZIOMETRO it indicates the value that operator can change handly operating the potentiometer in the picture 10 The application is available on our website in FTP MANUALS WARRANTY amp SERVICE TOOLS SOFTWARE Tecnord 2506 3007 Genie 44 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 3 Maintenance Inspections Maintenance Inspections 3 1 INTRODUCTION A e Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine e Scheduled maintenance must be carried out at the intervals indicated in the MAINTENANCE REPORT Failure to properly complete each inspection when required may cause death serious injury or substantial machine damage Immediately tag and remove from service damaged or malfunctioning machine Repairany machine damage or malfunction before operating machine Document 57 0009 0419 GTH 2506 3007 AGRI
118. educing the max temperatures inside the drive circuit The max displacement of this bent axis motor is 107 cm rev The engine is flanged to a two speed manual trasmission model 357 39 produced by Dana this strasmission is flanged to the front steering axle 26 model 325 211 251 The speeds are inserted by a hydraulic cylinder collocated into the trasmission while a 4 way 3 position solenoid valve 40 on off model and fed by the low pressure circuit sets first and second speed The mechanical torque produced by frontal axal 26 is transmitted to the rear axle 27 model 221 69 produced by Dana through a Cardan shaft The hydraulic drive 12 of load sensing type with a displacementof 125 cm rev receives oil from the priority line of pump 3 in relation to the load sensing signal sent by the hydraulic drive and connected to such pump with function of pilot signal In this way the input flow to the hydraulic drive is exactly the one needed for the instantaneous steering functions any excess flow of the pump is available for operating the different movements of the telescopic boom The steering circuit is protected against input overpressures by a pressure reducing valve set at 170 bar 2465 psi On the two delivery lines to the steering cylinders there are other two pressure reducing valves with anti shock function set at 225 bar 3262 psi These two valves are intended to limit possible shocks on the steering wheel d
119. elescopic boom This cylinder has one single acting Document 57 0009 0419 April 2008 Description compensation valve with safety function 18 Slider 2 of the main valve controls the attachment holding frame cylinder 19 of the telescopic boom This cylinder is equipped with a double acting compensation valve 21 serving also as a safety valve Parallel to this cylinder there is the fork levelling compensation cylinder 20 also called balancing cylinder which is equipped with a special double acting compensation valve B Inside this valve the one way valves are mounted in reversed manner with respect to the normal position to avoid the pressurisation of the cylinder when the rotation control of the attachment holding frame is activated Again inside this valve there are other two one way valves set at 5 bar 72 psi serving as anti cavitation check valves 6 These valves deliver oil taken from the low pressure line of the transmission pump 2 to the fork levelling compensation circuit when needed The two pressure relief valves 7 set at 300 bar 4351 psi which protect the automatic fork levelling circuit during the boom lifting lowering phases and in case of overload onthe attachment holding frame for instance inthe case of use of the bucket are installed in the two control lines of cylinder 19 and they are integral to module 2 Slider 3 of the main valve controls the extension cylinder 22 of the telescopic bo
120. elow the special or safety symbols according to the relative seriousness of the hazard situation A Draws the attention to situations that involve your own as well as the others safety and that can result in serious or lethal injury A DANGER 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 efficiency 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 efficiency Xii GTH 2506 3007 AGRI 625 730 NOTICE Draws the attention to important technical information or practical advice that allows for a safer and more efficient use of the machine 4 PROTECT THE Wd ENVIRONMENT Draws the attention to important environment related information gt 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 Document 57 0009 0419 April 2008 Section 1 Safety Rules SAFETY RULES 1 1 2 Workplace sa
121. epair Procedures TABLE 011 Procedure Cylinder disassembly table 011 Attachment rotation cylinder GTH 2506 3007 AGRI 625 730 2 Bridge crane payload 500 kg Standard tools Textile bridles or chains with hooks Adjustable stands Operation 1 Remove the attachment 2 Remove the screw fixing the pin rod side with two 17 mm wrenches 3 Knock out and extract the pin using a plug of soft material aluminium copper wood etc 4 Openentirely the cylinder by the hydraulic drive and then stop the machine 5 Place a container of suitable size under the hydraulic piping before disconnecting the same 6 Using a 13mm wrench remove the protection cover from the valve of the attachment rotation cylinder 9 PROTECT THE P Used oils must be handled and disposed of ac cording to local regulations Address to legally authorised centres Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 35 Section 7 Repair Procedures April 2008 TABLE 011 Procedure Cylinder disassembly Attachment rotation cylinder 7 Witha24 mm wrench disconnect two hydraulic hoses from the blocking valve then plug the disconnected connectors to prevent dust and impurities from entering the circuit 8 Place a wooden plug under the cylinder rod then lower the boom using the hydraulic controls as far as the rod rests on the wooden plug 9 Remove the screw fixing the cylinder pin bottom side
122. er the drain tap or under plug B Open thedraintap or remove the drain plug B located at the bottom of the radiator and allow the fluid to drain into the container Once the fluid has been drained close the drain tap or refit plug B and pour new antifreeze 50 water antifreeze through cap A This proportion will provide protection up to 38 C On delivery the machine is filled with a cooling mixture consisting of 50 water and 50 anti freeze TEREX PRO COOL Protection against boiling freezing Product Freezing Boiling point point 123 C 126 C Genie Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 49 Section 4 Maintenance Procedures April 2008 SSS SS TABLE G 4 9 TABLE G PROCEDURES G 1 CHECK THE MACHINE STRUCTURE Five years after the first placing into operation of the machine or after 6000 hours whichever occurs first check the state of the structure paying attention to the welded supporting joints and the boom pins DANGER After the first 5 years repeat this check every 2 years Genie 50 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 5 Problems Causes Solutions 5 1 INTRODUCTION A Maintenance inspections shall be completed by a p
123. erson trained and qualified on the maintenance of this machine Immediately tag and remove from service a damaged or malfunctioning machine Repair any damage or malfunction before operating machine Unless otherwise specified perform each procedure with the machine in the following configuration machine parked on a flat level surface boom in the stowed position key switch in the OFF position with the key removed A Before troubleshooting Read understand and obey the safety rules and operating instructions printed in the Operator Manual of the machine Be sure that all necessary tools are available and ready for use Read each appropriate flow chart thoroughly Pay special attention to the following warnings 44 DANGER Crushing hazard When testing or replacing any hydraulic component always support the structure and secure it from movement Electrocution hazard Contact with electrically charged circuits may result in death or serious injry Remove all rings watches and other jewerly Document 57 0009 0419 Problems Causes Solutions Spraying hydraulic oil can penetrate and burn skin loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Perform all troubleshooting on a firm level surface Two person will be required to safely perform some troubleshooting procedures GTH 2506 3007 AGRI 625 730
124. es are in suspension TABLE D Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 39 Section 4 Maintenance Procedures April 2008 E TABLE D D 6 CHANGE THE HYDRAULIC OIL FILTER IN THE TANK To change the hydraulic oil filter cartridge of the service circuits proceed as follows Stop the machine on a level ground and engage the parking brake Remove the inspection hatch A and unscrew the oil filter B fitted inside the tank Checkthe tankis clean thenfita new filtering element and refit the inspection hatch Check the oil level within the tank Add new oil if necessary 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 Flow rate I 1 STR 100 1 Filtering 60 cod 09 4604 0004 PROTECT THE 7 Ge ENVIRONMEN Handling and disposing of used oils may be ruled by local or national regulations Address to authorised waste centres When changing the oil drain it when itis still hot and the polluting substances are in suspension 40 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 4 Maintenance Procedures TABLE D 0 7 HAVETHEHYDRAULIC SYSTEMCHECKED BY A SKILLED TECHNICIAN Every six months we recommend having the system checked to be sure it is in efficient working order In pa
125. eset the steering selection switch to four wheel steer pos 2 Now the wheels should be re aligned 18 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 4 Maintenance Procedures A 17 CHECK THE EFFICIENCY OF THE FORK BALANCING SYSTEM Test the system without any load on the machine s forks To check the efficiency of the fork balancing system obey the instructions below Drive the machine to a flat smooth ground Move the retracted boom fully down and align the forks with the ground Start lifting the boom and check that the forks remain parallel to the ground If the forks do not remain parallel to the ground consult section 5 Problems Causes Solutions TABLE A A 18 MAKE SURE THE SAFETY DEVICES INSTALLED ARE IN EFFICIENT WORKING ORDER Attempt to start the engine with the forward or reverse gear put The engine must not start If the engine starts contact the GENIE Technical Service Repeat the operation putting first one gear then the other Genie Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 19 Section 4 Maintenance Procedures April 2008 TABLE A A 19 CHECK THE ENGINE COOLANT LEVEL 4a DANGER When the coolant is hot the cooling system is under pressure With warm engine loosen the radiator plug slowly and carefully without removing it to drain the pressure Use protection gloves and keep your face at a safe d
126. essary Reconnect or replace the wiring High hydraulic oil temperature ydraulic oil bulb damaged ndicator defective Radiador clogged ontrol unit boom feeding The joystick does not operate the boom extension retraction Road jobsite platform selector damaged Potentiometer on control lever ontrol block selection valve Broken or damaged wiring The joystick does not operate the attachment locking unlocking ontrol unit boom feeding ithe button on control lever ontrol block selection valve Check or replace the bulb if necessary Change the part Check the radiator and eliminate any impurities from the fins Check efficency Check and replace the selector if necessary Check the efficiency of the potentiometer Checkthe efficiency of the solenoids and replace if they are damaged Reconnect or replace the wiring Check the card Check the efficiency of the withe pushbutton Check the efficiency of the electrical coils and replace if they are damaged GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 Section 6 Schemes April 2008 6 1 HYDRAULIC SYMBOLS MOTORS CE Fixed motor with one irection of flow ixed motor with two irections of flow Variable motor with two d irections of flow Reversible fixed motor with two direction
127. et when working under or in the vici nity of suspended load Protective gloves e Working shoes e Breathing set or dust mask e Ear protectors or equivalent equipment e Goggles or facial screen Use only type approved protective equipment in good condition Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 SAFETY RULES 1 4 GENERAL SAFETY PRECAUTIONS A DANGER 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 e sure the area all around the machine is safe Always be aware of potential risks e During work keep the working area in order Ne ver leave objects scattered they could hinder the machine movements and represent a danger for personnel 1 4 2 PRECAUTIONS DURING WORK e Do not walk or stop under raised loads or machine parts supported by hydraulic cylinders or ropes only e Keep the machine handholds and access steps always clean from oil grease or dirt to prevent falls or slips e 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 e Before servicing the engine let
128. fety Be sure to keep sparks flames and lighted tobacco away from flammable and combustible materials like battery gases and engine fuels Always have an approved fire extinguisher within easy reach Be sure that all tools and working areas are A properly maintained and ready for use Keep work surfaces clean and free of debris that could getinto 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 d 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 A use i e cotter pins and self locking nuts Q are not reused These components may fail if they are used a second time Be sure to properly dispose of old oil or other fluids Use an approved container Please be environmentally safe ir Document 57 0009 0419 Section 1 Safety Rules April 2008 SAFETY RULES 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 pre
129. fore to the machine in use Selection ADLEADEETODONEEG IT _ C works DLESDLE1O 00 CFG IT Press OK to close the window 32 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 2 Technical Specification SE TECHNICAL SPECIFICATION Now highlight Hardware Configuration in the Utils menu cope Eni ied AT amp FEO I Message fe Stara era F For each type of machine you must select adequate parameters i e DLE_01 version _01 or higher e Hardware RS232 e Port usually this is the port but it can change in relation to the connected PC Baudrate 19200 If these parameters are wrongly configured it won t be possible to connect the units Press OK to confirm and close the window Now close and re open the program Genio Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 33 Section 2 Technical Specification April 2008 TECHNICAL SPECIFICATION Check that the PC is correctly connected to the relevant serial port and to the DLE unit with the special cord A code 07 0736 0014 and that the unit is supplied with power In the File menu select Salva Save if you want to download a setting of the machine onto a PC or Carica Load if you want to transfer a setting saved in the PC into the machine WinS cope 1 10 18 The follo
130. ging chain 3 Raise the boom to max height the hinging pin of the cylinder rod must be over the driving cabin operating alternately the bridge crane and the hydraulic boom raising control of the machine 4 Stop raising when the slinging chains are slightly under tension 5 Place a container of suitable size under the hydraulic piping before disconnecting 49 PROTECT THE P Used oils must be handled and disposed of according to local regulations Address to legally authorised centres 6 With a 24 mm wrench disconnect two hydraulic hoses from the blocking valve then plug the disconnected connectors to prevent dust and 6 2 impurities from entering the circuit Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 5 Section 7 Repair Procedures April 2008 TABLE 001 Procedure Cylinder disassembly Table 001 506 3007 Boom raising cylinder 7 move the boom using the up down controls of the bridge crane previously disconnect the rod of the fork balance cylinder 8 Remove the screw fixing the pitching cylinder pin with two 13 mm wrenches 9 Knock out and extract the pin using a plug of soft material aluminium copper wood etc 10 Fix the balance cylinder to the cabin with a sling and esnure it does not hinder the movement of the boom 11 Secure the raising cylinder to the boom with a sling Genie 6 GTH 2506 3007 AGRI 625 730 Document 57 00
131. he DLE connecting cable to the electrical system of the machine see Pict 1 Connect the PC power cord to the DLE and the computer see Pict 2 3 4 e Turn the ignition key of the machine to position I board ON and launch the Winscope program see Pict 5 If this is the very first time you use the system follow the instructions described from the first page of this document If you want to upload or download the setting from to the machine DLE you need a password which must be asked to TEREXLIFT to avoid any tampering with the system TEREXLIFT has also a database with all the values of the settings saved ordered by serial numbers which can be provided at any time for comparson purposes Genie Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 35 Section 2 Technical Specification April 2008 Sy TECHNICAL SPECIFICATION DISPLAYING CHANGING THE PARAMETERS A window appears pict 7 with the parameters within which the machine can work If you want to check the variables on the machine open the variables window as shown in picture 8 Clicking with the mouse another window opens see picture 9 which will display the real variations on the machine so you can compare the same with the parameters If during work the variables keep within the limits set by the calibration parameters the system is in efficient order otherwise an error message with the relevant identification code is displayed by the DLE
132. heck the fins of radiator C for sediments f necessary prepare a compressed air nozzle max 2 bar or a nozzle distributing water under pressure or steam Cleaning using compressed air Direct a jet of compressed air toward radiator C paying attention not to damage its fins Remove any loose particles of dirt with some water Cleaning using water under pressure or steam Spray radiator C with a cold commercial detergent and wait for at least 10 minutes to allow the detergent to react Wash radiator C using a jet of water or steam The core fouling depends on the dust of the outside environment and the presence of oil and fuel leaks in the motor area It is therefore advisable to remove oil and fuel leaks immediately in case of very dusty environments 10 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 4 Maintenance Procedures TABLE A A 10 CHECK THE HYDRAULIC OIL LEVEL IN THE TANK 4a DANGER Fine jets of hydraulic oil under pressure can penetrate the skin Do not use your fingers but a piece of cardboard to detect oil leaks Stop the engine and engage the parking brake Make sure the boom is completely retract and completely low Check visually the hydraulic oil livel through level on the tank f necessary add oil through plug A Check the oil level with the machine in the travel po sition tha is boom lowered and telescopes fully in
133. hem for an easier reassembly m Operation 1 Remove the central and side cover of the machine 2 Disconnect the delivery and return pipes with a 36 mm wrench Disconnect all users with a 24 mm wrench Disconnect all dyraulic pilot systems with a 17 mm wrench Disconnect all cablings of the electrovalve Remove the 2 fixing screws with two 13 mm wrenches 7 Remove the main valve from the machine and place it on to a bench A 26 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 7 Repair Procedures TABLE 009 Procedure Renewing the slide pads of the telescopic 009 GTH 2506 3007 AGRI 625 730 boom P Standard tools ADJUSTING THE PLAY WITH SHIMS If the play between the boom sections is too great 2 mm or more proceed in shimming the guide pads of the boom sections Usually the guide pads subject to premature wear are bottom pads of the fixed section top pads of the telescope Proceed as follows 1 Lower the boom to the ground and ensure the telescope is fully retracted 2 With a thickness gauge check the play of all 200 pads After adjustment the minimum play in the narrowest point must be 0 5 1 mm Thickn 1 2 mm if needed 3 Measure the thickness of the slide pads The value of the bottom pads of the fixed section and ofthe top pads of the telescope must be at least 13 mm For the remaining pads th
134. hten drain plug B new oil through plug A until it is level with the hole Refit and tighten plug A Recommended oil FUCHS TITAN GEAR LS 85 W 90 API GL 5 LS GL 5 Document 57 0009 0419 April 2008 Section 4 Maintenance Procedures TABLE E E 3 CHANGE THE OIL IN THE FOUR WHEEL REDUCTION GEARS To change the oil in the wheel reduction gears Stop the machine on a level ground and ensure the parking brake is engaged and plug A is oriented along the vertical axis PROTECT THE 7 Ge ENVIRONMEN Place a container of suitable size under the plug Unscrew plug and drain any oil from the reduction gear Rotate the wheel by 90 until the plug finds again on the horizontal axis Add new oil through hole A Refit and tighten plug A Recommended oil FUCHS TITAN GEAR LS 85 W 90 API GL 5 LS GL 5 gt HE Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 47 Section 4 Maintenance Procedures April 2008 TABLE E E 4 CHANGE THE HYDRAULIC OIL To change the hydraulic oil Stop the machine on a level ground and make sure the parking brake is engaged Release the pressure from the hydraulic circuit Place a container of suitable siz
135. ication IF TECHNICAL SPECIFICATION 2 20 LIST OF RECOMMENDED SPARE PARTS GHT 2506 AGRI 625 Cod 07 0700 0023 09 4604 0004 07 0700 0037 07 0700 0036 07 0723 0149 Description Hydraulic oil filter inside the tank Hydraulic oil filter Engine air primary filter Engine air secondary filter Air filter inside the cab 07 4501 0068 Fuel filter 07 4501 0067 Engine oil filter 07 0723 0149 Air cab filter 07 0741 0062 07 0741 0058 07 0741 0057 07 0741 0059 04 4240 0052 07 0728 0007 07 0709 0417 07 0701 0200 07 4529 0012 07 4529 0027 Negative brake electrovalve Negative brake and deadman electrovalve solenoid Main valve electrovalve solenoid Deadman electrovalve Steering electrovalve Steerin electrovalve solenoid Axals cylinders seals kit Transmission pump seals kit Service pump seals kit Break pedal seals kit 635965 Fork movement cylinder seals kit 07 0705 0081 Lift cylinder valve seals kit 640096 Lift cylinder seals kit 639993 Extension cylinder seals kit 07 0705 0085 Fork movement cylinder valve seals kit 639992 Fork balance cylinder seals kit 07 0705 0082 07 0700 0028 07 0738 0003 07 0701 0007 07 0701 0209 56 0016 0090 56 0016 0089 07 0704 0010 07 0704 0011 04 4239 0004 Fork balance cylinder valve seals kit Hydraulic oil return filter restriction indicator Cardan spider Transmission pump electrovalve coil Transmission pump electrovalve Speed switch Diesel engine ig
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137. ift cylinder rif B IV Fix the fasteners tightening the screws Document 57 0009 0419 April 2008 Section 4 Maintenance Procedures 4 6 TABLE D PROCEDURES D 1 VISUALLY CHECK THE SMOKE QUANTITY EVACUATED FROM THE ENGINE EXHAUST Tocheck the quantity of smoke evacuated from the engine exhaust proceed as follows Start the engine of the machine Wait for a few minutes so the engine can warm up correctly Visually check that the amount of smoke coming out of the exhaust is normal repeat the check while accelerating the engine NOTICE Do this check outdoors or use an adequate smoke extraction system In case of excess smoke strictly obey the instructions provided in the relevant Use and maintenance manual enclosed with the technical literature of the TABLE D 0 2 CHECK THE TIGHTENING OF THE ENGINE FIXING SCREWS Every 6 months check that the screws fixing the engine to the machine chassis are tight For this operation use a torque wrench and tighten the screws to a torque of 124 Nm machine Document 57 0009 0419 Genie A TEREX COMP GTH 2506 3007 AGRI 625 730 37 Section 4 Maintenance Procedures April 2008 TABLE D 0 3 CHECK THE TIGHTENING OF THE 0 4 CHECK THE BACKLASH BETWEEN PINS FIXING SCREWS AND BUSHINGS IN ALL JOINTS Every 6 months check that the screws fixing the cab to Every 6
138. ight pressure switch 10 FUSE Warning light 21 X182 Plug in Connector Stop light pressure switch F2 15A FUSE High beam 42 X196 Plug in Connector Air conditioning fan motor F3 15A FUSE Low beam 42 X2 Plug in Connector 21 way In Out relay card Fh 15A FUSE Horn X21 Plug in Connector 2 way In Out relay card FS 10A FUSE Road jobsite switch 33 X22 Plug in Connector Windscreen washer motor F6 5A FUSE Position light front right and rear left bh X25 Plug in Connector ECO Multipurpose Instruments F1 5A FUSE Position light front left and rear right L4 x26 Plug in Connector 12 way In Out relay card F8 10A FUSE Optional M x21 Plug in Connector 31 way In Out relay card F9 10A FUSE Auxiliary Hydraulic switch 25 X28 P F P M Plug in Connector Tecnord line FU 5A FUSE LMI display 23 x Plug in Connector 17 way Relay card 25 FUSE Heater fan switch 53 x33 Plug in Connector Extention cable LMI F12 10A FUSE Forward reverse switch 24 X34 Plug in Connector Stop engine F13 15A FUSE Spotlights work 53 35 5 Plug in Connector Spotlights work boom Fih 10A FUSE Rear wheels aligned sensor 25 36 5 Plug in Connector Auxiliary hydraulic circuit solenoid valve FAIS 10A FUSE Flashing beacon light 54 37 5 Plug in Connector Rear left road light F16 10A FUSE Stop light 45 x39 Plug in Connector Back up horn 10 FUSE Road light Xi Plug in Connector 5 way In Out relay card F18 10A FUSE Emergency
139. ill the engine through the hole of plug B see technical specifications table 2 13 Check the oil is level with the hole Operate the starting motor and let the engine run for a few seconds Start the engine and let it run AT IDLE and LOADLESS for some 2 minutes Stop the engine wait for a few minutes and then check that oil level reaches the MAX mark on the dipstick D 44 GTH 2506 3007 AGRI 625 730 For the engine maintenance please refer to the specific Operator handbook code SLBU 7853 00 supplied with the machine Park the machine on a level surface and stop the engine Place a collecting tray underneath to catch any escaping fuel Clean the fuel filter outside Open the drain valve E and allow the fuel to drain into the collecting tray Remove the filter bowl from the mounting base Free the filter element and clean all its parts thoroughly Install a new filter element by hand Bleed the fuel system Start the engine and let it run at idle for a few minutes Ema c p Ta Document 57 0009 0419 April 2008 Section 4 Maintenance Procedures TABLE E 4 7 TABLE E PROCEDURES E 1 CHANGE THE SAFETY ELEMENT OF ENGINE AIR FILTER To change the safety element Stop the engine and engage the parking brake Unlatch the fasteners A and remove cover B Pull out the filter cartridge C Loosen wing nut and remove the inner element D
140. in using a plug of soft material aluminium copper wood etc and extract it through the hole on the frame 10 Remove the cylinder from the machine using the bridge crane 10 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 7 Repair Procedures TABLE 003 Procedure Removing the engine from the machine table 003 GTH 2506 3007 AGRI 625 730 Bridge crane payload 500 kg Textile bridles or chains with hooks Operation 1 Open the engine cover 2 Secure the cover with a belt or hold it raised by hand so it cannot move 3 Using two 13mm wrenches remove the two screws of the spring 4 Again with two 13mm wrenches loosen the three screws that secure the cover to the frame 5 Remove the upper cover 6 Disconnect the two battery leads and remove the battery using a 13mm wrench 7 With two 17mm wrenches remove the six screws fixing the lower cover of the engine 8 Remove the lower cover Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 11 Section 7 Repair Procedures April 2008 TABLE 003 Procedure Removing the engine from the machine 9 With a screwdriver disconnect the fuel feeding and return piping held in position by the special hose clamps 10 Disconnect the throttle control cable removing the locking clip loosen the cable register with a 17 mm wrench to pull out the cable 11 Close the oil tank cocks 12 GTH 2506 30
141. ine a previous setting configuration saved in the PC click on STORE SETTINGS FROM FILE to save the current machine configuration in the PC Picture 6 42 GTH 2506 3007 AGRI 625 730 98 pth2506 3307 Fle Visuskzza Preferki Strumenti 7 Om 0 92 DXX Powe Indirizzo E C Documents and Settings TecnicolDesktop tecnordlgth2506 3307 4r MU NEZ s Sposta fie Teo Copia fie Q Attica af Web Picture 4 FARANI TE ead Shen nee ap B Duty Cte 20 Document 57 0009 0419 April 2008 Section 2 Technical Specification TECHNICAL SPECIFICATION For the diagnostics start the application dp gth 2506 3007 exe picture 7 Choose one of the serial ports for example COM 1 and click on ATTIVA DIAGNOSTICA fig 8 up CMLALLARME ALLARME MMACCIO UMITATORE ALTO POTENZ on or or POTENDOMET FO 0 In this page you ll find the system signals diagnostic i The graduated bars show you the movements of the boom and forks in real time according to their effective speed The joystick control button and the 4 function button become ON and OFF depending if they are pushed or not Example in the picture 9 you can see the following particular values P4 lock unlock attachment button UP d
142. ing 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 identification and hazard warning plates They shall be skilled and trained about the machine use Itisrecommended to take part atleast one technical training course organised by GENIE Assistance Office Ordinary and extraordinary maintenance of the machineare quite complex from a technical point of view and should be performed by an authoirsed service centre Document 57 0009 0419 April 2008 Section 1 Safety Rules 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 tors should wear neither clothes with large sleeves nor objects that can get stuck in moving parts of the machine e Protective helm
143. ing 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 fluid A DANGER Any intervention on the hydraulic or pneumatic cir cuit 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 fingers to check for pressure leaks Fine jets of air oil or fuel can injure you e Neither smoke nor use open flames if there is a risk of fire or close to fuel oil or batteries e Do not leave fuel cans or bottles in unsuitable places Do not empty catalytic mufflers or other vessels containing burning materials without taking the necessary precautions e Carefully handle all flammable or dangerous substances e 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 e Never give orders to several people at a ime Instructions and signs must be given by one person only e Always pay the due attention to the instructions given by the foreman e Never distract the operator during working phases or crucial manoeuvres e Do not call an operator suddenly if unnecessary Do not frighten an operator or throw objects by no means GTH 2506 3007
144. istance Every week before starting working with the coolant cold check the coolant level through the glass cap of plug A When necessary add clean water or an antifreeze mixture through cap B On delivery the machine is filled with a cooling mixture consisting of 50 water and 50 anti freeze TEREX PRO COOL Protection against boiling freezing Product Freezing Boiling point point 123 C 126 195 C 20 GTH 2506 3007 AGRI 625 730 Genie Document 57 0009 0419 April 2008 Section 4 Maintenance Procedures 4 4 TABLE B PROCEDURES B 1 CHECK THE MACHINE IS IN EFFICIENT WORKING ORDER Do a walk around inspection and check the machine is in efficient working order Check for fluid leaks Make sure that all hydraulic and electrical components are in efficient working order For the engine maintenance please refer to the specific Operator handbook code SLBU 7853 00 supplied with the machine Document 57 0009 0419 Genie A TEREX COMP GTH 2506 3007 AGRI 625 730 21 TABLE B B 2 CHECKTHETENSIONOFTHEALTERNATOR BELT Visually check belt A for damages or cracks this belt doesn t need to be tensioned as the system is equipped with an automatic tensioning device For the engine maintenance please refer to the specific Operator handbook code SLBU 7853 00 supplied with the machine Section 4 Maintenance Proce
145. l from tank 37 to operate the service brake located inside the front axle 26 The brake pump can provide a maximum pressure of 80 bar 1160 psi thus depending on the pressure exerted on the brake pedal placed inside the driving place The vi GTH 2506 3007 AGRI 625 730 pressure switch 4 set at 2 8 6 3 bar 40 90 psi placed on the pump head sends an electrical signal when the service brake is engaged The oil coming from the drain line of the main valve operating the telescopic boom 16 is cooled down by the heat exchanger 32 This exchanger is divided in two sectors the former absorbs heat from the cooling circuit of the diesel engine and the latter absorbs heat from the hydraulic circuit of the machine The oil cooled down by the heat exchanger is sent back to the special filter 34 and finally drained into tank 10 A one way valve 33 calibrated at 8 bar 116 psi is installed parallel to the input line of the heat exchanger and used as safety valve Its function is to avoid overpressure conditions of the heat exchanger as is the case of a machine starting at low temperatures by directly draining any excess oil into the tank Document 57 0009 0419 Description DESCRIPTION 5191 G9 Ayoedeo yue ewen x euo anen 81 29 9g 3ueuieaejdsip z seul yue S HN mu DIE od ix onejsoJpAH Ssa
146. ling antioverload system switch 24 X51 Plug in Connector Second gear solenoid valve K100 Relay fans air conditionig 22 X588 Plug in Connector Rpm gear box sensor K101 Relay air conditionig compressor 22 XL00 Plug in Connector Rpm gear box control unit K401 Relay lever forward reverse neutral position 53 x50 Plug in Connector 6 way Interface cabin chassis K402 Safety relay gear box engaged 53 X60 p Plug in Connector LMI setting jumper calibration M4 Windsceen cabin roof 55 60 5 Plug in Connector Calibration SAR MI Starter engine 1 Plug in Connector Steering unit bridge Heating fan 53 Plug in Connector Steering unit 2 Windscreen washer pump m Plug in Connector 3 way In Out relay card M21 Air conditioning 1 x8 Plug in Connector Brake accumulator only for the italian market M22 Windscreen washer motor 43 Windscreen rear cabin 55 M60 LMI setting 23 106 Air conditioning fan motor 22 COLOR WIRE LEGEND M196 Air conditioning fan motor 22 P25 Main gauges cluster 12 LIGHT BLUE P33 LMI display and board 23 B WHITE R36 Glow plugs 18 C ORANGE 51 Parking brake switch 34 D YELLOW 52 Continuous flow enabling switch 35 H 53 Road jobsite switch 33 L BLUE Sh Auxiliary hydraulic switch 25 M BROWN 55 Switch light s N BLACK S6 Work spotlight switch 53 R RED 59 Fan switch 52 S PINK 510 Air condition switch 51 V GREEN 513 Steering selector 7 s Emergency stop 14 51
147. mperature switch Plug in Connector Air conditionig fan motor Plug in Connector Heating fan Work spotlight Plug in Connector Windscreen washer pump Plug in Connector Trasmission forward mode solenoid valve Plug in Connector Air conditioning compressor Plug in Connector Air conditioning compressor Rear left road light Plug in Connector 2 way Power from battery License plate light 5 Rear right road light bh 42 Plug in Connector 15 way Power to engine Plug in Connector Stop light pressure switch Plug in Connector Air conditioning fan motor ht 21 15A FUSE High beam 42 15A FUSE Low beam 42 Plug in Connector 21 way In Out relay card Plug in Connector 2 way In Out relay card Plug in Connector Windscreen washer motor 15A FUSE Horn Plug in Connector ECO Multipurpose Instruments 10 FUSE Road jobsite switch 5A FUSE Position light front right and rear left 5A FUSE Position light front left and rear right Plug in Connector 12 way In Out relay card Plug in Connector 31 way In Out relay card Plug in Connector Tecnord line 10A FUSE Optional Plug in Connector 17 way Relay card 10A FUSE Auxiliary Hydraulic switch 5A FUSE LMI display Plug in Connector Extention cable LMI Plug in Connector Stop engine 25A FUSE Heater fan switch Plug in Connector Spotlights work boom 10 FUSE Forward reverse switch 10A
148. ms Software version existing in the DLE unit this function allows you to see the software version included in the DLE unit according to the lighted LEDs of the load bar No LED software 0 One LED software 1 Four LEDs software 4 No function Press to escape from the calibration and SAVE all changes the buzzer and the LED activate to confirm storage The limiter has now escaped from the calibration mode The LED is no longer ON steadily It is necessary to turn off and turn on the machine to eliminate all alarm messages display flashing ALARM CODES Alarm code Description Action Alarm code Description Action 1 E2PROM Error Internal comparison of data read from E2PROM failed Switch off and switch on the machine If the alarm continues recalibrate the machine otherwise replace DLE 2 CELL 1 reading out of range Check if the load cell is fixed well Check the connection between DLE and sensor for short circuits or signal interruptions due to a broken cable Check the DLE connector for signs of oxidation short circuits or absence of electrical contact in some pins If the alarm persists check if the cell is intact Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 29 Section 2 Technical Specification April 2008 SESE TECHNICAL SPECIFICATION Alarm code 4 Description Block Relay check error during work Check through re reading of the block output
149. ms which can produce sparks of naked flames or lit cigarettes Do not rest metal objects onto the battery This can result in a dangerous short especially during a recharge C 6 CHECKTHEAIRSUCTIONHOSEBETWEEN ENGINE AND FILTER Check the state of all the rubber sleeves A of the air suction line between engine and filter every month If yuusethe machine continuously for several days check these sleeves as well as the hose clamps more frequently 28 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 4 Maintenance Procedures C 7 CHECK THE CYLINDER CHROMIUM PLATED RODS Visually check the cylinder rods A for scoring every month For this operation fully extend all of the cylinders and check that their rods are intact In case of problems replace the cylinder Document 57 0009 0419 Genie A TEREX COMP GTH 2506 3007 AGRI 625 730 29 TABLE C C 8 CHECK THE HYDRAULIC LINES Every month do a random check of the oil dynamic hoses to be sure they are not worn In particular we recommend checking the hoses located near moving mechanical parts as they could rub against such parts and get damaged Replace any worn hoses immediately before using the machine again Section 4 Maintenance Procedures April 2008 TABLE C C 9 CHECK THE ELECTRIC CABLES Every month do a random check of the electrical ca bles to be s
150. n All pads can be adjusted by the special shims Adjusting the pads Remove or loosen the screws fixing the pads in re lation to type of shims used with or without slots Fit the necessary amount of shims If the residual thickness of the pad is insufficient or near the maximum wearing limit renew the pad Tighten the screws fixing the pads at the recom mended 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 recommended can cause the break of the pad or of the locking threaded bush Pads must compulsorily be replaced if the residual thickness of the plastic layer with respect to the iron bush fixing the block is equal or inferior to 1 mm Max wearing thickness Minimum 1 mm Genie 32 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 4 Maintenance Procedures SS eae TABLE C C 12 GREASE THE SLIDING PARTS OF THE BOOM SECTIONS Check every month that the telescopes are well greased in correspondence of the sliding pads If necessary scrape off the old grease and apply a thin film of new grease Use only INTERFLON grease FIN GREASE LS 2 cod 640772 Avoid mixing greases of different type or features and do not use greases of lower q
151. n new machines and when a wheel has been disassembled or replaced check the nut torque of the wheels every 2 hours until they stay correct Always use tyres having the dimensions indicated in the vehicle registration card GTH 2506 AGRI 625 GTH 3007 AGRI 730 Dimensions front and rear 12 16 5 405 70 20 Load index 10 pr 14 pr Rim 9 75x16 5 13x20 Wheel disc 8 holes DIN 70361 8 holes DIN 70361 Pressure bar 4 5 5 5 Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 23 April 2008 Section 4 Maintenance Procedures TABLE B B 5 CHECKTHE TIGHTENING OF THE CARDAN SHAFT SCREWS Check every week that the screws of the Cardan shaft A are tight please refer to par Technical Specifications For the correct tightening torques 2 13 in section 2 Document 57 0009 0419 G GTH 2506 3007 AGRI 625 730 24 April 2008 O M 4 5 TABLE C PROCEDURES C 1 CHANGE THE ENGINE OIL AND RELEVANT FILTER Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin Drain the crankcase while the oil is warm This allows waste particles that are suspended in the oil to drain As the oil cools the waste particles will settle to the bottom of the crankcase and cannot be drained through hole A Park the machine on a level surface Unscrew plug B engine filling plug Place a collecting
152. n valve Unlockable non return valve Document 57 0009 0419 Schemes Combined non return and throttle valve Switching valve Pressure relief valve with direct control Pressure relief valve with hydraulic control Pressure reducing valve Sequence valve Adjustable throttle valve Two way flow regulator Cut out cock POWER SOURCES Electric motor Thermal engine OTHER EQUIPMENT Accumulator Water tank Compressor Filter Cooler Pressure gauge Thermometer Flowmeter Pressure switch Drain to tank indication TEREX COMPANY Section 6 Schemes April 2008 ee ees SCHEMES DISTRIBUTION SETTING ELEMENTS Two position and two way distributor with manual lever control and spring return distributor with hydraulic control Three way and two position kn 773554571 Two position three way Fi E distributor with electro magnetic control and spring return Distributor with mechanical Ui i X control and span proportional to d the action of the same control Two position three way per distributor with representation of transient connection during passage phase Electro hydraulic single acting servo valve
153. nition switch White cap Push button cap Fork balance cylinder valve 07 0703 0080 5A Fuse 07 0703 0148 10A Fuse 634973 15A Fuse 07 0703 0071 25A Fuse 56 0005 0001 50A Big fuse 56 0005 0000 40A Big fuse 56 0021 0104 56 0013 0001 07 0723 0042 09 0803 0400 09 0803 0401 07 0723 0486 09 4670 0003 07 0723 0446 Fuses and relays label Fuel livel indicator Mirror Left mud guard Right mud guard Accelerator cable Thermal engine antivibrant element Cab roof wiper blade Genie Document 57 0009 0419 5 a Ll IR l amp GTH 2506 3007 AGRI 625 730 13 Section 2 Technical Specification Se TECHNICAL SPECIFICATION Cod 07 0723 0037 56 0017 0044 56 0017 0048 56 0017 0037 56 0017 0049 56 0017 0046 56 0012 0053 56 0017 0054 56 0017 0055 56 0017 0047 56 0017 0051 54 0702 0013 54 0702 0000 54 0702 0001 54 0702 0002 54 0702 0005 04 4210 0019 04 4210 0018 09 4604 0047 05 4309 0001 56 0016 0085 07 0741 0023 07 0741 0060 07 0741 0061 56 0016 0069 56 0021 0081 04 4210 0005 56 0012 0035 07 0741 0052 02 4102 0012 09 0803 0406 Description Frontal window wiper blade Brake road jobsite work light switch Air conditioning continous oil switch Lights cab fan switch 3 steering ways switch Break switch cover Road jobsite switch cover Cab fan switch c
154. o Parameters 20 21 22 and 23 are usually equivalent to parameters 0 1 4 and 5 They shall be used for a new calibration of the platform not depending on the proportional calibration done with the forks These parameters only apply to the platform Value saved in analog channel 1 during calibration with empty machine C1NavicellaCarico Value saved in analog channel 1 during calibration with loaded machine C2NavicellaVuoto Value saved in analog channel 2 during calibration with empty machine C2NavicellaCarico Value saved in analog channel 2 during calibration with loaded machine Machine selected on point 0 of the calibration Parameters CHECKSUM used by the safety functions Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 39 Section 2 Technical Specification April 2008 TECHNICAL SPECIFICATION LIST OF THE DLE VARIABLES N 7 WinscopeName Default Description 05 PCorder You can save changes effected to the parameters by setting this variable to 1 The variable will return to 0 once the value has been saved 10 C1swl Load percentage of cell 1 0 calibration without load 100 calibration under load EN C1adcFiltro NET Current value of cell 1 analog converted into bits 0 1023 40 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 2 Technical Specification 2 25 CHECK MAIN VALVE CONTROL UNIT BY COMPUTER To check the data efficency of the main val
155. of the handler or electric electronic parts If the electrolyte comes in contact with these parts contact the nearest authorised assistance centre TABLE C C 13 CHECK THE LEVEL OF THE BATTERY ELECTROLYTE Check the electrolyte level every 250 working hours if necessary add distilled water 34 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 4 Maintenance Procedures TABLE C C 14 CHECK THE EFFICIENCY OF THE BLOCK m VALVES Telescopic boom extension cylinder 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 valve on the telescope extension cylinder move the boom to maximum height and extend it some centimetres Loosen the oil hoses to the cylinder of which you are checking the valve with caution During the check the load shall remain blocked in po sition Should that not be the case the valve must be replaced Contact GENIE Technical Service PROTECT THE Place a container of suitable size under the plug for oil leaks 2 Attachment coupling cylinder Fork levelling cylinder Fork pitching cylinder Document 57 0009 0419 Sec
156. om which operates the movement of the second boom telescope andis equipped with a single acting compensation valve 31 used as well as safety valve Slider 4 of the main valve controls the attachment locking cylinder 23 This cylinder has a double one way valve 35 with hydraulic release and safety function On the feeding lines of this cylinder there are two quick fit connectors 24 for the connection of the hydraulic lines to those optional attachments necessitating hydraulic power for their operation ex hydraulic winch and maintenance jib mixing bucket etc Theheadhas been designed to group in a single element some valves of the lowpressure circuit fed through port G of pump 2 In particular the selection solenoid valve 29 operates the parking brake and the relevant valve controlling the flow rate of the calibrated throttle with 0 5mm diameter The pressure reducing valve with screw adjustment 38 set at 32 bar 464 psi allows a maximum pressure to move the sliders the negative emergency brake and the feeding line of the balancing cylinder The safety pressure switch 28 set at 20 bar 290 psi is collocated on one of the hydraulic ports of the feeding line ofthe parking brake This pressure switch prevents the machine from moving when the pressure of the parking brake line is too low to guarantee the complete release of this brake The circuit of the service brake is operated by a SAFIM 27 20 pump 25 which take
157. on front rear 12 16 5 405 70 20 Load index 10 pr 14 pr Rim 9 75x16 5 13x20 Wheel disc 8 holes DIN 70361 8holes DIN 70361 Pressure bar 4 5 5 5 Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 Section 4 Maintenance Procedures April 2008 TABLE A A 3 CHECK THE TIGHTENING OF ALL BOLTS 4 CHECK THE COUPLINGS FOR OIL AND NUTS LEAKS Before starting your daily work proceed with a random starting your work do a walk around inspection check of the bolts and check for oil leaks For the correct tightening torques please refer to par If you find them rectify before starting using the 2 14 in section 2 Technical Specifications machine Genie 6 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 4 Maintenance Procedures A 5 INSPECT THE OPERATOR MANUAL Maintaining the operator manual in good condition is essential to consult it if necessary Manual are included with each machine and should be stored in the cab An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition In particular check to be sure the storage container is in good condition check to make sure that the operator manual are present complete and in the storage container in the cab examine the pages of each manual to be sure that they are legible and in good condition always return the manual
158. on and sling it with the textile bridles connected to the bridge crane 22 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 7 Repair Porcedures Water oil cooler disassembly Procedure Operation PROTECT THE ENVIRONMEN Before disconnecting the hydraulic piping place containers of suitable size underneath to prevent oil spillage Carefully clean the area around the piping to be disconnected plug all disconnected parts with connectors clothes or adhesive tape to prevent dust or impurities from entering the circuit They can cause serious damage Empty the cooler opening the special cock N Disconnect the two inlet and outlet hoses from the cooler with a 36 mm wrench Disconnect the water pipes from to the engine loosening the hose clamps with a screwdriver TEREX COMPANY Document 57 0009 0419 Table 007 GTH 2506 3007 AGRI 625 730 TABLE 007 Lt gt gt A 2 2 p J 99 23 Section 7 Repair Procedures April 2008 TABLE 007 Procedure Water oil cooler disassembly AGRI 625 730 4 Remove the two screws of the vibration damping bracket with a 22 mm wrench 5 Remove the two screws which fix the radiator to the cover wall using a 13mm wrench 6 Securethe cooler with a textile bridle connected to the rising hoist
159. orizontal position for removing the top pads 9 With a 17mm hexagonal wrench remove the pad fixing screws 10 With a screwdriver pry off the worn pads Fit new pads after applying a few drops of Loctite 495 on the threads Tighten the pad fixing screws to 30 35 Nm To renew the pads of the telescope proceed as follows 11 Remove all pads from the fixed section to extend the telescope see instructions above 12 Fully extend the boom then lower the nose to the ground and place a stand underneath the telescope near the fixed section 13 Remove the pin from the extension cylinder rod side see table GTH2506 3007 AGRI 625 730 006 Move back with the machine slowly to extend about 20 cm of the telescope out of the fixed section Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 29 Section 7 Repair Procedures April 2008 TABLE 009 Procedure Renewing the slide pads of the telescopic boom AGRI 625 730 14 Check the internal measure of the fixed section and the external measure of the telescope to verify if some shims are necessary considering that the final tolerance must range 1 0 mm 1 5 mm 15 With a 6 mm hexagonal wrench remove the worn pads Fit new pads after applying a few drops of Loctite 495 on the threads ACAUTION gt gt Tighten the pad fixing screws to 30 35 Nm 15 Clean and grease the internal and external walls of the boom sections in the sli
160. over Lights switch cover Continous flow switch cover Work lights switch cover 1 boom section front superior slide pad 1 boom section front inferiore slide pad 274 boom section rear superior 1 boom section front side slide pad 2 boom section rear side slide pad 2 boom section rear inferior slide pad Quick coupling female 1 2 Faster Quick coupling male 1 2 Faster Return hydraulic oil filter Brake pump Handle joystick Extension boom joystick push button Distributor pressure control valve Pressure relief valve on distributor Joystick Main valve movement control box Pressure control minisocket Negative breake pressure switch on main valve Main valve seals kit Mechanic lock fork pin Rope with eyes LIST OF RECOMMENDED SPARE PARTS GTH 3007 AGRI 730 Cod 07 0700 0023 09 4604 0004 07 0700 0037 07 0700 0036 07 0723 0149 07 4501 0068 07 4501 0067 07 0723 0149 07 0741 0062 07 0741 0058 07 0741 0057 07 0741 0059 04 4240 0052 Description Hydraulic oil filter inside the tank Hydraulic oil filter Engine air primary filter Engine air secondary filter Air filter inside the cab Fuel filter Engine oil filter Air cab filter Negative breake electrovalve Negative breake and deadman electrovalve solenoid Main valve electrovalve solenoid Deadman electrovalve Steering electrovalve Genie April 2008 o 5 ec o S N c cl
161. pril 2008 MAINTENANCE PROCEDURES 4 2 ABOUT THIS SECTION This section describes the maintenance interventions to be carried outon the machine according to the indications of the maintenance inspection report see chapter 3 Safety symbols E Draws the attention to situations that involve your own as well as the others safety and that can result in serious or lethal injury DANGER 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 efficiency 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 efficiency NOTICE Drawstheattentionto importanttechnical information or practical advice that allows for a safer and more efficient use of the machine 4 PROTECT THE Naw ENVIRONMEN Draws the attention to important information on environment protection 2 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 4 Maintenance Procedures 4 3 TABLE A PROCEDURES 1 CHECKTHEOILLEVELWITHINREDUCTION GEARS DIFFERENTIAL GEARS AND POWER DIVIDER REDUCTION GEAR To check the oil level within the wheel reduc
162. r filer Every 10 working hours C 5 Clamping of the cableheads 5 Operator Manual to the battery terminals 6 Labels and plates C 6 suction hose between A 7 Engine oil livel engine and filer 8 Air suction filler C 7 Cylinder chromium plated rods M9 Radiator C 8 Check the hydraulic lines Hydraulic oil level in the tank C 9 Checkihe electric cables A41 Checkthegreasingoftheboom C 10 Wear of the sliding pads of section pads the boom sections M12 Grase the forks C 11 Play ofthe sliding pads of the A 13 Grease all joints of the boom boom sections the rear axle shaft joint the C 12 Sliding parts of the boom transmission shafts the frontand sections rearaxles andany equipment of C 13 Level of the battery electrolyte the machine C 14 Efficiency of the block valves A 14 Lighting electric system A 15 d 1 system Table D and parking brake A 16 Steering selection system Every 900 working hours A47 Fork balancing system D 1 5 from engine exhaust A 18 Safety devices 0 2 Tighteningofthe engine fixing 49 Engine coolant level ee 8 Engine 63 Tightening of the cab Fixing screws Table B 04 Backlash between pins and Within the first 50 working hours bushings in all joints Efficency of machine 0 5 Hydraulic oil filter of the transmission Every 50 working hours D 6 Hydraulic oil filter in the tank B 2 Alternator belt 0 7 Efficiency of hydraulic system B 3
163. rame using a 30mm open end wrench 19 Raise and lift the engine with its bracket make sure to rest it on a suitable plane and fix it Reassembling the engine Toreassemble the engine repeatthe steps above in reversed order considering the precautions below 1 Handle the engine with extreme caution to prevent it from crashing against the machine DDocument 57 0009 0419 GTH 2506 3007 AGRI 625 730 15 Section 7 Repair Procedures April 2008 TABLE 003 Procedure Reassembling the engine on the machine AGRI 625 730 Intentionally blank page GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 16 April 2008 Section 7 Reapair Procedures TABLE 004 Procedure Haydraulic pumps disassembly Table 004 GTH 2506 3007 AGRI 625 730 Bridge crane or swing hoist payload Standard tools 500 kg Operation 9 PROTECT THE Before disconnecting the hydraulic piping place containers of suitable size underneath to prevent oil spillage Carefully clean the area around the piping to be disconnected plug all disconnected parts with caps rags or adhesive tape to prevent dust or impurities from entering the circuit They can cause serious damage 1 Using two 17mm wrenches remove the six screws that fix the engine lower cover 2 Remove the lower cover 3 Close the oil tank cocks Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 17 Sec
164. ressure reducing valves are installed in the hydrostatic drive 12 and cannot be regulated from the outside The steering circuit is completed by the front steering cylinder 14 the rear steering cylinder 15 these cylinders being integral part of the front axle 26 and the rear axle 27 respectively and by a 4 way 3 position solenoid valve 13 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 13 is not energised the frontsteering cylinderis fed by the hydraulic drive and the rear cylinder is blocked When one magnet or the other of the solenoid valve 13 is energised the chambers of the cylinders are connected in a different manner thus causing the desired effect on the steering mode The Walvoil hydraulic 4 section main valve 16 receivesoilfromthe secondary line of pump 3 and feeds all the movements of the telescopic boom Each of the 4 sections of the main valve controls a specific function of the machine lifting lowering attachment holding plate rotation boom extension retraction attachment locking unlocking In the head there is a pressure relief valve set at 280 bar 4061 psi which reduces the max pressure at the main valve inlet and drains the excess oil Slider 1 of the main valve controls the lifting cylinder 17 of the telescopic boom This cylinder has one single acting compensation valve with s
165. rticular we recommend checking the max pressure of the main valve checking the pressure of the drive pump checking the pressure of the hydraulic drive unit checking the pressure of the braking system checking all hydraulic components and their movements In case of need please contact the GENIE Service Centre Genie Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 41 Section 4 Maintenance Procedures April 2008 TABLE D D 8 CHANGE THE MAIN CARTRIDGE OF THE ENGINE AIR FILTER Changing the external element Stop the engine and engage the parking brake Unlatch the fasteners A and remove cover B Pull out the filter cartridge C 146 26 007 S Clean the filter bowl Mount the new cartridge D and make sure it is cor rectly positioned Close cover B and lock in place with fasteners A AWARNING As soon as the warning lamp on the cab dashboard switches on replace the outer element Genie 42 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 4 Maintenance Procedures TABLE D D 9 CLEAN THE CAB AIR FILTER Clean the air filter in the cab every six months Replace the cartridge if the filtering cloth is damaged Cleaning and changing the cartridge Shut the engine down and engage the parking brake Pull out the filter A located to the right of the driving place Clean the filter bowl
166. rvesthe rightto make changes atany time and withoutundertakingto give prior notice therefore also this publication may be subject to modifications Contact us http www terexlift com e mail info terexlift it http www genielift com Copyright 2008 TEREXLIFT srl All rights reserved First Edition First Printing April 2008 Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 For going to Table of Contents click on Genie symbol Machine Identification MACHINE IDENTIFICATION Machine Identification CHASSIS SERIAL NUMBER The chassis serial number is punched on the front left part of the chassis side 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 Machine data plate iv GTH 2506 3007 AGRI 625 730 April 2008 TEREX ona Industriale 060 Umbertide PG Italy MODEL NUMBER SERIAL NUMBER YEAR OF MANUFACTURE UNLADEN TRUC MAXIMUN EIGHT Lb TRUC CAPACITY Lb THIS TRUC IS COMPLIANT TO PART Ill OF ASME B56 6 2002 HERE APPLICABLE MADE IN ITALY V MACHINE DATA PLATE Chassis serial number The chassis serial number is punched on the front left part of the chassis side inertio GTH 3007 P 07 17882
167. rward position Run the engine at 1200 rpm Check the value on the tachometer Adjust shutter D by means of the register until reading a value of 50 bar on the high pressure manometer TP2 During this operation the operator has to be on the side of the machine Hold the selector to neutral position and make sure the maximum speed of the engine does not exceed 2600 rpm The engine must run at a idle speed of 950 rpm Otherwise adjust the minimum speed Read the boost pressure on manometer and ensure it is about 25 30 bar with the engine running at idle speed The boost pressure has not a fixed value but varies from pump to pump Hold the machine blocked by disconnecting the power plug of the solenoid valve controlling the parking brake Genie Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 19 Section 2 Technical Specification April 2008 SSS Sy TECHNICAL SPECIFICATION 31 CALIBRATION OF THE MAXIMUM 4 CALIBRATING THE POWER STEERING PRESSURE Fit a coupling complete with mini socket Z in the Do this operation with extreme caution The proper position shown in annex 1 functioning of pump and transmission depends on this e Fit a 0 250 bar manometer to the mini socket Z Calibrate e Select the front axle steering mode Move the steering cylinder to stroke end and make e Selector 10 he sure the value of the power steering A is 170 bar j If the value is less tighten valve
168. s hydraulic oil from tank 37 to operate the service brake located inside the front axle 26 The brake pump can provide a maximum pressure of 80 bar 1160 psi thus depending on the pressure exerted on the brake pedal placed inside the driving place The DESCRIPTION pressure switch 4 set at 2 8 6 3 bar 40 90 psi placed on the pump head sends an electrical signal when the service brake is engaged The oil coming from the drain line of the main valve operating the telescopic boom 16 is cooled down by the heat exchanger 32 This exchanger is divided in two sectors the former absorbs heat from the cooling circuit of the diesel engine and the latter absorbs heat from the hydraulic circuit of the machine The oil cooled down by the heat exchanger is sent back to the special filter 34 and finally drained into tank 10 A one way valve 33 calibrated at 8 bar 116 psi is installed parallel to the input line of the heat exchanger and used as safety valve Its function is to avoid overpressure conditions of the heat exchanger as is the case of a machine starting at low temperatures by directly draining any excess oil into the tank Genie Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 ix April 2008 GTH 23007 AGRI 730 hydraulic schematic Decsription DESCRIPTION SJey 28 yue IIO yue seul uopong Bunojid pue Bulsuas eunsse
169. s of flow PUMP F ixed displacement pump with one direction of flow zm lt ixed displacement pump ith two directions of flow ariable displacement pump with one direction of flow lt ariable displacement pump with flow regulator CYLINDERS S S ingle acting cylinder ingle acting cylinder with spring return Double acting cylinder Double acting cylinder with bilateral rod 1 elescopic cylinder COMMANDS AND CONTROLS S S H H haft rotating in one direction haft rotating in two directions and operated control and operated control with pushbutton and operated control ith lever and operated control ith pedal echanical control ith pushbutton echanical control ith spring Mechanical control with roller Electro magnetic control with winding solendoid Control with electric motor Direct pressure control Indirect piloted pressure control Control with electromagnet and piloted distributor PIPES AND CONNECTIONS Induction and return pipe Piloting pipe Blow by pipe Flexible hose Connecting point Pipe cross without connection Breather Closed pressure fitting Pressure fitting with connected pipe Quick fitting Quick fitting with check valves DISTRIBUTION SETTING ELEMENTS Non return valve Calibrated non retur
170. sembly En 006 Boom extension cylinder AGRI 625 730 Bridge crane payload 500 kg Textile bridles or chains with hooks Operation 1 Set the boom to horizontal position with the telescope slightly extended to work on the cylinder connecting pin rod side 2 With a 13 mm wrench remove the screw fixing the pin drop shaped head 2 3 Extract out and knock the pin using a plug of C gt soft material aluminium copper wood etc 4 Remove the rear guard to gain access to the amp rear part of the boom gt 2 5 Place container of suitable size under the 629 hydraulic piping before disconnecting ip x PROTECT THE 2 lt P Used oils must be handled and disposed of according to local regulations Address to legally authorised centres 6 With a 27 mm wrench disconnect the two hydraulic hoses from the blocking valve then plug the disconnected connectors to prevent dust and impurities from entering the circuit TEREX COMPANY Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 21 Section 7 Repair Procedures April 2008 TABLE 006 Procedure Cylinder disassembly Boom extension cylinder AGRI 625 730 7 Loosen remove the screw fixing the cylinder pin bottom side with two 13 mm wrenches 8 Extract out and knock the pin using a plug of soft material aluminium copper wood etc 9 Pull out the cylinder from the boom secti
171. stop 14 Plug in Connector Trasmission reverse mode solenoid valve F19 10A FUSE Windscreen washer motor 43 Plug in Connector Windscreen cabin roof F20 10A FUSE ECO Multipurpose Instruments 1 2 X42 Plug in Connector Windscreen rear cabin F102 20A FUSE Fan 12 X401 Plug in Connector Fuel level gauge 261 60A FUSE Maxi fuse electric system power 11 X40 3 Plug in Connector Fuel level gauge FG2 40A FUSE Maxi fuse glow plugs 11 Xi2s Plug in Connector Rear right road light 6t Battery 11 XLE Plug in Connector Rear wheels aligned sensor 69 Alternator M X47 Plug in Connector Load cell a Relay hig beam 42 X49 Plug in Connector Parking brake solenoid valve K2 Relay low beam 51 X5 Plug in Connector 21 way In Out relay card K3 Relay horn X51 Plug in Connector Four wheels steering solenoid valve Relay optional 53 X52 Plug in Connector Crab steering solenoid valve K5 Relay securuty low pressure switch parking brake 22 X53 Plug in Connector Front right road light K6 Relay trasmission reverse mode 23 X54 Plug in Connector Front left road light K7 Relay trasmission forward mode 22 X51 Plug in Connector Road light switch Relay starter enabling switch X58 Plug in Connector Forward reverse switch K9 Timer 22 X59 Plug in Connector Emergency switch Preheating glow plugs 1L X6 Plug in Connector 12 way In Out relay card K02 Relay start engine 13 X56 Plug in Connector First gear solenoid valve Timer enab
172. suction line of the open loop pump 3 is protected by an immersed filter 8 placed inside the hydraulic fluid tank 10 whose capacity is 65 litres 17 gallons Just upstream of the connection with the suction line there is a gate valve with ball valve 9 which lets you cut outthe hydraulic oil tank in orderto perform maintenance interventions on the machine s hydraulic system without having to drain oil off the tank built in the same circuit The filter 34 placed in the line returning to pump 3 purifies mostoil comingfrom the hydraulic circuitoperating the telescopic boom before this oil returns to the tank In addition to purify the oil coming from the main open loop circuit ofthe machine telescopic boom operating circuit this filter can deliver oil at a minimum pressure of 0 5 bar to the suction line ofthe drive pump 2 This construction feature of the filter guarantees important advantages in terms of absence of cavitation in the transmission suction line especially when the machine is started from cold The one way valve 11 setat 2 5 bar 36 psi 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 of the drive pump 2 low pressure oil is taken 25 30 bar to feed anti cavitation circuit ofthe automatic fork levelling system the pilot circuit of the main valve of the telescopic boom 16
173. t YA 9 E E 11 18 x ed 4 4 z Fla Tie 5 a 223 DV 1 2 lt ws e DY E wl F gt S19 V 519 7 3 a 2 a gt ad pa i p yams jeas HC eo 5 4 219915 samog Hu Jesuan Em LA 8 uueje Comm ns Jawn m prom Lee 14 8 5 S 1 samog e IN c Aiddns samog 9 13 gl V5 iN D NL C PIs 3 plo zi ILE 25625 157 SIND IN Miis lt 15 1 1 2 qe anea plovajos 100 32 AD 2 syaaya sno XR SNI oR W TAA 5 amen plouajos Buuiaajs 3 110 S 4 zi EF us WR IN L a z AAAA A z Document 57 0009 0419 Section 6 Schemes April 2008
174. the battery efficiency replace if necessary Change the fuse Check the dashboard and replace if necessary Reconnect or replace the wiring Engine does not start starter does not run 60A fuse blown Dashboard damaged relay damaged Speed switch ruined K08 engine start relay damaged Starter defective Change the fuse Check the dashboard and replace if necessary Change the relay Check or replace the speed switch Change the relay Change the starter Engine does not start starter runs but engine does not start No fuel Fuel filter clogged Fuel ducts empty Fuel supplement solenoid damaged Engine stop solenoid damaged Broken or damaged wiring Refuel Clean or replace the filter Eliminate any air Check the efficiency and replace if necessary Check the efficiency and replace if necessary Reconnect or replace the wiring The machine does not move forward back Speed switch damaged Fuse F12 broken Relays K07 K06 K05 damaged Check the efficiency or replace the Switch if necessary Change the fuse Check the efficency of relays Genie GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 5 Problems Causes Solutions PROBLEMS CAUSES SOLUTIONS Problems Causes Solutions Forward reverse speed solenoid valves damaged Service brake micro switch damaged Parking brake switch
175. the engine and connected to the same by a Technodrive coupler complete with elastic joint and with a 1 to 1 ratio there is Bosch Rexroth closedloop pump for hydrostatic drives model A4VG56 2 with adjustment valve of DA type The max displacement of this swashplate pump is 56 cm3 rev and the max calibration pressure is 430 bar 6235 psi The max displacement of this swashplate pump is 56 cm3 rev and the max calibration pressure is 430 bar 6235 psi This pump is used to supply hydraulic power under form of pressure and flow rate which is then used for moving the machine On the through shaft of such drive pump there is a Casappa open loop gear pump with fixed displacement 3 with priority valve integrated in the housing The displacement of this pump is 27 cm rev Its function is to provide hydraulic power under form of pressure and flow rate to the steering circuit of the machine primary branch of the priority valve and to the circuit for the telescopic boom movements secondary branch of the priority valve The assembly of the two pumps involves they have a rotation velocity equal to the speed of the diesel engine The suction line of the open loop pump 3 is protected by an immersed filter 8 placed inside the hydraulic fluid tank 10 whose capacity is 65 litres 17 gallons Just upstream of the connection with the suction line there is a gate valve with ball valve 9 which lets you cut out the hydraulic oil tank in or
176. tion gears Stop the machine on a level ground and ensure the parking brake is engaged and plug A finds on the horizontal axis Clean the plug all around then remove it using a 12 mm six sided key and check if oil is level with the hole necessary add new oil through hole A until it is level Refit the plug PROTECT THE P Place a container of suitable size under the plug for oil leaks TABLE A To check the oil level in the front and rear differential gears Stop the machine on a level ground and ensure the parking brake is engaged Remove the plug using a 10 mm six sided and check if oil is level with the hole If necessary top up through hole A until oil comes out Refit the plug A e PROTECT THE ENVIRONMEN Place a container of suitable size under the plug for oil leaks Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 3 Section 4 Maintenance Procedures April 2008 TABLE To check the oil level the power divider reduction gear Stop the machine on a level ground and ensure the parking brake is engaged Clean the plug A all around then remove it using a 10 mm six sided key an
177. tion 4 Maintenance Procedures April 2008 TABLE C 44 DANGER Do the check of the valves taking all the possible precautionary measures Wear safety glasses Wear safety gloves Wear safety shoes Wear suitable working clothes Use guards against leaks of oil at high pressure Do the check in a free space with barriers all around to keep non authorised people away Ensure that the part to be checked is in safe condition and that the action generated does not result in an uncontrolled movement of the machine Telescopic boom lifting cylinder 36 GTH 2506 3007 AGRI 625 730 TO REMOVE THE BLOCK VALALVES OR THE CYLINDERS Lower the boom to the ground in a firm way since the removal of the block valve or the cylinder can cause an uncontrolled down movement After refitting the valve or the cylinder replenish the circuit and eliminate any air before starting working To eliminate the air from the circuit move the involved cylinders to end of stroke in the two directions opening closing To eliminate the air from the fork balance cylinder move the boom up and down and tilt the fork plate forwards back 4a DANGER Before operating some maintenance procedures on the cylinder or in the area below the boom apply the fasteners on the cylinder see below I Lift and extend the boom Il Loosen the two screws the frame rif A to unlock the fastener Apply the fastener on the l
178. tion 7 Repair Procedures April 2008 TABLE 004 Procedure Haydraulic pumps disassembly 4 With a screwdriver remove the two electrical connections of the electrovalve which controls the machine forward reverse movements 5 Disconnect the hydraulic piping disconnect the two drain lines of the hydraulic pump with a 36mm wrench disconnect the suction line of the hydraulic pump with a 50mm wrench disconnect the low pressure line duct with a 19mm wrench disconnect the four flanges which connect the drive pump to the drive motor with a 8mm Allen wrench disconnect the suction line of the service pump with a 8mm Allen wrench disconnect the delivery line ducts of the hydraulic drive and the main valve with a 36mm wrench and a 24mm wrench disconnect the load sensing signal line from the hydraulic drive with a 17mm wrench Once all operations have been performed make sure that all electrical wires and hydraulic lines are disconnected from the motor 6 Disconnect the service pump from the drive pump by driving out bolts A with a 19mm wrench Place the pump on to a bench and plug all the outlets 7 Remove the fixing screws B of the drive pump with a 14mm hex head wrench and then secure the pump to the bridge crane with a textile sling and pull it out of the motor Place the pump on to a bench and plug all the outlets 8 Proceed in reverse order to re assemble the hydraulic pumps
179. tions 11 2 19 Advice to renew flexible hoses 12 2 20 List of recommended spare parts GTH 2506 AGRI 625 13 List of recommended spare parts GTH 3007 AGRI 730 14 2 21 Machine paint colour 16 2 22 Checking the cylinder movement times 17 2 23 Hydraulic settings 18 1 Preliminary operations 18 2 Calibrating the boom main valve 18 2 1 Calibrating the main valve pressure control valve18 3 Setting the hydromatik pump hydrostatic transmission 19 3 1 Calibration of the maximum pressure 20 4 Calibrating the power steering 20 5 Negative parking brake pressure 20 6 Service brake pressure 20 2 24 DLE system 22 2 25 Check main valve control unit by computer 41 Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 xvii April 2008 TABLE OF CONTENTS Section3 Rev Section4 Rev Maintenance Inspections 3 1 Introduction 3 2 About this section 3 83 Maintenance table 3 4 Maintenance inspection report Maintenance Procedures 4 1 Introduction 4 2 About this section 4 3 Table A procedures A 1 Check the oil level within reduction gears differential gears and power divider reduction gears 2 Check the tightening of the wheel bolts A 3 Check the tightening of all bolts and nuts A 4 Check the couplings for oil leaks A 5 Inspect the Operator manual A 6 Inspect the decals and plates A 7 Check the engine oil level A 8 Clean the air suction filter A 9 Check and clean the radiator A 10 Check the hydraulic oil level in the t
180. tray under plug A and with an appropriate wrench unscrew this plug and allow the oil to drain into the tray If the engine has two drain plugs allow the oil to drain off from both Once oil has been drained clean plug A with care and refit it If necessary replace the plug gasket Unscrew filter C with an appropriate tool Remove it from its seat Check the filter surface and the filter housing base are clean Apply a thin film of clean engine oil to the seal of the filter Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 Section 4 Maintenance Procedures TABLE C Install the filter by hand Remove dipstick D engine level check Fill the engine through the hole of plug B see technical specifications table 2 13 Check the oil is level with the hole Operate the starting motor and let the engine run for a few seconds Start the engine and let it run AT IDLE and LOADLESS for some 2 minutes Stop the engine wait for a few minutes and then check that oil level reaches the MAX mark on the dipstick D For the engine maintenance please refer to the specific Operator handbook code SLBU 7853 00 supplied with the machine Section 4 Maintenance Procedures April 2008 TABLE C C 2 CHECK THE OIL LEVEL IN THE DIFFERENTIAL GEARS AND POWER DIVIDER To check the oil level in the wheel flow dividers Stop the machine on a level ground and ensure the parking
181. uality Genie Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 33 Section 4 Maintenance Procedures April 2008 4a DANGER Risk of explosion or shorts During the recharge an explosive mixture with release of hydrogen gas Ensure the fluid is 5 6 mm above the plates forms the cell levels are correct Protect the terminals smearing them with pure vaseline Remove the battery and store it in a dry place when the machine is not used for a long time Do not add sulphuric acid add only distilled water 44 DANGER Battery electrolyte contains sulphuric acid It can burn you if it touches your skin and eyes Always wear goggles 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 Aa DANGER 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 positive lead first Recharge the battery far from the machine in a well ventilated place Keep out of items which can produce sparks of naked flames or lit cigarettes Do not rest metal objects onto the battery This can result in a dangerous short especially during a recharge Because the electrolyte is highly corrosive it must never come in contact with the frame
182. ue to overstress caused by the wheels on the steering cylinders These pressure reducing valves are installed in the hydrostatic drive 12 and cannot be regulated from the outside The steering circuit is completed by the front steering cylinder 14 the rear steering cylinder 15 these cylinders being integral part of the front axle 26 and the rear axle 27 respectively and by a 4 way 3 position solenoid valve 13 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 13 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 13 is energised the chambers of the cylinders are connected in a different manner thus causing the desired effect on the steering mode The Walvoil hydraulic 4 section main valve 16 receives oil from the secondary line of pump 3 and feeds all the movements of the telescopic boom Each of the 4 sections of the main valve controls a specific function of the machine lifting lowering attachment holding plate rotation boom extension retraction attachment locking unlocking In the head there is a pressure relief valve set at 280 bar 4061 psi which reduces the max pressure at the main valve inlet and drains the excess oil Slider 1 of the main valve controls the lifting cylinder 17 ofthe t
183. ure they are not damaged In particular we recommend checking the cables located near moving mechanical parts as they could rub against such parts and get damaged Replace any worn hoses immediately before using the machine again Tav 605040 pos 1 30 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 4 Maintenance Procedures ae TABLE C C 10 CHECK THE WEAR OF THE SLIDING PADS OF THE BOOM SECTIONS Any boom section is fitted with adjustable pads located on the four sides of the profile These pads are secured to both fixed and mobile part of every section All pads can be adjusted by the special shims Pads must compulsorily be replaced if the residual thickness of the plastic layer with respect to the iron bush fixing the block is equal or inferior to 1 mm Max wearing thickness Minimum 1 mm Genie Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 31 Section 4 Maintenance Procedures April 2008 TABLE C C 11 ADJUST THE PLAY OF THE SLIDING PADS OF THE BOOM SECTIONS Any boom section is fitted with adjustable pads located on the four sides of the profile These pads are secured to both fixed and mobile part of every sectio
184. valves B proceed as follows e Increase the pressure of valve A of the main valve to 310 bar moving the lifting cylinder to end of stroke fully out With the engine running at maximum speed tilt the forks to one direction by means of the joystick and act on one of the two valves B until reaching a 18 GTH 2506 3007 AGRI 625 730 pressure of 300 bar Adjust the second valve B by pitching the forks back e When both fork inclination valves have been calibrated reset the pressure control valve to 280 bar by adjusting the adjustment screw A e With the engine at max speed extend completely the 2 boom section to the end of stroke Check the pressure on mini socket TP1 is 120 bar otherwise set it by valve C see image 2 For safety reasons do not hold the cylinder to end of stroke and do not let the engine run at max speed for more than 5 seconds IMAGE 2 Document 57 0009 0419 April 2008 Section 2 Technical Specification 3 SETTING THE HYDROMATIK PUMP HYDROSTATIC TRANSMISSION Do the calibration of the hydrostatic transmission with the hydraulic oil at 60 C e Connect 0 60 bar manometer to the mini socket TP3 to read the boost pressure see image 1 e Connect 0 60 bar manometer to the mini socket TP2 to read high pressure see image 1 TECHNICAL SPECIFICATION STARTING THE CALIBRATION Set the forward neutral reverse selector to the fo
185. ve control unit proceed as follows Liftthe boom the safety ring on the rising cylinder and remove the side cab cover to access to the control unit located under the joystick picture 1 Connect the computer to the control unit using the cable cod 55 0602 0419 picture 2 Connect to the control unit only the three wire socket picture 3 Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 Genie TECHNICAL SPECIFICATION 41 Section 2 Technical Specification April 2008 TECHNICAL SPECIFICATION DIAGNOSTIC CONTROL PROGRAM Starting the application picture 4 you ll find a window picture 5 with a dialog box choose one of the serial portes for example COM 1 and push the bottom CONNECT NOTICE Please note that this software doesen t work in offline In picture 5 you can see the setting windows In the movements selector box you can choose the movement you want to set among braccio boom raising and lowering telescopico boom extension and retraction and movim forche fork forward back pitching Once you ve chosen the movement you can set in the MIN and MAX boxes the value in percentage of the movement speed you desire MIN minimum speed MAX maximum speed RAMP UP and RAMP DOWN represent the increasing and decreasing of the reaction time of the real movement of joystick Click on LOAD SETTINGS FROM FILE to load in the mach
186. ve pump to the drive motor with a 8mm Allen wrench disconnect the suction line of the service pump with a 8mm Allen wrench rif A disconnect the delivery line ducts of the hydraulic drive and the main valve with a 36mm wrench and a 24mm wrench disconnect the load sensing signal line from the hydraulic drive with a 17mm wrench Once all operations have been performed make sure that all the electrical wires and the hydraulic lines are disconnected from the motor 17 Remove the four screws two on the front and two at the back of the vibration damping brackets with a 22 mm wrench 14 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 7 Repair Procedures TABLE 003 Procedure Removing the engine from the machine Reassembling the engine on the machine 18 Sling the engine using a two leg chain with hook to be coupled to the front lug and the rear supporting bracket of the battery 19 Raise the engine with caution and ensure no Y parts are still connected b u 20 Remove the engine from the machine rest it on a wooden pallet and hold it in position with some plugs 21 For removing the engine with its bracket executing the procedure up to number 16 checking all hydraulic and electrical joints are disconnected 22 Hook the engine executing the procedure up to number 18 and put the chains in tension 23 Remove the five screws that fix the bracket of the engine to the f
187. vent accidents For instance this handbook makes use of special safety symbols to highlight potentially hazardous situations NOTICE 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 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 machi ne directly or indirectly or make it unsafe contact GENIE Assistance Service for any sugge stion 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 Xiv GTH 2506 3007 AGRI 625 730 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 substan ces that may alter their psycho physical conditions and consequently their work
188. wing window will be displayed so you can type in the password For any changes you must enter the following data User Name contact the TEREXLIFT Service Centre to get your ID code Password contact the TEREXLIFT Service Centre to get your ID code Save File Cre Desktop de Documenti 34 GTH 2506 3007 AGRI 625 730 Document 57 0009 0419 April 2008 Section 2 Technical Specification EE TECHNICAL SPECIFICATION Choose the folder where to save the setting and save the file with a name showing the serial number of the machine e g T4013 SX sn 10578 Press the Save button If you have chosen to upload a setting previously saved in memory select the Carica Load command from the File menu The following window will be displayed Open File E Documenti Nome d a Risorse del computer 5 Scambio Cronologia E Risorse di rete Schede macchine 74 ce Documenti Choose the setting file you want to upload on the machine and press Apri Open Save the setting as explained below DLE e Ifyou want save the setting contact the TEREXLIFT Service Centre to get more information and be registered as an authorised user of the system e To gain access to the parameters and variables no password is needed All you have to do is connecting the DLE display with the power cord supplied by TEREXLIFT code 07 0736 0014 and proceed as explained below Connect t
189. working hours A 1 Check the oil level within reduction gears power divider and differential gears A 2 Check the tightening of the wheel bolts A 3 Check the tightening of all bolts and nuts A 4 Check the couplings for oil leaks Every 10 working hours or daily A 5 Check the Operator Manual inside the machine A 6 Check the labels and plates are well visible A 7 Check the engine oil level A 8 Check and clean the air suction filter A 9 Check and clean the radiator A 10 Check the hydraulic oil level in the tank A 11 Check the greasing of the boom section pads A 12 Grease the forks A 13 Grease all joints of the boom the rear axle shaft joint the transmission shafts the front and rear axles and any equipment of the machine A 14 Check the efficiency of the lighting electric system A 15 Check the efficiency of braking system and parking brake A 16 Check the efficiency of the steering selection system A 17 Check the efficiency of the fork balancing system A 18 Make sure the safety devices installed are in efficient working order A 19 Check the engine coolant level Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 3 Section 3 Maintenance Inspections April 2008 MAINTENANCE INSPECTIONS TABLE B Within the first 50 working hours B 1 Check the general efficency of the machine Every 50 working hours or weekly B 2 Check
190. y Document 57 0009 0419 GTH 2506 3007 AGRI 625 730 Section 5 Problems Causes Solutions PROBLEMS CAUSES SOLUTIONS April 2008 Problems Causes Solutions The boom lifting is not not efficient The seals of the lifting cylinder are damaged Cylinder rod damaged Leakage in the cylinder block valve Fit a new kit of seals and check the tightness of the cylinder Check the rod condition Check the valve operation if necessary clean or replace the valve During the down movement the boom jerks Leakage in the cylinder block valve Check the valve operation if necessary clean or replace the valve Operating the joystick no fun ction is activated Joystick damaged Valve of the main valve damaged Low piloting pressure Check the joystick efficiency replace if necessary Check the efficiency of the valve replace if necessary Check boost pressure of the drive pump The steering wheel is slow and noisy Couplings damaged Hydraulic drive damaged Replace the couplings Replace the hydraulic drive Differential noisy and high temperature on the body No oil Bearings damaged Check the oil level and refill If trouble cannot be rectified dismantle the unit Replace the bearings The boom is hard to move in when it is fully extended in the horizontal position Sliding blocks worn out Check all the front bottom pads and

PN 57.0009.0419

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