Genie GTH-4013 SX, Service Manual

Page 1: ...English Service Manual GTH 4013 sx GTH 4017 sx Serial number range From serial n 19275 From serial n 19300 Part No 57 4403 4200 May 2008 Courtesy of Crane Market ...

Page 2: ...Document 57 4403 4200 GTH 4013 SX GTH 4017 SX ii Intentionally blank page Service Manual May 2008 Courtesy of Crane Market ...

Page 3: ...ipment Intheseinstances westronglyrecommendlettingservice and repair the machine at an authorized TEREXLIFT service center Technical Publications No part of this publication may be reproduced stored in a retrievalsystemortransmittedinanyformorbyanymeans without prior written permission from TEREXLIFT srl In pursuing a policy of constant quality improvement TEREXLIFTsrlreservestherighttomakechanges...

Page 4: ...ERIAL NUMBER Chassis serial number The chassis serial number is punched on the front left part of the chassis side member GTH 4013 P 07 17882 MODEL ENGINE TYPE YEAR OF MANUFACTURER SERIAL NUMBER Lb ona Industriale 0 0 Umbertide PG Italy TRUC CAPACITY UNLADEN TRUC MA IMUN EIG T SERIAL NUMBER MADE IN ITALY MODEL NUMBER YEAR OF MANUFACTURE Lb T IS TRUC IS COMPLIANT TO PART III OF ASME B 2002 ERE APPL...

Page 5: ... in this way the temperature From port M3 of the drive pump 2 low pressure oil is taken 25 30 bar and used for the anti cavitation circuit of the automatic fork levelling system The hydraulic energy produced by the drive pump 2 is converted into mechanical power by a closed loop hydrostatic motor model Sauer danfoos 51D110 5 The max displacement of this bent axis motor is 80 cm3 rev The motor is d...

Page 6: ...y 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 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 activat...

Page 7: ...heat from the cooling circuit of the diesel engine and the other absorbing heat from the hydraulic circuit of the machine The oil cooled down by the heat exchanger is sent back to the special filter 34 which is also used to deliver fluid at pressure to the transmission booster pump and finally drained into tank 10 A one way valve calibrated at 8 bar 33 is installed parallel to the input line of th...

Page 8: ...kes pedal pump 150 bar Forks attachment quick coupling cylinder Boom functions main valve X31 X18 X19 X30 X17 Rear axle pivoting lockout cylinder Rear axle pivoting lockout valve 2 ways 2 positions A1 B1 B3 A3 B2 A2 A4 A5 A6 B4 B5 B6 T T P 270 bar Functions enabling valve TP1 T A1 A2 B B1 B2 A Telescoping forks tilt selector valve 6 ways 2 positions 295 bar 295 bar 200 bar HYDRAULIC CIRCUI T COLOR...

Page 9: ... Boom functions main valve X31 X18 X19 X30 X17 Rear axle pivoting lockout cylinder Rear axle pivoting lockout valve 2 ways 2 positions A1 B1 B3 A3 B2 A2 A4 A5 A6 B4 B5 B6 T T P 270 bar Functions enabling valve TP1 T A1 A2 B B1 B2 A Telescoping forks tilt selector valve 6 ways 2 positions 295 bar 295 bar 200 bar HYDRAULIC CIRCUI T COLORS LEGENDA Hydraulic lines to from actuators Low pressure lines ...

Page 10: ...Description May 2008 Intentionally blank page Document 57 4403 4200 GTH 4013 SX GTH 4017 SX x Courtesy of Crane Market ...

Page 11: ...zards 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 appropria...

Page 12: ...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 WARNING 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 m...

Page 13: ...ris thatcouldgetintomachinecomponentsand cause damage Be sure that your workshop or work area is properly ventilated and well lit Be sure any forklift overhead crane or other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted Use only chains or straps that are in good condition and of ample capacity Be sure that fasteners intended for one time use i...

Page 14: ... are in doubt Contact GENIE the assistance service is at your disposal Addresses phone and fax numbers are given in the cover and in the title page of this manual 1 3 SERVICEMEN S REQUISITES The operators who use the machine regularly or occasionally e g for maintenance or transport shall have the following requisites health before and during any operation operators shall never take alcoholic beve...

Page 15: ...he machine movements and represent a danger for personnel 1 4 2 PRECAUTIONS DURING WORK Do not walk or stop under raised loads or machine parts supported by hydraulic cylinders or ropes only Keep the machine handholds and access steps always clean from oil grease or dirt to prevent falls or slips When entering leaving the cab or other raised parts always face the machine never turn the back When c...

Page 16: ...ck for pressure leaks Fine jets of air oil or fuel can injure you Neither smoke nor use open flames if there is a risk of fire or close to fuel oil or batteries Do not leave fuel cans or bottles in unsuitable places Do not empty catalytic mufflers or other vessels containing burning materials without taking the necessary precautions Carefully handle all flammable or dangerous substances After any ...

Page 17: ... 2 9 Hydraulic system 3 2 10 Electrical system 3 2 11 Machine sounds level 4 2 12 Vibration level 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 instructions 11 2 19 Advice to renew flexible hoses 12 2 20 List of recommended spare parts GTH 4013 SX GTH 4017 SX 13 2 21 Machi...

Page 18: ...ion system 18 A 17 Check the efficency of the fork balancing system 19 A 18 Check the efficient working order of the safety devices 20 A 19 Check the engine coolant level 23 A 20 Check the efficency of the overload warning system 24 A 21 Check the re sequence of the boom telescope GTH 4013sx 25 4 4 Table B procedures 26 B 1 Check the efficency of the machine 26 B 2 Check the tension of the alterna...

Page 19: ...ter 51 4 8 Table F procedures 52 F 1 Change the engine coolant 52 4 9 Table G procedures 53 G 1 Check the machine structure 53 Section 5 Rev Problems Causes Solutions 1 5 1 Introduction 1 5 2 About this section 2 5 3 Electrical faults 3 5 4 Hydraulic faults 10 Section 6 Rev Schemes 1 6 1 Hydraulic symbols 1 6 2 Hydraulic schemes 3 6 2 1 GTH 4013 SX 3 6 2 2 GTH 4017 SX 4 6 3 Electrical symbols 5 6 ...

Page 20: ...X GTH 4017 SX xx TABLE OF CONTENTS 013 Renewing the flexible hoses inside the boom GTH 4013 SX 39 014 Renewing the flexible hoses inside the boom GTH 4017 SX 41 015 Cylinder disassembly Attachment rotation cylinder 45 Courtesy of Crane Market ...

Page 21: ... 780 780 E Track mm 1920 1920 F Wheelbase mm 2950 2950 G Lenght to the front tyres mm 4790 4830 H Lenght to the attachment holding plate mm 6060 6570 I Ground clerance center mm 390 430 J Max width with ext outriggers mm 2890 2890 K Ground clerance axle mm 441 491 Inside turning radius mm 2425 2425 Outside turning radius mm 4650 4650 GTH 4013 SX GTH 4017 SX Technical Specification D E C J K B A I ...

Page 22: ...105 Break out force Kg 6000 shovel 800It SAE J732 80 6000 shovel 800It SAE J732 80 Chassis levelling 6 6 TELELIFT 3512 401 2 6 PAYLOAD AND REACH GTH 4013 SX GTH 4017 SX Lifting height max with without outriggers mm 13000 12810 17190 16720 Forward reach max mm 9080 13330 Reach at maximum height mm 1900 3560 Fork holder plate rotation 138 138 Lifting capacity max kg 4000 4000 Lift capacity at maximu...

Page 23: ...placement cm3 4 4 4 4 Cylinder arrangement vertical in line vertical in line Combustion system direct injection direct injection Max power output 2200 rpm kW 74 5 74 5 Max torque output 1400 rpm Nm 392 392 Aspiration turbocharged turbocharged Cylinder s number 4 4 Bore x Stroke mm 105x127 105x127 Max Load With Fork 2 9 HYDRAULIC SYSTEM GTH 4013 SX GTH 4017 SX Make PERKINS PERKINS Hydraulic output ...

Page 24: ...ar with reduction gear l 8 7 8 7 Rear differential gear l 8 7 8 7 Front wheel reduction gears l 0 75 0 75 Rear wheel reduction gears l 0 75 0 75 Engine coolant l 15 15 Products Engine Oil SHELL RIMULA SAE 15W 40 API CH 4 CG 4 CF 4 CF ACEA E3 MB228 3 Power divider Differential gears Reduction gears TRACTORENAULT THFI 208 LF SAE 80W API GL4 FORD M2C 86B MASSEY FERGUSON M 1135 Hydraulic system and br...

Page 25: ... 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 1 687 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 1...

Page 26: ... 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 ...

Page 27: ...20 M 12 x 1 75 10 44 10 10 10 20 x 1 5 10 68 10 38 10 50 M 14 x 2 12 21 11 83 12 00 x 1 5 12 68 12 38 12 50 M 16 x 2 14 21 13 84 14 00 x 1 5 14 68 14 38 14 50 M 18 x 2 5 15 74 15 29 15 50 x 1 5 16 68 16 38 16 50 M 20 x 2 5 17 74 17 29 17 50 x 1 5 18 68 18 38 18 50 M 22 x 2 5 19 74 19 29 19 50 x 1 5 20 68 20 38 20 50 M 24 x 3 21 25 20 75 21 00 x 2 22 21 21 83 22 00 M 27 x 3 24 25 23 75 24 00 x 2 25...

Page 28: ... 11 16 12 190 1 5 8 12 225 1 7 8 12 270 2 12 245 2 1 4 12 360 FRONT O LOK Parker SEALS Thread TIGHTENING diameter TORQUES 0 10 FRONT O LOK PARKER SEALS inc mm Nm 9 16 18 25 11 16 16 40 13 16 16 55 1 14 80 1 3 16 12 115 1 7 16 12 130 1 11 16 12 190 2 12 245 37 COUNTER SUNK CONICAL SEALS JIC Thread TIGHTENING diameter TORQUES 0 10 37 CONICAL SEALS JIC inc mm Nm 7 16 20 M10x1 15 1 2 20 M12x1 5 20 9 1...

Page 29: ...5 G 1 8 M20x1 5 L 42 245 G 1 4 M12x1 5 S 6 50 G 1 4 M14x1 5 S 8 50 G 3 8 M16x1 5 S 10 80 G 3 8 M18x1 5 S 12 80 G 1 2 M22x1 5 S 16 105 G 3 4 M27x2 S 20 220 G 1 M33x2 S 25 370 G 1 1 4 M42x2 S 30 500 G 1 1 2 M48x2 S 38 600 FITTING ASSEMBLY Thread TIGHTENING diameter TORQUE 0 10 JOINTS A B inc mm Nm Nm G 1 8 M10x1 25 12 M12x1 5 30 18 G 1 4 40 18 M14x1 5 50 20 M16x1 5 60 35 M18x1 5 80 50 G 3 8 95 40 M2...

Page 30: ...llent Loctite 573 Formed in place gasket 150 0 2 Slow Excellent Loctite 574 Formed in place gasket 150 0 5 Rapid Excellent Loctite 510 Formed in place gasket 200 0 2 Moderate Excellent Loctite 5699 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 plac...

Page 31: ...h 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 sure that all fixing bolts have been removed all hydraulic and electrical parts have been disconnected the part to be removed is not blocked ST...

Page 32: ...ecting point to the line NO YES YES NO YES YES NO NO YES NO Useful advice for mounting flexible hoses 2 19 ADVICE TO RENEW FLEXIBLE HOSES PROTECT THE ENVIRONMENT Before disconnecting a hydraulic pipe place containers of suitable size underneath to prevent oil spillage CAUTION Plug all disconnected parts to prevent dust or impurities from entering the circuit They can cause serious damage DANGER Be...

Page 33: ...005 manifold 1 53 3001 6000 evaqueted smoke flexible hose 1 09 4645 0000 throttle cable 1 640101 gasket kit 1 640102 gasket kit 1 04 0605 0505 twin hose 1 56 0009 0002 horn 1 09 4604 0045 vacuometer 1 07 0740 0050 handle 1 07 0740 0041 glass 1 07 0703 0494 switch 1 07 0703 0417 speed switch 1 07 0703 0418 lights switch 1 07 0704 0133 handle 1 07 0741 0011 pushbutton 1 07 0703 0029 starter switch 1...

Page 34: ...trol unit 1 07 0703 0640 diode 1 634975 fuse 1 56 0010 0005 flashing beacon 1 07 0703 0384 bulb 1 Cod Description Q ty 2 21 MACHINE PAINT COLOUR GENIE machine BLU GENIE GREY GENIE BLACK RAL 9500 RED RAL 3002 RAL 2002 RAL 3020 YELLOW RAL 1003 RAL 1018 RAL 1007 RAL 1021 RAL 1016 RAL 1028 ORANGE RAL 2009 RAL 2011 RAL 2004 GREEN RAL 6029 SUNBELT GREEN WHITE RAL 9002 RAL 9010 RAL 9016 RAL 1013 TEREX GR...

Page 35: ...re max 4 3 CAUTION 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 2 22 CHECKING THE CYLINDER MOVEMENT TIMES CAUTION 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 GTH 4017 SX Time s Up Dow Max eingine speed 11 8 GTH 4017 SX Ti...

Page 36: ...tion May 2008 TECHNICAL SPECIFICATION OUTRIGGERS CONTROL MACHINE SWAY GTH 4013 SX Time s Up Down Max engine speed 6 7 Min engine speed 14 19 GTH 4013 SX Time s from right to left from left to right Max engine speed 13 12 Min engine speed 17 17 Lift Lower Courtesy of Crane Market ...

Page 37: ...ut of the pressure relief valve A of the main valve see image 1 Using joystick E with the engine running at max speed lift completely the boom and set the valve A to 280 bar B B A C To check the safety valves B proceed as follows Increase the pressure of valve A of the main valve to 310 bar moving the lifting cylinder to end of stroke With the engine running at maximum speed tilt the forks to one ...

Page 38: ...TP2 is 425 bar annex 1 0 60 30 20 10 50 40 600 300 200 100 500 400 TP3 TP2 IMAGE 3 3 1 HYDROSTATIC TRANSMISSION PUMP ANNEX 2 Pump check points A high pression manometric socket MB B low pression manometric socket M3 C pressure cut off valves max 450 bar D high pression safety valves 480 bar E boost pressure valve F forward revers speed solenoids Max pressure of the valves C is 450 bar 3 2 CHECK TR...

Page 39: ...Document 57 4403 4200 GTH 4013 SX GTH 4017 SX 19 May 2008 Section 2 Technical Specification TECHNICAL SPECIFICATION TRANSMISSION annex 1 TP3 TP2 Courtesy of Crane Market ...

Page 40: ...20 GTH 4013 SX GTH 4017 SX Document 57 4403 4200 Section 2 Technical Specification May 2008 TECHNICAL SPECIFICATION annex 2 TRANSMISSION PUMP B A C D E D F 48 48 Courtesy of Crane Market ...

Page 41: ...Document 57 4403 4200 GTH 4013 SX GTH 4017 SX 21 May 2008 Section 2 Technical Specification TECHNICAL SPECIFICATION POWER STEERING SYSTEM annex 3 X A Z Courtesy of Crane Market ...

Page 42: ...22 GTH 4013 SX GTH 4017 SX Document 57 4403 4200 Section 2 Technical Specification May 2008 TECHNICAL SPECIFICATION annex 4 TRANSMISSION ENGINE M4 B XB A XA Courtesy of Crane Market ...

Page 43: ...sher ø 10 3 fixing screw M10x40 cl 10 9 A To avoid damaging strain cage and to get maximum results proceed as follows 1 PREPARATION Thoroughly clean whole tightening system especially the ground and unpainted area A of rear axle 2 ASSEMBLY 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 N...

Page 44: ...wn CONNECTOR X1 FOR CHECKS WITH TESTER Electrical power to control unit DLE Pin 1 12 V Pin 2 GND Overload signal 12V generated by the DLE Pin 18 12 V normal conditions 0 Valarm 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 lo...

Page 45: ...ccess code currently used is 1001 Therefore you should enter the following sequence 1 0 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 Description of the controls 1 Calibration selection button 2 Display 3 Stability indic...

Page 46: ...erturning distance is from the front part of the wheels to the center of the load see the diagram inside the cab 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 3 With outriggers ...

Page 47: ...kg 1250 kg 71 6 1 43 1500 kg 2500 kg 3500 kg 4 0 0 0 k g 60 m LOAD DIAGRAM GTH 4013 SX ON OUTRIGGERS 1500 kg 20 0 1 2 3 4 5 6 7 8 9 10 0 1 1 2 3 4 5 6 7 8 9 10 11 12 13 0 10 30 40 50 60 68 8 A B C D E 4 18 3 5 0 0 k g 2 5 0 0 k g 9 08 m 12 80 m 3 0 0 0 k g 4000 kg 2 0 0 0 k g 1000 kg 500 kg 250 kg 60 m LOAD DIAGRAM GTH 4013 SX ON TYRES LOAD DIAGRAM GTH 4017 SX ON OUTRIGGERS LOAD DIAGRAM GTH 4017 S...

Page 48: ...rlock relay is active machine safe without alarms D 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 LED software 4 E No function F Press to escape from the calibration and SAVE all changes the buzzer and the LED activate to confirm storage ...

Page 49: ...n 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 A Description RAM data error Checks that the parameters load in the RAM at start up remain unal tered Action Switch off and on the limiter Alarm code B Description Outriggers congruence Action Check that the signal of stabi...

Page 50: ...admissible delta between readings of analog channels 1 and 2 expressed as a default 10 current 20 11 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 relevant procedure during calibration When the platform is...

Page 51: ...hine 22 C2NavicellaVuoto Value saved in analog channel 2 during calibration with empty machine 23 C2NavicellaCarico Value saved in analog channel 2 during calibration with loaded machine 24 CurMacchina Machine selected on point 0 of the calibration 28 VersioneSW Software version 29 WPsum Parameters CHECKSUM used by the safety functions LIST OF THE DLE VARIABLES N Winscope Name Default Description ...

Page 52: ...image 1 Proceed as follows Click FILE Click OPEN Choose the diagnostic file image 1 Select and click INVIO Click on to open the dialog windows image 2 Check the installed SOFTWARE is right image 3 Select SYSTEM Select SYSTEM INFORMATION Check the customer specific is 401702 for GTH 4013SX and for GTH 4017SX Open the first control system page Select SYSTEM Select ELECTRICAL The window image 4 shows...

Page 53: ...Document 57 4403 4200 GTH 4013 SX GTH 4017 SX 33 May 2008 Section 2 Technical Specification TECHNICAL SPECIFICATION 4 6 5 Courtesy of Crane Market ...

Page 54: ...ge 38 in the FAULT TABLE A Select PARAMETERS FUNCTIONS to check the parameters Proceed as follows Select ALLPARAMETERS V168 8 Press F2 to ensure the present parameters are up loaded on the control unit Click on import values from a parameter data filer Select the right FILE 401702 Press F4 to up load the parameters on the control unit The control unit can work Perform the pedal inching calibration...

Page 55: ... PRESS F4 Inside the window calibrate inch Potentiometer select the value 0 see image 11 PRESS F 4 select the Setup Status menu see image 12 The system recognizes the calibration minimum value automatically for example Min Value 1038 image 12 Step down the brake pedal until calibration complited appears see image 13 with the maximum calibrate inching value Max Value 7790 To finish the calibration ...

Page 56: ...rol unit Image 16 functional scheme of the transmission The following elements are not used in the present system Creeper drive Creeper drive switch PPU motor Brake pressure defeat Parking brake Connector 1 Pin Controller Function C1 P1 Power ground C1 P2 Power supply 12 volts C1 P3 CAN H C1 P4 CAN L C1 P5 AIN CAN shield C1 P6 Forward C1 P7 Reverse C1 P8 Power 5 Volts inch pedal C1 P9 Ground inch ...

Page 57: ...Document 57 4403 4200 GTH 4013 SX GTH 4017 SX 37 May 2008 Section 2 Technical Specification TECHNICAL SPECIFICATION 16 Courtesy of Crane Market ...

Page 58: ...38 GTH 4013 SX GTH 4017 SX Document 57 4403 4200 Section 2 Technical Specification May 2008 TECHNICAL SPECIFICATION Intentionally blank page Courtesy of Crane Market ...

Page 59: ...achine Scheduled maintenance must be carried out at the intervals indicated in the MAINTENANCE REPORT WARNING Failure to properly complete each inspection when required may cause death serious injury or substantial machine damage Immediately tag and remove from service a damaged or malfunctioning machine Repairanymachinedamageormalfunctionbefore operating machine Maintenance Inspections Courtesy o...

Page 60: ...hly A B C Every 2 months A B C D Every 6 months A B C D E Yearly 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 Themaintena...

Page 61: ...n 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 sy...

Page 62: ...k the oil level in the four wheel reduction gears C 5 Check the main filtering element of the engine air filter Replace if necessary C 6 Check the clamping of the cableheads to the battery terminals C 7 Check the air suction hose between engine and filter Replace if necessary C 8 Check the cylinder chromium plated rods C 9 Check the hydraulic lines are not worn because of rubbing against the frame...

Page 63: ...the engine air filter D 8 Change the engine oil filter and fuel filter every 500 working hours or once an year D 9 Clean the air filter in the cab D 10 Change the oil in the differential gears D 11 Boom chain tensioning GTH 4017 SX TABLE E Every 1000 working hours or every six months E 1 Change the safety element of engine air filter E 2 Change the oil in the power divider gearbox E 3 Change the o...

Page 64: ...r axles and any equipment of the machine A 14 Lighting electric system A 15 Efficiency of braking system and parking brake A 16 Steering selection system A 17 Fork balancing system A 18 Safety devices A 19 Engine coolant level A 20 Overload warning system A 21 Re sequenceboomextension GTH 4013 SX Table B Y N R Within the first 50 working hours B 1 Efficency of machine Every 50 working hours B 2 Al...

Page 65: ... in the appropriate box after each inspection procedure is completed Use the maintenance tables in this sectionandthestep by stepprocedures in section 4 to learn how to perform these inspection If any inspection receives an N tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable N no remove from service R repaired Table E Y...

Page 66: ...Section 3 Maintenance Inspections May 2008 Document 57 4403 4200 GTH 4013 SX GTH 4017 SX 8 MAINTENANCE INSPECTIONS Intentionally blank page Courtesy of Crane Market ...

Page 67: ... to properly complete each inspection when required may cause death serious injury or substantial machine damage Immediately tag and remove from service a da maged or malfunctioning machine Immediately tag and remove from service a da maged or malfunctioning machine Unless otherwise specified perform each procedure with the machine in the following configuration machine parked on a flat level surf...

Page 68: ...others safety and that can result in serious or lethal injury WARNING 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 CAUTION Draws the attention either to situations that involve your own as well as the others safety and that can result in minor or moder...

Page 69: ... oil is level with the hole If necessary add new oil through hole A until it is level Refit the plug PROTECT THE ENVIRONMENT 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 ensure the parking brake is engaged Remove the plug A using a 12 mm Allen wrench and check if oil is level w...

Page 70: ... the machine on a level ground and ensure the parking brake is engaged Clean the plug A all around then remove it using a 12 Allen wrench and check if oil is level with the hole If necessary top up through hole A until oil comes out Refit the plug PROTECT THE ENVIRONMENT Place a container of suitable size under the plug for oil leaks A Courtesy of Crane Market ...

Page 71: ...er the machine to the ground Re tighten all nuts to a torque 440 Nm WARNING Checkthetighteningofwheelsonehourafterthejob They might get loose until they do not stay correct WARNING 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 WARNING Always use tyres having the dimensions indicated in the vehicle registr...

Page 72: ...ing your daily work proceed with a random check of the bolts For the correct tightening torques please refer to par 2 13 in section 2 Technical Specifications A 4 CHECK THE COUPLINGS FOR OIL LEAKS Before starting your work do a walk around inspection and check for oil leaks If you find them rectify before starting using the machine Courtesy of Crane Market ...

Page 73: ... always return the manual to the storage container after use NOTICE Contact TEREXLIFT Service Centre if replacement manuals are needed A 6 INSPECT THE DECALS AND PLATES Maintaining all of safety and instructional decals and placards in good condition is mandatory for safe machine operation Decals alert operators and personnel to the many possible hazards associated with using this machine Anillegi...

Page 74: ...a level ground stop the engine and ensure the parking brake is engaged Pull out the rod of the level A and ensure the oil comes to the maximum height B MAX MAX MIN Pull out the rod A again and ensure the oil comes to the maximum level B Refit the rod A and the plug C If the oil is below this level remove the pluh C and add new oil in the engine using a gradueted cup B A C Courtesy of Crane Market ...

Page 75: ...filtering cartridge C Clean the inside of the filter Knockoutthefilteringcartridgeusingawoodenboard to eliminate the dust Dry clean the cartridge max pressure 6 bar Check for cracks in the filtering element Refit the clean cartridge or a new one correctly appling some grease on the gaskets Refit the plug B WARNING As soon as the warning lamp on the cab dashboard switches on replace the filtering e...

Page 76: ...am Cleaning using compressed air Direct a jet of compressed air toward radiator 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 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 NOTICE The core fouling d...

Page 77: ... to detect oil leaks Check visually the hydraulic oil level through level A on the tank visible through a hole on the right side of the chassis If necessary add oil through plug B WARNING Check the oil level with the machine in the travel position tha is boom lowered and telescopes fully in PROTECT THE ENVIRONMENT The handling and disposing of used oils can be ruled by local or national regulation...

Page 78: ...s 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 If necessary scrape off the old grease and brush new grease We recommend using Grasso PTFE INTERFLON FIN GREASE LS 2 CAUTION Avoid mixing greases of different type or features and do not use greases of lower qua...

Page 79: ...Document 57 4403 4200 GTH 4013 SX GTH 4017 SX 13 May 2008 Section 4 Maintenance Procedures TABLE A 4017 SX Courtesy of Crane Market ...

Page 80: ...e intervention zone 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 Smear pin A with grease to help the forks slide on it Recommended grease AGIP graphitized grease type GR NG 3 A Courtesy of Crane Market ...

Page 81: ...an 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 grant it efficient condi tions 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 follow...

Page 82: ...e the table below as a reference WARNING When switched on lamps get hot Before touching a lamp with your fingers let it cool down CAUTION 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 Front low high beam 12 V...

Page 83: ...rking brake Check the parking brake with the forward or reverse gear put and ensure the machine is stopped 2 CHECK SERVICE BRAKE Load the maximum payload onto the forks 4000 Kg Retract boom and forks fully Lift the forks at about 50 cm on the ground Ensure the space is enough to stop the machine Start the machine at maximum speed Brake using the service brake until the machine is completely stoppe...

Page 84: ...stop either to the right or to the left 4 Setthesteeringselectionswitchto two wheelsteer 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 steer pos 0 9 Rotate the...

Page 85: ...achine 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 Startliftingtheboomandcheckthattheforksremain parallel to the ground NOTICE If the forks do not remain parallel to the ground consult section 5 Problems Causes Solutions Courtesy of Crane Mar...

Page 86: ...R OF THE SAFETY DEVICES Check the emergency stop pushbutton at every use To check the efficency of the emergency stop pushbutton A push it during one of movement operations of the machine the operation and the machine engine has to stop Check of the machine ignition control at every use Start diesel engin using lever B to forward revers The diesel engine has not start B P A Courtesy of Crane Marke...

Page 87: ...rmed immediately replace the part Check of the limit switches at every use Limit switches C on boom Lift the boom over the zero position until a maximum angle of 20 and check if machine sway function and outriggers controls can be activated Limit switches D on boom Lift the boom with a tilt angle over 50 GTH 4013SX e il GTH 4017SX and check that the rear axle is stopped Limit switche E GTH 4013SX ...

Page 88: ...check the efficency of the three main valve levers follow the procedure below Sit in the driving seat engage the parking brake and move the lever to forward in neutral position Using a screwdriver remove the locking screws of the carter open it until seeing the sensor G H I Turn the ignition key to the position 1 Move the lever M lock unlock attachment to right unlock attachment and check the ligh...

Page 89: ...otection gloves and keep your face at a safe distance Every week before starting working with the coo lant cold check the coolant level through the glass cap of plug B When necessary add clean water or an antifreeze mixture through plug A 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 Fre...

Page 90: ...weight on the forks and extend the boom fully in zero position until the DLE system enters in alarm Then using a measure check the distance is in the area indicated in the load chart inside the cab see below In case of defects make a diagnosis and adjust the system 5 8 10 2 57 2900 0217 rev A 20 0 1 2 3 4 5 6 7 8 9 10 0 1 1 2 3 4 5 6 7 8 9 10 11 12 13 9 02 m 12 99 m 0 10 30 40 50 60 70 3000 kg A B...

Page 91: ...lly Then hold the system over relief for approx 20 40 seconds to change the hydraulic oil inside the system If after performing this procedure the boom still remains out of sequence proceed with the steps below 2 Move the boom to the zero position fully retract the boom and hold the retract system over relief for approx 20 40 seconds 3 Extend the boom fully retract it and hold it over relief for a...

Page 92: ...ng order NOTICE Fortheenginemaintenance pleaserefertothespecific Operator s manual supplied with the machine B 2 CHECK THE TENSION OF THE ALTERNATOR BELT Open the carter with engine cold and stopped 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 In necessary change the belt A NOTICE Fortheenginemainte...

Page 93: ...ow On new machines and when a wheel has been disasembled or replaced check the nut torque of the wheels every 2 hours until they stay correct Torque 400 N m WARNING Always use tyres having the dimensions indicated in the vehicle registration card WRONG OK GTH 4013 SX GTH 4017 SX Standard Optional Dimensions front and rear 405 70 R20 400 70 R24 405 70 R24 Load index 14 pr 14 pr 14 pr Rim 13x20 13X2...

Page 94: ...hine to the ground Re tighten all nuts to a torque 400 Nm WARNING Checkthetighteningofwheelsonehourafterthejob They might get loose until they do not stay correct WARNING 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 WARNING Always use tyres having the dimensions indicated in the vehicle registration card...

Page 95: ...ntenance Procedures TABLE B B 5 CHECK THE TIGHTENING OF THE CARDAN SHAFT SCREWS Check every week that the screws of the Cardan shaft A B are tight For the correct tightening torques please refer to par 2 13 in section 2 Technical Specifications B A Courtesy of Crane Market ...

Page 96: ...Pulizia a mezzo aria compressa Direct a jet of compressed air toward radiator 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 with a cold commercial detergent and wait for at least 10 minutes to allow the detergent to react Wash radiator B using a jet of water or steam NOTICE The core fouling dep...

Page 97: ...entirely Rotate the wheel by 90 until the plug is on the hori zontal axis Add the oil through hole A Refit the plug A Recommended oil TRACTORENAULT THFI 208 LF SAE 80W API GL 4 FORD M2C 86 B Massey Ferguson M 1135 To change the oil in thefront and rear differential gears Stop the machine on a level ground and ensure the parking brake is engaged PROTECT THE ENVIRONMENT Place a container of suitable...

Page 98: ...the plug A until it is level with hole Refit the plug A Recommended oil TRACTORENAULT THFI 208 LF SAE 80W API GL 4 FORD M2C 86 B Massey Ferguson M 1135 C 2 CHANGE THE ENGINE OIL AND RELEVANT FILTER Stop the machine on a level ground and ensure the parking brake is engaged NOTICE Fortheenginemaintenance pleaserefertothespecific Operator s manual supplied with the machine Remove the plug A Remove th...

Page 99: ... from the hole A Refit the plugs A e B PROTECT THE ENVIRONMENT Place a container of suitable size under the plug for oil leaks C 4 CHECK THE OIL LEVEL IN THE FOUR WHEEL REDUCTION GEARS To check the oil level in the four wheel reduction 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 an...

Page 100: ... cartridge C Clean the filter bowl Knockthecartridgeusingawoodentabletoeliminate the dust Dry clean the cartridge at max 6 bar pressure Check the filter element for cracks Refit the clean cartridge or a new one using some grease on the seal and make sure it is properly positioned Close the cover B WARNING As soon as the warning lamp on the cab dashboard switches on replace the outer element WARNIN...

Page 101: ...eep 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 C 7 CHECK THE AIR SUCTION HOSE BETWEEN ENGINE AND FILTER Check the state of all the rubber sleeves A of the air suction line between engine and filter every month CAUTION Ifyouusethemachinecontinuouslyforseveraldays...

Page 102: ... fully extend all of the cylinders and check that their rods are intact C 9 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 CAUTION Replace any worn hoses immediately before using the machine again A Co...

Page 103: ...e any worn cables immediately before using the machine again A A A C 11 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 Allpadscanbeadjustedbythespecialshimsnotsupplied by GENIE CAUTION Pads must compulsorily be replaced if the resid...

Page 104: ... 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 th...

Page 105: ...ONS 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 Grasso INTERFLON FIN GREASE LS 2 cod 640772 CAUTION Avoid mixing greases of different type or features and do not use greases of lower quality Courtesy of Crane Market ...

Page 106: ...e they can short the terminals and burn you DANGER Beforedisconnectingthebattery setallswitches within the cab to OFF Todisconnectthebattery disconnectthenegative 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 n...

Page 107: ...and extend it some centimetres Loosen the oil hoses to the cylinder of which you are checking the valve with caution Tochecktheefficentworkingorderoftheblockvalves on the outriggers lower the outriggers to ground and unload the wheel weight without lifting them from the ground To check the efficency of the valve loosen the hoses During the check the load shall remain blocked in position Should tha...

Page 108: ...does not result in an uncontrolled movement of the machine TO REMOVE THE BLOCK VALVES 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 invo...

Page 109: ...unt of smoke coming out of the exhaust is normal repeat the check while accelerating the engine CAUTION Do this check outdoors or use an adequate smoke extraction system NOTICE In case of excess smoke strictly obey the instruc tions provided in the relevant Use and maintenance manual enclosed with the technical literature of the machine D 2 CHECK THE TIGHTENING OF THE ENGINE FIXING SCREWS Every 6 ...

Page 110: ...s operation use a torque wrench and tighten the screws to a torque of 188 Nm D 4 CHECK THE BLACKLASH BETWEEN PINS AND BUSHINGS IN ALL JOINTS Every 6 months check the machine randomly to be sure the backlash between pins and relevant bushings on the joints is not too high CAUTION If you have to change some parts please refer to the spare parts catalogue enclosed with the technical literature of the...

Page 111: ... then before fitting a new one thoroughly clean and grease both seat and gasket Refit and tighten the filter cover PROTECT THE ENVIRONMENT Handling and disposing of used oils may be ruled by local or national regulations Address to authorised waste centres NOTICE Hydraulic oil filter canisters cannot be cleaned or washed and refitted They must be replaced with new ones of the type recommended by t...

Page 112: ...ANGE THE MAIN CARTRIDGE OF THE ENGINE AIR FILTER Changing the main cartridge air filter Stop the engine and engage the parking brake Unlatch the four fasteners A Remove cover B Pull out the external cartridge C Clean the filter bowl Refit the clean cartridge or a new one using some grease on the seal and make sure it is properly positioned Close the cover B WARNING As soon as the warning lamp on t...

Page 113: ...w oil through the plug A Using the rod C check the right engine oil level Remove the fuel filter E and change it with a new one B A C D E 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 From the external of the cab pull out the ...

Page 114: ...at the procedure Lock the chain tensioners by means of a counternut and locknut Change the chains if during the procedure described above all threaded part of the screws have been used in this case please contact the GENIE Service Centre C D 10 CHANGE THE OIL OF THE FRONT AND REAR DIFFERENTIAL GEARS To change the oil of the front and rear differential gears Stop the machine on a level ground and e...

Page 115: ...ld be replaced every second time the outer element is replaced WARNING Do not wash the cartridge using water or other kind of solvents For tensioning the two chains above the second section boom loosen the locknuts and the screws G using a 19 mm combination wrench and loosen the locknuts H and M using a 27 mm wrench Tensioning the chain until a maximum 40Nm value operatingonthescrew I usinga27mmdy...

Page 116: ...ecommended oil TRACTORENAULT THFI 208 LF SAE 80W API GL 4 FORD M2C 86 B Massey Ferguson M 1135 E 3 CHANGE THE OIL IN THE FOUR WHEEL REDUCTION GEARS To change the oil in the four wheel reduction gears Stop the machine on a level ground and ensure the parkingbrakeisengagedandplugAisorientedalong the vertical axis PROTECT THE ENVIRONMENT Place a container of suitable size under the plug for oil leaks...

Page 117: ... to flow in the container Using a 13 mm combination wrench remove the screws of the inspection cover D and then remove it Carefully wash the tank with Diesel oil and blow a jet of compressed air Change the inner cartridge E Refit the drain plug C and the inspection cover D Add new oil through hole B by making sure that it matches the recommended type indicated until it is level with A Recommended ...

Page 118: ...ng a screwdriver loosen the clamp and remove the rubber hose B Allow the coolant to flow out into a special container Refit the hose and pour new antifreeze 50 water antifreeze in the plug A This proportion will provide protection up to 38 C Refit the plug A and start the Diesel engine After few minutes check the level by the hole C If necessary add new coolant until it is level On delivery the ma...

Page 119: ...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 the boom pins the platform and all attachment if installed DANGER After the first 5 years repeat this check every 2 years Courtesy of Crane Market ...

Page 120: ...54 GTH 4013 SX GTH 4017 SX Document 57 4403 4200 Section 4 Maintenance Procedures May 2008 Intentionally blank page Courtesy of Crane Market ...

Page 121: ...rinted 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 DANGER Crushing hazard When testing or replacing any hydrauliccomponent alwayssupportthestructure and secure it from movement WARNING Electrocution hazard Contact with electrically charged circuits ...

Page 122: ...tsindicatedin 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 analysethepossiblecausesexplainedinthe causes column proceed with the check or replacement according to the instructions provided in the solutions column check that the ...

Page 123: ... is in the correct position and works fine Replace if damaged Check that the ground braid between chassis and engine is correctly connected and intact Check the fuse in the box inside the engine compartment replace if necessary Check that contact 30 of the ignition key is powered if you have not 12V on contact 15 54 change the key Check the wiring up to the input of the fuses and relays board for ...

Page 124: ...A fuse F14 blown Parking brake micro switch S6b damaged Speed selector damaged Check the fuse and the emergency button replace if necessary Check the wiring for continuity Check the starting motor coil is powered If the coil is powered and the motor doesn t work change the motor Check and replace if necessary Check and if necessary reconnect the grounding system to the chassis Refuel Check the pum...

Page 125: ... mechanical operation of the limit switches replace if necessary Check the fuse replace if necessary Check you have 12V on solenoid when the forward gear is put and 12V on solenoid when the reverse gear is put If necessary change the coils of the solenoid valves Check the relays and replace if necessary Check the relays and replace if necessary Check the board and replace if necessary Check the wi...

Page 126: ...to the stabilised machine condition The steer mode selection of the machine doesn t work The horn doesn t work Check the fuse replace if necessary Check the micro switches and replace if necessary Check the wiring for continuity Check the socket and replace if necessary Change the DLE Check the fuse replace if necessary Check the spools and replace if necessary Check that the selector is in the Jo...

Page 127: ... I O mode damaged Limit switch damaged Problem of the wiring line Dashboard indicator light Filter restriction sensor B15 damaged Problem of the wiring line Check the fuse and replace if necessary Check the flashing beacon and replace if necessary Check the lamp and replace if necessary Check the wiring for continuity Check the fuse and replace if necessary Check the switch and replace if necessar...

Page 128: ...ture transducer B16 damaged 3A fuse F8 blown Problem of the wiring line 3A fuse F8 blown Dashboard fuel gauge damaged Fuel detector B12 damaged Problem of the wiring line Check the pressure switch and replace if necessary Check the indicator light and replace the lights group if necessary Check the wiring for continuity Check the efficiency of the bulb and replace if necessary Check the indicator ...

Page 129: ...lown DLE display damaged Problem of the wiring line Back up horn H25 damaged Problem of the wiring line Bulb B17 damaged Indicator light H113 Problem of the wiring line Check the hour meter and replace if necessary Check the alternator and replace if necessary Check the wiring for continuity Check the fuse and replace if necessary Change the DLE Check the wiring for continuity Check the efficiency...

Page 130: ...an tank and pipes empty the pumps and add new oil Re calibrate the pump see par 2 section Technical Specifications Check the coil and the the movement of the inner electrovalve pin Tension the cables and check the relevant clamps Check the control lever and replace if necessary Check or replace the internal seals if necessary Check the sliders and the coils of the electrovalves Problems Causes Sol...

Page 131: ...d if the pilot activates the priority valve Check the efficiency and the internal seals of the cylinders The pump doesn t deliver oil Check the max output pressure of the pump Replace if damaged Valve restricted or damaged remove and check the seals and the efficiency of the slider Check the efficiency of the control block see par 2 sect Technical Specifications Remove the pressure relief valve an...

Page 132: ... interno braccio danneggiata only GTH 4013 SX Blockvalveoftheboomexternalextension cylinder damaged Check the pump thoroughly see section 2 Technical specifications for calibration Check the efficiency of the disks replace if necessary Check the efficiency of the cylinder re place the internal seals if necessary Check and replace if necessary Check and replace any damaged or clogged hose Change th...

Page 133: ...e internal piston Check if the main valve reaches the max working pressure see par 2 section Technical Specifications Check the efficiency of the internal sliders of the Walvoil main valve Check the boom In case of mechanical jamming rectify Check and replace any defective parts which stop the flow of the hydraulic oil to the cylinders Change the seals and check the tightness of the cylinder Remov...

Page 134: ...k the efficiency of the safety valves fitted to ports A and B of the module re calibrate or replace Remove and clean the valve check its seal and replace if necessary Remove and clean the valve check its seal and replace if necessary Check and replace any damaged or restricted hose Check the pads for wear and replace if necessary Smear the sliding zone of the pad with the grease recommended by Ter...

Page 135: ... Mechanical control with roller Electro magnetic control with winding solendoid Control with electric motor M Direct pressure control Indirect piloted pressure control Control with electromagnet and piloted distributor Induction and return pipe Piloting pipe Blow by pipe MOTORS PUMP CYLINDERS COMMANDS AND CONTROLS PIPES AND CONNECTIONS Flexible hose Connecting point Pipe cross without connection B...

Page 136: ... way and two position distributor with hydraulic control Electro hydraulic single acting servo valve Distributor with mechanical control and span proportional to the action of the same control Two position three way distributor with representation of transient connection during passage phase Two position three way distributor with electro magnetic control and spring return Courtesy of Crane Market...

Page 137: ...h activating pressure 70 bar Hydraulically powered service emergency brakes pedal pump 150 bar Forks attachment quick coupling cylinder Boom functions main valve X31 X18 X19 X30 X17 Rear axle pivoting lockout cylinder Rear axle pivoting lockout valve 2 ways 2 positions A1 B1 B3 A3 B2 A2 A4 A5 A6 B4 B5 B6 T T P 270 bar Functions enabling valve TP1 T A1 A2 B B1 B2 A Telescoping forks tilt selector v...

Page 138: ...cally powered service emergency brakes pedal pump 150 bar Forks attachment quick coupling cylinder Boom functions main valve X31 X18 X19 X30 X17 Rear axle pivoting lockout cylinder Rear axle pivoting lockout valve 2 ways 2 positions A1 B1 B3 A3 B2 A2 A4 A5 A6 B4 B5 B6 T T P 270 bar Functions enabling valve TP1 T A1 A2 B B1 B2 A Telescoping forks tilt selector valve 6 ways 2 positions 295 bar 295 b...

Page 139: ...attery ACCUMULATORS Thermocouple Element Ring TERMINALS AND GROUNDS Ground Terminal Ground to frame Knot Protection ground Frame ground 2 Coil COILS Mechanical coupling coil Winding A C coil Coil with diode Winding with diode Connector CONNECTORS Auto transformer STATIC APPLICATIONS Transformer Motor DYNAMIC APPLICATIONS M G Generator M 3 As_3p_motor Rectifier ELECTRONIC PARTS Light emitting diode...

Page 140: ...S Thermal CONTACTS Normally open NO Normally closed NC NO limit switch NC limit switch Contactor Magneto thermal closure Thermal closure Thermal opening Exchange NC proximity NO proximity NO mechanical NC mechanical Selector Selector2 Magneto thermal opening Courtesy of Crane Market ...

Page 141: ...Document 57 4403 4200 GTH 4013 SX GTH 4017 SX 7 May 2008 Section 6 Schemes SCHEMES 6 4 ELECTRICAL SCHEMES 6 4 1 GTH 4013 SX GTH 4017 SX 1 10 Courtesy of Crane Market ...

Page 142: ...8 GTH 4013 SX GTH 4017 SX Document 57 4403 4200 Section 6 Schemes May 2008 SCHEMES 2 10 Courtesy of Crane Market ...

Page 143: ...Document 57 4403 4200 GTH 4013 SX GTH 4017 SX 9 May 2008 Section 6 Schemes SCHEMES 3 10 Courtesy of Crane Market ...

Page 144: ...10 GTH 4013 SX GTH 4017 SX Document 57 4403 4200 Section 6 Schemes May 2008 SCHEMES 4 10 Courtesy of Crane Market ...

Page 145: ...Document 57 4403 4200 GTH 4013 SX GTH 4017 SX 11 May 2008 Section 6 Schemes SCHEMES 5 10 Courtesy of Crane Market ...

Page 146: ...12 GTH 4013 SX GTH 4017 SX Document 57 4403 4200 Section 6 Schemes May 2008 SCHEMES 6 10 Courtesy of Crane Market ...

Page 147: ...Document 57 4403 4200 GTH 4013 SX GTH 4017 SX 13 May 2008 Section 6 Schemes SCHEMES 7 10 Courtesy of Crane Market ...

Page 148: ...14 GTH 4013 SX GTH 4017 SX Document 57 4403 4200 Section 6 Schemes May 2008 SCHEMES 8 10 Courtesy of Crane Market ...

Page 149: ...Document 57 4403 4200 GTH 4013 SX GTH 4017 SX 15 May 2008 Section 6 Schemes SCHEMES 9 10 Courtesy of Crane Market ...

Page 150: ...16 GTH 4013 SX GTH 4017 SX Document 57 4403 4200 Section 6 Schemes May 2008 SCHEMES 10 10 Courtesy of Crane Market ...

Page 151: ...Document 57 4403 4200 GTH 4013 SX GTH 4017 SX 17 May 2008 Section 6 Schemes SCHEMES 6 4 2 1 GENERAL WIRING DIAGRAM GTH 4013 SX GTH 4017 SX Courtesy of Crane Market ...

Page 152: ...18 GTH 4013 SX GTH 4017 SX Document 57 4403 4200 Section 6 Schemes May 2008 SCHEMES 6 4 2 2 FUSES AND RELAYS GTH 4013 SX GTH 4017 SX Courtesy of Crane Market ...

Page 153: ...Document 57 4403 4200 GTH 4013 SX GTH 4017 SX 19 May 2008 Section 6 Schemes SCHEMES Boom feelers Rear axle Front axle Reductor Courtesy of Crane Market ...

Page 154: ... 4013 SX GTH 4017 SX Document 57 4403 4200 Section 6 Schemes May 2008 SCHEMES 6 ways 2 positions electrical switch EV steering Fuses and relays boards Hydraulic oil filter 3B6 Display Courtesy of Crane Market ...

Page 155: ...Document 57 4403 4200 GTH 4013 SX GTH 4017 SX 21 May 2008 Section 6 Schemes SCHEMES Y30 Main valve Joystick Swtichs Outriggers Courtesy of Crane Market ...

Page 156: ...22 GTH 4013 SX GTH 4017 SX Document 57 4403 4200 Section 6 Schemes May 2008 Intentionally blank page Courtesy of Crane Market ...

Page 157: ...boom lifting cylinder 1 1 00 change the cylinder inside the boom 2 2 50 cad change the extension cylinder kit inside the boom 1 2 30 change the block valve of the extension cylinder inside the boom 1 1 00 change the extension cylinder on the boom 2 1 00 cad change the extension cylinder kit on the boom 1 1 30 change the valve of the extension cylinder on the boom 1 0 30 change the re sequencing va...

Page 158: ...king 1 2 30 change the boom pads 1 3 00 check the transmission pump pressure 2 1 00 cad check the main valve pressure of the boom movement control 2 1 00 cad check the brake pump pressure and the hydraulic drive 1 1 00 check the safety valves 1 1 00 change the drive pump 1 3 00 change the drive motor 1 3 00 change transmission motor transmission pump transmission hoses and test 1 6 00 change main ...

Page 159: ...fuses and search for troubles 1 1 00 bleed the braking system 2 1 00 cad change the return filter of the hydraulic oil tank 1 1 00 change the hydrostatic steering unit 1 2 00 change the flashing beacon 1 0 30 change the battery 1 1 00 change the exhaust pipe 1 1 00 change the mud guard supports 1 1 00 change the mud guard 1 1 00 change the parking brake cord 1 1 00 change the steering wheel 1 1 00...

Page 160: ...Section 7 Repair Procedures May 2008 4 GTH 4013 SX GTH 4017 SX Document 57 4403 4200 REPAIR PROCEDURES Intentionally blank page Courtesy of Crane Market ...

Page 161: ... 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 PROTECT THE ENVIRONMENT Used oils must be handled and disposed of according to local re...

Page 162: ... 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 ensure it does not hinder the movement of the boom 11 Secure the raising cylinder to the boom with a slin...

Page 163: ...tract the pin using a plug of soft material aluminium copper wood etc 14 Put two wooden plugs each 100mm high on the oil tank 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 ...

Page 164: ... 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 CAUTION To reassemble the cylinder repeat the steps above in reversed order Remember to set the circuit under pressure before releasing the bridge ...

Page 165: ...inder disassembly Fork balance cylinder Bridge crane payload 500 kg Textile bridles or chains with hooks Standard tools Adjustable stands 26 2 1 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 3 Courtesy of Crane Market ...

Page 166: ...ils must be handled and disposed of according to local regulations Address to legally authorised centres 6 Using a 24 mm and a 19 mm wrenches disconnect three 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 17 mm wrenches 9 Knock o...

Page 167: ...e the two screws of the spring A 4 Again with two 13mm wrenches loosen the five screws B that secure the cover to the frame of the machine 5 Remove the upper cover 6 Disconnect the two battery leads and remove the battery using a 13mm wrench and a 4mm Allen wrench remove the two screws of engine fuse box using a 10mm combination wrench 7 Using two 17mm wrenches remove the six screws fixing the low...

Page 168: ...l pressure bulb d electrical stop d water temperature bulb d the three alternator connections d starter motor d ground between chassis and engine d the two coils of the transmission pump solenoid valve 15 Disconnect the radiator tremove the clamps fixing the sleeves to the radiator disconnect the radiator hyraulic hoses using a 41mm combination wrench 16 Remove the screw C of the bracket fixing th...

Page 169: ...h d disconnect the suction line of the hydraulic pump with a 50mm wrench d disconnect the low pressure line duct with a 19mm wrench d disconnect the four flanges which connect the drive pump to the drive motor with a 10mm Allen wrench d disconnect the two pilot circuits using a 17mm combination wrench d disconnect the suction line of the service pump using a 50mm combination wrench A d disconnect ...

Page 170: ...at the back of the vibration damping brackets with a 22 mm wrench 19 Sling the engine using a two leg chain with hook to be coupled to the two top lugs 20 Raise the engine with caution and ensure no parts are still connected 21 Remove the engine from the machine rest it on a wooden pallet and hold it in position with some plugs Reassembling the engine CAUTION Toreassembletheengine repeatthestepsab...

Page 171: ...e containersofsuitablesizeunderneathtoprevent oil spillage CAUTION 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 Open the carter engine and disconnect the battery using a 13mm wrench 2 Using two 17mm wrenches remove the six screws that ...

Page 172: ...isconnect the suction line of the service pump using a 50mm combination wrench d disconnect the delivery line ducts of the hydraulic drive C and the main valve with a 36mm wrench and a 24mm wrench d disconnect the load sensing signal line from the hydraulic drive with a 17mm wrench d disconnect the hydraulic pump hoses using a 24mm combination wrench and a 36mm combination wrench WARNING Once all ...

Page 173: ...aulic pumps disassembly to a bench and plug all the outlets 9 Disconnect the second service pump removing the four nuts G using a 13mm wrench and remove the screw F using a 10mm wrench Pull out the pump and place it on to a bench and plug all the outlets 10 Proceed in reverse order to re assemble the hydraulic pumps G F Courtesy of Crane Market ...

Page 174: ...Procedure Table 004 GTH 4013 SX GTH 4017 SX 18 GTH 4013 SX GTH 4017 SX Document 57 4403 4200 Section 7 Repair Procedures May 2008 TABLE 004 Intentionally blank page Courtesy of Crane Market ...

Page 175: ...CAUTION Carefully clean the area around the piping to be disconnected plug all disconnected parts with connectors clothes or adhesive tape to prevent dustorimpuritiesfromenteringthecircuit They can cause serious damage 1 Remove the central covers A B of the machine by driving out the seven screws using a 13mm wrenche 2 Disconnect the electric link of the electrovalve 3 Disconnect the drainage hydr...

Page 176: ...es May 2008 TABLE 005 Disassembling the hydraulic motor 6 Remove the four locking screws of the hydraulic motor using a 14mm Allen wrench 7 Pull out the motor from the power divider using a textile sling and a bridge crane 8 Protect the engine compartment to prevent the entrance of impurities 6 Courtesy of Crane Market ...

Page 177: ...ve the screw fixing the pin to the boom section using two 17mm wrench 3 Extract out and knock the pin using a plug of soft material aluminium copper wood etc 4 Remove the two screws of the bracket A using a 22mm wrench 5 Place a container of suitable size under the hydraulic piping before disconnecting PROTECT THE ENVIRONMENT Used oils must be handled and disposed of according to local regulations...

Page 178: ...ly Boom extension cylinder GTH 4017 SX 7 Loosen and remove the screw fixing the cylinder pin bottom side using two 17 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 section and sling it with the textile bridles connected to the bridge crane 7 8 Courtesy of Crane Market ...

Page 179: ...move the screw fixing the pin to the boom section using two 17mm wrench 3 Extract out and knock the pin using a plug of soft material aluminium copper wood etc 4 Remove the two screws of the bracket A using a 22mm wrench 5 Place a container of suitable size under the hydraulic piping before disconnecting PROTECT THE ENVIRONMENT Used oils must be handled and disposed of according to local regulatio...

Page 180: ...om extension external cylinder GTH 4013 SX 7 Loosen and remove the screw fixing the cylinder pin bottom side using two 17 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 section and sling it with the textile bridles connected to the bridge crane 7 8 Courtesy of Crane Market ...

Page 181: ...material aluminium copper wood etc If necessary lift the cylinder using a jack under the boom corrisponding to the hole inside the 3rd boom section 4 Retract the boom entirely remove the screw that locks the pin B using two 13mm wrench Extract out and knock the pin using a plug of soft material aluminium copper wood etc 5 Place a container of suitable size under the hydraulic piping before disconn...

Page 182: ... fixing the cylinder to the 3dr section boom using a 22mm ratchet socket 8 Pull out the cylinder from the boom section and sling it with the textile bridles connected to the bridge crane When half cylinder is out sling it in the center so it can be in horizontal position 9 Extract the cylinder from the boom entirely and place it on to a bench 10 Lock the cylinder to avoid damnage for people and th...

Page 183: ...revent dustorimpuritiesfromenteringthecircuit They can cause serious damage 1 Open the carter and disconnect the two battery terminals using a 13mm wrench then remove the screws fixing the fuse box to carter using a 4mm Allen wrenc and a 10mm combination wrench 2 Install a handler under the carter and remove the six screws fixing the lower carter to the chassis using two 10mm wrenches then remove ...

Page 184: ... the two screws of the vibration damping bracket using a 22 mm wrench 8 Remove the two screws which fix the radiator to the chassis wall using two 13mm wrenchs 9 Secure the cooler with a textile bridle connected to the rising hoist 10 Rise with caution by tilting the cooler forward to prevent damage to the fixed fan of the engine 11 Place it on to a bench and lock it to avoid damnage for people an...

Page 185: ...ts with connectors clothes or adhesive tape to prevent dustorimpuritiesfromenteringthecircuit They can cause serious damage DANGER Before disconnecting the hydraulic piping ensurethelineisnotunderpressure Releasethe 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 protect...

Page 186: ...n easier reassembly 2 Disconnect all pipes of the main valve using the following combination wrenchs 17 mm 22 mm 24 mm 36 mm 41 mm 3 Disconnect all wires 4 Remove the screws fixing the inside cab protection carter of the main valve 5 Loosen the locknuts fixing the main valve levers using a 17mm combination wrench and a 19mm combination wrench 6 Remove the three screws fixing the main valve to the ...

Page 187: ...r the boom to the ground and ensure the telescope is fully retracted 2 With a thickness gauge check the play of all pads After adjustment the minimum play in the narrowest point must be 0 5 1 mm 3 Measure the thickness of the slide pads The value of the bottom pads of the fixed section and of the top pads of the telescope must be at least 13 mm For the remaining pads the minimum thickness must nev...

Page 188: ...scopic boom GTH 4013 SX 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 Minimum thickness 9 mm New pad thickness 15 mm Max wearing thickness 6 mm Torque 30 35 Nm Courtesy of Crane Market ...

Page 189: ...ng screws 10 Using a screwdriver pry off the worn pads Fit new pads after applying a few drops of Loctite 495 on the threads CAUTION Tighten the pad fixing screws to 30 35 Nm RENEWING THE FRONT PADS B To renew the front pads of the section extend the boom of about 1 meter and proceed as follows 11 Stop the machine lower the nose to the ground for an easier removal of the bottom pads Hold it in hor...

Page 190: ... of the telescopic boom GTH 4013 SX 13 Clean and grease the internal and external walls of the boom sections in the sliding points of the pads To this end use INTERFLON FIN GREASE LS2 14 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 13 14 Courtesy of Crane Market ...

Page 191: ...wer the boom to the ground and ensure the telescope is fully retracted 2 With a thickness gauge check the play of all pads After adjustment the minimum play in the narrowest point must be 0 5 1 mm 3 Measure the thickness of the slide pads The value of the bottom pads of the fixed section and of the top pads of the telescope must be at least 13 mm For the remaining pads the minimum thickness must n...

Page 192: ...it 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 Minimum thickness 9 mm New pad thickness 15 mm Max wearing thickness 6 mm Torque 30 35 Nm FIRST SECTION SECOND SECTION THIRD SECTION FOURTH SECTION Courtesy of Crane M...

Page 193: ...s 10 Using a screwdriver pry off the worn pads Fit new pads after applying a few drops of Loctite 495 on the threads CAUTION Tighten the pad fixing screws to 30 35 Nm RENEWING THE FRONT PADS B To renew the front pads of the section extend the boom of about 1 meter and proceed as follows 11 Stop the machine lower the nose to the ground for an easier removal of the bottom pads Hold it in horizontal ...

Page 194: ... of the telescopic boom GTH 4013 SX 13 Clean and grease the internal and external walls of the boom sections in the sliding points of the pads To this end use INTERFLON FIN GREASE LS2 14 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 14 13 Courtesy of Crane Market ...

Page 195: ...me 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 How to renew flexible hoses PROTECT THE ENVIRONMENT Beforedisconnectingthehydraulicpiping place containersofsuitablesizeunderneathtoprevent oil spillage CAUTION Plug all disconnected parts to prevent dust or impurities f...

Page 196: ...X GTH 4017 SX 40 GTH 4013 SX GTH 4017 SX Document 57 4403 4200 Section 7 Repair Procedures May 2008 TABLE 013 Renewing the flexible hoses inside the boom GTH 4013 SX Useful advice for mounting flexible hoses Courtesy of Crane Market ...

Page 197: ... 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 How to renew flexible hoses PROTECT THE ENVIRONMENT Beforedisconnectingthehydraulicpiping place containersofsuitablesizeunderneathtoprevent oil spillage CAUTION Plug all disconnected parts to pr...

Page 198: ...ed in reverse order and re assemble the new hose 5 How to renew the flexible hoses inside the boom extend the boom until the holes inside the fourth section are visible disconnect the hose using a 24mm wrench A plug the hole to avoid dusty or impurities come inside read and execute the instructions in the following paragraph 6 once the iron pipes are removed renew the holes disconnecting them in t...

Page 199: ...ing the flexible hoses inside the boom GTH 4017 SX disconnect the holes C using a 24mm combination wrench then plug them to avoid dusty or impurities come inside remove the lock screws of the metal holes D using a 17mm combination wrench pull out the metal holes by hand proceed in reverse order to re assemble 6 B 6 D D B Courtesy of Crane Market ...

Page 200: ...X GTH 4017 SX 44 GTH 4013 SX GTH 4017 SX Document 57 4403 4200 Section 7 Repair Procedures May 2008 TABLE 014 Renewing the flexible hoses inside the boom GTH 4017 SX Useful advice for mounting flexible hoses Courtesy of Crane Market ...

Page 201: ...m copper wood etc 4 Open entirely 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 24mm wrench and a 27mm wrenchm disconnect the two hydraulic hoses from the blocking valve then plug the disconnected connectors to prevent dust and impurities from entering the circuit PROTECT THE ENV...

Page 202: ...8 Remove the screw fixing the cylinder pin bottom side using two 17 mm wrenches 9 Knock out and extract the pin using a plug of soft material aluminium copper wood etc 10 Secure the cylinder to the bridge crane with a textile bridle then slightly raise the boom to set the cylinder free 11 Remove the cylinder using the bridge crane 8 9 Powered by TCPDF www tcpdf org Courtesy of Crane Market ...