Genie GTH-4013 sx Service Manual
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Genie GTH-4013 sx Service Manual

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See also: Operator's Manual
Service Manual
GTH-4013 sx
GTH-4017 sx
English
Serial number range
From serial n.: 19275
From serial n.: 19300
Part. No.
57.4403.4200
May 2008
Courtesy of Crane.Market

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Summary of Contents for Genie GTH-4013 sx

  • Page 1 Service Manual Serial number range GTH-4013 sx From serial n.: 19275 GTH-4017 sx From serial n.: 19300 Part. No. 57.4403.4200 May 2008 English Courtesy of Crane.Market...
  • Page 2 Service Manual May 2008 Intentionally blank page Document 57.4403.4200 GTH-4013 SX GTH-4017 SX Courtesy of Crane.Market...
  • Page 3 Introduction IMPORTANT Read, understand and obey the safety rules and operating instructions in the GTH-4013 SX and GTH- 4017 SX Operator's manual (cod. 57.0009.0300) before attempting any maintenance or repair procedure. This manual provides the machine owner and user with detailed information on the scheduled maintenance.
  • Page 4 (The chassis serial number is punched on the front left YOUR SERIAL part of the chassis side member) NUMBER GTH-4013 P 07 17882 MODEL SERIAL NUMBER ENGINE TYPE YEAR OF MANUFACTURER Machine data plate Document 57.4403.4200 GTH-4013 SX GTH-4017 SX Courtesy of Crane.Market...

  • Page 5: Description

    This monoblock valve is the certain circulation of the drain oil to the hydrostatic motor 6-way type, with oil which flows through the main valve reducing, in this way, the temperature. From port “M3” of Document 57.4403.4200 GTH-4013 SX GTH-4017 SX Courtesy of Crane.Market...
  • Page 6 (21) and (22 only cylinder (30) equipped with double-acting compensation for GTH-4013 SX) of the telescopic boom, connected in valve serving also as a safety valve, through the series with each other. Cylinder (21), which activates...
  • Page 7 When, on the contrary, the boom inclination is below such pre-set value, the two solenoids of the solenoid valves are energised thus letting the oil circulating freely Document 57.4403.4200 GTH-4013 SX GTH-4017 SX Courtesy of Crane.Market...
  • Page 8 capacity: 0.5 Litri precharge Double overcenter safety valve Double overcenter safety valve pressure piloting ratio: 4.2 1 Double overcenter safety valve piloting ratio: 4.2 1 50 bar Hydraulically piloted cracking pressure: 350 bar piloting ratio: 4.2 1 cracking pressure: 350 bar Right stabilizer cylinder cracking pressure: 350 bar double check valve...
  • Page 9 capacity: 0.5 Litri precharge Double overcenter safety valve pressure Double overcenter safety valve Double overcenter safety valve piloting ratio: 4.2 1 50 bar piloting ratio: 4.2 1 Hydraulically piloted cracking pressure: 350 bar piloting ratio: 4.2 1 cracking pressure: 350 bar Right stabilizer cylinder double check valve cracking pressure: 350 bar...
  • Page 10 Description May 2008 Intentionally blank page Document 57.4403.4200 GTH-4013 SX GTH-4017 SX Courtesy of Crane.Market...

  • Page 11: Safety Rules

    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. Document 57.4403.4200 GTH-4013 SX GTH-4017 SX Courtesy of Crane.Market...

  • Page 12: Personal Safety

    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. Document 57.4403.4200 GTH-4013 SX GTH-4017 SX Courtesy of Crane.Market...

  • Page 13: Workplace Safety

    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. Document 57.4403.4200 xiii GTH-4013 SX GTH-4017 SX Courtesy of Crane.Market...

  • Page 14: General Remarks

    The instructions given in this handbook are the ones emotional: established by GENIE. They do not exclude other they shall keep calm and always be able to evaluate their safe and most convenient ways for the machine own physical and mental conditions.

  • Page 15: Personal Protective Equipment

    • Before applying voltage to electric cables or components, ensure they are properly connected and efficient. • Do not carry out interventions on electric components with voltage over 48V. Document 57.4403.4200 GTH-4013 SX GTH-4017 SX Courtesy of Crane.Market...
  • Page 16 Always pay the due attention to the instructions given by the foreman. • Never distract the operator during working phases or crucial manoeuvres. • Do not call an operator suddenly, if unnecessary. Document 57.4403.4200 GTH-4013 SX GTH-4017 SX Courtesy of Crane.Market...

  • Page 17: Table Of Contents

    2.16 Standard tightening torques for fitting seals 2.17 Locking material 2.18 Hoisting instructions 2.19 Advice to renew flexible hoses 2.20 List of recommended spare parts GTH-4013 SX/ GTH-4017 SX 13 2.21 Machine paint colour 2.22 Checking the cylinder movement times 2.23 Hydraulic settings...

  • Page 18: Rev

    C-11 Check the wear of the sliding pads of the boom sections C-12 Adjust the play of the sliding pads of the boom sections C-13 Grease the sliding parts of the boom sections Document 57.4403.4200 xviii GTH-4013 SX GTH-4017 SX Courtesy of Crane.Market...
  • Page 19 6.2.2 GTH-4017 SX Electrical symbols Electrical schemes 6.4.1 GTH-4013 SX GTH-4017 SX 6.4.1.1 General wiring diagram GTH-4013 SX GTH-4017 SX 17 6.4.1.2 Fuses and relays GTH-4013 SX GTH-4017 SX 18 Section 7 Rev. Repair Procedures Time schedule 001 - Cylinder disassembly - Boom raising cylinder...
  • Page 20 013 - Renewing the flexible hoses inside the boom GTH 4013 SX 014 - Renewing the flexible hoses inside the boom GTH 4017 SX 015 - Cylinder disassembly - Attachment rotation cylinder Document 57.4403.4200 GTH-4013 SX GTH-4017 SX Courtesy of Crane.Market...

  • Page 21: Main Dimensions

    Lenght to the attachment holding plate 6060 6570 Ground clerance, center Max width with ext. outriggers 2890 2890 Ground clerance, axle • Inside turning radius 2425 2425 • Outside turning radius 4650 4650 GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 22: Tyres

    Fork-holder plate rotation ° • Lifting capacity (max) 4000 4000 • Lift capacity at maximum height 3000 2000 • Lift capacity at maximum reach 1250 • Floor loading* with/without outriggers 469/479 397/522 GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 23: Forks (Floating Type)

    * Max Load; **With Fork HYDRAULIC SYSTEM GTH-4013 SX GTH-4017 SX • Make PERKINS PERKINS • Hydraulic output L/min • Pressure TELELIFT 3512 4010 2.10 ELECTRICAL SYSTEM GTH-4013 SX GTH-4017 SX • Voltage • Tension GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 24: Machine Sounds Level

    TECHNICAL SPECIFICATION 2.11 MACHINE SOUNDS LEVEL - Not applicable 2.12 VIBRATION LEVEL GTH-4013 SX GTH-4017 SX • Vibrations (at seat level) 0,23 Values calculated in accordance with standard prEN13059 CAUTION This is a Class A device. In a residential environment, such device can cause radio disturbance.
  • Page 25 3400,0 3060,0 1610,0 1450,0 2300,0 2070,0 2690,0 2420,0 2600,0 2340,0 3700,0 3330,0 4300,0 3870,0 2800,0 2520,0 3900,0 3510,0 4600,0 4140,0 3400,0 3060,0 4800,0 4320,0 5600,0 5040,0 3600,0 3240,0 5100,0 4590,0 5900,0 5310,0 GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...
  • Page 26 1850,0 850,0 1160,0 1450,0 2050,0 910,0 1280,0 1650,0 2310,0 1050,0 1470,0 1980,0 2770,0 1270,0 1780,0 2120,0 2970,0 1360,0 1900,0 2550,0 3570,0 1630,0 2280,0 2730,0 3820,0 1750,0 2450,0 3250,0 4550,0 2080,0 2910,0 GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...
  • Page 27 27,00 M 33 x 3,5 27,77 29,21 29,50 31,21 30,83 31,00 M 36 x 4 32,27 31,65 32,00 33,25 32,75 33,00 M 39 x 4 35,27 34,67 35,00 36,25 35,75 36,00 GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 28: Tightening Torques

    TORQUES (0+10%) 2"-12 37° CONICAL 2.1/4"-12 SEALS (JIC) inc. 7/16"-20 M10x1 1/2"-20 M12x1.5 9/16"-18 M14x1.5 M16x1.5 3/4"-16 M18x1.5 7/8"-14 M22x1.5 1.1/16"-12 M27x2 1.3/16"-12 1.5/16"-12 M33x2 1.5/8"-12 M42x2 1.7/8"-12 M48x2 2.1/4"-12 M10x1 GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...
  • Page 29 G 1/2" M22x1.5 G 1.1/2" G 3/4" M27x2 M48x2 G 1" M33x2 G 1.1/4" M42x2 G 1.1/2" M48x2 Male face Mechanical seal or copper washer Male face Soft seal with O-ring GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 30: Locking Material

    Excellent Loctite 5999 Formed-in-place gasket 200° Instantaneous Excellent Loctite 5910 Formed-in-place gasket 200° Rapid Excellent Loctite 5900 Formed-in-place gasket 200° Instantaneous Excellent Loctite 5920 Formed-in-place gasket 250° M 36 Slow Good GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 31: Hoisting Instructions

    2800 30¡ 60¡ 90¡ 120¡ 150¡ 3600 4400 22.4 5600 10000 18000 28000 40000 The value of the admissible load has been considered as equal to 1/6 the rope breaking load. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 32: Advice To Renew Flexible Hoses

    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: GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 33: List Of Recommended Spare Parts Gth-4013 Sx/Gth-4017 Sx

    07.4529.0110 gasket kit 07.4529.0109 gasket kit 04.4229.0024 hose 06.0401.0219 o-ring 637650 fuse 634972 fuse 634973 fuse 07.0703.0485 relay 07.0703.0487 relay 07.0703.0486 relay 56.0021.0073 gear card 56.0021.0057 card 56.0013.0036 termistore GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 34: Machine Paint Colour

    YELLOW RAL 1003 RAL 5002 RAL 1018 RAL 5003 RAL 1007 RAL 5010 RAL 1021 RAL 1016 RAL 1028 ORANGE RAL 2009 RAL 2011 RAL 2004 GREEN RAL 6029 SUNBELT GREEN GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 35: Checking The Cylinder Movement Times

    Max eingine speed 26" 18" ATTACHMENT DUMPING with fork GTH-4013 SX Time (s) Roll-back Dump Regime motore max. 4" 3" Roll-back GTH-4017 SX Time (s) Roll-back Dump Max eingine speed 3" 4" Dump GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...
  • Page 36 Min engine speed 14” 19” Lower MACHINE SWAY GTH 4013 SX Time (s) from right to left - from left to right Max engine speed 13” 12” Min engine speed 17” 17” GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 37: Hydraulic Settings

    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. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 38: Check Calibrating Hydrostatic Transmission

    A is 170 bar. If the value is less, tighten valve X; if the value is greater, loosen the valve. N.B.: To gain access to valve X, remove the protection cap (annex 3). GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...
  • Page 39 May 2008 Section 2 - Technical Specification TECHNICAL SPECIFICATION TRANSMISSION annex 1 GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...
  • Page 40 Section 2 - Technical Specification May 2008 TECHNICAL SPECIFICATION TRANSMISSION PUMP annex 2 GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...
  • Page 41 May 2008 Section 2 - Technical Specification TECHNICAL SPECIFICATION POWER STEERING SYSTEM annex 3 GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...
  • Page 42 Section 2 - Technical Specification May 2008 TECHNICAL SPECIFICATION TRANSMISSION ENGINE annex 4 GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 43: Dle System

    Mark the position of the screws with paint in order to machine side make possible loosening visible to the eye. (output extensometer rope) resin side view rear axle plane ground and unpainted area for strain cage support GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...
  • Page 44 Pin 9 and 10: 0,1 - 0,2 - 0,3 - 0,4 mV Outriggers down signal Pin 20: 12 V Pin 21: 12 V Pin 16 Pin 23 GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...
  • Page 45 The display shows a number that ISN’T blinking, starting from “0”. After calibrating, using different weights, check the cor- respondece with the load charts (lenghts from the front tyres to the center of the weight on the fork). GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...
  • Page 46 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. Starting to work. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...
  • Page 47 May 2008 Section 2 - Technical Specification TECHNICAL SPECIFICATION LOAD DIAGRAM LOAD DIAGRAM GTH-4013 SX - ON OUTRIGGERS GTH-4013 SX - ON TYRES 71.6° 70° 68.8° 60° 60° 50° 50° 40° 40° .60 m 30° .60 m 30° 20° 20°...
  • Page 48 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. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...
  • Page 49 07.0736.0014), switch on the board and start the Winscope application. Below, the list of the parameters and of the variables visualizable on the PC. In bold, the values interesting for the GTH-4013 SX and GTH-4017 SX. GTH-4013 SX GTH-4017 SX Document 57.4403.4200...
  • Page 50 (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). GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...
  • Page 51 C1swl Load percentage of cell 1 (0% = calibration without load; 100% = calibration under load). C1adcFiltro Current value of cell 1 (analog, converted into bits 0 - 1023). GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...
  • Page 52 It is possible to check the signal. ROAD SITE It is possible to check the windows are when the push button on the dashboard is pressed ROAD SITE (C2P01 - C2P02) GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...
  • Page 53 May 2008 Section 2 - Technical Specification TECHNICAL SPECIFICATION GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...
  • Page 54 Select the right (401702..) FILE • Press F4 to up-load the parameters on the control unit • The control unit can work • Perform the pedal inching calibration (see next chapter) GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...
  • Page 55 (see image 13), with the maximum calibrate inching value - Max Value 7790 • To finish the calibration procedure, press "Stop logging" or F6 (see image 14) • The machine can work. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...
  • Page 56 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. pedal C1-P10 Inch. pedal segnal C1-P11 - C1-P12 Engine rpm GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...
  • Page 57 May 2008 Section 2 - Technical Specification TECHNICAL SPECIFICATION GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...
  • Page 58 Section 2 - Technical Specification May 2008 TECHNICAL SPECIFICATION Intentionally blank page GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 59: Introduction

    • Immediately tag and remove from service a damaged or malfunctioning machine. • Repair any machine damage or malfunction before operating machine. Document 57.4403.4200 GTH-4013 SX GTH-4017 SX Courtesy of Crane.Market...

  • Page 60: About This Section

    This card can be photocopied to be used at the different service intervals and to keep a trace of all interventions carried out. Document 57.4403.4200 GTH-4013 SX GTH-4017 SX Courtesy of Crane.Market...

  • Page 61: Maintenance Table

    Make sure the safety devices installed are in efficient working order. A-19 Check the engine coolant level. A-20 Check the efficiency of the overload system. A-21 Check the re-sequence of the boom extenxion of the GTH 4013 SX. Document 57.4403.4200 GTH-4013 SX GTH-4017 SX Courtesy of Crane.Market...
  • Page 62 Remove any grease from the boom, then re-grease the sliding parts of the boom sections. C-14 Check the level of the battery electrolyte. C-15 Check the efficiency of the block valves. (every 250 working hours or every 3 working months). Document 57.4403.4200 GTH-4013 SX GTH-4017 SX Courtesy of Crane.Market...
  • Page 63 TABLE G At 6000 hours or 5 years and, subsequently, every 2 years: Check that the structure is intact paying a special attention to the welded supporting joints and the boom pins. Document 57.4403.4200 GTH-4013 SX GTH-4017 SX Courtesy of Crane.Market...

  • Page 64: Maintenance Inspection Report

    Air filter in the cab. D-10 Oil in the differential gears. Y = yes, acceptable D-11 Boom chains tensioning N = no, remove from service (GTH 4017 SX) R = repaired. Document 57.4403.4200 GTH-4013 SX GTH-4017 SX Courtesy of Crane.Market...
  • Page 65 After repair, place a check in the “R” box. Legend: Y = yes, acceptable N = no, remove from service R = repaired. Document 57.4403.4200 GTH-4013 SX GTH-4017 SX Courtesy of Crane.Market...
  • Page 66 Section 3 - Maintenance Inspections May 2008 MAINTENANCE INSPECTIONS Intentionally blank page Document 57.4403.4200 GTH-4013 SX GTH-4017 SX Courtesy of Crane.Market...
  • Page 67 OFF position with the key removed. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 68: About This Section

    PROT ECT T H E EN V I RON M EN T Draws the attention to important information on environment protection. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 69: Check The Oil Level Within Reduction Gears, Differential Gears And Power Divider Reduction Gears

    EN V I RON M EN T Place a container of suitable size under the plug for Place a container of suitable size under the plug for oil leaks. oil leaks. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...
  • Page 70 If necessary, top-up through hole A until oil comes out. Refit the plug. PROT ECT T H E EN V I RON M EN T Place a container of suitable size under the plug for oil leaks. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 71: Check The Tightening Of The Wheel Bolts

    14 pr - 14 pr 14 pr 13x20 - 13X24 13x24 Wheel disc 8 fori DIN 70361 - 8 fori DIN 70361 8 fori DIN 70361 Pressure bar/Psi 5.5/80 - 4.6/65 4.5/65 GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 72: A-3 Check The Tightening Of All Bolts And Nuts

    If you find them, rectify before starting using the For the correct tightening torques, please refer to par. machine. 2.13 in section 2 “Technical Specifications”. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 73: Inspect The Operator's Manual

    Contact TEREXLIFT Service Centre if replacement decals are needed. NOTICE Contact TEREXLIFT Service Centre if replacement manuals are needed. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 74: Check The Engine Oil Level

    Pull out the rod of the level A and ensure the oil comes to the maximum height B. If the oil is below this level, remove the pluh C and add new oil in the engine using a gradueted cup. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 75: Clean The Air Suction Filter

    Refit the plug B. WARNING As soon as the warning lamp on the cab dashboard switches on, replace the filtering element. WARNING Do not wash the cartridge using water or other kind of solvents. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 76: Check And Clean The Radiator

    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. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 77: Check The Hydraulic Oil Level In The Tank

    PROT ECT T H E EN V I RON M EN T The handling and disposing of used oils can be ruled by local or national regulations. Address to authorised centres. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 78: Check The Greasing Of The Boom Section 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 quality. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...
  • Page 79 May 2008 Section 4 - Maintenance Procedures TABLE A 4017 SX GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 80: A-12 Grease The Forks

    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 GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 81: 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

    The greasing points are shown in the following figures: the symbol represents the points to be greased by a pump the symbol represents the points to be greased by a brush. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 82: Check The Efficency Of The Lighting Electric System

    Dashboard indicators and cab lighting 12 V W 2x4,6d 1,2 W • Interior lamp 12 V SV 8,5-8 • License plate lights 12 V BA 15s • Back-up lamps 12 V BA 15s GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 83: Check The Efficency Of Braking System

    - Measure the space between the beginning and the end of the raking. - Maximum value: meter 12,4 for GTH 4013 SX; meter 12,4 for GTH 4017 SX (see TEST REPORT cod. 57.1400.8105) With fork GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 84: Check The Efficency Of The Steering Selection System

    (pos. 2). wheels are aligned (see rear wheels on position B). The sensor C on the steering cylinder of the rear axle gives Now the wheels should be re-aligned. the aligned wheels. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 85: Check The Efficency Of The Fork Balancing System

    - Start lifting the boom and check that the forks remain parallel to the ground. NOTICE If the forks do not remain parallel to the ground, consult section 5 “Problems - Causes - Solutions”. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 86: Check The Efficient Working Order Of The Safety Devices

    Check of the machine ignition control (at every use) Start diesel engin using lever B to forward/revers. The diesel engine has not start. ERROR GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...
  • Page 87 Lift the boom with a tilt angle until 50° (sensor D), retrac it fully and check the outriggers and the right/ left sway. Check the outriggers and the right/left sway are stopped with a tilt angle over 50°. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...
  • Page 88 G switchs • Move the lever N, lift/low boom, to revers (lift boom) and check the light of sensor H switchs on. In case of defects, adjust the sensors. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 89: A-19 Check The Engine Coolant Level

    50% water and 50% anti-freeze. TEREX PRO COOL Protection against boiling / freezing Product % Freezing Boiling point point -17 °C 123 °C -24 °C 126 °C -36 °C 128 °C -67 °C 135 °C GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 90: Check The Efficency Of The Overload Warning System

    57.2900.0217 rev. A 70° 72.4° 70° 60° 60° 50° 50° 40° 40° .60 m 30° 30° 20° 0.6 m 20° 4000 kg 10° 10° 0° -1.43° 0° 9.02 m 13.36 m GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 91: Check The Re-Sequence Of The Boom Telescope (Gth 4013Sx)

    20-40 seconds. Extend the boom fully, retract it and hold it over relief for approx. 60 seconds. Repeat this operation for maximum three times. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 92: Check The Efficency Of The Machine

    NOTICE For the engine maintenance, please refer to the specific For the engine maintenance, please refer to the specific Operator’s manual supplied with the machine. Operator’s manual supplied with the machine. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 93: Check The Tyre Inflation

    2 hours until they stay correct. Torque 400 N/m. WARNING Always use tyres having the dimensions indicated in the vehicle registration card. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 94: Check The Tightening Of The Wheel Nuts

    14 pr - 14 pr 14 pr 13x20 - 13X24 13x24 Wheel disc 8 fori DIN 70361 - 8 fori DIN 70361 8 fori DIN 70361 Pressure bar/Psi 5.5/80 - 4.6/65 4.5/65 GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 95: Check The Tightening Of The Cardan Shaft Screws

    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”. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 96: Clean The Radiator Fins

    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. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 97: Change The Oil In The Reduction Gears, Differential Gears And Power Divider Reduction Gear

    API GL-4 / FORD M2C 86 B / Massey Ferguson M 1135 Recommended oil: - TRACTORENAULT THFI 208 LF SAE 80W API GL-4 / FORD M2C 86 B / Massey Ferguson M 1135 GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 98: Change The Engine Oil And Relevant Filter

    Using the rod C, check the right engine oil level. Recommended oil: - TRACTORENAULT THFI 208 LF SAE 80W API GL-4 / FORD M2C 86 B / Massey Ferguson M 1135 GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 99: Check The Oil Level In The Front And Rear Differential Gears

    EN V I RON M EN T Place a container of suitable size under the plug for Place a container of suitable size under the plug for oil leaks. oil leaks. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 100: Check And Clean The Engine Air Filter

    Close the cover B. WARNING As soon as the warning lamp on the cab dashboard switches on, replace the outer element. WARNING Do not wash the cartridge using water or other kind of solvents. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 101: Check The Clamping Of The Cableheads To The Battery Terminals

    Keep out of items which can produce sparks, of more frequently. naked flames or lit cigarettes. Do not rest metal objects onto the battery. This can result in a dangerous short especially during a recharge. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 102: Check The Cylinder Chromium-Plated Rods

    For this operation, fully extend all of the cylinders and and get damaged. check that their rods are intact. CAUTION Replace any worn hoses immediately before using the machine again. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 103: C-10 Check The Electric Cables

    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 GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 104: Adjust The Play Of The Sliding Pads Of The Boom Sections

    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 GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 105: Grease The Sliding Parts Of The Boom Sections

    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. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 106: Check The Level Of The Battery Electrolyte

    Because the electrolyte is highly corrosive, it must never come in contact with the frame of the handler or electric/electronic parts. If the electro- lyte comes in contact with these parts, contact the nearest authorised assistance centre. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 107: Check The Efficency Of The Block Valves

    PROT ECT T H E EN V I RON M EN T Place a container of suitable size under the plug for oil leaks. Balance cylinder Boom extension cylinder Cilindro brandeggio attrezzi terminali GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 108: Courtesy Of Crane.market

    (opening/closing. To eliminate the air from the fork balance cylinder, move the boom up and down and tilt the fork plate forwards/back. Rear axle locking cylinder Machine compensation cylinder GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 109: Visually Check The Smoke Quantity Evacuated From The Engine Exhaust

    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. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 110: Check The Tightening Of The Cab Fixing Screws

    For this operation, use a torque wrench and tighten the screws to a torque of 188 Nm. CAUTION If you have to change some parts, please refer to the spare parts catalogue enclosed with the technical literature of the machine. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 111: Change The Hydraulic Oil Filter Cartridge

    Flow rate l/1’ = 150 Filtering = 10 π Attachment = 1” 1/4 BSP NOTICE When changing the oil, drain it when it is still hot and the polluting substances are in suspension. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 112: Have The Hydraulic System Checked By A Skilled Technician

    CAUTION Pull out the external cartridge C. Clean the filter bowl. In case of need, please contact the GENIE Service Refit the clean cartridge, or a new one, using some Centre. grease on the seal and make sure it is properly positioned.

  • Page 113: Change The Engine Oil Filter And The Fuel Filter

    Using the rod C, check the right engine oil level. Paper filters must never be cleaned using compressed Remove the fuel filter E and change it with a new air or washed with water and/or solvents. one. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 114: Change The Oil Of The Front And Rear Differential Gears

    API GL-4 / FORD M2C 86 B / Massey Ferguson M 1135 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. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 115: Change The Safety Element Of Engine Air Filter

    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. The inner element should be replaced every second time the outer element is replaced.

  • Page 116: Change The Oil In The Power Divider Gears

    - TRACTORENAULT THFI 208 LF SAE 80W API GL-4 / FORD M2C 86 B / Massey Ferguson M API GL-4 / FORD M2C 86 B / Massey Ferguson M 1135 1135 GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 117: Change The Hydraulic Oil And The Inner Hydraulic Oil Filter

    PROT ECT T H E EN V I RON M EN T Handling and disposing of used oils might be ruled by local or national regulations. Address to authorised waste centres. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 118: Change The Engine Coolant

    50% water and 50% anti-freeze. TEREX PRO COOL Protection against boiling/freezing Product % Freezing Boiling point point -17 °C 123 °C -24 °C 126 °C -36 °C 128 °C -67 °C 135 °C GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 119: Check The Machine Structure

    (if installed). DANGER After the first 5 years, repeat this check every 2 years. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 120: Courtesy Of Crane.market

    Section 4 - Maintenance Procedures May 2008 Intentionally blank page GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 121: Introduction

    WARNING Electrocution hazard. Contact with electrically charged circuits may result in death or serious injry. Remove all rings, watches and other jewerly. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 122: About This Section

    "causes" column and proceed accordingly. CAUTION For any further information, contact the GENIE Service Centre. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 123: Electrical Faults

    Problem of the wiring line from relay K11 Check the wiring for continuity. to relay K01. Speed selector not in neutral position. Check if the speed is engaged or change the speed selector. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 124: Courtesy Of Crane.market

    Check the micro-switch and replace, damaged. if necessary; with the parking brake released, you must have 12V on the pink-yellow wire. Speed selector damaged. Check and replace the speed selector if necessary. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 125: Courtesy Of Crane.market

    Machine control board damaged Check the board inputs and outputs; replace the board if necessary. Rear axle cylinder solenoid valves Y30 Check the solenoid valves and replace and Y31 damaged. if necessary. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 126: Courtesy Of Crane.market

    Horn H20 damaged. Check you have 12V between the two wires connected to the horn; if there is power, change the horn. Problem of the wiring line. Check the wiring for continuity. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 127: Courtesy Of Crane.market

    Check the indicator light and replace doesn't work the lights group if necessary. Filter restriction sensor B15 damaged. Check the sensor and replace if necessary. Problem of the wiring line. Check the wiring for continuity. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 128: Courtesy Of Crane.market

    Dashboard fuel gauge damaged. Check the fuel gauge and replace if necessary. Fuel detector B12 damaged. Check the fuel detector and replace if necessary. Problem of the wiring line. Check the wiring for continuity. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 129: Courtesy Of Crane.market

    Check the efficiency of the bulb and indicator light doesn’t work replace, if necessary. Indicator light H113. Check the indicator light. Problem of the wiring line. Check the wiring for continuity. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 130: Hydraulic Faults

    The right - left sway function doesn't Sway cyilinders damaged. Check or replace the internal seals, if work necessary. Block valves damaged. Check the sliders and the coils of the electrovalves. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 131: Courtesy Of Crane.market

    Check the efficiency of the valve and the damaged. proper sliding of the internal piston. When the brake pedal is stepped Auxiliary gear pump damaged. Check the pump thoroughly. down, the machine doesn't brake GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 132: Courtesy Of Crane.market

    Valvola di blocco cilindro sfilo interno Check the valve, clean or replace if braccio danneggiata. (only GTH 4013 necessary. Block valve of the boom external extension Check the valve, clean or replace if cylinder damaged. necessary. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 133: Courtesy Of Crane.market

    Bleed (see Operator's manual). When the boom is moved up or Balancing cylinder damaged. Check the cylinder efficiency and the down, the forks cannot be levelled state of the internal seals. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 134: Courtesy Of Crane.market

    The rear axle unlocking device Cylinder damaged. Change the seals and check the doesn't work tightness of the cylinder. Block valve damaged. Remove and clean the valve; check its seal and replace if necessary. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 135: Hydraulic Symbols

    Hand-operated control with lever Non-return valve Flowmeter Hand-operated control with pedal Pressure switch Calibrated non-return valve Mechanical control with pushbutton Drain to tank Unlockable non-return Mechanical control indication valve with spring GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 136: Gth-4017 Sx

    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 Electro-hydraulic single-acting servo valve GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 137: Courtesy Of Crane.market

    capacity: 0.5 Litri precharge Double overcenter safety valve pressure Double overcenter safety valve piloting ratio: 4.2 1 Double overcenter safety valve 50 bar piloting ratio: 4.2 1 Hydraulically piloted cracking pressure: 350 bar piloting ratio: 4.2 1 cracking pressure: 350 bar Right stabilizer cylinder double check valve cracking pressure: 350 bar...

  • Page 138: Courtesy Of Crane.market

    capacity: 0.5 Litri precharge Double overcenter safety valve pressure Double overcenter safety valve Double overcenter safety valve piloting ratio: 4.2 1 50 bar piloting ratio: 4.2 1 piloting ratio: 4.2 1 Hydraulically piloted cracking pressure: 350 bar cracking pressure: 350 bar Right stabilizer cylinder cracking pressure: 350 bar double check valve...

  • Page 139: Electrical Symbols

    Winding with diode Buzzer NO level CONNECTORS Siren Connector Pushbutton with NC return Bell STATIC APPLICATIONS Pushbutton with NO return Horn Auto-transformer NC tie-rod FUSES AND RELAYS Transformer Horizontal fuse NO tie-rod Relay GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 140: Courtesy Of Crane.market

    Normally open (NO) Normally closed (NC) NO limit switch NC limit switch Contactor Magneto-thermal closure Magneto-thermal opening Thermal closure Thermal opening Exchange NC proximity NO proximity NO mechanical NC mechanical Selector Selector2 GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 141: Electrical Schemes

    May 2008 Section 6 - Schemes SCHEMES ELECTRICAL SCHEMES 1/10 6.4.1 GTH-4013 SX GTH-4017 SX GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 142: Gth-4013 Sx Gth-4017 Sx

    Section 6 - Schemes May 2008 SCHEMES 2/10 GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 143: Courtesy Of Crane.market

    May 2008 Section 6 - Schemes SCHEMES 3/10 GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 144: Courtesy Of Crane.market

    Section 6 - Schemes May 2008 SCHEMES 4/10 GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 145: Courtesy Of Crane.market

    May 2008 Section 6 - Schemes SCHEMES 5/10 GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 146: Courtesy Of Crane.market

    Section 6 - Schemes May 2008 SCHEMES 6/10 GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 147: Courtesy Of Crane.market

    May 2008 Section 6 - Schemes SCHEMES 7/10 GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 148: Courtesy Of Crane.market

    Section 6 - Schemes May 2008 SCHEMES 8/10 GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 149: Courtesy Of Crane.market

    May 2008 Section 6 - Schemes SCHEMES 9/10 GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 150: Courtesy Of Crane.market

    Section 6 - Schemes May 2008 SCHEMES 10/10 GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 151: 6.4.2.1 General Wiring Diagram Gth 4013-Sx Gth-4017 Sx

    May 2008 Section 6 - Schemes SCHEMES 6.4.2.1 GENERAL WIRING DIAGRAM GTH 4013-SX GTH-4017 SX GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 152: 6.4.2.2 Fuses And Relays Gth-4013 Sx Gth-4017 Sx

    Section 6 - Schemes May 2008 SCHEMES 6.4.2.2 FUSES AND RELAYS GTH-4013 SX GTH-4017 SX GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 153: Courtesy Of Crane.market

    May 2008 Section 6 - Schemes SCHEMES Boom feelers Rear axle Reductor Front axle GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 154: Courtesy Of Crane.market

    Section 6 - Schemes May 2008 SCHEMES Display Fuses Hydraulic oil fi lter relays boards EV steering 6-ways/2-positions electrical switch GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 155: Courtesy Of Crane.market

    May 2008 Section 6 - Schemes SCHEMES Main valve Swtichs Outriggers Joystick GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 156: Courtesy Of Crane.market

    Section 6 - Schemes May 2008 Intentionally blank page GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 157: Time Schedule

    1,00 change locking fork cylinder kit 1,30 change block valve of the attachment locking cylinder 1,00 change the outrigger up/down movement cylinder 1,30 change the outrigger up/down movement cylinder kit 1,30 GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 158: Courtesy Of Crane.market

    3,00 change the rear axle shaft 3,00 change 1 cardan joint 1,00 change the cardan joints 2,00 change the axle shaft hub 1,30 change the boom assy 5,00 cad. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 159: Courtesy Of Crane.market

    2,00 cad. change a wheel (n° 1) 1,00 change the rear axle locking cylinder 1,00 change the outriggers 1,00 change flexible hoses 0,30 change the parking brake lever 1,00 GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 160: Courtesy Of Crane.market

    Section 7 - Repair Procedures May 2008 REPAIR PROCEDURES Intentionally blank page GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 161: Cylinder Disassembly - Boom Raising Cylinder

    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. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 162: Courtesy Of Crane.market

    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 sling GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 163: Courtesy Of Crane.market

    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 GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 164: Courtesy Of Crane.market

    CAUTION To reassemble the cylinder, repeat the steps above in reversed order. Remember to set the circuit under pressure before releasing the bridge crane. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 165: Courtesy Of Crane.market

    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.) GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 166: Courtesy Of Crane.market

    9 Knock out the pin 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 GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...
  • Page 167 8 Remove the lower cover using a stacker. 9 With a screwdriver, disconnect the fuel feeding and return piping held in position by the special hose-clamps GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 168: Removing The Engine From The Machine

    13mm wrench, and remove the nuts (D) of the vibration-damping brackets using a 22mm wrench. Extract the radiator using a bridle and a bridge crane, make sure do not damnage the parts. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 169: Courtesy Of Crane.market

    17mm wrench. disconnect the two holes of the hydraulic pump (B) using a 24mm combination wrench and a 36mm combination wrench. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 170: Courtesy Of Crane.market

    Reassembling the engine: CAUTION To reassemble the engine, repeat the steps above in reversed order considering the precautions below. Handle the engine with extreme caution to prevent it from crashing against the machine GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...
  • Page 171 13mm wrench. 2 Using two 17mm wrenches, remove the six screws that fix the engine lower cover 3 Remove the lower cover using a stacker 4 Close the oil tank cock GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 172: Courtesy Of Crane.market

    8 Remove the fixing screws B of the drive pump using a 22mm combination wrench, then secure the pump to the bridge crane with a textile sling and pull it out of the motor. Place the pump on GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 173: Hydraulic Pumps Disassembly

    (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. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 174: Courtesy Of Crane.market

    Section 7 - Repair Procedures May 2008 TABLE Procedure: Table: GTH-4013 SX GTH-4017 SX Intentionally blank page GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...
  • Page 175 3 Disconnect the drainage hydraulic tubes using a 36 mm wrench and a 24 mm wrench. 4 Disconnect the two hoses using a 16 mm wrench. 5 Disconnect the pilots using a 17mm combination wrench. GTH-4013 SX GTH-4017 SX Documento 57.4403.4200 Courtesy of Crane.Market...

  • Page 176: Disassembling The Hydraulic Motor

    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. GTH-4013 SX GTH-4017 SX Document 57. 4403.4200 Courtesy of Crane.Market...

  • Page 177: Courtesy Of Crane.market

    6 With a 24 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. GTH-4013 SX GTH-4017 SX Documento 57.4403.4200 Courtesy of Crane.Market...

  • Page 178: Cylinder Disassembly Boom Extension Cylinder Gth 4017 Sx

    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 GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 179: Courtesy Of Crane.market

    6 Using a 24 mm wrench, disconnect the two hydraulic hoses (B) and the two hoses (C) , then plug the disconnected connectors to prevent dust and impurities from entering the circuit. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 180: Cylinder Disassembly Boom Extension External Cylinder Gth 4013 Sx

    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. GTH-4013 SX GTH-4017 SX Document 574403.4200 Courtesy of Crane.Market...

  • Page 181: Courtesy Of Crane.market

    6 With a 24 mm wrench, disconnect the two hydraulic hoses (C) from the blocking valve, then plug the disconnected connectors to prevent dust and impurities from entering the circuit. GTH-4013 SX GTH-4017 SX Documento 57.4403.4200 Courtesy of Crane.Market...

  • Page 182: Cylinder Disassembly Boom Extension Internal Cylinder Gth 4013 Sx

    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 things. GTH-4013 SX GTH-4017 SX Document 574403.4200 Courtesy of Crane.Market...

  • Page 183: Water-Oil Cooler Disassembly

    4 Disconnect the two hydraulic oil hoses from the cooler using a 41mm wrench. 5 Disconnect the water and air pipes from/to the thermal motor loosening the hose-clamps with a screwdriver. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 184: Courtesy Of Crane.market

    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 and things. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 185: Main Valve Disassembly

    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. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 186: Courtesy Of Crane.market

    6 Remove the three screws fixing the main valve to the chassis using a 13mm wrench. 7 Remove the main valve from the machine and place it on to a bench. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 187: Renewing The Slide Pads Of The Telescopic Boom Gth 4013 Sx

    5 Remove the fixing screws from the pads and position as many shims as necessary to reach the normal thickness value GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 188: Courtesy Of Crane.market

    INTERFLON FIN GREASE LS2 New pad thickness: 15 mm Max wearing thickness: 6 mm Torque: 30÷35 Nm Minimum thickness: 9 mm GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 189: Courtesy Of Crane.market

    12 Using a 17mm hex wrench or a 6mm Allen wrench, remove the pad fixing screws. Using a screwdriver, pry off the worn pads. Fit new pads after applying a few drops of Loctite 495 on the threads. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 190: Courtesy Of Crane.market

    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 GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 191: Renewing The Slide Pads Of The Telescopic Boom Gth 4017 Sx

    5 Remove the fixing screws from the pads and position as many shims as necessary to reach the normal thickness value GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 192: Courtesy Of Crane.market

    INTERFLON FIN GREASE LS2 THIRD SECTION SECOND SECTION FIRST SECTION New pad thickness: 15 mm Max wearing thickness: 6 mm Torque: 30÷35 Nm Minimum thickness: 9 mm GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 193: Courtesy Of Crane.market

    12 Using a 17mm hex wrench or a 6mm Allen wrench, remove the pad fixing screws. Using a screwdriver, pry off the worn pads. Fit new pads after applying a few drops of Loctite 495 on the threads. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 194: Courtesy Of Crane.market

    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. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 195: Renewing The Flexible Hoses Inside The Boom Gth 4013 Sx

    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. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 196: Courtesy Of Crane.market

    Section 7 - Repair Procedures May 2008 TABLE Procedure: Renewing the flexible hoses inside the boom GTH 4013 SX Table: GTH-4013 SX GTH-4017 SX Useful advice for mounting flexible hoses: GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 197: Renewing The Flexible Hoses Inside The Boom Gth 4017 Sx

    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. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 198: Courtesy Of Crane.market

    - plug the hole to avoid dusty or impurities come inside - retract the boom completely - remove the lock screws of the two half pulleys (B) using a 13mm combination wrench GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 199: Courtesy Of Crane.market

    - 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. GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 200: Courtesy Of Crane.market

    Section 7 - Repair Procedures May 2008 TABLE Procedure: Renewing the flexible hoses inside the boom GTH 4017 SX Table: GTH-4013 SX GTH-4017 SX Useful advice for mounting flexible hoses: GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 201: Courtesy Of Crane.market

    Address to legally authorised centres. 7 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 GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

  • Page 202: Courtesy Of Crane.market

    (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 GTH-4013 SX GTH-4017 SX Document 57.4403.4200 Courtesy of Crane.Market...

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