Terex Genie GTH-4017 EX Service Manual
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Terex Genie GTH-4017 EX Service Manual

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Service Manual
GTH-4017
GTH-4514
GTH-4013
English
Serial number range
EX
From serial n.: 19296
EX
From serial n.: 19286
EX
From serial n.: 19266
Part. No.
57.0009.0427
November 2008

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Summary of Contents for Terex Genie GTH-4017 EX

  • Page 1 Service Manual Serial number range GTH-4017 From serial n.: 19296 GTH-4514 From serial n.: 19286 GTH-4013 From serial n.: 19266 Part. No. 57.0009.0427 November 2008 English...
  • Page 2 Service Manual November 2008 Intentionally blank page Document 57.0009.0427 GTH-4017EX GTH-4514EX GTH-4013EX...

  • Page 3: Introduction

    November 2008 Introduction Introduction IMPORTANT Read, understand and obey the safety rules and operating instructions in the GTH-4013EX - GTH-4514EX - GTH- 4017EX Operator's manual (cod. 57.0009.0454) before attempting any maintenance or repair procedure. This manual provides the machine owner and user with detailed information on the scheduled maintenance.
  • Page 4 Machine Identification November 2008 IDENTIFICATION MACHINE Machine Identification CHASSIS SERIAL NUMBER The chassis serial number is punched on the front left part of the chassis side member. ona Industriale 0 0 Umbertide (PG) Italy MODEL NUMBER IDENTIFICATION PLATES OF THE MAIN PARTS SERIAL NUMBER The plates of the main components, not directly YEAR OF MANUFACTURE...

  • Page 5: Description

    November 2008 Description Description DESCRIPTION OF THE MACHINE OPERATION GTH-4017 EX - GTH-4514 EX The motor is directly flanged to the Dana single-speed reduction gear (26), which is fixed with brackets to the The mechanical energy source of these machines is a central zone of the chassis.
  • Page 6 Description November 2008 DESCRIPTION rotation, boom extension/ retraction, attachment locking/ limits the load when the boom is extended in those unlocking). working zones where the electronic overturning control In the head there is a pressure relief valve set at 280 system cannot detect overload conditions with respect bar which, acting on the line of the “load sensing”...
  • Page 7 November 2008 Description DESCRIPTION A one-way valve calibrated at 8 bar (33), is installed parallel to the input line of the heat exchanger and used as safety valve. Its function is to avoid overpressure conditions of the heat exchanger (as is the case of a machine starting at low temperatures) by directly draining any excess oil into the tank.
  • Page 8 Description November 2008 DESCRIPTION GTH-14017EX - GTH-4514EX hydraulic schematic viii Document 57.0009.0427 GTH-4017EX GTH-4514EX GTH 4013EX...

  • Page 9: Rev

    November 2008 Description Description DESCRIPTION OF THE MACHINE OPERATION GTH-4013EX The motor is directly flanged to the Dana single-speed reduction gear (26), which is fixed with brackets to the The mechanical energy source of these machines is a central zone of the chassis. The mechanical torque at (1) Perkins diesel engine model 1104/d-44T, which supplies a 74,5 kW at 2200 rev/min with a max torque the gearbox output is transmitted to the front axle (6)
  • Page 10 Description November 2008 DESCRIPTION In the head there is a pressure relief valve set at 280 On the control line of the circular chamber of the cylinders bar which, acting on the line of the “load sensing” signal, (21) and (40) there is a pressure relief valve set at 230 limits the maximum pressure at the inlet of the main bar which limits the load when the boom is extended in valve through such 3-way compensator.
  • Page 11 November 2008 Description DESCRIPTION parallel to the input line of the heat exchanger and used as safety valve. Its function is to avoid overpressure conditions of the heat exchanger (as is the case of a machine starting at low temperatures) by directly draining any excess oil into the tank.
  • Page 12 Description November 2008 DESCRIPTION GTH-4013EX hydraulic schematic Document 57.0009.0427 GTH-4017EX GTH-4514EX GTH 4013EX...

  • Page 13: Safety Rules

    November 2008 Section 1 - Safety Rules Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the appropriate Operator's Manual on your machine will result in death or serious injury. Many of the hazards identified in the Operator's Manual are also safety hazards when maintenace and repair procedures are performed..

  • Page 14: Personal Safety

    Section 1 - Safety Rules November 2008 SAFETY RULES NOTICE SAFETY RULES 1.1-1 PERSONAL SAFETY Draws the attention to important technical information or practical advice that allows for a safer and more In this manual, any important information is preceded by efficient use of the machine.

  • Page 15: Workplace Safety

    November 2008 Section 1 - Safety Rules SAFETY RULES 1.1-2 WORKPLACE SAFETY Be sure to keep sparks, flames and lighted tobacco away from flammable and combustible materials like battery gases and engine fuels. Always have an approved fire extinguisher within easy reach. Be sure that all tools and working areas are properly maintained and ready for use.

  • Page 16: General Remarks

    Section 1 - Safety Rules November 2008 SAFETY RULES GENERAL REMARKS SERVICEMEN'S REQUISITES The operators who use the machine regularly or Most accidents occurring while working, servicing or occasionally (e.g. for maintenance or transport) shall maintaining operation machines, are caused by not have the following requisites: complying with the basic safety precautions.

  • Page 17: Personal Protective Equipment

    November 2008 Section 1 - Safety Rules SAFETY RULES GENERAL SAFETY PRECAUTIONS 1.3-1 PERSONAL PROTECTIVE EQUIPMENT DANGER During work, but especially when maintaining or repairing the machine, operators must wear suitable protective clothing and equipment: Read and understand the following safety instructions •...
  • Page 18 Section 1 - Safety Rules November 2008 SAFETY RULES • Do not connect wet plugs or sockets. • Do not frighten an operator or throw objects by no • Signs and stickers shall never be removed, hidden means. or become unreadable. •...

  • Page 19: Table Of Contents

    November 2008 Table of Contents Rev. Introduction Important Machine Identification Description Description of the machine operation GTH-4017EX - GTH-4514EX Hydraulic schematic GTH-4017EX - GTH-4514EX viii Description of the machine operation GTH-4013EX Hydraulic schematic GTH-4013EX Xiii Section 1 Rev. Safety Rules Safety rules 1.1-1 Personal safety...

  • Page 20: Rev

    November 2008 TABLE OF CONTENTS Section 3 Rev. Maintenance Inspections Introduction About this section Maintenance table Maintenance inspection report Section 4 Rev. Maintenance Procedures Introduction About this section Table A procedures Check the oil level within reduction gears, differential gears and power divider reduction gears Check the tightening of the wheel bolts Check the tightening of all bolts and nuts...
  • Page 21 November 2008 TABLE OF CONTENTS Check the hydraulic lines C-10 Check the electric cables 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 C-14 Check the level of the battery electrolyte C-15 Check the efficency of the block valves Table D procedures...
  • Page 22 November 2008 TABLE OF CONTENTS Section 7 Rev. Repair Procedures Time schedule 001 - Cylinder disassembly - Boom raising cylinder 002 - Cylinder disassembly - Fork balance cylinder 003 - Removing the engine from the machine 004 - Hydraulic pumps disassembly 005 - Disassembling the hydraulic motor 006 - Cylinder disassembly - Boom extension cylinder GTH-4017EX - GTH-4514EX...

  • Page 23: Technical Specification

    November 2008 Section 2 - Technical Specification Technical Specification MAIN DIMENSIONS GTH-4017 EX GTH-4514 EX GTH-4017 EX GTH-4514 EX GTH-4017 EX GTH-4514 EX GTH-4013 EX Height 2610 2560 2400 Height at steering whell 1650 1600 1600 Width 2450 2450 2320 Inside cab width Track 1980...

  • Page 24: Tyres

    Section 2 - Technical Specification November 2008 TECHNICAL SPECIFICATION TYRES GTH-4017 EX GTH-4514 EX GTH-4013 EX - Dimension 405/70-24 405/70-20 405/70-20 - Load index 14 pr 14 pr 14 pr - Rim 13x24 13x20 13x20 - Wheel disc 8 holes DIN 70631 8 holes DIN 70631 8 holes DIN 70631 - Pressure...

  • Page 25: Forks (Floating Type)

    November 2008 Section 2 - Technical Specification TECHNICAL SPECIFICATION FORKS (FLOATING TYPE) GTH-4017 EX GTH-4514 EX GTH-4013 EX • Dimension 1200x120x50 1200x120x50 1200x120x50 • Weight TELELIFT 3512 4010 DIESEL ENGINE 3512 4010 GTH-4017 EX GTH-4514 EX GTH-4013 EX • Make PERKINS PERKINS PERKINS...

  • Page 26: Machine Sounds Level

    Section 2 - Technical Specification November 2008 TECHNICAL SPECIFICATION 2.11 MACHINE SOUNDS LEVEL - Not applicable 2.12 VIBRATION LEVEL GTH-4017 EX GTH-4514 EX GTH-4013 EX • Vibrations (at seat level) 0,23 0,23 0,23 Values calculated in accordance with standard prEN13059 CAUTION This is a Class A device.

  • Page 27: Fastener Torques

    November 2008 Section 2 - Technical Specification TECHNICAL SPECIFICATION 2.14 FASTENER TORQUE SAE FASTENER TORQUE CHART • This chart is to be used as a guide only unless noted elsewhere in this manual • A574 High Strength Grade 5 Grade 8 SIZE THREAD Black Oxide Bolts LUBED...

  • Page 28: Locking Material

    Section 2 - Technical Specification November 2008 TECHNICAL SPECIFICATION 2.15 LOCKING MATERIAL THREAD LOCKERS Product APPLICATION Characteristics Locking Resistance Temp. °C Thread speed Loctite 290 Thread locking to 150° M 12 Rapid Medium Loctite 222 Thread locking to 150° M 20 Moderate Loctite 243 Thread locking...

  • Page 29: Hoisting Instructions

    November 2008 Section 2 - Technical Specification TECHNICAL SPECIFICATION • Attach the load to the natural seat of the hook. 2.16 HOISTING INSTRUCTIONS DANGER Attaching a load to an end can cause the load to fall down during raising and result in serious injury. All parts weighing more than 25 kg MUST COMPULSORILY be handled with suitable hoisting means.

  • Page 30: Advice To Renew Flexible Hoses

    Section 2 - Technical Specification November 2008 TECHNICAL SPECIFICATION 2.17 ADVICE TO RENEW FLEXIBLE HOSES Before disconnecting or refitting a flexible hose, carefully clean the area all around. PROTECT THE Blow some compressed air to remove any impurity. ENVIRONMENT For an easier renewal of the hoses, whose run is not clearly visible, proceed as follows: •...

  • Page 31: List Of Recommended Spare Parts Gth-4013Ex

    November 2008 Section 2 - Technical Specification TECHNICAL SPECIFICATION 2.18 LIST OF RECOMMENDED SPARE PARTS GTH-4013EX Cod. Description Q.ty 07.0741.0015 Outrigger main valve gaskets kit 07.4529.0108 Levelling chassis cylinder gaskets kit 07.4529.0093 Rear axle levelling cylinder gaskets kit 04.4240.0025 Rear axle levelling cylinder solenoid valve 07.4529.0106 Outrigger cylinder gaskets kit 07.4529.0110...
  • Page 32 Section 2 - Technical Specification November 2008 TECHNICAL SPECIFICATION Cod. Description Q.ty 638243 Engine oil filter 07.4501.0084 Engine air filter cartridge 07.4501.0085 Engine air filter safety cartridge 53.3001.6700 Engine air filter pipe 07.0728.0007 Changing speed solenoid valve 04.4240.0052 Steering mode solenoid valve 07.0741.0004 Boom main valve module 07.0741.0005...

  • Page 33: List Of Recommended Spare Parts Gth-4017Ex - Gth-4514Ex

    November 2008 Section 2 - Technical Specification TECHNICAL SPECIFICATION Cod. Description Q.ty 56.0013.0036 Cooler temperature sensor 07.0703.0192 Therma engine box relay 56.0005.0001 50A fuse 07.0703.0061 70A fuse 56.0012.0020 Engine speed meter 56.0012.0017 Outrigger micro-switch 56.0013.0028 Hydraulic oil level gauge 07.0703.0535 Relay 56.0021.0059 Boom, outrigger and chassis movement control unit...
  • Page 34 Section 2 - Technical Specification November 2008 TECHNICAL SPECIFICATION Cod. Description Q.ty 695970 54.0702.0040 695959 54.0702.0021 54.0702.0038 54.0200.0000 Pad bushing 07.4529.0065 Extension boom cylinder gaskets kit 07.0741.0006 Boom main valve enabling function swicth solenoid valve 56.0021.0091 Main valve module 56.0021.0090 Main valve module 56.0021.0089 Main valve module...

  • Page 35: Machine Paint Colour

    2.19 MACHINE PAINT COLOUR GENIE machine BLU GENIE WHITE RAL 9002 GREY GENIE RAL 9010 RAL 9016 BLACK RAL 9500 RAL 1013 TEREX GREY RAL 3002 RAL 7039 RAL 2002 RAL 7038 RAL 3020 RAL 7032 TEREX YELLOW RAL 1003...

  • Page 36: Checking The Cylinder Movement Times

    Section 2 - Technical Specification November 2008 TECHNICAL SPECIFICATION 2.20 CHECKING THE CYLINDER MOVEMENT TIMES CAUTION CAUTION The check of the movement times of the cylinders To check the engine speed, the area easy to reach shall be done with the hydraulic oil at a temperature is the shaft of the CASAPPA pump.
  • Page 37 November 2008 Section 2 - Technical Specification TECHNICAL SPECIFICATION ATTACHMENT DUMPING with fork GTH-4017 EX Time (s) Roll-back Dump Max engine speed 4" 3" Roll-back GTH-4514 EX Time (s) Roll-back Dump Max engine speed 4" 3" GTH-4013 EX Time (s) Roll-back Dump Dump...

  • Page 38: Hydraulic Settings

    Section 2 - Technical Specification November 2008 TECHNICAL SPECIFICATION CAUTION 2.21 HYDRAULIC SETTINGS PRELIMINARY OPERATIONS For safety reasons, do not hold the cylinder to end Check that the engine idle is set at 950 rpm and that of stroke and do not let the engine run at max speed the engine maximum speed is set at 2300 rpm for for more than 5 seconds.

  • Page 39: Hydrostatic Transmission Pump

    November 2008 Section 2 - Technical Specification TECHNICAL SPECIFICATION HYDROSTATIC TRANSMISSION PUMP (ANNEX 4) Pump check points. • A. high pression manometric socket MB. • B. low pression manometric socket M3 • C. pressure cut-off valves (max 450 bar). • D.
  • Page 40 Section 2 - Technical Specification November 2008 TECHNICAL SPECIFICATION HYDRAULIC SYSTEM - CONTROL MAIN VALVE annex 1 GTH 4514EX-GTH 4017EX GTH 4013EX Document 57.0009.0427 GTH-4017EX GTH-4514EX GTH-4013EX...
  • Page 41 November 2008 Section 2 - Technical Specification TECHNICAL SPECIFICATION HYDRAULIC SYSTEM - OUTRIGGERS annex 2 GTH 4013EX GTH 4514EX-GTH 4017EX Document 57.0009.0427 GTH-4017EX GTH-4514EX GTH-4013EX...
  • Page 42 Section 2 - Technical Specification November 2008 TECHNICAL SPECIFICATION HYDRAULIC SYSTEM - TRANSMISSION PUMP annex 3 Document 57.0009.0427 GTH-4017EX GTH-4514EX GTH-4013EX...
  • Page 43 November 2008 Section 2 - Technical Specification TECHNICAL SPECIFICATION HYDRAULIC SYSTEM - TRANSMISSION PUMP annex 4 Document 57.0009.0427 GTH-4017EX GTH-4514EX GTH-4013EX...
  • Page 44 Section 2 - Technical Specification November 2008 TECHNICAL SPECIFICATION HYDRAULIC SYSTEM - POWER STEERING annex 5 Document 57.0009.0427 GTH-4017EX GTH-4514EX GTH-4013EX...
  • Page 45 November 2008 Section 2 - Technical Specification TECHNICAL SPECIFICATION HYDRAULIC SYSTEM - TRANSMISSION ENGINE annex 6 Document 57.0009.0427 GTH-4017EX GTH-4514EX GTH-4013EX...

  • Page 46: Dle System

    Section 2 - Technical Specification November 2008 TECHNICAL SPECIFICATION 2.22 DLE SYSTEM To avoid damaging strain cage and to get maximum results, proceed as follows: INSTALLATION OF THE EXTENSIMETRIC CELL 1 - PREPARATION: = strain cage Thoroughly clean whole tightening system, especially = washer ø...
  • Page 47 November 2008 Section 2 - Technical Specification TECHNICAL SPECIFICATION DLE Display 23 16 CONN. DESCRIPTION CODE AMP CONNECTOR 23 C. MV 770680-1 FEMALE DEUTSCH CONNECTOR MV DT068P SUPER SEAL MALE MV 282107/1 SUPER SEAL FEMALE MV 282089/1 SUPER SEAL FEMALE MV 282089/1 SUPER SEAL MALE MV 282107/1...
  • Page 48 Section 2 - Technical Specification November 2008 TECHNICAL SPECIFICATION CALIBRATING THE DLE SYSTEM NOTICE During the calibration mode the limiter device • doesn’t block any manoeuvres so the calibration can be done. • With outriggers, calibrate the system without load and with load and outriggers fully at ground.
  • Page 49 November 2008 Section 2 - Technical Specification TECHNICAL SPECIFICATION DISPLAY FUNCTION The LED bar indicates the type of machine in use: 1 LED on -GTH 4013EX - GTH 4017EX - GTH 4017EX To select the machine to be calibrated press to increase the number of LED's lit or press to reduce the number of LED's lit.
  • Page 50 Section 2 - Technical Specification November 2008 TECHNICAL SPECIFICATION LOAD DIAGRAM LOAD DIAGRAM GTH-4013 EX - ON OUTRIGGERS GTH-4013 EX - ON TYRES LOAD DIAGRAM LOAD DIAGRAM GTH-4017 EX - ON OUTRIGGERS GTH-4017 EX - ON TYRES Document 57.0009.0427 GTH-4017EX GTH-4514EX GTH-4013EX...
  • Page 51 November 2008 Section 2 - Technical Specification TECHNICAL SPECIFICATION LOAD DIAGRAM LOAD DIAGRAM GTH-4514 EX - ON OUTRIGGERS GTH-4514 EX - ON TYRES Document 57.0009.0427 GTH-4017EX GTH-4514EX GTH-4013EX...
  • Page 52 Section 2 - Technical Specification November 2008 TECHNICAL SPECIFICATION DIAGNOSTIC FUNCTION IN CALIBRATION MODE FUNCTION DISPLAY Display of the value read by the ADC converter-cell channel 1 (A) and cell channel 2 (B). This diagnosis function allows you to check proper reading of the load cell. As you move the boom, you can see the LEDs of the load bar progressively go on/off (valid if calibration has already been done).
  • Page 53 November 2008 Section 2 - Technical Specification TECHNICAL SPECIFICATION Alarm code Description CELL 2 reading out of range. Action Similar to alarm 2, but referred to the second analog channel (Cell 2). Alarm code Description Block Relay check error during work. Check through.re-reading of the block output of the congruence with the current state of the limiter.
  • Page 54 Section 2 - Technical Specification November 2008 TECHNICAL SPECIFICATION LIST OF THE DLE PARAMETERS N° Winscope Name Description C1cellaVuoto Value saved in analog channel 1 - calibration with unloaded machine (best setting around 700). C1cellaCarico Value saved in analog channel 1 - calibration with loaded machine (best setting around 300).
  • Page 55 November 2008 Section 2 - Technical Specification TECHNICAL SPECIFICATION C1NavicellaVuoto Parameters 20, 21, 22 and 23 are usually equivalent to parameters 0, 1, 4 and 5. They shall be used for a new calibration of the platform not depending on the proportional % calibration done with the forks. These parameters only apply to the platform.
  • Page 56 Section 2 - Technical Specification June 2008 CALIBRATING THE PLATFORM SYSTEM With the machine properly stabilised, the boom If the sequence is correct, the LED next to comes lowered, the ignition key turned to the left (pos. P), on with a solid light to confirm the proper operation the platform controls enabled (key of the Road- of the instrument in the calibration mode.

  • Page 57: Hydrostatic Transmission Control Unit Check System

    November 2008 Section 2 - Technical Specification TECHNICAL SPECIFICATION 2.23 HYDROSTATIC TRANSMISSION CONTROL UNIT CHECK SYSTEM An electronic control unit gives power to the SAUER hydrostatic transmission; the software PLUS+1 lets to control the transmission. • Connect the computer to the cable CAN/USB (cod. 55.0602.0331).
  • Page 58 Section 2 - Technical Specification November 2008 TECHNICAL SPECIFICATION 4 4 4 Document 57.0009.0427 GTH-4017EX GTH-4514EX GTH-4013EX...
  • Page 59 November 2008 Section 2 - Technical Specification TECHNICAL SPECIFICATION Click on • STATUS • ELECTRICAL to open the ELECTRICAL STATUS window and to find some possible mistakes on the system (image 7). The signal of ERROR is present on the instrument panel too.
  • Page 60 Section 2 - Technical Specification November 2008 TECHNICAL SPECIFICATION To get acces to the from INCHING PARAMETERS FUNCTIONS select: • arameter Functions (10). • Inputs. • Inching. • Set Defaults. • Inside the window "calibrate inch Potentiometer" select the value 1 (see image 11). •...
  • Page 61 November 2008 Section 2 - Technical Specification TECHNICAL SPECIFICATION FAULT TABLE "A" Error code Error description Machine state Battery Voltage or Sensor Voltage Error SAFE Mode Pump Current Forward EV SAFE Mode Pump Current Reverse EV SAFE Mode Motor Current EV SAFE Mode Diesel Engine Speed RPM SAFE Mode...
  • Page 62 Section 2 - Technical Specification November 2008 TECHNICAL SPECIFICATION Document 57.0009.0427 GTH-4017EX GTH-4514EX GTH-4013EX...

  • Page 63: Maintenance Inspections

    November 2008 Section 3 - Maintenance Inspections Maintenance Inspections INTRODUCTION • Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine. • Scheduled maintenance must be carried out at the intervals indicated in the MAINTENANCE REPORT.

  • Page 64: About This Section

    Section 3 - Maintenance Inspections November 2008 MAINTENANCE INSPECTIONS ABOUT THIS SECTION Intervention times Maintenance interventions have been divided into 7 different groups in relation to the time at which they must be carried out, say daily, weekly, monthly, every 2 months, every 6 months, yearly and every 5 years (afterwards every 2 years).

  • Page 65: Maintenance Table

    November 2008 Section 3 - Maintenance Inspections MAINTENANCE INSPECTIONS MAINTENANCE TABLE TABLE A During the first 10 working hours: Check the oil level within reduction gears, power divider and differential gears. Check the tightening of the wheel bolt. Check the tightening of all bolts and nuts. Check the couplings for oil leaks.
  • Page 66 Section 3 - Maintenance Inspections November 2008 MAINTENANCE INSPECTIONS TABLE B Within the first 50 working hours: Check the general efficency of the machine. Every 50 working hours or weekly: Check the tension of the alternator belt. Check the tyre inflation. Check the tightening of the wheel nuts.
  • Page 67 November 2008 Section 3 - Maintenance Inspections MAINTENANCE INSPECTIONS TABLE D Every 500 working hours or every two months: Visually check the smoke quantity evacuated from the engine exhaust. Check the tightening of the engine fixing screws. Check the tightening of the cab fixing screws. Check the backlash between pins and bushings in all joints.

  • Page 68: Maintenance Inspection Report

    Section 3 - Maintenance Inspections November 2008 MAINTENANCE INSPECTIONS MAINTENANCE INSPECTION REPORT Table A Y N R Table C Y N R Within the first 10 working hours: Within the first 10 working hours: Model Oil level within reduction gears, Oil level in the differential Serial number power divider and differential...
  • Page 69 November 2008 Section 3 - Maintenance Inspections MAINTENANCE INSPECTIONS Table E Y N R Model Every 1000 working hours: Safety element of engine air Serial number filter Power divider gearbox oil Date Four wheel reduction gears oil Hour meter Hydraulic oil and hydraulic oil filter Machine owner Table F...
  • Page 70 Section 3 - Maintenance Inspections November 2008 MAINTENANCE INSPECTIONS Intentionally blank page Document 57.0009.0427 GTH-4017EX GTH-4514EX GTH-4013EX...

  • Page 71: Maintenance Procedures

    November 2008 Section 4 - Maintenance Procedures Maintenance Procedures INTRODUCTION • Maintenance inspections shall be completed by a trained and qualified person on the maintenance of this machine. • Scheduled maintenance must be carried out at the intervals indicated in the MAINTENANCE REPORT.

  • Page 72: About This Section

    Section 4 - Maintenance Procedures June 2008 MAINTENANCE PROCEDURES ABOUT THIS SECTION This section describes the maintenance interventions to be carried out on the machine according to the indications of the maintenance inspection report (see chapter 3).. Safety symbols: Draws the attention to situations that involve your own as well as the others’...

  • Page 73: Check The Oil Level Within Reduction Gears, Differential Gears And Power Divider Reduction Gears

    November 2008 Section 4 - Maintenance Procedures TABLE A TABLE A PROCEDURES CHECK THE OIL LEVEL WITHIN REDUCTION GEARS, DIFFERENTIAL GEARS AND POWER DIVIDER REDUCTION GEAR To check the oil level within the wheel reduction To check the oil level in the front and rear differential gears: gears: Stop the machine on a level ground and ensure the...
  • Page 74 Section 4 - Maintenance Procedures November 2008 TABLE A To check the oil level in the power divider reduction CHECK THE TIGHTENING OF THE WHEEL gear: BOLTS Stop the machine on a level ground and ensure the If you have to check the tightening of the wheel bolts or parking brake is engaged.
  • Page 75 November 2008 Section 4 - Maintenance Procedures TABLE A GTH 4013 EX GTH 4514 EX Standard - Optional Standard - Optional Dimensions (front, rear) 405/70 R20 - 405/70 R24 405/70 R20 - 405/70 R24 Load Index 14 pr - 14 pr 14 pr - 14 pr 13x20 - 13X24 13x20 - 13X24...

  • Page 76: Check The Tightening Of All Bolts And Nuts

    Section 4 - Maintenance Procedures November 2008 TABLE A CHECK THE TIGHTENING OF ALL BOLTS CHECK THE COUPLINGS FOR OIL LEAKS AND NUTS Before starting your work, do a walk-around inspection Before starting your daily work, proceed with a random and check for oil leaks.

  • Page 77: Inspect The Operator's Manual

    November 2008 Section 4 - Maintenance Procedures TABLE A INSPECT THE OPERATOR’S MANUAL INSPECT THE DECALS AND PLATES Maintaining the operator manual in good condition is Maintaining all of safety and instructional decals and essential to consult it if necessary.. placards in good condition is mandatory for safe machine operation.

  • Page 78: Check The Engine Oil Level

    Section 4 - Maintenance Procedures November 2008 TABLE A CHECK THE ENGINE OIL LEVEL Pull out the rod A again and ensure the oil comes to the maximum level B. To check the engine oil leve, proceed as follows: Refit the rod A and the plug C. Stop the machine on a level ground, stop the engine and ensure the parking brake is engaged.

  • Page 79: Clean The Air Suction Filter (Gth-4013Ex)

    November 2008 Section 4 - Maintenance Procedures TABLE A CLEAN THE AIR SUCTION FILTER (GTH- 4013EX) Clean the engine air filter every 10 working hours: Stop the engine and engage the parking brake. Lift the engine carter. Unlock the four clamps A. Remove the cap B.

  • Page 80: Clean The Air Suction Filter (Gth-4017Ex - Gth-4514Ex)

    Section 4 - Maintenance Procedures November 2008 TABLE A CLEAN THE AIR SUCTION FILTER (GTH- 4017EX - GTH-4514EX) Clean the engine air filter every 10 working hours: Stop the engine and engage the parking brake. Lift the engine carter. Remove the screw A locking the filter cap. Remove the cap B.

  • Page 81: Check And Clean The Radiator

    November 2008 Section 4 - Maintenance Procedures TABLE A CHECK AND CLEAN THE RADIATOR GTH 4013 EX DANGER When using a steam-washer, always wear protective clothes. Hot steam may cause serious injury. Open the engine carter to check the radiator. Check the fins of the radiator for sediments.

  • Page 82: Check The Hydraulic Oil Level In The Tank

    Section 4 - Maintenance Procedures November 2008 TABLE A A-10 CHECK THE HYDRAULIC OIL LEVEL IN THE GTH 4013 EX TANK DANGER Fine jets of hydraulic oil under pressure can penetrate the skin. Do not use your fingers, but a piece of cardboard to detect oil leaks.

  • Page 83: Check The Greasing Of The Boom Section Pads (Gth-4013Ex - Gth-4514Ex)

    November 2008 Section 4 - Maintenance Procedures TABLE A A-11 CHECK THE GREASING OF THE BOOM SECTION PADS (GTH-4013EX - GTH-4514EX) 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.

  • Page 84: Check The Greasing Of The Boom Section Pads (Gth-4017Ex)

    Section 4 - Maintenance Procedures November 2008 TABLE A CHECK THE GREASING OF THE BOOM SECTION PADS (GTH 4017 EX) Document 57.0009.0427 GTH-4017EX GTH-4514EX GTH-4013EX...

  • Page 85: A-12 Grease The Forks

    November 2008 Section 4 - Maintenance Procedures TABLE A A-12 GREASE THE FORKS CAUTION Before use grease, thoroughly clean the intervention zone to avoid that mud, dust or other matters can mix with the lubricant and reduce or annihilate the lubrication effect.

  • Page 86: 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

    Section 4 - Maintenance Procedures November 2008 TABLE A 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 CAUTION Before injecting grease into the greasers, thoroughly clean them to avoid that mud, dust or other matters can mix with the lubricant and reduce or annihilate the lubrication effect.

  • Page 87: Check The Efficency Of The Lighting Electric System

    November 2008 Section 4 - Maintenance Procedures TABLE A A-14 CHECK THE EFFICENCY OF THE LIGHTING ELECTRIC SYSTEM WARNING Check every day that the electrical system powering the lights of the machine is in efficient working order. Use the assistance of a second technician to check that When switched on, lamps get hot.
  • Page 88 Section 4 - Maintenance Procedures November 2008 TABLE A A-15 CHECK EFFICENCY BRAKING GTH 4013 EX SYSTEM (STANDARD ISO 6292) 1 CHECK PARKING BRAKE: - Load the maximum payload onto the forks (4000 Kg for GTH 4013 EX - GTH 4017 EX; 4500 Kg for GTH 4514 EX).

  • Page 89: Check The Efficency Of The Steering Selection System

    November 2008 Section 4 - Maintenance Procedures TABLE A A-16 CHECK THE EFFICENCY OF THE STEERING GTH 4017 EX SELECTION SYSTEM GTH 4514 EX During operation, the alignment of the front and rear axles of the machine can be subject to variations. This can depend on an oil blow-by from the steering control circuit, or on a steering of both axles when front and rear wheels are not perfectly aligned.

  • Page 90: Check The Efficency Of The Fork Balancing System

    Section 4 - Maintenance Procedures November 2008 TABLE A NOTICE A-17 CHECK THE EFFICENCY OF THE FORK BALANCING SYSTEM WARNING If the forks do not remain parallel to the ground, consult section 5 “Problems - Causes - Solutions”. Test the system without any load on the machine’s forks.

  • Page 91: Check The Efficient Working Order Of The Safety Devices

    November 2008 Section 4 - Maintenance Procedures TABLE A A-18 CHECK THE EFFICIENT WORKING ORDER 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.
  • Page 92 Section 4 - Maintenance Procedures November 2008 TABLE A Check of the limit switches on the outriggers (at every use) To check the limit switches (A) on the outriggers: • Lower the outriggers to the ground and attempt to engage a gear. Accelering the machine has to be stopped.
  • Page 93 November 2008 Section 4 - Maintenance Procedures TABLE A Limit switches F on the parking brake GTH 4013 EX (at every use) To check the efficency of the limit switches on the parking brake, follow the procedure below: • Sit in the driving seat, engage the parking brake and make sure the machine does not move.

  • Page 94: A-19 Check The Engine Coolant Level

    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 % Freezing...

  • Page 95: Check The Efficency Of The Overload Warning System

    November 2008 Section 4 - Maintenance Procedures TABLE A A-20 CHECK THE EFFICENCY OF THE OVERLOAD WARNING SYSTEM When the machine starts, the DLE system executes a check. When power is turned on, the DLE load limiting system runs a self-test. In the case of troubles, LED’s 5, 8 and 10 start flashing, the buzzer sounds, an error code is shown on the display 2 and the machine enters the alarm mode and cannot be operated.

  • Page 96: Check The Re-Sequence Of The Boom Telescope (Gth-4013Ex)

    Section 4 - Maintenance Procedures November 2008 TABLE A A-21 CHECK THE RE-SEQUENCE OF THE BOOM If, despite these procedures, the boom does not return TELESCOPE (GTH-4013EX) in sequence, check the cylinders and their re-sequence valves A. Before this procedure, disassemble the cylinders.

  • Page 97: Check The Efficency Of The Machine

    November 2008 Section 4 - Maintenance Procedures TABLE B TABLE B PROCEDURES CHECK THE TENSION OF THE ALTERNATOR BELT CHECK THE EFFICENCY OF THE MACHINE • Open the carter with engine cold and stopped. • Check visually the the machine is in efficient working •...

  • Page 98: Check The Tyre Inflation

    Section 4 - Maintenance Procedures November 2008 TABLE B CHECK THE TYRE INFLATION DANGER Over-inflated or overheated tyres can burst. Do not flame-cut or weld the wheel rims. For any repair work, call in a qualified technician. WRONG For the tyre inflation or substitution, please refer to the table below: GTH 4013 EX-GTH 4514 EX GTH 4017 EX...

  • Page 99: Check The Tightening Of The Wheel Nuts

    November 2008 Section 4 - Maintenance Procedures TABLE B CHECK THE TIGHTENING OF THE WHEEL NUTS If you have to check the tightening of the wheel bolts or replace a wheel, proceed as follows: Raise the machine using a hydraulic jack Remove the wheel rolling it on the ground.

  • Page 100: Check The Tightening Of The Cardan Shaft Screws

    Section 4 - Maintenance Procedures November 2008 TABLE B 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”. Document 57.0009.0427 GTH-4017EX GTH-4514EX GTH-4013EX...

  • Page 101: Clean The Radiator Fins

    November 2008 Section 4 - Maintenance Procedures TABLE B CLEAN THE RADIATOR FINS DANGER When using a steam-washer, always wear protective clothes. Hot steam may cause serious injury. Open the engine carter to check the radiator. Check the fins of the radiator for sediments. If necessary, prepare a compressed air nozzle (max.

  • Page 102: Change The Oil In The Reduction Gears, Differential Gears And Power Divider Reduction Gear

    Section 4 - Maintenance Procedures November 2008 TABLE C TABLE C PROCEDURES To change the oil in the front and rear differential gears: CHANGE THE OIL IN THE REDUCTION GEARS, DIFFERENTIAL GEARS AND POWER DIVIDER Stop the machine on a level ground and ensure the REDUCTION GEAR parking brake is engaged.

  • Page 103: Change The Engine Oil And Relevant Filter

    November 2008 Section 4 - Maintenance Procedures TABLE A To change the oil in the power divider reduction CHANGE THE ENGINE OIL AND RELEVANT gears: FILTER Stop the machine on a level ground and ensure the Stop the machine on a level ground and ensure the parking brake is engaged.

  • Page 104: Check The Oil Level In The Front And Rear Differential Gears

    Section 4 - Maintenance Procedures November 2008 TABLE C CHECK THE OIL LEVEL IN THE FRONT AND CHECK THE OIL LEVEL IN THE FOUR WHEEL REAR DIFFERENTIAL GEARS REDUCTION GEARS To check the oil level in the front and rear differential To check the oil level in the four wheel reduction gears: gears:...

  • Page 105: Check And Clean The Engine Air Filter (Gth-4013Ex)

    November 2008 Section 4 - Maintenance Procedures TABLE C CHECK AND CLEAN THE ENGINE AIR FILTER (GTH-4013EX) To check and clean the engine air filter: Stop the engine and engage the parking brake. Unlatch the four fasteners A. Remove the cover B. Pull out the filter cartridge C.

  • Page 106: Check And Clean The Engine Air Filter (Gth-4017Ex - Gth-4514Ex)

    Section 4 - Maintenance Procedures November 2008 TABLE C CHECK AND CLEAN THE ENGINE AIR FILTER (GTH-4017EX - GTH-4514EX) To check and clean the engine air filter: Stop the engine and engage the parking brake. Unlatch the four fasteners A. Remove the cover B.

  • Page 107: Check The Clamping Of The Cableheads To The Battery Terminals

    November 2008 Section 4 - Maintenance Procedures TABLE C CHECK THE CLAMPING OF THE CABLEHEADS CHECK THE AIR SUCTION HOSE BETWEEN TO THE BATTERY TERMINALS ENGINE AND FILTER Check the cable clips are well secured to the battery Check the state of all the rubber sleeves A of the air terminals.

  • Page 108: Check The Cylinder Chromium-Plated Rods

    Section 4 - Maintenance Procedures November 2008 TABLE C CHECK THE CYLINDER CHROMIUM-PLATED CHECK THE HYDRAULIC LINES RODS Every month, do a random check of the oil-dynamic Visually check the cylinder rods A for scoring every hoses to be sure they are not worn. In particular, we month.

  • Page 109: C-10 Check The Electric Cables

    November 2008 Section 4 - Maintenance Procedures TABLE C C-11 CHECK THE WEAR OF THE SLIDING PADS C-10 CHECK THE ELECTRIC CABLES OF THE BOOM SECTIONS Every month, do a random check of the electrical cables Any boom section is fitted with adjustable pads located to be sure they are not damaged.

  • Page 110: Adjust The Play Of The Sliding Pads Of The Boom Sections

    Section 4 - Maintenance Procedures November 2008 TABLE C C-12 ADJUST THE PLAY OF THE SLIDING PADS OF THE BOOM SECTIONS Any boom section is fitted with adjustable pads located on the four sides of the profile. These pads are secured to both fixed and mobile part of every section.

  • Page 111: Grease The Sliding Parts Of The Boom Sections

    November 2008 Section 4 - Maintenance Procedures TABLE C C-13 GREASE THE SLIDING PARTS OF THE BOOM SECTIONS Check every month that the telescopes are well greased in correspondence of the sliding pads. If necessary, scrape off the old grease and apply a thin film of new grease.

  • Page 112: Check The Level Of The Battery Electrolyte

    Section 4 - Maintenance Procedures November 2008 TABLE C DANGER C-14 CHECK THE LEVEL OF THE BATTERY ELECTROLYTE Check the electrolyte level every 250 working hours; Risk of explosion or shorts. During the recharge, if necessary, add distilled water. an explosive mixture with release of hydrogen gas Ensure the fluid is 5÷6 mm above the plates and the forms.

  • Page 113: Check The Efficency Of The Block Valves

    November 2008 Section 4 - Maintenance Procedures TABLE C C-15 CHECK THE EFFICENCY OF THE BLOCK VALVES The piloted blocking valves A allow to held the load in position in case of burst of a flexible hose. To check the efficiency of a valve, proceed as follows: Load a weight near the maximum payload onto the boom (4000 kg for GTH 4017 EX and GTH 4013 EX).
  • Page 114 Section 4 - Maintenance Procedures November 2008 TABLE C DANGER Outriggers cylinder Do the check of the valves taking all the possible precautionary measures: - Wear safety glasses - Wear safety gloves - Wear safety shoes - Wear suitable working clothes - Use guards against leaks of oil at high pressure - Do the check in a free space with barriers all around to keep non-authorised people away...

  • Page 115: Check The Tightening Of The Engine Fixing Screws

    November 2008 Section 4 - Maintenance Procedures TABLE D TABLE D PROCEDURES CHECK THE TIGHTENING OF THE ENGINE FIXING SCREWS VISUALLY CHECK THE SMOKE QUANTITY EVACUATED FROM THE ENGINE EXHAUST Every 6 months, check that the screws fixing the engine to the machine chassis are tight.

  • Page 116: Check The Tightening Of The Cab Fixing Screws

    Section 4 - Maintenance Procedures November 2008 TABLE D CHECK THE TIGHTENING OF THE CAB CHECK THE BLACKLASH BETWEEN PINS FIXING SCREWS AND BUSHINGS IN ALL JOINTS Every 6 months, check that the screws fixing the cab to Every 6 months, check the machine randomly to be sure the machine chassis are tight.

  • Page 117: Change The Hydraulic Oil Filter Cartridge (Gth-4013Ex)

    November 2008 Section 4 - Maintenance Procedures TABLE D CHANGE THE HYDRAULIC OIL FILTER CARTRIDGE (GTH-4013EX) To change the hydraulic oil filter element, proceed as follows (GTH-4013EX): Stop the machine on a level ground and engage the parking brake. Place a container of suitable size under the filter to collect any oil leaks.

  • Page 118: Change The Hydraulic Oil Filter Cartridge (Gth-4017Ex - Gth-4514Ex)

    Section 4 - Maintenance Procedures November 2008 TABLE D CHANGE THE HYDRAULIC OIL FILTER HAVE THE HYDRAULIC SYSTEM CHECKED CARTRIDGE (GTH-4017EX - GTH-4514EX) BY A SKILLED TECHNICIAN To change the hydraulic oil filter element, proceed as Every six months we recommend having the system follows (GTH-4017EX - GTH-4514EX): checked by a skilled technician, to be sure it is in efficient Stop the machine on a level ground and engage the...

  • Page 119: Change The Main Cartridge Of The Engine Air Filter (Gth-4013Ex)

    November 2008 Section 4 - Maintenance Procedures TABLE D CHANGE THE MAIN CARTRIDGE OF THE CHANGE THE MAIN CARTRIDGE OF THE ENGINE AIR FILTER (GTH-4013EX) ENGINE AIR FILTER (GTH-4017EX - GTH- 4514EX) Changing the main cartridge air filter: Changing the main cartridge air filter: Stop the engine and engage the parking brake.
  • Page 120 Section 4 - Maintenance Procedures November 2008 TABLE D CHANGE THE ENGINE OIL FILTER AND THE CLEAN THE CAB AIR FILTER FUEL FILTER Clean the air filter in the cab every six months. Replace Stop the machine on a level ground and engage the the cartridge if the filtering cloth is damaged.

  • Page 121: Change The Oil Of The Front And Rear Differential Gears

    November 2008 Section 4 - Maintenance Procedures TABLE D D-10 CHANGE THE OIL OF THE FRONT AND REAR D-11 BOOM CHAIN TENSIONING (GTH-4017EX - DIFFERENTIAL GEARS GTH-4514EX) To change the oil of the front and rear differential To tighten the boom chains, follow the instructions gears: below: Stop the machine on a level ground and engage the...

  • Page 122: Change The Safety Element Of Engine Air Filter

    Section 4 - Maintenance Procedures November 2008 TABLE D TABLE E PROCEDURES CHANGE THE SAFETY ELEMENT AIR FILTER CHANGE THE SAFETY ELEMENT AIR FILTER (GTH 4013EX) (GTH 4017EX - GTH 4514EX) To change the safety element: To change the safety element: Stop the engine and engage the parking brake.
  • Page 123 November 2008 Section 4 - Maintenance Procedures TABLE D CHANGE THE OIL IN THE POWER DIVIDER CHANGE THE OIL IN THE FOUR WHEEL GEARS REDUCTION GEARS To change the oil in the power divider gears: To change the oil in the four wheel reduction gears: Stop the machine on a level ground and engage the Stop the machine on a level ground and ensure the parking brake.

  • Page 124: Change The Hydraulic Oil And The Inner Hydraulic Oil Filter

    Section 4 - Maintenance Procedures November 2008 TABLE D CHANGE THE HYDRAULIC OIL AND THE INNER HYDRAULIC OIL FILTER GTH 4013 EX To change the hydraulic oil: Stop the machine on a level ground and make sure the parking brake is engaged. Release the pressure from the hydraulic circuit.

  • Page 125: Change The Engine Coolant

    C. If necessary, add new coolant until it is level. 25 27 On delivery, the machine is filled with a cooling mixture consisting of 50% water and 50% anti-freeze. TEREX PRO COOL Protection against boiling/freezing Product % Freezing Boiling...

  • Page 126: Check The Machine Structure

    Section 4 - Maintenance Procedures November 2008 TABLE G PROCEDURE TABELLA G CHECK THE MACHINE STRUCTURE Five years after the first placing into operation of the machine or after 6000 hours (whichever occurs first), check the state of the structure paying attention to the welded supporting joints, the boom pins, the platform and all attachment (if installed).

  • Page 127: Problems-Causes-Solutions

    November 2008 Section 5 - Problems-Causes-Solutions Problems-Causes-Solutions INTRODUCTION WARNING • Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine. • Immediately tag and remove from service a Spraying hydraulic oil can penetrate and burn damaged or malfunctioning machine.

  • Page 128: About This Section

    Section 5 - Problems-Causes-Solutions November 2008 PROBLEMS CAUSES SOLUTIONS ABOUT THIS SECTION The tables on the following pages should be used to find and rectify problems that can occur when using the machine. Prepare adequate tools, and especially a voltmeter and a pressure gauge to carry out the checks explained on next pages.

  • Page 129: Electrical Faults

    November 2008 Section 5 - Problems-Causes-Solutions PROBLEMS CAUSES SOLUTIONS ELECTRICAL FAULTS Problems Causes Solutions When key is turned to 1, the Battery discharged. C h e c k t h e b a t t e r y , r e p l a c e i f dashboard is not powered necessary.
  • Page 130 Section 5 - Problems-Causes-Solutions November 2008 PROBLEMS CAUSES SOLUTIONS Problems Causes Solutions Emergency button 10A F20 feeding Check the fuse and replace if fuse blown. necessary. Problem of the wiring line from Check the wiring for continuity. dashboard to 70A relays in the engine box.
  • Page 131 November 2008 Section 5 - Problems-Causes-Solutions PROBLEMS CAUSES SOLUTIONS Problems Causes Solutions Outrigger limit switches (S51-S52 GTH Check the mechanical operation 4017EX - GTH 4514EX) damaged. of the limit switches; replace if necessary. 10A F18 fuse blown. C h e c k t h e f u s e ; r e p l a c e i f necessary.
  • Page 132 Section 5 - Problems-Causes-Solutions November 2008 PROBLEMS CAUSES SOLUTIONS Problems Causes Solutions The 3B6 moment limiter doesn't Outrigger micro-switches damaged. Check the micro-switches and change scale when passing replace if necessary. from the "machine on wheels" condition "stabilised Problem of the DLE wiring line to the Check the wiring for continuity.
  • Page 133 November 2008 Section 5 - Problems-Causes-Solutions PROBLEMS CAUSES SOLUTIONS Problems Causes Solutions The flashing beacon doesn't Flashing beacon damaged. Check the flashing beacon and work replace if necessary. Flashing beacon lamp damaged. Check the lamp and replace if necessary. Problem of the wiring line. Check the wiring for continuity.
  • Page 134 Section 5 - Problems-Causes-Solutions November 2008 PROBLEMS CAUSES SOLUTIONS Problems Causes Solutions The light warning of a low engine Pressure switch for low engine oil Check the pressure switch and oil pressure doesn't work. pressure damaged. replace if necessary. X1 dashboard indicator light. Check the indicator light and replace the lights group if necessary.
  • Page 135 November 2008 Section 5 - Problems-Causes-Solutions PROBLEMS CAUSES SOLUTIONS Problems Causes Solutions Hour-meter damaged. Check the hour-meter and replace The hour-meter doesn’t work. if necessary. Alternator A1 damaged. Check the alternator and replace if necessary. Problem of the wiring line. Check the wiring for continuity.

  • Page 136: Hydraulic Faults

    Section 5 - Problems-Causes-Solutions November 2008 PROBLEMS CAUSES SOLUTIONS HYDRAULIC FAULTS Problems Causes Solutions The machine does not move Drive pump not well calibrated. Re-calibrate the pump (see par. 2 - section “Technical Specifications”) Valves damaged. Check and replace the valves if necessary.
  • Page 137 November 2008 Section 5 - Problems-Causes-Solutions PROBLEMS CAUSES SOLUTIONS Problems Causes Solutions The electrovalves don't work. Check the sliders and the efficiency of the electrovalves. The outriggers do not work Outrigger cylinders damaged. Check the efficiency and the internal seals of the cylinder. Outrigger cylinders’...
  • Page 138 Section 5 - Problems-Causes-Solutions November 2008 PROBLEMS CAUSES SOLUTIONS Problems Causes Solutions Brake pump damaged. Check the pump thoroughly. Brakes damaged or worn out. Check the efficiency of the disks; replace, if necessary. The attachment locking cylinder Attachment locking cylinder damaged. Check the efficiency of the cylinder;...
  • Page 139 November 2008 Section 5 - Problems-Causes-Solutions PROBLEMS CAUSES SOLUTIONS Problems Causes Solutions Main valve not well calibrated. 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 main valve.
  • Page 140 Poor lubrication of the boom. Smear the sliding zone of the pad with the grease recommended by Terex. Paint or abrasion on the pad sliding rail. Grind out any signs of abrasion on the boom and polish the sliding area of the pad, then smear with grease.

  • Page 141: Schemes

    November 2008 Section 6 - Schemes Schemes HYDRAULIC SYMBOLS MOTORS Fixed motor with one Mechanical control Combined non-return direction of flow with roller and throttle valve Fixed motor with two Electro-magnetic control Switching valve directions of flow with winding (solendoid) Variable motor with two Control with electric Pressure relief valve...
  • Page 142 Section 6 - Schemes November 2008 SCHEMES DISTRIBUTION - SETTING ELEMENTS Two-position and two-way distributor, with manual lever control and spring return Three-way and two-position distributor, with hydraulic control Two-position, three-way distributor, with electro-magnetic control and spring return Distributor with mechanical control and span proportional to the action of the same control Two-position, three-way...

  • Page 143: Hydraulic Schemes

    November 2008 Section 6 - Schemes SCHEMES HYDRAULIC SCHEME 6.2.1 GTH-4017EX GTH-4514EX Document 57.0009.0427 GTH-4017EX GTH-4514EX GTH-4013EX...

  • Page 144: Gth-4013Ex

    Section 6 - Schemes November 2008 SCHEMES 6.2.2 GTH-4013EX Document 57.0009.0427 GTH-4017EX GTH-4514EX GTH-4013EX...

  • Page 145: Electrical Symbols

    November 2008 Section 6 - Schemes SCHEMES ELECTRICAL SYMBOLS ACTUATORS ACCUMULATORS DYNAMIC APPLICATIONS Emergency controls Battery Motor Pushbutton control Thermocouple Rotary control Element Generator TERMINALS AND GROUNDS Pedal control Ring Proximity control Ground As_3p_motor Lever control Terminal ELECTRONIC PARTS Timed control Ground to frame Rectifier Mechanical/manual control...
  • Page 146 Section 6 - Schemes November 2008 SCHEMES CONTACTS Thermal 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 Document 57.0009.0427 GTH-4017EX GTH-4514EX GTH-4013EX...

  • Page 147: Electrical Schemes

    November 2008 Section 6 - Schemes SCHEMES ELECTRICAL SCHEMES 1/11 6.4.1 GTH-4013EX Document 57.0009.0427 GTH-4017EX GTH-4514EX GTH-4013EX...
  • Page 148 Section 6 - Schemes November 2008 SCHEMES 2/11 Document 57.0009.0427 GTH-4017EX GTH-4514EX GTH-4013EX...
  • Page 149 November 2008 Section 6 - Schemes SCHEMES 3/11 Document 57.0009.0427 GTH-4017EX GTH-4514EX GTH-4013EX...
  • Page 150 Section 6 - Schemes November 2008 SCHEMES 4/11 Document 57.0009.0427 GTH-4017EX GTH-4514EX GTH-4013EX...
  • Page 151 November 2008 Section 6 - Schemes SCHEMES 5/11 Document 57.0009.0427 GTH-4017EX GTH-4514EX GTH-4013EX...
  • Page 152 Section 6 - Schemes November 2008 SCHEMES 6/11 Document 57.0009.0427 GTH-4017EX GTH-4514EX GTH-4013EX...
  • Page 153 November 2008 Section 6 - Schemes SCHEMES 7/11 Document 57.0009.0427 GTH-4017EX GTH-4514EX GTH-4013EX...
  • Page 154 Section 6 - Schemes November 2008 SCHEMES 8/11 Document 57.0009.0427 GTH-4017EX GTH-4514EX GTH-4013EX...
  • Page 155 November 2008 Section 6 - Schemes SCHEMES 9/11 Document 57.0009.0427 GTH-4017EX GTH-4514EX GTH-4013EX...
  • Page 156 Section 6 - Schemes November 2008 SCHEMES 10/11 Document 57.0009.0427 GTH-4017EX GTH-4514EX GTH-4013EX...

  • Page 157: Fuses And Relays Gth-4013Ex

    November 2008 Section 6 - Schemes SCHEMES 6.4.1.1 FUSES AND RELAYS GTH-4013EX 11/11 Document 57.0009.0427 GTH-4017EX GTH-4514EX GTH-4013EX...

  • Page 158: Gth-4017Ex Gth-4514Ex

    Section 6 - Schemes November 2008 SCHEMES 6.4.2 GTH-4017EX GTH-4514EX 1/11 Document 57.0009.0427 GTH-4017EX GTH-4514EX GTH-4013EX...
  • Page 159 November 2008 Section 6 - Schemes SCHEMES 2/11 Document 57.0009.0427 GTH-4017EX GTH-4514EX GTH-4013EX...
  • Page 160 Section 6 - Schemes November 2008 SCHEMES 3/11 Document 57.0009.0427 GTH-4017EX GTH-4514EX GTH-4013EX...
  • Page 161 November 2008 Section 6 - Schemes SCHEMES 4/11 Document 57.0009.0427 GTH-4017EX GTH-4514EX GTH-4013EX...
  • Page 162 Section 6 - Schemes November 2008 SCHEMES 5/ 11 Document 57.0009.0427 GTH-4017EX GTH-4514EX GTH-4013EX...
  • Page 163 November 2008 Section 6 - Schemes SCHEMES 6/11 Document 57.0009.0427 GTH-4017EX GTH-4514EX GTH-4013EX...
  • Page 164 Section 6 - Schemes November 2008 SCHEMES 7/ 11 Document 57.0009.0427 GTH-4017EX GTH-4514EX GTH-4013EX...
  • Page 165 November 2008 Section 6 - Schemes SCHEMES 8/11 Document 57.0009.0427 GTH-4017EX GTH-4514EX GTH-4013EX...
  • Page 166 Section 6 - Schemes November 2008 SCHEMES 9/ 11 Document 57.0009.0427 GTH-4017EX GTH-4514EX GTH-4013EX...
  • Page 167 November 2008 Section 6 - Schemes SCHEMES 10/11 Document 57.0009.0427 GTH-4017EX GTH-4514EX GTH-4013EX...

  • Page 168: 6.4.2.2 Fuses And Relays Gth-4017 Ex Gth-4514 Ex

    Section 6 - Schemes November 2008 SCHEMES 6.4.2.2 FUSES AND RELAYS GTH-4017 EX GTH-4514 EX 11/ 11 Document 57.0009.0427 GTH-4017EX GTH-4514EX GTH-4013EX...

  • Page 169: Position Of Components On The Machine

    November 2008 Section 6 - Schemes SCHEMES POSITION OF THE COMPONENTS ON THE MACHINE Pos. Descrizione Diesel engine Drive pump Service pump Hydraulic oil return filter Drive motor Combined engine fluid/hydraulic oil radiator Front axle Hydraulic oil tank Rear axle Hydraulic steering Steering selection solenoid valve Brake pump...
  • Page 170 Section 6 - Schemes November 2008 SCHEMES Document 57.0009.0427 GTH-4017EX GTH-4514EX GTH-4013EX...
  • Page 171 November 2008 Section 6 - Schemes SCHEMES Document 57.0009.0427 GTH-4017EX GTH-4514EX GTH-4013EX...
  • Page 172 Section 6 - Schemes November 2008 SCHEMES Intentionally blank page Document 57.0009.0427 GTH-4017EX GTH-4514EX GTH-4013EX...

  • Page 173: Repair Procedures

    November 2008 Section 7 - Repair Procedures Repair Procedures TIME SCHEDULE Operators Expected needed time (h) change the ignition key 1,00 change the speed selector 0,30 change the lights and horn selector 0,30 change the overload warning system display 0,15 re-calibrate the overload system 1,00 change the load cell...
  • Page 174 Section 7 - Repair Procedures November 2008 REPAIR PROCEDURES Operators Expected needed time (h) change the valve of the outrigger up/down movement cylinder 1,00 change fork levelling control cylinder 2,00 change fork levelling control cylinder kit 1,30 change fork levelling control cylinder valve 1,30 check the one-way valves of the fork levelling control cylinder...
  • Page 175 November 2008 Section 7 - Repair Procedures REPAIR PROCEDURES Operators Expected needed time (h) change the boom anchoring pin 1,00 cad. change the attachment locking cylinder pins 0,30 change the outrigger cylinder pin 0,30 change a cab pushbutton 0,30 change and test the actuator pressure relief valve or the sliders 2,00 change and test the actuator safety valve 1,00...
  • Page 176 Section 7 - Repair Procedures November 2008 REPAIR PROCEDURES Intentionally blank page Document 57.0009.0427 GTH-4017EX GTH-4514EX GTH-4013 EX...
  • Page 177 November 2008 Section 7 - Repair Procedures TABLE Cylinder disassembly Procedure: Table: Boom raising cylinder GTH-4017EX GTH-4514EX Hours Min. GTH-4013EX Bridge crane, payload 5000 kg Standard tools Adjustable stands Textile bridles or chains with hooks Operation: 1 Release the attachment. 2 Anchor the attachment holding frame to the hooks of the slinging chain.
  • Page 178 Section 7 - Repair Procedures November 2008 TABLE Procedure: Cylinder disassembly Table: GTH-4017EX Boom raising cylinder GTH-4514EX GTH-4013EX 7 To move the boom using the up/down controls of the bridge crane, previously disconnect the rod of the fork balance cylinder. 8 Remove the screw fixing the pitching cylinder pin with two 13 mm wrenches.
  • Page 179 November 2008 Section 7 - Repair Procedures TABLE Procedure: Cylinder disassembly Table: GTH-4017EX Boom raising cylinder GTH-4514EX GTH-4013EX 12 Remove the screw which fixes the rod pin to the boom using two 19 mm wrenches. 13 Knock out and extract the pin using a plug of soft material (aluminium, copper, wood, etc.).
  • Page 180 Section 7 - Repair Procedures November 2008 TABLE Procedure: Cylinder disassembly Table: GTH-4017EX Boom raising cylinder GTH-4514EX GTH-4013EX 18 Knock out the pin using a plug of soft material (aluminium, copper, wood, etc.) and extract it through the hole on the frame. 19 Lower the boom onto the adjustable stand to remove the slinging chains.

  • Page 181: Cylinder Disassembly Fork Balance Cylinder

    November 2008 Section 7 - Repair Procedures TABLE Cylinder disassembly Procedure: Table: Fork balance cylinder GTH-4017EX GTH-4514EX Hours Min. GTH-4013EX Bridge crane, payload 500 kg Standard tools Adjustable stands Textile bridles or chains with hooks Operation: 1 Release the attachment. 2 Remove the screw fixing the rod pin with two 13 mm wrenches.
  • Page 182 Section 7 - Repair Procedures November 2008 TABLE Procedure: Cylinder disassembly Table: GTH-4017EX Fork balance cylinder GTH-4514EX GTH-4013EX 4 Fix the cylinder with a textile bridle connected to the bridge crane to support its weight. 5 Place a container of suitable size under the hydraulic piping before disconnecting.
  • Page 183 November 2008 Section 7 - Repair Procedures TABLE Removing the engine from the Procedure: Table: machine GTH-4017EX GTH-4514EX Hours Min. GTH-4013EX Bridge crane, payload 500 kg Standard tools Textile bridles or chains with hooks Operation: 1 Open the engine cover. 2 Secure the engine cover to a bridge crain using a textile bridle.

  • Page 184: Removing The Engine From The Machine

    Section 7 - Repair Procedures November 2008 TABLE Removing the engine from the machine Procedure: Table: GTH-4017EX GTH-4514EX GTH-4013EX 10 Disconnect the throttle control cable removing the locking clip; remove the screws fixing the rope sheath to the engine using a 10mm combination wrench.
  • Page 185 November 2008 Section 7 - Repair Procedures TABLE Procedure: Removing the engine from the machine Table: GTH-4017EX GTH-4514EX GTH-4013EX PROTECT THE ENVIRONMENT Before disconnecting the hydraulic piping, place containers of suitable size underneath to prevent oil spillage. CAUTION Plug all disconnected parts to prevent dust and impurities from entering the circuit.
  • Page 186 Section 7 - Repair Procedures November 2008 TABLE Procedure: Removing the engine from the machine Table: GTH-4017EX GTH-4514EX GTH-4013EX WARNING Once all operations have been performed make sure that all the electrical wires and the hydraulic lines are disconnected from the motor. 18 Remove the four screws (two on the front and two at the back) of the vibration-damping brackets with a 22 mm wrench.

  • Page 187: Hydraulic Pumps Disassembly

    November 2008 Section 7 - Repair Procedures TABLE Hydraulic pumps disassembly Procedure: Table: GTH-4017EX GTH-4514EX Hours Min. GTH-4013EX Bridge crane or swing hoist, payload Standard tools 500 kg Operation: PROTECT THE ENVIRONMENT Before disconnecting the hydraulic piping, place containers of suitable size underneath to prevent oil spillage.
  • Page 188 Section 7 - Repair Procedures November 2008 TABLE Procedure: Haydraulic pumps disassembly Table: GTH-4017EX GTH-4514EX GTH-4013EX 5 Remove the two electrical connections (B) of the electrovalve which controls the machine forward/ reverse movements 6 Disconnect the hydraulic piping: disconnect the two drain lines of the hydraulic pump using a 36mm wrench, disconnect the suction line of the hydraulic pump with a 50mm wrench,...
  • Page 189 November 2008 Section 7 - Repair Procedures TABLE Haydraulic pumps disassembly Procedure: Table: GTH-4017EX GTH-4514EX GTH-4013EX 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.
  • Page 190 Section 7 - Repair Procedures November 2008 TABLE Procedure: Table: GTH-4017EX GTH-4514EX GTH-4013EX Intentionally blank page Document 57.0009.0427 GTH-4017EX GTH-4514EX GTH-4013 EX...

  • Page 191: Disassembling The Hydraulic Motor

    November 2008 Section 7 - Repair Procedures TABLE Disassembling the hydraulic motor Procedure: Table: GTH-4017EX GTH-4514EX Hours Min. GTH-4013EX Bridge crane or swing hoist, payload Standard tools 500 kg Operation: PROTECT THE ENVIRONMENT Before disconnecting the hydraulic piping, place containers of suitable size underneath to prevent oil spillage.
  • Page 192 Section 7 - Repair Procedures November 2008 TABLE Procedure: Disassembling the hydraulic motor Table: GTH-4017EX GTH-4514EX GTH-4013EX 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.

  • Page 193: Cylinder Disassembly - Boom Extension Cylinder

    November 2008 Section 7 - Repair Procedures TABLE Cylinder disassembly Procedure: Table: Boom extension cylinder GTH-4017EX GTH-401 EX - GTH-451 EX GTH-4514EX Hours Min. GTH-4013EX Bridge crane, payload 500 kg Standard tools Textile bridles or chains with hooks Operation: 1 Set the boom to horizontal position with the telescope slightly extended to work on the cylinder connecting pin (rod side).
  • Page 194 Section 7 - Repair Procedures November 2008 TABLE Procedure: Cylinder disassembly Table: GTH-4017EX Boom extension cylinder GTH-401 EX - GTH-451 EX GTH-4514EX GTH-4013EX 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.).

  • Page 195: Cylinder Disassembly - Boom Extension External Cylinder Gth-4013Ex

    November 2008 Section 7 - Repair Procedures TABLE Cylinder disassembly Procedure: Table: Boom extension external cylinder GTH-4017EX GTH-4013EX GTH-4514EX Hours Min. GTH-4013EX Bridge crane, payload 500 kg Standard tools Textile bridles or chains with hooks Operation: 1 Set the boom to horizontal position with the telescope slightly extended to work on the cylinder connecting pin (rod side).
  • Page 196 Section 7 - Repair Procedures November 2008 TABLE Procedure: Cylinder disassembly Table: GTH-4017EX Boom extension external cylinder GTH-4013EX GTH-4514EX GTH-4013EX 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.).

  • Page 197: Cylinder Disassembly - Boom Extension Internal Cylinder Gth-4013Ex

    November 2008 Section 7 - Repair Procedures TABLE Cylinder disassembly Procedure: Table: Boom extension internal cylinder GTH-4017EX GTH-4013EX GTH-4514EX Hours Min. GTH-4013EX Bridge crane, payload 500 kg Standard tools Textile bridles or chains with hooks Operation: 1 Set the boom to horizontal position and extend it until the pin A is on the 3 boom section.
  • Page 198 Section 7 - Repair Procedures November 2008 TABLE Procedure: Cylinder disassembly Table: GTH-4017EX Boom extension internal cylinder GTH-4013EX GTH-4514EX GTH-4013EX 7 Remove the four screws fixing the cylinder to the 3 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.

  • Page 199: Water-Oil Cooler Disassembly

    November 2008 Section 7 - Repair Procedures TABLE Water-oil cooler disassembly Procedure: Table: GTH-4017EX GTH-4514EX Hours Min. GTH-4013EX Standard tools Operation: PROTECT THE ENVIRONMENT Before disconnecting the hydraulic piping, place containers of suitable size underneath to prevent oil spillage. CAUTION Carefully clean the area around the piping to be disconnected, plug all disconnected parts with connectors, clothes or adhesive tape to prevent...
  • Page 200 Section 7 - Repair Procedures November 2008 TABLE Water-oil cooler disassembly Procedure: Table: GTH-4017EX GTH-4514EX GTH-4013EX 6 Remove the screws fixing the fan guard using a 13mm wrench. 7 Remove 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.

  • Page 201: Main Valve Disassembly

    November 2008 Section 7 - Repair Procedures TABLE Main valve disassembly Procedure: Table: Boom main valve GTH-4017EX GTH-4514EX Hours Min. GTH-4013EX Standard tools PROTECT THE ENVIRONMENT Before disconnecting the hydraulic piping, place containers of suitable size underneath to prevent oil spillage. CAUTION Carefully clean the area around the piping to be disconnected, plug all disconnected parts with...
  • Page 202 Section 7 - Repair Procedures November 2008 TABLE Procedure: Main valve disassembly Table: GTH-4017EX Boom main valve GTH-4514EX GTH-4013EX CAUTION Before disconnecting any flexible hoses, label them for an easier reassembly. 2 Disconnect all pipes of the main valve using the following combination wrenchs: 17 mm, 19 mm, 24 mm.
  • Page 203 November 2008 Section 7 - Repair Procedures TABLE Main valve disassembly Procedure: Table: GTH-4017EX Outriggers main valve GTH-4514EX GTH-4013EX Operation: 1 Remove the central carter (A) of the machine using a 4 mm Allen wrench (GTH 4514 EX - GTH 4017 EX) or open the engine carter using the handle (GTH 4013 EX).
  • Page 204 Section 7 - Repair Procedures November 2008 TABLE Procedure: Table: GTH-4017EX GTH-4514EX GTH-4013EX Intentionally blank page Document 57.0009.0427 GTH-4017EX GTH-4514EX GTH-4013 EX...

  • Page 205: Renewing The Slide Pads Of The Telescopic Boom Gth-4013Ex

    November 2008 Section 7 - Repair Procedures TABLE Renewing the slide pads of the telescopic Procedure: Table: boom GTH-4013EX GTH-4017EX GTH-4514EX Hours Min. GTH-4013EX Standard tools ADJUSTING THE PLAY WITH SHIMS If the play between the boom sections is too great (2 mm or more), proceed in shimming the guide pads of the boom sections.
  • Page 206 Section 7 - Repair Procedures November 2008 TABLE Procedure: Renewing the slide pads of the telescopic boom Table: GTH-4017EX GTH-4013EX GTH-4514EX GTH-4013EX 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...
  • Page 207 November 2008 Section 7 - Repair Procedures TABLE Procedure: Renewing the slide pads of the telescopic boom Table: GTH-4017EX GTH-4013EX GTH-4514EX GTH-4013EX RENEWING THE REAR PADS (A) To renew the rear pads of the section, retract the boom entirely and proceed as follows: 8 Stop the machine, lower the nose to the ground for an easier removal of the top pads.
  • Page 208 Section 7 - Repair Procedures November 2008 TABLE Procedure: Renewing the slide pads of the telescopic boom Table: GTH-4017EX GTH-4013EX GTH-4514EX GTH-4013EX 13 Clean and grease the internal and external walls of the boom sections in the sliding points of the pads.

  • Page 209: Renewing The Slide Pads Of The Telescopic Boom Gth-4017Ex Gth-4514Ex

    November 2008 Section 7 - Repair Procedures TABLE Renewing the slide pads of the telescopic Procedure: Table: boom GTH-4017EX GTH-4514EX GTH-4017EX GTH-4514EX Hours Min. GTH-4013EX Standard tools ADJUSTING THE PLAY WITH SHIMS If the play between the boom sections is too great (2 mm or more), proceed in shimming the guide pads of the boom sections.
  • Page 210 Section 7 - Repair Procedures November 2008 TABLE Procedure: Renewing the slide pads of the telescopic boom Table: GTH-4017EX GTH-4017EX GTH-4514EX GTH-4514EX GTH-4013EX 6 Refit the fixing screws (torque: 30÷35 Nm) after pouring some Loctite 495 on their threads. FOURTH SECTION 7 After shimming, fully extend the boom, carefully clean the sliding rails of the pads, then smear with a thin coat of grease:...
  • Page 211 November 2008 Section 7 - Repair Procedures TABLE Procedure: Renewing the slide pads of the telescopic boom Table: GTH-4017EX GTH-4017EX GTH-4514EX GTH-4514EX GTH-4013EX RENEWING THE REAR PADS (A) To renew the rear pads of the section, retract the boom entirely and proceed as follows: 8 Stop the machine, lower the nose to the ground for an easier removal of the top pads.
  • Page 212 Section 7 - Repair Procedures November 2008 TABLE Procedure: Renewing the slide pads of the telescopic boom Table: GTH-4017EX GTH-4017EX GTH-4514EX GTH-4514EX GTH-4013EX 13 Clean and grease the internal and external walls of the boom sections in the sliding points of the pads.

  • Page 213: Renewing The Flexible Hoses Inside The Boom Gth-4013Ex Gth-4514Ex

    November 2008 Section 7 - Repair Procedures TABLE Renewing the flexible hoses inside Procedure: Table: the boom GTH-4013EX GTH-4514EX GTH-4017EX GTH-4514EX Hours Min. GTH-4013EX Standard tools How to renew flexible hoses: 1 Before disconnecting or refitting a flexible hose, carefully clean the area all around. PROTECT THE 2 Blow some compressed air to remove any impurity.
  • Page 214 Section 7 - Repair Procedures November 2008 TABLE Procedure: Renewing the flexible hoses inside the boom Table: GTH-4017EX GTH-4013EX GTH-4514EX GTH-4514EX GTH-4013EX Useful advice for mounting flexible hoses: Document 57.0009.0427 GTH-4017EX GTH-4514EX GTH-4013 EX...

  • Page 215: Renewing The Flexible Hoses Inside The Boom Gth-4017Ex

    November 2008 Section 7 - Repair Procedures TABLE Renewing the flexible hoses inside the boom Procedure: Table: GTH-4017EX GTH-4017EX GTH-4514EX Hours Min. GTH-4013EX Standard tools How to renew flexible hoses: 1 Before disconnecting or refitting a flexible hose, carefully clean the area all around. PROTECT THE 2 Blow some compressed air to remove any impurity.
  • Page 216 Section 7 - Repair Procedures November 2008 TABLE Procedure: Renewing the flexible hoses inside the boom GTH-4017EX Table: GTH-4017EX GTH-4514EX GTH-4013EX 4 To renew the flexible hoses inside the boom remove the chain and proceed as follows: - remove the safety clamp on the rod of the lifting cylinder - start the thermal engine and hold the boom in horizonthal position and fully retracted...
  • Page 217 November 2008 Section 7 - Repair Procedures TABLE Cylinder disassembly Procedure: Table: Attachment rotation cylinder GTH-4017EX GTH-4514EX Hours Min. GTH-4013EX Bridge crane, payload 500 kg Standard tools Adjustable stands Textile bridles or chains with hooks Operation: 1 Remove the attachment 2 Remove the screw fixing the pin (rod side) with two 17 mm wrenches 3 Knock out and extract the pin using a plug of...

  • Page 218: Cylinder Disassembly - Attachment Rotation Cylinder

    Section 7 - Repair Procedures November 2008 TABLE Procedure: Cylinder disassembly Table: GTH-4017EX Attachment rotation cylinder GTH-4514EX GTH-4013EX 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.).

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