Genie GTH-4013 sx GTH-4017 sx Service Manual 57.4402.4200 – PDF DOWNLOAD
Language : English
Pages : 202
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie GTH-4013 sx GTH-4017 sx Service Manual 57.4402.4200 – PDF DOWNLOAD
Rev. Introduction iii
Important iii
Machine Identification iv
Description v
Description of the machine operation v
Section 1 Rev. Safety Rules xi
1.1 Safety rules xii
1.1-1 Personal safety xii
1.1-2 Workplace safety xiii
1.2 General remarks xiv
1.3 Servicemen’s requisites xiv
1.3-1 Personal protective equipment xv
1.4 General safety precautions xv
1.4-1 Working area xv
1.4-2 Precautions during work xv
Section 2 Rev. Technical Specification 1
2.1 Main dimensions 1
2.2 Tyres 2
2.3 Limit of use 2
2.4 Weight 2
2.5 Speed 2
2.6 Payload and reach 2
2.7 Forks (floating type) 3
2.8 Diesel engine 3
2.9 Hydraulic system 3
2.10 Electrical system 3
2.11 Machine sounds level 4
2.12 Vibration level 4
2.13 Refuelling 4
2.14 Tightening torques 5
2.15 Drill diameters for threads 7
2.16 Standard tightening torques for fitting seals 8
2.17 Locking material 10
2.18 Hoisting instructions 11
2.19 Advice to renew flexible hoses 12
2.20 List of recommended spare parts GTH-4013 SX/ GTH-4017 SX 13
2.21 Machine paint colour 14
2.22 Checking the cylinder movement times 15
2.23 Hydraulic settings 17
1. Preliminary operations 17
2. Calibrating the boom main valve 17
2.1 Calibrating the main valve pressure control valve 17
3. Check calibrating hydrostatic transmission 18
3.1 Hydrostatic transmission pump 18
3.2 Check transmission piloting 18
4. Calibrating the power steering 18
2.24 DLE system 23
2.25 Hydrostatic transmission control unit check system 32
Section 3 Rev. Maintenance Inspections 1
3.1 Introduction 1
3.2 About this section 2
3.3 Maintenance table 3
3.4 Maintenance inspection report 6
Section 4 Rev. Maintenance Procedures 1
4.1 Introduction 1
4.2 About this section 2
4.3 Table A procedures 3
A-1 Check the oil level within reduction gears, differential gears
and power divider reduction gears 3
A-2 Check the tightening of the wheel bolts 5
A-3 Check the tightening of all bolts and nuts 6
A-4 Check the couplings for oil leaks 6
A-5 Inspect the Operator’s Manual 7
A-6 Inspect the decals and plates 7
A-7 Check the engine oil level 8
A-8 Clean the air suction filter 9
A-9 Check and clean the radiator 10
A-10 Check the hydraulic oil level in the tank 11
A-11 Check the greasing of the boom section pads 12
A-12 Grease the forks 14
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 15
A-14 Check the efficency of the lighting electric system 16
A-15 Check the efficency of braking system 17
A-16 Check the efficency of the steering selection system 18
A-17 Check the efficency of the fork balancing system 19
A-18 Check the efficient working order of the safety devices 20
A-19 Check the engine coolant level 23
A-20 Check the efficency of the overload warning system 24
A-21 Check the re-sequence of the boom telescope (GTH 4013sx) 25
4.4 Table B procedures 26
B-1 Check the efficency of the machine 26
B-2 Check the tension of the alternator belt 26
B-3 Check the tyre inflation 27
B-4 Check the tightening of the wheel nuts 28
B-5 Check the tightening of the cardan shaft screws 29
B-6 Clean the radiator fins 30
4.5 Table C procedures 31
C-1 Change the oil in the reduction gears, differential gears
and power divider reduction gear 31
C-2 Change the engine oil and relevant filter 32
C-3 Check the oil level in the front and rear differential gears 33
C-4 Check the oil level in the four wheel reduction gears 33
C-5 Check and clean the engine air filter 34
C-6 Check the clamping of the cableheads to the battery terminals 35
C-7 Check the air suction hose between engine and filter 35
C-8 Check the cylinder chromium-plated rods 36
C-9 Check the hydraulic lines 36
C-10 Check the electric cables 37
C-11 Check the wear of the sliding pads of the boom sections 37
C-12 Adjust the play of the sliding pads of the boom sections 38
C-13 Grease the sliding parts of the boom sections 39
C-14 Check the level of the battery electrolyte 40
C-15 Check the efficency of the block valves 41
4.6 Table D procedures 43
D-1 Visually check the smoke quantity evacuated from the engine exhaust 43
D-2 Check the tightening of the engine fixing screws 43
D-3 Check the tightening of the cab fixing screws 44
D-4 Check the blacklash between pins and bushings in all joints 44
D-5 Change the hydraulic oil filter cartridge 45
D-6 Have the hydraulic system checked by a skilled technician 46
D-7 Change the main cartridge of the engine air filter 46
D-8 Change the engine oil filter and the fuel filter 47
D-9 Clean the cab air filter 47
D-10 Change the oil of the front and rear differential gears 48
D-11 Boom chain tensioning (GTH 4017SX only) 48
4.7 Table E procedures 49
E-1 Change the safety element of engine air filter 49
E-2 Change the oil in the power divider gears 50
E-3 Change the oil in the four wheel reduction gears 50
E-4 Change the hydraulic oil and the inner hydraulic oil filter 51
4.8 Table F procedures 52
F-1 Change the engine coolant 52
4.9 Table G procedures 53
G-1 Check the machine structure 53
Section 5 Rev. Problems-Causes-Solutions 1
5.1 Introduction 1
5.2 About this section 2
5.3 Electrical faults 3
5.4 Hydraulic faults 10
Section 6 Rev. Schemes 1
6.1 Hydraulic symbols 1
6.2 Hydraulic schemes 3
6.2.1 GTH-4013 SX 3
6.2.2 GTH-4017 SX 4
6.3 Electrical symbols 5
6.4 Electrical schemes 7
6.4.1 GTH-4013 SX GTH-4017 SX 7
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 1
7.1 Time schedule 1
001 – Cylinder disassembly – Boom raising cylinder 5
002 – Cylinder disassembly – Fork balance cylinder 9
003 – Removing the engine from the machine 11
004 – Hydraulic pumps disassembly 15
005 – Disassembling the hydraulic motor 19
006 – Cylinder disassembly – Boom extension cylinder GTH 4017 SX 21
007 – Cylinder disassembly – Boom extension external cylinder GTH 4013 SX 23
008 – Cylinder disassembly – Boom extension internal cylinder GTH 4013 SX 25
009 – Water-oil cooler disassembly 27
010 – Main valve disassembly 29
011 – Renewing the slide pads of the telescopic boom GTH 4013 SX 31
012 – Renewing the slide pads of the telescopic boom GTH 4017 SX 35
013 – Renewing the flexible hoses inside the boom GTH 4013 SX 39
014 – Renewing the flexible hoses inside the boom GTH 4017 SX 41
015 – Cylinder disassembly – Attachment rotation cylinder 45
S.S 05/24