Genie GTH-4017 EX GTH-4514 EX GTH-4013 EX Service Manual 57.0009.0427 – PDF

Description

Genie GTH-4017 EX GTH-4514 EX GTH-4013 EX Service Manual 57.0009.0427 – PDF DOWNLOAD

Language : English
Pages : 218
Downloadable : Yes
File Type : PDF

Table of Contents:

Genie GTH-4017 EX GTH-4514 EX GTH-4013 EX Service Manual 57.0009.0427 – PDF DOWNLOAD

Rev. Introduction iii
Important iii
Machine Identification iv
Description v
Description of the machine operation GTH-4017EX – GTH-4514EX v
Hydraulic schematic GTH-4017EX – GTH-4514EX viii
Description of the machine operation GTH-4013EX ix
Hydraulic schematic GTH-4013EX xii
Section 1 Rev. Safety Rules Xiii
1.1 Safety rules xiv
1.1-1 Personal safety xiv
1.1-2 Workplace safety xv
1.2 General remarks xvi
1.3 Servicemen’s requisites xvi
1.3-1 Personal protective equipment xvii
1.4 General safety precautions xvii
1.4-1 Working area xvii
1.4-2 Precautions during work xvii
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 Fastener torques 5
2.15 Locking material 6
2.16 Hoisting instructions 7
2.17 Advice to renew flexible hoses 8
2.18 List of recommended spare parts GTH-4013EX 9
List of recommended spare parts GTH-4017EX – GTH-4514EX 11
2.19 Machine paint colour 13
2.20 Checking the cylinder movement times 14
2.21 Hydraulic settings 16
1. Preliminary operations 16
2. Calibrating the boom main valve 16
3. Check calibrating hydrostatic transmission 16
3.1 Hydrostatic transmission pump 17
3.2 Check transmission piloting 17
4. Calibrating the power steering 17
2.22 DLE system 24
2.23 Hydrostatic transmission control unit check system 35
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 (GTH-4013EX) 9
Clean the air suction filter (GTH-4017EX – GTH-4514EX) 10
A-9 Check and clean the radiator 11
A-10 Check the hydraulic oil level in the tank 12
A-11 Check the greasing of the boom section pads
(GTH-4013EX – GTH-4514EX) 13
Check the greasing of the boom section pads (GTH-4017EX) 14
A-12 Grease the forks 15
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 16
A-14 Check the efficency of the lighting electric system 17
A-15 Check the efficency of braking system 18
A-16 Check the efficency of the steering selection system 19
A-17 Check the efficency of the fork balancing system 20
A-18 Check the efficient working order of the safety devices 21
A-19 Check the engine coolant level 24
A-20 Check the efficency of the overload warning system 25
A-21 Check the re-sequence of the boom telescope (GTH-4013EX) 26
4.4 Table B procedures 27
B-1 Check the efficency of the machine 27
B-2 Check the tension of the alternator belt 27
B-3 Check the tyre inflation 28
B-4 Check the tightening of the wheel nuts 29
B-5 Check the tightening of the cardan shaft screws 30
B-6 Clean the radiator fins 31
4.5 Table C procedures 32
C-1 Change the oil in the reduction gears, differential gears
and power divider reduction gear 32
C-2 Change the engine oil and relevant filter 33
C-3 Check the oil level in the front and rear differential gears 34
C-4 Check the oil level in the four wheel reduction gears 34
C-5 Check and clean the engine air filter (GTH-4013EX) 35
Check and clean the engine air filter (GTH-4017EX – GTH-4514EX) 36
C-6 Check the clamping of the cableheads to the battery terminals 37
C-7 Check the air suction hose between engine and filter 37
C-8 Check the cylinder chromium-plated rods 38
C-9 Check the hydraulic lines 38
C-10 Check the electric cables 39
C-11 Check the wear of the sliding pads of the boom sections 39
C-12 Adjust the play of the sliding pads of the boom sections 40
C-13 Grease the sliding parts of the boom sections 41
C-14 Check the level of the battery electrolyte 42
C-15 Check the efficency of the block valves 43
4.6 Table D procedures 45
D-1 Visually check the smoke quantity evacuated frin the engine exhaust 45
D-2 Check the tightening of the engine fixing screws 45
D-3 Check the tightening of the cab fixing screws 46
D-4 Check the blacklash between pins and bushings in all joints 46
D-5 Change the hydraulic oil filter cartridge (GTH-4013EX) 47
Change the hydraulic oil filter cartridge (GTH-4017EX – GTH-4514EX) 48
D-6 Have the hydraulic system checked by a skilled technician 48
D-7 Change the main cartridge of the engine air filter (GTH-4013EX) 49
Change the main cartridge of the engine air filter
(GTH-4017EX – GTH-4514EX) 49
D-8 Change the engine oil filter and the fuel filter 50
D-9 Clean the cab air filter 50
D-10 Change the oil of the front and rear differential gears 51
D-11 Boom chain tensioning (GTH-4017EX – GTH-4514EX) 51
4.7 Table E procedures 52
E-1 Change the safety element of engine air filter (GTH-4013EX) 52
Change the safety element of engine air filter
(GTH-4017EX – GTH-4514EX) 52
E-2 Change the oil in the power divider gears 53
E-3 Change the oil in the four wheel reduction gears 53
E-4 Change the hydraulic oil and the inner hydraulic oil filter 54
4.8 Table F procedures 55
F-1 Change the engine coolant 55
4.9 Table G procedures 56
G-1 Check the machine structure 56
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-4017EX – GTH-4514EX 3
6.2.2 GTH-4013EX 4
6.3 Electrical symbols 5
6.4 Electrical schemes 7
6.4.1 GTH-4013EX 7
6.4.1.1 Fuses and relays GTH-4013EX 17
6.4.2 GTH-4017EX – GTH-4514EX 18
6.4.2.2 Fuses and relays GTH-4017EX – GTH-4514EX 28
6.5 Position of components on the machine 29
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-4017EX – GTH-4514EX 21
007 – Cylinder disassembly – Boom extension external cylinder GTH-4013EX 23
008 – Cylinder disassembly – Boom extension internal cylinder GTH-4013EX 25
009 – Water-oil cooler disassembly 27
010 – Main valve disassembly 29
011 – Renewing the slide pads of the telescopic boom GTH-4013EX 33
012 – Renewing the slide pads of the telescopic boom
GTH-4017EX – GTH-4514EX 37
013 – Renewing the flexible hoses inside the boom
GTH-4013EX – GTH-4514EX 41
014 – Renewing the flexible hoses inside the boom GTH-4017EX 43
015 – Cylinder disassembly – Attachment rotation cylinder 45

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