Terex Genie GTH-4017 EX

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Document 57.0009.0427

GTH-4017EX GTH-4514EX GTH-4013EX

Intentionally blank page

Service Manual November 2008

Main Page

Introduction3
Description5
Rev9
Safety Rules13
Personal Safety14
Workplace Safety15
General Remarks16
Servicemen's Requisites16
Personal Protective Equipment17
General Safety Precautions17
Working Area17
Precautions During Work17
Table of Contents19
Rev20
Technical Specification23
Main Dimensions23
Tyres24
Limit of Use24
Weight24
Speed24
Payload and Reach24
Forks (Floating Type)25
Diesel Engine25
Hydraulic System25
Electrical System25
Machine Sounds Level26
Vibration Level26
Refuelling26
Fastener Torques27
Locking Material28
Hoisting Instructions29
Advice to Renew Flexible Hoses30
List of Recommended Spare Parts GTH-4013EX31
List of Recommended Spare Parts GTH-4017EX - GTH-4514EX33
Machine Paint Colour35
Checking the Cylinder Movement Times36
Hydraulic Settings38
Preliminary Operations38
Calibrating the Boom Main Valve38
Check Calibrating Hydrostatic Transmission38
Hydrostatic Transmission Pump39
Check Transmission Piloting39
Calibrating the Power Steering39
DLE System46
Hydrostatic Transmission Control Unit Check System57
Maintenance Inspections63
Introduction63
About this Section64
Maintenance Table65
Maintenance Inspection Report68
Maintenance Procedures71
About this Section72
Check the Oil Level Within Reduction Gears, Differential Gears and Power Divider Reduction Gears73
Check the Tightening of All Bolts and Nuts76
Check the Couplings for Oil Leaks76
Inspect the Operator's Manual77
Inspect the Decals and Plates77
Check the Engine Oil Level78
Clean the Air Suction Filter (GTH-4013EX)79
Clean the Air Suction Filter (GTH-4017EX - GTH-4514EX)80
Check and Clean the Radiator81
Check the Hydraulic Oil Level in the Tank82
Check the Greasing of the Boom Section Pads (GTH-4013EX - GTH-4514EX)83
Check the Greasing of the Boom Section Pads (GTH-4017EX)84
A-12 Grease the Forks85
Grease All Joints of the Boom, the Rear Axle Shaft Joint, the Transmission Shafts, the Front and Rear Axles and any Equipment of the Machine86
Check the Efficency of the Lighting Electric System87
Check the Efficency of the Steering Selection System89
Check the Efficency of the Fork Balancing System90
Check the Efficient Working Order of the Safety Devices91
A-19 Check the Engine Coolant Level94
Check the Efficency of the Overload Warning System95
Check the Re-Sequence of the Boom Telescope (GTH-4013EX)96
Check the Efficency of the Machine97
Check the Tension of the Alternator Belt97
Check the Tyre Inflation98
Check the Tightening of the Wheel Nuts99
Check the Tightening of the Cardan Shaft Screws100
Clean the Radiator Fins101
Change the Oil in the Reduction Gears, Differential Gears and Power Divider Reduction Gear102
Change the Engine Oil and Relevant Filter103
Check the Oil Level in the Front and Rear Differential Gears104
Check the Oil Level in the Four Wheel Reduction Gears104
Check and Clean the Engine Air Filter (GTH-4013EX)105
Check and Clean the Engine Air Filter (GTH-4017EX - GTH-4514EX)106
Check the Clamping of the Cableheads to the Battery Terminals107
Check the Air Suction Hose between Engine and Filter107
Check the Cylinder Chromium-Plated Rods108
Check the Hydraulic Lines108
C-10 Check the Electric Cables109
Check the Wear of the Sliding Pads of the Boom Sections109
Adjust the Play of the Sliding Pads of the Boom Sections110
Grease the Sliding Parts of the Boom Sections111
Check the Level of the Battery Electrolyte112
Check the Efficency of the Block Valves113
Check the Tightening of the Engine Fixing Screws115
Check the Tightening of the Cab Fixing Screws116
Check the Blacklash between Pins and Bushings in All Joints116
Change the Hydraulic Oil Filter Cartridge (GTH-4013EX)117
Change the Hydraulic Oil Filter Cartridge (GTH-4017EX - GTH-4514EX)118
Have the Hydraulic System Checked by a Skilled Technician118
Change the Main Cartridge of the Engine Air Filter (GTH-4013EX)119
Change the Main Cartridge of the Engine Air Filter119
Change the Oil of the Front and Rear Differential Gears121
Change the Safety Element of Engine Air Filter122
(Gth-4017Ex - Gth-4514Ex122
Change the Hydraulic Oil and the Inner Hydraulic Oil Filter124
Change the Engine Coolant125
Check the Machine Structure126
Problems-Causes-Solutions127
Introduction127
About this Section128
Electrical Faults129
Hydraulic Faults136
Schemes141
Hydraulic Symbols141
Hydraulic Schemes143
Gth-4017Ex Gth-4514Ex143
Gth-4013Ex144
Electrical Symbols145
Electrical Schemes147
Gth-4013Ex147
Fuses and Relays GTH-4013EX157
Gth-4017Ex Gth-4514Ex158
6.4.2.2 Fuses and Relays Gth-4017 Ex Gth-4514 Ex168
Position of Components on the Machine169
Repair Procedures173
Time Schedule173
Cylinder Disassembly Fork Balance Cylinder181
Removing the Engine from the Machine184
Hydraulic Pumps Disassembly187
Disassembling the Hydraulic Motor191
Cylinder Disassembly - Boom Extension Cylinder193
Gth-4017Ex - Gth-4514Ex193
Cylinder Disassembly - Boom Extension External Cylinder GTH-4013EX195
Cylinder Disassembly - Boom Extension Internal Cylinder GTH-4013EX197
Water-Oil Cooler Disassembly199
Main Valve Disassembly201
Renewing the Slide Pads of the Telescopic Boom GTH-4013EX205
Renewing the Slide Pads of the Telescopic Boom GTH-4017EX GTH-4514EX209
Renewing the Flexible Hoses Inside the Boom GTH-4013EX GTH-4514EX213
Renewing the Flexible Hoses Inside the Boom GTH-4017EX215
Cylinder Disassembly - Attachment Rotation Cylinder218

Terex Genie GTH-4017 EX - Page 2

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