Service Training

GTH
 MANIPULADOR TELESCOPICO Telelift 4013 (GTH 4013)
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Cilindro de Cilindro do Cilindro do Cilindro de Cilindro do Estabilizador Direito
Travamento do Telescópio da Estabilizado Inclinação
Eixo Traseiro Segunda seção r Esquerdo do Garfo
Cilindro de
do Braço Travamento
Rápido do
Implemento
Clindro de
Cilindro Nivelamento
Escravo do Chassis

Motor Hidrostático da
Transmissão

Bloco de Válvulas dos

Estabilizadores e
Nivelamento do
Chassi
Cilindro de Caixa de
Elevação Fusíveis e
Bloco de Válvulas Relés do Motor
Das Funções do
Braço Bomba de Bomba
Cilindro do Telescópio
Circuitos Motor Bomba de de
da Terceira seção do
Auxiliares Diesel Deslocamento Funções
Braço
6
GTH 4013 componentes principais e localização no equipamento
 Motor Diesel – Localização de Componentes Alternador

Filtro de Ar

Alternador

Motor de Partida
Duto de Exaustão
Motor Diesel Filtro de Ar Filtro de Ar

Tanque de Expansão
7
do Radiador Radiador
 Bomba de Transmissão Hidrostatica Bosch-Rexroth A4VG71
Principais Componentes e Localização no Equipamento
Valvula Solenoide Valvula Solenoide
de deslocamento para frente de deslocamento reverso
Válvula Limitadora de
Pressão Máxima 430 bar

Porta de Teste de
Pressão da Linha B

Regulagem do Cam Excentrico

Válvula de
Alívio de
DA valve
Pressão
Máxima
450 bar

Para o Reservatório
Hidráulico 2,5 bar

Válvula de Alívio do Circuito

8 da Bomba de Carga 25 bar Porta de Teste da
Bomba de Carga Bomba de Funções
Bomba de Transmissão Hidrostática
Bosch-Rexroth A4VG

9
 A4VG DA: Válvula Direcional

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 A4VG DA: Bomba de Carga

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 A4VG DA: Válvula de Pressão Máxima

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 A4VG DA: Válvula de Alívio de Pressão

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 A4VG DA: Válvula DA

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A4VG DA: Cam Excentrico

15
 A4VG DA: Configuração do Cam Excentrico

Alta Pressão

Pressão de Carga
16
A4VG DA: Válvula de Alívio da Bomba de Carga

17
18 Hydrostatic transmission pump - reference to Service Manual
Motor de Transmissão Hidrostatica Bosch-Rexroth A6VM80
Localização dos Principais Componentes Para o reservatório
Hidráulico
Parafuso de ajuste de Parafuso de Ajuste da
deslocamento máximo Válvula de Controle DA

Válvula de
descarga’

Parafuso de ajuste de
deslcamento mínimo

Portas de Alta Pressão Válvula de Controle DA

Portas Hidráulicas do
Atuador de Seleção de Marchas
2 speed mechanical gear
To oil tank

From pump
case drain
X1, X2 piloting ports
Hydrostatic transmission motor
19
Case drain port Cardan shaft
 Hydrostatic transmission motor Bosch-Rexroth A6VM - pictorial view

20
 A6VM DA: directional valve

21
 A6VM DA: DA1 valve

22
 A6VM DA: flushing valve

23
 Boom pump with priority valve - main components and location on the machine

Priority port Secondary port

Pump suction port (to boom main valve)
(to steering pump)

Priority port
(to steering pump)

Load sensing port

Secondary port (from steering pump)
Pump shaft
(to boom main valve)

to steering pump Hydrostatic transmission pump

To boom main valve

To boom main valve

to
steering
pump

Boom pump
24 Diesel engine flywheel
From tank Hydrostatic transmission pump From tank
 Boom pump with priority valve - internal components view

25
 Boom pump with priority valve - reference to Parts Manual

26
 Brake circuit pump - main components and location on the machine

Pressure port
(to service brake pump)

27 Suction port (from the joint

Diesel engine PTO on distribution boom circuit suction port)
 Oil level indicator tank line
from the
cooler
Oil tank
Transmission pump suction line

Tank cleaning and

inspection door
To pump
service
brake

Shutoff valves
To Boom pump
suction line

Tank lines

Oil tank, filters and suction ports

Oil filter on tank line
28
- views and main components
 Proposal to improve the hydraulic oil filtration
Return port Suction port

• On the new machine we propose to

dramatically improve the filtration of the
hydraulic oil (more appropriate to the
typical rental market scenario).
• A special filter, extensively used by our
company on bigger models, is proposed as
represented in the side pictures .
• This filter has a double function. It works as
a filter on the return line and as a filter on
the suction line of the transmission charge
pump (two filters in one single manifold).
• Minor risks of cavitation on the
Filter cartridge transmission charge pump line at the start-
up of the machine at low temperatures
conditions due to a pressurization of the
suction line of 0,5 bar (7 psi) minimum.
• Easier maintenance of the filter element.
• Better filtration of the oil.
Filter clogged
• The effect on the cost will be minimum
by-pass duct
 Module n° 3 Telescoping out max pressure Forks tilt anti-shock valves:
Max pressure relief valve boom telescoping in/out relief valve: cracking pressure 150 bar cracking pressure 290 bar
cracking pressure: 280 bar

Module n° 4
Forks quick coupling
and auxiliaries

Module n° 1
Boom up/down
Module n° 2
Piloting lines inlet block
Forks tilt up/down
Inlet block with pressure
compensator and
max pressure relief valve
Outlet block

From boom pump

To heat exchager

Boom hydraulic
circuit test port

Electroproportional modules
Main shutoff valve

Max pressure relief valve

cracking pressure: 280 bar

30
Bucher-Tecnord boom main valve - main components and location on the machine
 Module n° 1 Module n° 3
Boom up/down boom telescoping in/out
Bucher-Tecnord boom main valve –
main components and location on the machine Module n° 2
Forks tilt up/down

Module ON/OFF n° 4
Forks quick coupling
and auxiliaries

Outlet block

Inlet block with pressure

Main valve compensator and
max pressure relief valve
To heat exchager

Main shutoff
valve
Piloting lines inlet block

Pressure damping accumulator

located on boom down line
capacity: 0,5 liters
31pre-charge pressure: 40 bar Boom hydraulic Max pressure relief valve
circuit test port cracking pressure: 280 bar
Bucher-Tecnord boom main valve - main components

Main valve

Proportional valve

Proportional module Max Torcque 2

Nm

Spool position trasducer

Proportional valve

32
Proportional module
Bucher-Tecnord boom main valve - main components Max Torcque 2 Nm

Main valve
Max Torcque 2 Nm

Proportional module

Trimmer to adjuste
Trimmer to adjuste Electric Zero position
Electric Zero position

33
Proportional module Main components proportional valve
 Bucher-Tecnord boom main valve - hydraulic schematic

34
 Bucher-Tecnord boom main valve circuit - boom up/down damping accumulator

Pressure damping accumulator

located on boom down line
capacity: 0,5 liters
pre-charge pressure: 40 bar

35 accumulator view from the cab

 Module n° 1 Module n° 3 Module n° 2
Left stabilizer chassis leveling Right stabilizer
Outlet block

Inlet block with max

pressure relief valve

Max pressure relief valve

cracking pressure: 220 bar

Bucher stabilizers and chassis leveling valve - main components and location on the machine

Max pressure relief valve

Solenoids
cracking pressure: 220 bar

From service
brake pump
To tank Line to tank

36
Solenoids
 Right stabilizer cylinder Right stabilizer safety valve Left stabilizer safety valve Left stabilizer cylinder

Left stabilizer foot

Right stabilizer foot

Right stabilizer arm

Left stabilizer arm

Stabilizers and chassis leveling circuit - main components and location on the machine
chassis leveling
safety valve chassis leveling
cylinder

Front axle

chassis
37 Front axle
leveling
cylinder
 Dana axles - specification data

38
 Wheel hub with planetary reducer
Dana axles - main components and views
Steering rods

Wheel hub with planetary reducer

Front axle

Cardan shaft
Rear axle Front axle

Steering cylinder Service brakes Rear axle

Steering cylinder Front axle
bleed port

Service brakes
circuit port’
Service brakes Service brakes Service brakes Air venting port Optical
bleed port circuit port bleed port Sensor
port

Service brakes circuit ports

Air venting port
Service brakes
bleed port Mechanical hand brakes
Mechanical hand brakes

39
Central box with differential and service brakes
Central box with differential, service brake and parking brakes
 Dana axles - reference to Parts Manual

40
Dana 2 speeds mechanical gear
specification data

41
 Hydrostatic transmission motor 2 speed mechanical gear box

Dana 2 speeds mechanical

gear - main components and
location on the machine
Cardan shaft end yokes Hydrostatic transmission motor

Mechanical gear box

Gear selection switch

42 Gear selection actuator Cardan shaft

hydraulic ports Speed sensor
 Solenoids

A port

Dana 2 speeds mechanical gear selector valve

B port
- views and location on the machine

To mechanical gear

Tank port

To mechanical gear

To tank
43
From low pressure line Pressure port
 Solenoids From/to transmission
pump case drain

Solenoids

Cartridge type safety valve

(2 ways/2 positions)

Rear axle lockout circuit - views and main components Cartridge type safety valve
(2 ways/2 positions)

Air bleed port Rear axle

lockout
cylinder
Solenoids

Solenoids

From/to transmission
pump case drain

Rear axle Rear axle

Rear axle lockout cylinder

44
 Boom up/down cylinder - views and main components
Boom up/down cylinder

Boom up/down cylinder

Single overcenter/safety valve

piloting ratio: 4/1
cracking pressure: 350 bar
Single overcenter/safety valve
piloting ratio: 4/1
Overcenter and max
cracking pressure: 350 bar From/to module n° 1 of Single overcenter/safety valve
relief valve cartridge
boom main valve piloting ratio: 4/1
cracking pressure: 350 bar

Piloting line damping

adjustment screw
45 From/to module n° 1 of
Boom up/down cylinder Boom up/down cylinder boom main valve
 Overcenter and max Forks leveling slave cylinder
Overcenter and max relief valve cartridges
relief valve cartridges

Double overcenter/safety valve

piloting ratio: 7,6/1
cracking pressure: 350 bar

Forks leveling slave cylinder

views and main components
From/to module n° 2 of
boom main valve
Forks leveling slave cylinder
Double overcenter/safety valve
piloting ratio: 7,6/1
cracking pressure: 350 bar
Piloting line 25 bar
from Transmission pump

From/to module n° 2 of
boom main valve

46 Anti-cavitation check valves

cracking pressure: 5 bar
 Forks leveling slave cylinder - functioning principles

47
 Forks leveling slave cylinder - functioning principles

48
 Double overcenter/safety valve Piloting line damping Double overcenter/safety valve
piloting ratio: 4/1 adjustment screw piloting ratio: 4/1
cracking pressure: 350 bar cracking pressure: 350 bar

From/to module n° 2 of
boom main valve

Forks tilt cylinder

Forks attachment boom articulation Forks tilt cylinder

Forks tilt cylinder - views and main components

From/to module n° 2 of Overcenter and max

boom main valve relief valve cartridge

From/to module n° 2 of
boom main valve Piloting line damping
adjustment screw

Double overcenter/safety valve

49 piloting ratio: 4/1 Overcenter and max
cracking pressure: 350 bar relief valve cartridge
 Double overcenter/safety valve Overcenter and max
piloting ratio: 4/1 Boom telescoping cylinder
relief valve cartridge
cracking pressure: 350 bar
Boom
telescoping
cylinder

Piloting line damping

adjustment screw
Telescoping boom

Double overcenter
safety valve
Boom telescoping cylinder piloting ratio: 4/1
views and main components cracking pressure: 350 From/to module n° 3 of
bar boom main valve
Boom telescoping cylinder
Double overcenter/safety valve Double overcenter/safety valve
piloting ratio: 4/1 piloting ratio: 4/1 Overcenter and max
cracking pressure: 350 bar cracking pressure: 350 bar relief valve cartridge

50 From/to module n° 3 of
boom main valve Boom telescoping cylinder
 Boom telescoping cylinder - views and main components
Telescoping boom
Third section boom
telescoping cylinder

From/to module n° 3 of
Signle overcenter/safety valve boom main valve
piloting ratio: 4/1
Boom telescoping cylinder cracking pressure: 350 bar Third section boom
telescoping cylinder

Overcenter and max

relief valve cartridge

Boom telescoping cylinder

From/to module n° 4 of
boom main valve

51 From/to module n° 2 of
boom main valve Hoses guide
 Forks attachment quick coupling cylinder - views and main components
Hydraulically piloted
double check valve Hydraulically piloted
piloting ratio: 4/1 Forks attachment quick coupling pins
double check valve
piloting ratio: 4/1

Forks attachment boom articulation

Forks attachment quick coupling pin

Forks attachment quick coupling cylinder

Hydraulically piloted From/to module n° 4 of

double check valve boom main valve
piloting ratio: 4/1
Hydraulically piloted
double check valve
piloting ratio: 4/1

Forks attachment boom articulation

52
Forks attachment quick coupling cylinder
 Heat exchanger general assembly - views and main components
Diesel engine

Heat exchanger general assembly

Oil cooler to filter tank Heat exchanger general assembly

Heat exchanger assembly with cooling fan

Cooling fan

oil

53
cooling
 Steering actuator - views and main components

To tank

Steering actuator

To/from port P To/from front axle

Selector valve Steering cylinder

Steering actuator
From boom functions pump with
Integrated priority valve displacement
54
 Steering modes selector valve - views and location on the machine
Solenoids P port Pressure port
From steering
actuator

T port

Tank port to front axle

To/from steering
actuator

To/from front axle To/from rear axle

Solenoids steering cylinder B port steering cylinder

A port
To/from rear axle
steering cylinder

55 To/from rear axle Solenoids

steering cylinder
 Service brakes pedal Accumulator charging Hydraulically powered
valve setting pressure service brakes pump
adjustment screw

Hydraulically powered
service brakes pump

To/from front axle service To/from rear axle service

Service brakes circuit - views and main components brake accumulator brake accumulator

Service brake minimum

Service brakes on Accumulator charging
pressure switch port
pressure switch port valve setting pressure
(activating pressure 70 bar)
(activating pressure 2-10 bar) adjustment screw

To tank

From service
brakes
circuit pump To/from rear axle To/from front axle
service brakes service brakes
To stabilizers and chassis
Hydraulically powered levelling selector valve Hydraulically powered
56
service brakes pump service brakes pump
Service brakes circuit - main components and locations on the machine

Service brakes on
pressure switch port
Service brakes pedal Accelerator pedal
(activating pressure 2-10 bar)
Cabin floor

Cabin floor

Hydraulically powered
service brakes pump Service brake minimum
pressure switch port
(activating pressure 70 bar)

Service brakes on Front axle service brakes accumulator

Cabin floor pressure switch port capacity: 0,5 liters
(activating pressure 2-10 bar) pre-charge pressure: 50 bar

Service brake minimum

pressure switch port
(activating pressure 70 bar) Reart axle service brakes accumulator
Hydraulically powered capacity: 0,5 liters
57
service brakes pump pre-charge pressure: 50 bar
 Service brakes circuit - reference to Parts Manual

58
 Parking brake circuit - views and main components

Parking brake lever

Microswitch

Cabin floor

59
 Parking brake circuit - reference to Parts Manual

60
 main components and location on the machine

61
 Main Instruments panel

Ignition switch

Engine fuses and relays box

K11 start
engine 70 Amp
50 Amp

K01 70 Amp

Cabin fuses and relays box

Alternator
Engine start motor

62
PAG 1
 Relay circuit main line

Emergency stop
pushbutton

Emergency pump switch

(only with man-platform)

K12 electrostop
K13 emergency pump
63 PAG 2
Forward/rearward
selector switch

Mechanical Gear box speed switch

Gear box control board K8 reverse

Gear box control board

Input gear box
First gear solenoid valve
speed sensor
K7 forward
Forward mode
Solenoid valve

Second gear solenoid valve

Rearward mode
64
Solenoid valve
PAG 3
 Fog lamp
switch
Road lights
switch

Hydraulic oil
temperatur gauge

K1 high beam
K2 low beam

K4 work
light opt

Service brakes switch

K3 Horn activating pressure 2-10 bar

65
Front light Rear light
PAG 4
 Hazard warning light switch

Switch: turn signals,

Windscreen washer,
horn

K23 Hazard warning

66
PAG 5
 Air conditioning switch

First/second
speed switch

Service brake minimum

Pressure switch port
activating pressure 70 bar Air conditioning compressor

67

PAG 6
Load limiter disabling key Cab/road/Platform switch

Load moment indicator

Tecnord Control box

K19 fork coupling closed

Rear wheels aligned

optical sensor
Mechanical switch

68
PAG 7
 Chassi leveling
switch ( left/right)

RIght stabilizer
UP/DOWN
Left stabilizer switch Left stabilizer
UP/DOWN
Right stabilizer Switch

Tecnord Control box

69
Chassi leveling (left/right)
PAG 8A
 Tecnord control box
Steering mode diagnostic/programming
selector knob interface connector

Tecnord Control box

Steering mode
selector valve
70 PAG 8B
 joystick

Module 2
Boom tilt
Up/down

Module 4 Fork quick

Module 1 Boom Up/down Coupling Closed/open

Lock out
solenoids
Valve rear
axle

71
PAG 9A
Module 3 Telescopin In/out
 joystick

Platform main connector

Boom main connector

K16 cut-off
boom down

K15 cut-of f
boom out Tecnord Control box

K 21 lock out Boom functions

Rear axle enabling solenoid valve

PAG 9B
72
 Fuses and relays box into the cab

X7
X1
X9
X6
X8

X18
X4
X17
X5

73
 Electric
Connector X7
RELAYS
Electric
Connector X18

Electric
Connector X16

Electric
connector X4

Electric
Connector X9

Electric
connector X17

Electric
FUSES Connector X6

Electric
connector X5

Electric
Connector X8
74