Terex Genie GTH-4016 SR Service Manual
  1. Manuals
  2. Brands
  3. Terex Manuals
  4. Boom Lifts
  5. Genie GTH4016 SR
  6. Service manual

Terex Genie GTH-4016 SR Service Manual

Hide thumbs Also See for Genie GTH-4016 SR:
Table of Contents

Advertisement

Quick Links

Service Manual
GTH-4016 SR
GTH-4018 SR
English
Serial number range
From serial n.: 20094
From serial n.: 19785
Part. No.
57.4400.9203
Rev A
March 2010

Advertisement

Table of Contents
loading

Related Manuals for Terex Genie GTH-4016 SR

Summary of Contents for Terex Genie GTH-4016 SR

  • Page 1 Service Manual Serial number range GTH-4016 SR From serial n.: 20094 GTH-4018 SR From serial n.: 19785 Part. No. 57.4400.9203 Rev A March 2010 English...
  • Page 2 Introduction March 2010 Introduction Important Contact us: Read, understand and obey the safety rules and Genie Service Dept: operating instructions in the appropriate Operator's Area Phone Manual on your machine before attempting any maintenance or repair procedure. +44 1476 584 345 This manual provides detailed scheduled France +33 237 260 986...

  • Page 3: Introduction

    March 2010 INTRODUCTION Machine Identifi cation Chassis Serial Number The chassis serial number is punched on the front right part of the chassis side member. GTH-4016 P 10 20000 MODEL SERIAL NUMBER ENGINE TYPE YEAR OF MANUFACTURER Machine Data Plate The identification plate contains the main identification data of the machine like model, serial number and year of manufacture.
  • Page 4 March 2010 Intentionally blank page GTH-4016SR • GTH-4018SR Part No. 57.4400.9203...

  • Page 5: Safety Rules

    March 2010 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 6 Section 1 • Safety Rules March 2010 SAFETY RULES Personal Safety Be sure to wear protective eye wear and other protective clothing if the situation warrants it. Any person working on or around a machine must be aware of all known safety hazards. Personal Be aware of potential crushing hazards safety and the continued safe operation of the such as moving parts, free swinging or...

  • Page 7: Table Of Contents

    March 2010 Table of Contents Introduction Important Information................... ii Machine Identification ..................iii Section 1 Safety Rules Personal Safety Rules ..................v Section 2 Specifi cations Operation Description ..................1 Performance Specifications ................. 8 Hydraulic Specifications..................9 Perkins 1104C-44T Engine................10 Carraro 2632M FR Drive Axle ................
  • Page 8 March 2010 TABLE OF CONTENTS Section 3 Scheduled Maintenance Procedures, continued A-13 Emergency Pump Operation, if present ............ 25 A-14 Hydraulic Oil Level In The Tank ..............25 Checklist B Procedures B-1 Gear Box Oil Level ..................26 B-2 Turntable Reduction Gear Oil Level ............26 B-3 Cylinder Rods.....................
  • Page 9 March 2010 TABLE OF CONTENTS Section 4 Repair Procedures Introduction ......................39 Boom Components 1-1 How to Replace the Boom Wear Pads ............40 1-2 How to Remove the Lifting Fork Frame ............40 1-3 How to Remove the Boom................41 1-4 How to Disassemble the GTH-4018 SR Boom..........
  • Page 10 March 2010 TABLE OF CONTENTS Section 4 Repair Procedures, continued Hydraulic Tanks 5-1 How to Test and Adjust the Function Pump ..........57 5-2 How to Remove the Boom Gear Function Pump ........57 5-3 How to Test the Boom Function Gear Pump ..........58 5-4 How to Remove the Auxiliary Gear Pump ...........
  • Page 11 March 2010 TABLE OF CONTENTS Section 6 Troubleshooting Introduction ....................... 81 Overload Warning System Fault Codes ............82 How to Troubleshoot the Boom Movements............84 How to Troubleshoot the Transmission ............. 85 How to Troubleshoot the Mechanical Gear ............86 Section 6 Troubleshooting, continued How to Troubleshoot the Jobsite Position ............
  • Page 12 March 2010 Intentionally blank page GTH-4016SR • GTH-4018SR Part No. 57.4400.9203...

  • Page 13: A Operation Description

    March 2010 Section 2 • Specification Specifi cation REV A GTH-4016SR & GTH-4018SR Operation Description The function of this pump is to provide hydraulic The system layout of this machine consists of two main sections: an undercarriage and a slewing power to the braking systems (service and parking) and to the air conditioning system compressor turret;...
  • Page 14 Section 2 • Specification March 2010 SPECIFICATION REV A temperatures. rear axle (21), both manufactured by Carraro, so This filter package, which is flanged directly on the transmitting to the wheels the torque generated by top side of the tank, is provided with a electrical the hydrostatic motor.
  • Page 15 March 2010 Section 2 • Specification REV A SPECIFICATION When the pressure upstream of the heat exchanger pressure of 10 bar which makes stronger the effect exceeds 8 bar, the flow rate in excess is directly of the anti-slipping device, device which is installed discharged to the tank through the check valve (30) inside the front axle.
  • Page 16 Section 2 • Specification March 2010 SPECIFICATION REV A circuit. Off course, when the steering is not used, The second section of the valve, not pressure most of the flow rate is available for the secondary compensated, controls the forks tilt up/down circuit.
  • Page 17 March 2010 Section 2 • Specification REV A SPECIFICATION block (59). The four valves of the block (59) are linked to the four stabilizer cylinder (60, 62, 64 and 66) which are equipped with hydraulically piloted double check valves (61, 63, 65 and 67) preventing any movement of the cylinders when they are not pressurized.
  • Page 18 Section 2 • Specification March 2010 SPECIFICATION REV A GTH-4016SR Hydraulic Schematic Hydraulically piloted Third section boom Double overcenter safety valve Sing le overcenter safety valve Quick coupling telescoping cylinder double check valve piloting ratio: 4/1 piloting ratio: HYDRAULIC CIRCUIT hydraulic ports cracking pressure: 350 bar piloting ratio: 4 1 /...
  • Page 19 March 2010 Section 2 • Specification REV A SPECIFICATION GTH-4018SR Hydraulic Schematic Hydraulically piloted Double overcenter safety valve Forks attachment Quick coupling double check valve piloting ratio: 4/1 quick coupling cylinder HYDRAULIC CIRCUIT hydraulic ports piloting ratio: 4 1 / cracking pressure: 350 bar (optional) COLORS LEGENDA...

  • Page 20: Performance Specifications

    Section 2 • Specification March 2010 SPECIFICATION REV A Performance Specifi cations Drive speed, maximum Fluid capacities GTH-4016SR & GTH-4018SR 35 km/h Fuel tank 205 L Hydraulic tank 220 L Towing capacity at dinamometer Tires and wheels max load 7,000 kg Tire size 18-19.5 without load...

  • Page 21: Hydraulic Specifications

    March 2010 Section 2 • Specification REV A SPECIFICATION Hydraulic Specifi cations Main Valve Hydraulic Oil Specifi cations (all models) Hydraulic oil type SHELL TELLUS 46 System relief valve pressure, maximum 280 bar DENISON HF-1 Forks tilt section relief valves pressure, max. 320 bar DIN51524 part2&3 ISO viscosity grade...

  • Page 22: Perkins 1104C-44T Engine

    Section 2 • Specification March 2010 SPECIFICATION REV A Perkins 1104D-44T Engine Carraro 2632M FR Drive Axle Displacement 4400cc GTH-4016SR and GTH-4018SR Number of cylinders Steering Intergrated steer cylinder Bore and stroke 105 x 127 mm Joints Heavy duty double U-joints Horsepower 74.5 kW @ 2300 rpm Steering angle, maximum...

  • Page 23: Hydraulic Hose And Fitting Torque Specifications

    March 2010 Section 2 • Specification REV A SPECIFICATION Hydraulic Hose and Fitting Torque Specifi cations Your machine is equipped with ORFS type fittings 3 Working clockwise on the body hex fitting, and hose ends. Genie specifications require that make a second mark with a permanent ink fittings and hose ends be torqued to specification marker to indicate the proper tightening when they are removed and installed or when new...

  • Page 24: Metric Fasteners Torque Charts

    Section 2 • Specification March 2010 SPECIFICATION REV A METRIC FASTENER TORQUE CHART • This chart is to be used as a guide only unless noted elsewhere in this manual • Class 4.6 Class 8.8 Class 10.9 Class 12.9 Size 10.9 12.9 (m m )

  • Page 25: Rev Scheduled Maintenance Procedures A Introduction

    March 2010 Section 3 • Scheduled Maintenance Procedures Scheduled Maintenance Procedures About This Section This section contains detailed procedures for each scheduled maintenance inspection. Each procedure includes a description, safety warnings and step-by-step instructions. Observe and Obey: Symbols Legend Safety alert symbol—used to alert ...

  • Page 26: Pre-Delivery Preparation Report

    Section 3 • Scheduled Maintenance Procedures March 2010 SCHEDULED MAINTENANCE PROCEDURES Maintenance Symbols Legend Pre-delivery Preparation Report NOTICE The following symbols have The pre-delivery preparation report contains been used in this manual to checklists for each type of scheduled inspection. help communicate the intent of Make copies of the Pre-delivery Preparation report the instructions.
  • Page 27 Pre-Delivery Preparation Fundamentals Instructions It is the responsibility of the dealer to perform the Use the operator’s manual on your machine. Pre-delivery Preparation. The Pre-delivery Preparation consists of completing The Pre-delivery Preparation is performed prior to the Pre-operation Inspection, the Maintenance items each delivery.
  • Page 28 Section 3 • Scheduled Maintenance Procedures March 2010 Intentionally blank page GTH-4016SR • GTH-4018SR Part No. 57.4400.9203...

  • Page 29: Maintenance Inspection Report

    March 2010 Section 3 • Scheduled Maintenance Procedures Maintenance Inspection Report Model Checklist A - Rev A Y N R Checklist C - Rev A Y N R A-1 Manuals and decals Smoke from the Serial number exaust muffler A-2 Pre-operation inspect Date Change engine oil and A-3 Function tests...

  • Page 30: Checklist A Procedures

    Section 3 • Scheduled Maintenance Procedures March 2010 Checklist A Procedures REV A Inspect the Manuals and Decals 3 Open the operator's manual to the decals Maintaining the operator’s manual in good inspection section. Carefully and thoroughly condition is essential to safe machine operation. inspect all decals on the machine for legibility Manual is included with each machine and and damage.

  • Page 31: Perform Pre-Operation Inspection

    March 2010 Section 3 • Scheduled Maintenance Procedures CHECKLIST A PROCEDURES REV A Perform Pre-operation Inspection Perform Function Tests Completing a Pre-operation Inspection is essential Completing the function tests is essential to safe to safe machine operation. The Pre-operation machine operation. Function tests are designed to Inspection is a visual inspection performed by the discover any malfunctions before the machine is operator prior to each work shift.

  • Page 32: Machine Greasing

    Section 3 • Scheduled Maintenance Procedures March 2010 CHECKLIST A PROCEDURES REV A Machine Greasing 5 Return the boom to the stowed position. 6 Locate a grease fitting at one of the locations shown in the illustration. NOTICE 7 Pump grease into the fitting until the joint is Genie specifications require that thoroughly lubricated.

  • Page 33: Epicyclic Reduction Gears Oil Level

    March 2010 Section 3 • Scheduled Maintenance Procedures CHECKLIST A PROCEDURES REV A Epicyclic Reduction Gears Oil Axles Oil Level Level 1. Stop the machine on a level ground and engage the parking brake.  2. Loosen level plug and check if oil is level with the hole.

  • Page 34: Tyre Inflation

    Section 3 • Scheduled Maintenance Procedures March 2010 CHECKLIST A PROCEDURES REV A Engine Oil Level Tyre Infl ation 1. Put on protective clothing and eye wear 2. Rotate the wheel until the tire stem is at the 12 o’clock position. NOTICE Engine specifications require 3.

  • Page 35: Engine Cooling System

    March 2010 Section 3 • Scheduled Maintenance Procedures CHECKLIST A PROCEDURES REV A A-10 Engine Cooling System Lighting System 1. Stop the machine on a level ground and ensure the parking brake is engaged. 2. Switch on the different traffic and work lights NOTICE and check the inside cabin warning lights are Engine specifications require...

  • Page 36: Clean Engine Air Filter

    Section 3 • Scheduled Maintenance Procedures March 2010 CHECKLIST A PROCEDURES REV A A-12 A-11 Safety Devices Clean Engine Air Filter 1. Moment Limiting System 1. Cleaning the External Element - Load a weight of 1000 kg. - Shut the engine down and put the parking - Raise the boom about 30 cm above the brake.

  • Page 37: Emergency Pump Operation, If Present

    March 2010 Section 3 • Scheduled Maintenance Procedures CHECKLIST A PROCEDURES REV A A-13 A-14 Emergency Pump Operation, if Hydraulic Oil Level In The Tank present WARNING Fine jets of hydraulic oil under pressure can penetrate the skin. 1. stop the engine, Do not use your fingers, but a 2.

  • Page 38: A Checklist B Procedures

    Section 3 • Scheduled Maintenance Procedures March 2010 Checklist B Procedures REV A Gear Box Oil Level Turntable Reduction Gear Oil Level 1. Stop the machine on a level ground and make sure the parking brake is engaged. 1. Stop the machine on a level ground and engage ...

  • Page 39: Cylinder Rods

    March 2010 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES REV A Cylinder Rods Inspect the Electrical Wiring NOTICE Genie requires that this procedure NOTICE be performed every 250 hours or Genie requires that this procedure quarterly, whichever comes first. be performed every 250 hours or quarterly, whichever comes first.

  • Page 40: Boom Sliding Pads Adjusting

    Section 3 • Scheduled Maintenance Procedures March 2010 CHECKLIST B PROCEDURES REV A Boom Sliding Pads Adjusting Battery Electrolyte Level 1. Check the electrolyte level every 250 working hours; if necessary, add distilled water. Any boom section is fitted with adjustable pads located on the four sides of the profile.

  • Page 41: Block Valves

    March 2010 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES REV A Block Valves Tensioning The Boom Chains (Only for GTH-4018 SR) NOTICE Genie requires that this procedure be performed every 250 hours or To tighten the boom chains, follow the instructions quarterly, whichever comes first.

  • Page 42: Checklist C Procedures

    Section 3 • Scheduled Maintenance Procedures March 2010 Checklist C Procedures REV A Change Engine Oil and Filter Smoke From the Exaust Muffl er To check the quantity of smoke evacuated from the engine exhaust, proceed as follows: 1. Start the engine of the machine. NOTICE 2.

  • Page 43: Change Engine Air Outer Filter

    March 2010 Section 3 • Scheduled Maintenance Procedures CHECKLIST C PROCEDURES REV A Change Engine Air Outer Filter Change Hydraulic Oil Filter 1. Stop the machine on a level ground and engage NOTICE the parking brake. Engine specifications require 2. Place a container of suitable size under the filter to that this procedure be collect any oil leaks.

  • Page 44: Clean Cabin Air Filter

    Section 3 • Scheduled Maintenance Procedures March 2010 CHECKLIST C PROCEDURES REV A Clean Cabin Air Filter 1. Shut the engine down and engage the parking brake. 2. Pull filter out of the housing accessible from the outside of the cab. 3.

  • Page 45: Checklist D Procedures

    March 2010 Section 3 • Scheduled Maintenance Procedures Checklist D Procedures REV A Change Gear Box Oil Change Oil in the Turntable Gear 1. Stop the machine on a level ground and engage 1. Place a container of suitable size under the drain the parking brake.

  • Page 46: Change Engine Air Inner Filter

    Section 3 • Scheduled Maintenance Procedures March 2010 CHECKLIST D PROCEDURES REV A Change Engine Air Inner Filter Change Hydraulic Oil 1. Stop the machine on a level ground and make NOTICE sure the parking brake is engaged. Engine specifications require 2.

  • Page 47: Change Cabin Air Filter

    March 2010 Section 3 • Scheduled Maintenance Procedures CHECKLIST D PROCEDURES REV A Change Cabin Air Filter Change Oil in the Axles 1. Place a container of suitable size under drain 1. Shut the engine down and engage the parking ...

  • Page 48: Change Oil In The Epicyclic Reduction Gears

    Section 3 • Scheduled Maintenance Procedures March 2010 CHECKLIST D PROCEDURES REV A Change Oil in the Epicyclic Reduction Gears 1. Before draining the oil from wheel end rotate  the wheel end so that the plug is at the highest position [pos.A] and partially unscrew to release possible pressure.

  • Page 49: Checklist E Procedures

    March 2010 Section 3 • Scheduled Maintenance Procedures Checklist E Procedures REV A Change Engine Coolant Machine Structure NOTICE Terexlift require that this NOTICE procedure be performed after Engine specifications require 5 years or after 6000 hours, that this procedure be whichever comes first performed after 2 years or after 2000 hours, whichever comes...
  • Page 50 Section 3 • Scheduled Maintenance Procedures March 2010 REV A Intentionally blank page GTH-4016SR • GTH-4018SR Part No. 57.4400.9203...

  • Page 51: Rev Repair Procedures Introduction

    March 2010 Section 4 • Repair Procedures Repair Procedures About This Section Most of the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop. Select the appropriate repair procedure after troubleshooting the problem.

  • Page 52: Boom Components

    Section 4 • Repair Procedures March 2010 Boom Components REV A 1-2 How to Remove the Lifting 1-1 How to Replace the Boom Fork Frame Wear Pads 1. Extend the boom until the wear pads are 1. With the boom in the stowed position, attach accessible.

  • Page 53: 1-3 How To Remove The Boom

    March 2010 Section 4 • Repair Procedures BOOM COMPONENTS REV A 1-3 How to Remove the Boom 8. Using a punch and a hammer, remove the rod end pivot pin from the lifting cylinder. Keep attention to choose a punch smaller than the pivot pin! WARNING Bodily injury hazard.

  • Page 54: How To Disassemble The Gth-4018 Sr Boom

    Section 4 • Repair Procedures March 2010 BOOM COMPONENTS REV A 1-4 How to Disassemble the GTH- 4018 SR Boom 5. Extend the boom for making accesible the inspection holes on inner section of boom. 6. Inserting a spanner through the inspection holes, remove the screws which fix the hoses WARNING Bodily injury hazard.

  • Page 55: How To Assemble The Gth-4018 Sr Boom

    March 2010 Section 4 • Repair Procedures BOOM COMPONENTS REV A 1-5 How to Assemble the GTH- 4018 SR Boom 12. Slide in the third boom section into the second 1. Fit the two brackets with the relative pulleys (7) boom section, pull the rope hooked up to the in the boom rear part;...
  • Page 56 Section 4 • Repair Procedures March 2010 BOOM COMPONENTS REV A 25. fix the hydraulic hoses to the hoses holder block (20); 26. Follow these instructions to register the chains: • for the lower side chains, completely extend the boom and then retract it of 1 meter.

  • Page 57: How To Disassemble The Gth-4016 Sr Boom

    March 2010 Section 4 • Repair Procedures BOOM COMPONENTS REV A 1-6 How to Disassemble the GTH- 4016 SR Boom WARNING 5. Remove the internal hydraulic hoses for Bodily injury hazard. This extension, fork levelling and attachment procedure requires specific repair locking cylinder (when present).

  • Page 58: How To Assemble The Gth-4016 Sr Boom

    Section 4 • Repair Procedures March 2010 BOOM COMPONENTS REV A 1-7 How to Assemble the GTH- 4016 SR Boom 1. Insert the cylinder (1) inside the third boom 13. Insert the pins (18-19-21), the fork levelling section and fit the pin; cylinder (20) and the fork frame (22);...

  • Page 59: How To Remove A Lift Cylinder

    March 2010 Section 4 • Repair Procedures BOOM COMPONENTS REV A 1-8 How to Remove a Lift Cylinder 8. Remove the screw fixing the pitching cylinder pin. 9. Knock out and extract the pin using a plug of soft material (aluminium, copper, wood, etc.). 10.

  • Page 60: How To Remove The Second Boom Section Extension Cylinder

    Section 4 • Repair Procedures March 2010 BOOM COMPONENTS REV A 1-9 How to Remove the Second 1-10 How to Remove the Third Boom Section Extension Cylinder Boom Section Extension Cylinder (only for GTH-4016 SR) WARNING Bodily injury hazard. This WARNING procedure requires specific repair Bodily injury hazard.

  • Page 61: How To Remove The Fork Level Cylinder

    March 2010 Section 4 • Repair Procedures BOOM COMPONENTS REV A 1-11 How to Remove the Fork Level Cylinder 7. Remove the four screws fixing the cylinder to the 3dr section boom. 8. Pull out the cylinder from the boom section and sling it with the textile bridles connected to the bridge crane.

  • Page 62: How To Replace The Fork Level Cylinder Hoses (Only For Gth-4016 Sr)

    Section 4 • Repair Procedures March 2010 BOOM COMPONENTS REV A 1-12 How to Replace the Fork Level Cylinder Hoses (only for GTH-4016 SR) WARNING Bodily injury hazard. This procedure requires specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant...

  • Page 63: Operator's Compartment

    March 2010 Section 4 • Repair Procedures Operator’s Compartment REV A 2-1 How to Remove the Operator’s Compartment 5. Disconnect the wire of the manual throttle: • Disconnect the wire of the manual accelerator. • Remove the screws fixing the throttle The operator’s compartment is used to activate bracket.

  • Page 64: How To Remove The Steering Column

    Section 4 • Repair Procedures March 2010 OPERATOR’S COMPARTMENT REV A 2-3 How to Test the Steering 2-2 How to Remove the Steering Column Column 1. Remove the lower part of the dashboard 2. Tag the hoses. 1. Completly raise the boom. 3.

  • Page 65: How To Remove The Steering Selector

    March 2010 Section 4 • Repair Procedures OPERATOR’S COMPARTMENT REV A 2-4 How to Remove the Steering 2-5 How to Remove the Joystick Selector 1. Locate and open the battery access door. 1. Locate and open the battery access door. 2.

  • Page 66: 2-6 How To Test The Brake Pedal

    Section 4 • Repair Procedures March 2010 OPERATOR’S COMPARTMENT REV A 2-6 How to Test the Brake Pedal 2-7 How to Remove the Brake Pedal 1. Disconnect the hose which goes to the accumulator. 1. Set the ignition switch in position 1 2.

  • Page 67: Fuel And Hydraulic Tanks

    March 2010 Section 4 • Repair Procedures Fuel and Hydraulic Tanks REV A 3-1 How to Remove the Fuel Tank and the Hydraulic Tank. WARNING Bodily injury hazard. This procedure requires specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant...

  • Page 68: Transmission

    Section 4 • Repair Procedures March 2010 Transmission REV A 4-1 How to Remove the WARNING Transmission Pump Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic WARNING Bodily injury hazard. This connections very slowly to allow procedure requires specific repair the oil pressure to dissipate skills, lifting equipment and a...

  • Page 69: How To Test And Adjust The Function Pump

    March 2010 Section 4 • Repair Procedures Hydraulic Pumps REV A 5-1 How to Test and Adjust the 5-2 How to Remove the Boom Function Pump Gear Function Pump NOTICE When removing a hose assembly or fitting, the O-ring on the fitting 1.

  • Page 70: How To Test The Boom Function Gear Pump

    Section 4 • Repair Procedures March 2010 HYDRAULIC PUMPS REV A 5-3 How to Test the Boom 5-4 How to Remove the Auxiliary Function Gear Pump Gear Pump 1. Insert the 600 bar manometer in the TP1 port 1. Closed the valve of the main hydraulic line. It is above the main valve behind the cabin steps.

  • Page 71: How To Test The Auxiliary Gear Pump

    March 2010 Section 4 • Repair Procedures HYDRAULIC PUMPS REV A 5-5 How to Test the Auxiliary Gear Pump 1. Insert the 0-60psi manometer in the TP4 port 2. Start the engine. 3. Increase the engine up to 2000rpm 4. Close the valve placed near to the relief valve. 5.

  • Page 72: Main Valve

    Section 4 • Repair Procedures March 2010 Main Valve REV A 6-1 How to Remove the Main 6-2 How to Test the Main Valve Valve 1. Closed the valve of the main hydraulic line. It 1. Insert the 600 bar manometer in the TP1 port, is behind the stair for the cabin.

  • Page 73: How To Remove The Outriggers Valves Block

    March 2010 Section 4 • Repair Procedures Outriggers REV A 7-1 How to Remove the 7-2 How to Test the Pressure on Outriggers Valves Block the Outriggers Valves Block 1. Tag all the hoses connected to the outriggers valves block placed in the front part of the 1.

  • Page 74: How To Test The Outriggers Retracion Valve (Only For Gth-4018 Sr)

    Section 4 • Repair Procedures March 2010 OUTRIGGERS REV A 7-3 How to Test the Outriggers Retracion Valve (only for GTH-4018 SR) 1. Insert a 600 bar pressure gauge in the TP5 port placed into the engine compartment. 2. Start the engine and completly retract (or extend) the outriggers.

  • Page 75: How To Remove The Boom Lenght And Angle Sensor

    March 2010 Section 4 • Repair Procedures Sensors REV A 8-1 How to Remove the Boom 8-2 How to Test the Boom Lenght Lenght and Angle Sensor and Angle Sensor 1. Disconnect the connector 2. Remove the retainer on the cable keeping a lot 1.

  • Page 76: How To Remove The Trasducer Pressure Switches

    Section 4 • Repair Procedures March 2010 SENSORS REV A 8-3 How to Remove the Trasducer 8-4 How to Test the Trasducer Pressure Switches Pressure Switches 1. Lift the boom up to 50°. 1. See paragraph “Overload Warning System Fault Codes”, point 11 and 12. 2.

  • Page 77: How To Test The Turret Proximity Switches

    March 2010 Section 4 • Repair Procedures SENSORS REV A 8-5 How to Test the Turret 8-6 How to Test the Chassis Proximity Switches Proximity Switches 1. Align the turret to the chassis. 1. Remove the outriggers steel guards. 2. Insert the turret locking pin. 2.

  • Page 78: How To Remove The Outriggers Load Pins

    Section 4 • Repair Procedures March 2010 SENSORS REV A 8-7 How to Remove the Outriggers Load Pins 1. Lower the outriggers. 2. Remove the connectors. 3. Remove the screws. 4. Using a teflon punch and a hammer, pull out the load cell pin.

  • Page 79: How To Test The Emergency Pump

    March 2010 Section 4 • Repair Procedures Miscellaneous REV A 9-1 How to Test the Emergency 9-2 How to Test the Differential Pump Lock Pressure Reducing Valve 1. Set the ignition switch in position 1. 1. In the valve placed on the front right side of 2.

  • Page 80: How To Check The Engine Rpm

    Section 4 • Repair Procedures March 2010 MISCELLANEOUS REV A 9-3 How to Check the Engine 1. Take a multimeter and set it on “freq or Hrz” 2. Connect the negative prod to the ground 3. Connect the positive prod to the “W” pin of the alternator 4.

  • Page 81: Rev Settings A Introduction

    March 2010 Section 5 • Settings Settings Observe and Obey: Before Repairs Start:  Repair procedures shall be completed by a  Read, understand and obey the safety rules person trained and qualified on the repair of and operating instructions in the appropriate this machine.

  • Page 82: How To Read The Overload Warning System Display

    Section 5 • Settings March 2010 SETTINGS REV A How to Read the Overload Warning System Display 10. Press button ARROW UP 11. Page 4 - “TILT SENSOR” 1. Start the engine • it represents (in bit) the electronic levelling sensor and it ranges between ±...
  • Page 83 March 2010 Section 5 • Settings SETTINGS REV A 20. Press button ARROW UP 26. Press button ARROW UP 21. Page 9 - “RIGHT JOYSTICK” 27. Page 10 - “MAIN VALVE DRIVER” it indicates the right joystick movement values indicates the INPUT values to the control unit from •...

  • Page 84: How To Set The Overload Warning System

    Section 5 • Settings March 2010 SETTINGS REV A How to Set the Overload Warning System 22. ENTER 23. By using PLUS (+) and MINUS (-) 1. Start the engine. pushbuttons, select “MIN” 2. Stabilize the machine on a level ground. 24.
  • Page 85 March 2010 Section 5 • Settings SETTINGS REV A 45. By using PLUS (+) and MINUS (-) 65. ENTER pushbuttons, select “ZERO” 66. By using ARROW UP or ARROW DOWN 46. ENTER pushbuttons, select the attachment that have to be modified 47.

  • Page 86: How To Set The Machine Functions

    Section 5 • Settings March 2010 SETTINGS REV A How to Set the Machine Functions PARAMETERS - SETTING By means of each one of parameter setting menu 1. Open the dashboard and find the connector is possible to: X941 behind the fuses board. •...
  • Page 87 March 2010 Section 5 • Settings SETTINGS REV A Once clicked on Parameters - Setting- Functions, following window will be displayed: READ DATA is enabled only if COM port has been selected WRITE DATA is enabled only if COM port has been selected AND a FILE OPEN or a READ DATA are executed...
  • Page 88 Section 5 • Settings March 2010 SETTINGS REV A After opening a file or reading from display unit, all function parameters available for the place where functions are operated will be displayed GTH-4016SR • GTH-4018SR Part No. 57.4400.9203...
  • Page 89 March 2010 Section 5 • Settings SETTINGS REV A Now it is possible to change parameters by clicking on arrow in the box of the parameter, arrow up to increase the value and arrow down to decrease it. When the system detect that parameter is different form the initial value the box will become orange.
  • Page 90 Section 5 • Settings March 2010 SETTINGS REV A Once clicked on Parameters - Setting- Slowing, following window will be displayed: READ DATA is enabled only if COM port has been selected WRITE DATA is enabled only if COM port has been selected AND a FILE OPEN or a READ DATA are executed...
  • Page 91 March 2010 Section 5 • Settings SETTINGS REV A After opening a file or reading from display unit, all slowing parameters will be displayed Part No. 57.4400.9203 GTH-4016SR • GTH-4018SR...
  • Page 92 Section 5 • Settings March 2010 REV A Intentionally blank page GTH-4016SR • GTH-4018SR Part No. 57.4400.9203...

  • Page 93: Rev Troubleshooting A Introduction

    March 2010 Section 6 • Troubleshooting Troubleshooting DANGER Crushing hazard. When testing or replacing any hydraulic component, always support the structure and secure it from movement Observe and Obey: WARNING Electrocution hazard. Contact  Troubleshooting and repair procedures shall be with electrically charged circuits completed by a person trained and qualified on could result in death or serious...

  • Page 94: Overload Warning System Fault Codes

    Section 6 • Troubleshooting March 2010 TROUBLESHOOTING REV A Overload Warning System Fault Codes 8. ERR ANG SENS 1 VBAT / ERR ANG SENS 2 VBAT 1. CAN ERROR Angle sensor 1 or 2 signal is larger than maximum display unit does not receive correct CAN messages possible (4.5V or 920 BIT) then telehandler can or does not receive at all CAN messages from Control not work.
  • Page 95 March 2010 Section 6 • Troubleshooting TROUBLESHOOTING REV A 14. ONLY PLATFORMS Platform/Road/Jobsite switch is on Platform position but an implement is selected therefore telehandler can not work 15. ERR MODE SELECTOR Both jobsite signal and platform signal are at +12Vdc, it is not a possible configuration then telehandler can not work.

  • Page 96: How To Troubleshoot The Boom Movements

    Section 6 • Troubleshooting March 2010 TROUBLESHOOTING REV A How to Troubleshoot the Boom Movements If there are 12V, move the joystick and simultaneously make the same 1. Check if the display is in alarm. movements using the main valve manual controls: if the boom works, 2.

  • Page 97: How To Troubleshoot The Transmission

    March 2010 Section 6 • Troubleshooting TROUBLESHOOTING REV A How to Troubleshoot the Transmission If all listed above is confirmed, check pin 48 (L-rear) and pin 49 (L-front) of the connector X935 (main unit, behind MOTION SENSOR the seat), and pin 50 (R-rear) and pin 51 RAISED STAB (R-front) of the connector X934;...

  • Page 98: How To Troubleshoot The Mechanical Gear

    Section 6 • Troubleshooting March 2010 TROUBLESHOOTING REV A How to Troubleshoot the Jobsite How to Troubleshoot the Position Mechanical Gear 1. Check if the Jobsite/Road/Platform selector is 1. Check if the gear selector is in neutral position. in Jobsite position. 2.

  • Page 99: How To Troubleshoot The Outriggers Movements

    March 2010 Section 6 • Troubleshooting TROUBLESHOOTING REV A How to Troubleshoot the Outriggers Movements 1. Verify the boom is under 20° and that the machine is not in alarm. 2. Verify the Jobsite/Road/Platform selector is in Jobsite position. 3. Check fuse F13-10A integrity. STABILIZERS PUSHBUTT EXTENSION RETRACT...

  • Page 100: How To Troubleshoot The Working Mode Selecting

    Section 6 • Troubleshooting March 2010 TROUBLESHOOTING REV A How to Troubleshoot the Working Mode Selecting • If the value of one of the load cell, STAB DOWN, is 0, verify, using the screen page STABILIZER SENSOR, the value of the cell: 1.

  • Page 101: Rev Schematics A Introduction

    March 2010 Section 7 • Schematics Schematics REV A About This Section There are two groups of schematics in this section. An illustration legend precedes each group of drawings. Electrical Schematics WARNING Observe and Obey: Electrocution hazard. Contact with electrically charged circuits could ...

  • Page 102: Electrical Component Legend

    Section 7 • Schematics March 2010 Electrical Component Legend REV A 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...
  • Page 103 March 2010 Section 7 • Schematics ELECTRICAL COMPONENT LEGEND REV A 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...

  • Page 104: Hydraulic Component Legend

    Section 7 • Schematics March 2010 Hydraulic Component Legend REV A 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 105 March 2010 Section 7 • Schematics HYDRAULIC COMPONENT LEGEND REV A 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...

  • Page 106: Electrical Schematic

    Section 7 • Schematics March 2010 Electrical Schematic - GTH-4016SR and GTH-4018SR REV A Page 1 of 16 GTH-4016SR • GTH-4018SR Part No. 57.4400.9203...
  • Page 107 March 2010 Section 7 • Schematics Electrical Schematic - GTH-4016SR and GTH-4018SR REV A Page 2 of 16 Part No. 57.4400.9203 GTH-4016SR • GTH-4018SR...
  • Page 108 Section 7 • Schematics March 2010 Electrical Schematic - GTH-4016SR and GTH-4018SR REV A Page 3 of 16 GTH-4016SR • GTH-4018SR Part No. 57.4400.9203...
  • Page 109 March 2010 Section 7 • Schematics Electrical Schematic - GTH-4016SR and GTH-4018SR REV A Page 4 of 16 Part No. 57.4400.9203 GTH-4016SR • GTH-4018SR...
  • Page 110 Section 7 • Schematics March 2010 Electrical Schematic - GTH-4016SR and GTH-4018SR REV A Page 5 of 16 GTH-4016SR • GTH-4018SR Part No. 57.4400.9203...
  • Page 111 March 2010 Section 7 • Schematics Electrical Schematic - GTH-4016SR and GTH-4018SR REV A Page 6 of 16 Part No. 57.4400.9203 GTH-4016SR • GTH-4018SR...
  • Page 112 Section 7 • Schematics March 2010 Electrical Schematic - GTH-4016SR and GTH-4018SR REV A Page 7 of 16 GTH-4016SR • GTH-4018SR Part No. 57.4400.9203...
  • Page 113 March 2010 Section 7 • Schematics Electrical Schematic - GTH-4016SR and GTH-4018SR REV A Page 8 of 16 Part No. 57.4400.9203 GTH-4016SR • GTH-4018SR...
  • Page 114 Section 7 • Schematics March 2010 Electrical Schematic - GTH-4016SR and GTH-4018SR REV A Page 9 of 16 GTH-4016SR • GTH-4018SR Part No. 57.4400.9203...
  • Page 115 March 2010 Section 7 • Schematics Electrical Schematic - GTH-4016SR and GTH-4018SR REV A Page 10 of 16 Part No. 57.4400.9203 GTH-4016SR • GTH-4018SR...
  • Page 116 Section 7 • Schematics March 2010 Electrical Schematic - GTH-4016SR and GTH-4018SR REV A Page 11 of 16 GTH-4016SR • GTH-4018SR Part No. 57.4400.9203...
  • Page 117 March 2010 Section 7 • Schematics Electrical Schematic - GTH-4016SR and GTH-4018SR REV A Page 12 of 16 Part No. 57.4400.9203 GTH-4016SR • GTH-4018SR...
  • Page 118 Section 7 • Schematics March 2010 Electrical Schematic - GTH-4016SR and GTH-4018SR REV A Page 13 of 16 GTH-4016SR • GTH-4018SR Part No. 57.4400.9203...
  • Page 119 March 2010 Section 7 • Schematics Electrical Schematic - GTH-4016SR and GTH-4018SR REV A Page 14 of 16 Part No. 57.4400.9203 GTH-4016SR • GTH-4018SR...
  • Page 120 Section 7 • Schematics March 2010 Electrical Schematic - GTH-4016SR and GTH-4018SR REV A Page 15 of 16 GTH-4016SR • GTH-4018SR Part No. 57.4400.9203...
  • Page 121 March 2010 Section 7 • Schematics Electrical Schematic - GTH-4016SR and GTH-4018SR REV A Page 16 of 16 Part No. 57.4400.9203 GTH-4016SR • GTH-4018SR...

  • Page 122: Hydraulic Schematic (Gth-4016 Sr)

    Section 7 • Schematics March 2010 Hydraulic Schematic - GTH-4016 SR REV A Hydraulically piloted Third section boom Double overcenter safety valve Sing le overcenter safety valve Quick coupling telescoping cylinder double check valve piloting ratio: 4/1 piloting ratio: HYDRAULIC CIRCUIT hydraulic ports cracking pressure: 350 bar piloting ratio: 4 1 /...

  • Page 123: Hydraulic Schematic (Gth-4018 Sr)

    March 2010 Section 7 • Schematics Hydraulic Schematic - GTH-4018 SR REV A Hydraulically piloted Double overcenter safety valve Forks attachment Quick coupling double check valve piloting ratio: 4/1 quick coupling cylinder HYDRAULIC CIRCUIT hydraulic ports piloting ratio: 4 1 / cracking pressure: 350 bar (optional) COLORS LEGENDA...

This manual is also suitable for:

Genie gth-4018 sr

Table of Contents