Genie GTH-4016 SR GTH-4018 SR Service Manual 57.4400.9203 – PDF DOWNLOAD
Language : English
Pages : 124
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie GTH-4016 SR GTH-4018 SR Service Manual 57.4400.9203 – PDF DOWNLOAD
Introduction
Important Information ii
Machine Identification iii
Section 1 Safety Rules
Personal Safety Rules v
Section 2 Rev Specifi cations
A Operation Description 1
Performance Specifications 8
Hydraulic Specifications 9
Perkins 1104C-44T Engine 10
Carraro 2632M FR Drive Axle 10
Hydraulic Hose and Fitting Torque Specifications 11
Metric Fasteners Torque Charts 12
Section 3 Rev Scheduled Maintenance Procedures
A Introduction 13
Pre-delivery Preparation Report 15
Maintenance Inspection Report 17
A Checklist A Procedures
A-1 Inspect the Manuals and Decals 18
A-2 Perform Pre-operation Inspection 19
A-3 Perform Function Test 19
A-4 Machine Greasing 20
A-5 Epicyclic Reduction Gears Oil Level 21
A-6 Axles Oil Level 21
A-7 Tyre Inflation 22
A-8 Engine Oil Level 22
A-9 Engine Cooling System 23
A-10 Lighting System 23
A-11 Clean Engine Air Filter 24
A-12 Safety Devices 24
Section 3 Rev Scheduled Maintenance Procedures, continued
A-13 Emergency Pump Operation, if present 25
A-14 Hydraulic Oil Level In The Tank 25
A Checklist B Procedures
B-1 Gear Box Oil Level 26
B-2 Turntable Reduction Gear Oil Level 26
B-3 Cylinder Rods 27
B-4 Inspect the Electrical Wiring 27
B-5 Boom Sliding Pads Adjusting 28
B-6 Battery Electrolyte Level 28
B-7 Block Valves 29
B-8 Tensioning The Boom Chains (Only for GTH-4018 SR) 29
A Checklist C Procedures
C-1 Smoke From the Exaust Muffler 30
C-2 Change Engine Oil and Filter 30
C-3 Change Engine Air Outer Filter 31
C-4 Change Hydraulic Oil Filter 31
C-5 Clean Cabin Air Filter 32
A Checklist D Procedures
D-1 Change Gear Box Oil 33
D-2 Change Oil in the Turntable Gear 33
D-3 Change Engine Air Inner Filter 34
D-4 Change Hydraulic Oil 34
D-5 Change Cabin Air Filter 35
D-6 Change Oil in the Axles 35
D-7 Change Oil in the Epicyclic Reduction Gears 36
A Checklist E Procedures
E-1 Change Engine Coolant 37
E-2 Machine Structure 37
Section 4 Rev Repair Procedures
Introduction 39
A 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 42
1-5 How to Assemble the GTH-4018 SR Boom 43
1-6 How to Disassemble the GTH-4016 SR Boom 45
1-7 How to Assemble the GTH-4016 SR Boom 46
1-8 How to Remove a Lift Cylinder 47
1-9 How to Remove the Second Boom Section Extension Cylinder 48
1-10 How to Remove the Third Boom Section Extension Cylinder (only for GTH-
4016 SR) 48
1-11 How to Remove the Fork Level Cylinder 49
1-12 How to Replace the Fork Level Cylinder Hoses (only for GTH-4016 SR) 50
A Operator’s Compartment
2-1 How to Remove the Operator’s Compartment 51
2-2 How to Remove the Steering Column 52
2-3 How to Test the Steering Column 52
2-4 How to Remove the Steering Selector 53
2-5 How to Remove the Joystick 53
2-6 How to Test the Brake Pedal 54
2-7 How to Remove the Brake Pedal 54
A Fuel and Hydraulic Tanks
3-1 How to Remove the Fuel Tank and the Hydraulic Tank 55
A Transmission
4-1 How to Remove the Transmission Pump 56
Section 4 Rev Repair Procedures, continued
A 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 58
5-5 How to Test the Auxiliary Gear Pump 59
A Main Valve
6-1 How to Remove the Main Valve 60
6-2 How to Test the Main Valve 60
A Outriggers
7-1 How to Remove the Outriggers Valves Block 61
7-2 How to Test the Pressure on the Outriggers Valves Block 61
7-3 How to Test the Outriggers Retracion Valve (only for GTH-4018 SR) 62
A Sensors
8-1 How to Remove the Boom Lenght and Angle Sensor 63
8-2 How to Test the Boom Lenght and Angle Sensor 63
8-3 How to Remove the Trasducer Pressure Switches 64
8-4 How to Test the Trasducer Pressure Switches 64
8-5 How to Test the Turret Proximity Switches 65
8-6 How to Test the Chassis Proximity Switches 65
8-7 How to Remove the Outriggers Load Pins 66
A Miscellaneaous
9-1 How to Test the Emergency Pump 67
9-2 How to Test the Differential Lock Pressure Reducing Valve 67
9-3 How to Check the Engine RPM 68
Section 5 Rev Settings
A Introduction 69
How to Read the Overload Warning System Display 70
How to Set the Overload Warning System 72
How to Set the Machine Functions 74
Section 6 Rev Troubleshooting
A 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 Rev Troubleshooting, continued
How to Troubleshoot the Jobsite Position 86
How to Troubleshoot the Outriggers Movements 87
How to Troubleshoot the Working Mode Selecting 88
Section 7 Rev Schematics
A Introduction 89
Electrical Component Legend 90
Hydraulic Component Legend 92
Electrical Schematic 94
Hydraulic Schematic (GTH-4016 SR) 110
Hydraulic Schematic (GTH-4018 SR) 111
S.S 04/24