Genie GTH-4016R GTH-4018R GTH-5021R Service Manual 57.4400.9209 – PDF

Description

Genie GTH-4016R GTH-4018R GTH-5021R Service Manual 57.4400.9209 – PDF DOWNLOAD

Language : English
Pages : 232
Downloadable : Yes
File Type : PDF

Table of Contents:

Genie GTH-4016R GTH-4018R GTH-5021R Service Manual 57.4400.9209 – PDF DOWNLOAD

Introduction
Important Information ii
Revision History iii
Serial Number Legend v
Section 1 Safety Rules
General Safety Rules vii
Section 2 Specifications
Machine Specifications 2 – 1
Performance Specifications 2 – 2
Hydraulic Specifications 2 – 3
Hydraulic Component Specifications 2 – 4
Function Manifold Specifications 2 – 5
Air Conditioner Refrigerant Specifications 2 – 5
Perkins 1104D-E44TA Engine 2 – 6
Perkins 854E-E34TA Engine 2 – 7
Carraro TB172/2 STOP&GO Gearbox 2 – 8
Carraro 26 32M Drive Axle 2 – 8
Hydraulic Hose and Fitting Torque Specifications 2 – 9
Torque Procedure 2 – 10
SAE and Metric Fasteners Torque Charts 2 – 11
Section 3 Scheduled Maintenance Procedures
Introduction 3 – 1
Pre-delivery Preparation Report 3 – 3
Maintenance Inspection Report 3 – 4
Section 3 Scheduled Maintenance Procedures, continued
Checklist A Procedures
A-1 Inspect the Manuals and Decals 3 – 5
A-2 Perform Pre-operation Inspection 3 – 6
A-3 Perform Function Tests 3 – 6
A-4 Lubricate the Boom 3 – 7
A-5 Perform Engine Maintenance – Perkins Models 3 – 8
A-6 Safety Devices 3 – 9
A-7 Perform 30 Day Service 3 – 9
A-8 Emergency Pump Operations (if equipped) 3 – 10
A-9 Perform Axle Maintenance 3 – 10
A-10 Perform Engine Maintenance – Perkins 854E Models 3 – 11
A-11 Perform Engine Maintenance – Perkins Models 3 – 11
A-12 Perform Axle Maintenance 3 – 12
Checklist B Procedures
B-1 Inspect the Electrical Wiring 3 – 13
B-2 Gearbox Oil Level 3 – 14
B-3 Slewing upper structure Reduction Gear Oil Level 3 – 14
B-4 Check the Exhaust System 3 – 15
B-5 Inspect the Engine Air Filter 3 – 16
B-6 Inspect the Tires, Wheels and Lug Nut Torque 3 – 17
B-7 Perform Hydraulic Oil Analysis 3 – 17
B-8 Check the Boom Wear Pads 3 – 18
B-9 Perform Axle Maintenance 3 – 19
Section 3 Scheduled Maintenance Procedures, continued
Checklist C Procedures
C-1 Perform Engine Maintenance – Perkins Models 3 – 20
C-2 Perform Engine Maintenance – Perkins Models 3 – 20
C-3 Inspect and Lubricate the Sequencing Chains –
GTH-4018R/GTH-5021R 3 – 21
Checklist D Procedures
D-1 Inspect the Forks 3 – 23
D-2 Tighten the Boom Chains 3 – 23
D-3 Replace the Hydraulic Tank Return Filter Element 3 – 24
D-4 Change Gearbox Oil 3 – 25
D-5 Change Slewing upper structure Reduction Gear Oil 3 – 26
D-6 Perform Engine Maintenance – Perkins Models 3 – 26
D-7 Perform Axle Maintenance 3 – 27
D-8 Perform Engine Maintenance – Perkins 854E Models 3 – 27
Checklist E Procedures
E-1 Test or Replace the Hydraulic Oil 3 – 28
E-2 Perform Engine Maintenance – Perkins Models 3 – 29
E-3 Perform Engine Maintenance – Perkins Models 3 – 29
E-4 Perform Engine Maintenance – Perkins Models 3 – 30
E-5 Perform Engine Maintenance – Perkins Models 3 – 30
E-6 Perform Engine Maintenance – Perkins 854E Models 3 – 31
E-7 Perform Engine Maintenance – Perkins Models 3 – 31
Section 4 Repair Procedures
Introduction 4 – 1
Boom Components
1-1 Boom Sensors 4 – 2
1-2 Boom 4 – 3
1-3 Boom Lift Cylinder 4 – 17
1-4 Boom Extend Cylinder 4 – 18
1-5 Fork Level Slave Cylinder 4 – 20
1-6 Fork Tilt Cylinder 4 – 22
Operator’s compartment
2-1 Operator’s Compartment 4 – 23
2-2 Machine Controls 4 – 25
Fuel and Hydraulic Tanks
3-1 Fuel tank 4 – 29
3-2 Hydraulic tank 4 – 30
Engines
4-1 Engines 4 – 31
4-2 Engine Fault Codes 4 – 32
Transmission
5-1 Gearbox 4 – 33
5-2 Axle 4 – 33
Hydraulic pumps
6-1 Boom Function Gear Pump 4 – 35
6-2 Auxiliary Gear Pump 4 – 38
6-3 Hydrostatic Transmission Pump 4 – 41
Manifolds
7-1 Function Manifold components – Models with Single Joystick 4 – 45
7-2 Valve coils 4 – 48
Section 5 Settings
Introduction 5 – 1
How to Read the Overload Warning System Display 5 – 2
How to Set the Overload Warning System Display 5 – 4
Section 6 Fault Codes
Introduction 6 – 1
Diagnostic Display 6 – 2
Engine Fault Codes – Models with Perkins 854E-E34TA Engine 6 – 3
Overload Warning System Fault Codes 6 – 10
Section 7 Schematics
Introduction 7 – 1
Electrical and Hydraulic Symbol Legends 7 – 2
Electrical Schematic 7 – 3
Hydraulic Schematic 7 – 82

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