PDF Service Manual Genie GTH-4016R, GTH-4018R & GTH-5021R - 2 MB
This is the factory service manual for the Genie GTH-4016R, GTH-4018R, and GTH-5021R telehandlers.
It provides comprehensive technical information required for maintenance, troubleshooting, and major repairs.
Technicians will find detailed procedures for hydraulics, engine service, electrical systems, and structural components.
This manual is essential for any workshop that services these powerful Genie telehandlers.
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1.
Service Manual
Serial number range
GTH-4016 R From serial n.: GTH4016R15M-101
Stage 3A
Stage 3B
GTH-4018 R From serial n.: GTH4018R15M-101
Stage 3A
Stage 3B
GTH-5021 R From serial n.: GTH5021R14B-101
Stage 3A
Stage 3B
Part No. 57.4400.9209
Rev A
January 2016
--- Page 3 ---
January 2016
TABLE OF CONTENTS
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
Part No. 57.4400.9209 GTH-4016 R - 4018 R - 5021 R xi
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January 2016 Section 2 • Specifications
SPECIFICATIONS
Perkins 854E-E34TA Engine Fuel requirements
For fuel requirements, refer to the engine Operation
Displacement 207 cu in Manual on your machine.
3.4 liters Fuel injection pressure 23000 psi
Number of cylinders 4 1585 bar
Bore and stroke 3.9 x 4.3 inches Engine coolant
99 x 110 mm Capacity 4.9 gallons
Horsepower 100.5 @ 2200 rpm 18.5 liters
83 kW @ 2200 rpm Type Extended Life
Peak Torque 303 lb-ft @ 1400 rpm Alternator
411 Nm @ 1400 rpm
Output 120 A, 12V DC
Firing order 1-3-4-2
Starter Motor
Compression ratio 17:1
Normal load 68 A
Governor Electronic
Relay max 50 A
Low idle 1000 rpm
Relay continuous 20 A
Frequency 100 Hz
Cranking speed 130 - 200 rpm
High idle 2700 rpm
Frequency 270 Hz Glow Plugs
Lubrication system Initial load (0-10 sec) 80 amps
Minimum oil pressure 12 psi Continuous load (>10 sec) 40 amps
0.83 bar Battery
Maximum oil capacity 8.8 quarts Type 12V DC
(including filter) 8.3 liters
Group C31
Oil viscosity requirements
Quantity 1
Units ship with 15W-40 API CJ4 low ash oil.
Cold cranking ampere @ 0°F 1000A
Extreme operating temperatures may require the use
of alternative engine oils. For oil requirements, refer Reserve capacity @ 25A rate 200 minutes
to the Engine Operation and Maintenance Manual on
your machine.
Continuous improvement of our products
is a Genie policy. Product specifications are
subject to change without notice.
Part No. 57.4400.9209 GTH-4016 R - 4018 R - 5021 R 2-7
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January 2016 Section 3 • Scheduled Maintenance Procedures
Checklist A Procedures
A-1 Result: The operator's manual is not
appropriate for the machine or all manuals are
Inspect the Manuals and not in good condition or is illegible. Remove
Decals the machine from service until the manual is
replaced.
Genie specifications require that this procedure
be performed every 8 hours or daily, whichever 3 Open the operator's manual to the decals
comes first. inspection section. Carefully and thoroughly
inspect all decals on the machine for legibility
Maintaining the operator’s and safety manuals and damage.
in good condition is essential to safe machine
operation. Manuals are included with each Result: The machine is equipped with all
machine and should be stored in the container required decals, and all decals are legible and
provided in the operator's compartment. An in good condition.
illegible or missing manual will not provide safety
and operational information necessary for a safe Result: The machine is not equipped with all
operating condition. required decals, or one or more decals are
illegible or in poor condition. Remove the
In addition, maintaining all of the safety and machine from service until the decals are
instructional decals in good condition is mandatory replaced.
for safe machine operation. Decals alert operators
and personnel to the many possible hazards 4 Always return the manuals to the storage
associated with using this machine. They also container after use.
provide users with operation and maintenance
information. An illegible decal will fail to alert Note: Contact your authorized Genie distributor or
personnel of a procedure or hazard and could Genie Industries if replacement manuals or decals
result in unsafe operating conditions. are needed.
1 Check to make sure that the operator's and
safety manuals are present and complete
in the storage container in the operator's
compartment.
2 Examine the pages of each manual to be sure
that they are legible and in good condition.
Result: The operator's manual is appropriate
for the machine and all manuals are legible and
in good condition.
Part No. 57.4400.9209 GTH-4016 R - 4018 R - 5021 R 3-5
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January 2016 Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-4
Check the Exhaust System
Genie requires that this procedure be performed
every 250 hours or quarterly, whichever comes
first.
Maintaining the exhaust system is essential
to good engine performance and service life.
Running the engine with a damaged or leaking
exhaust system can cause component damage
and unsafe operating conditions.
WARNING Bodily injury hazard. Do not
inspect while the engine is
running. Remove the key to
secure from operation.
CAUTION Bodily injury hazard. Beware of
hot engine components. Contact
with hot engine components may
cause severe burns.
1 Open the engine access cover.
2 Be sure that all fasteners are tight.
3 Inspect all welds for cracks.
4 Inspect for exhaust leaks; i.e., carbon buildup
around seams and joints.
5 Close the engine access cover.
Part No. 57.4400.9209 GTH-4016 R - 4018 R - 5021 R 3-15
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January 2016 Section 3 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES
9 Inspect the filter assembly to be sure that there D-4
are no leaks.
Change Gearbox Oil
10 Clean up any oil that may have spilled during
the installation procedure.
Note: Transmission specifications require that this
procedure be performed every 1500 hours.
1 Place a container of suitable size under drain
plug (A).
2 Remove plug (B).
3 Remove drain plug (A) and empty the gearbox.
4 Refit and tighten drain plug (A).
5 Pour in new oil through filler (B) placed at the
top of the reduction gear of the power divider.
Stop when oil is level with hole (B).
6 Refit and tighten plug (B).
B
A
Part No. 57.4400.9209 GTH-4016 R - 4018 R - 5021 R 3-25
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January 2016 Section 4 • Repair Procedures
BOOM COMPONENTS
1-2 How to Remove the Lifting
Boom Fork Frame
1 With the boom in the stowed position, attach a
How to Replace the lifting strap from an overhead crane to the top
Boom Wear Pads of the lifting fork frame at the front of the boom.
Support the frame. Do not apply any lifting
1 Extend the boom until the wear pads are pressure.
accessible.
2 If the machine is equipped with the lifting fork
2 Lower wear pads: Using a lifting strap from frame locking cylinder, disconnect the locking
an overhead crane or a fork lift of sufficient cylinder hoses from the boom.
capacity, lift the boom tube just enough to WARNING Bodily injury hazard. Spraying
remove the weight from the pads. hydraulic oil can penetrate and
burn skin. Loosen hydraulic
3 Remove the wear pad retainer plates and connections very slowly to allow
remove the wear pads from the boom. the oil pressure to dissipate
gradually. Do not allow oil to
4 Lubricate the wear surface of the new pads. squirt or spray.
Refer to Maintenance Procedure A-4, Lubricate
the Boom. 3 Remove the screw securing the fork level
cylinder pivot pin to the lifting fork.
Note: Do not lubricate the side wear pads.
4 Use a soft metal drift to remove the pivot pin.
5 Install the wear pads. Install and securely
tighten the retainer plates. Do not over tighten. 5 Remove the screw securing the fork frame
pivot pin to the boom.
6 Use a soft metal drift to remove the pivot pin.
7 Using the overhead crane, lift and remove the
fork frame from the boom.
CAUTION Crushing hazard. The fork
frame could fall if not properly
supported when the lock pin is
removed from the machine.
Part No. 57.4400.9209 GTH-4016 R - 4018 R - 5021 R 4-3
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January 2016 Section 4 • Repair Procedures
BOOM COMPONENTS
How to Disassemble and 8 Cut and remove the cable ties securing the
electrical harness near connectors “b”.
Reassemble the Boom 9 Pull the cord to remove the harness
Electrical Harness - GTH- subassembly “a” from the hole of cover “h”
previously removed.
4018R/GTH-5021R
10 Disconnect the cord from the harness
Note: Electrical harnesses pass inside the boom subassembly “a” and attach it to one end of the
and are divided into 3 subassemblies; moreover new harness subassembly.
there are two connection points inside the boom.
Note: For this procedure, two operators are
Harness subassembly "a" removal needed: one standing near connectors “c” and the
1 Raise the boom to a horizontal position and other near cover “h”.
fully extend it.
11 Pull the cord towards the fork end of the boom
2 At the fork end of the boom, disconnect until the replacement harness subassembly
connectors "c". comes out of the hole near connectors “c”.
3 Disconnect the harness connectors “c” from the 12 Refit all wire terminals and connect the wires to
wires of the harness subassembly "a" and then connectors “b”.
remove all wire terminals.
13 Reconnect the new harness subassembly “a”
4 Replace the harness connectors with a cord of to subassembly “g”.
at least 395 inches / 10000 mm.
14 Secure the new harness subassembly with new
5 Remove cover “h”. cable ties.
6 Disconnect connectors “b” that connect the 15 Install cover “h” back in place on the boom.
harness subassembly “a” to subassembly “g”.
16 Refit all wire terminals and connect the wires to
7 Remove all connectors “b” and wire terminals connectors “c”.
from the harness subassembly “a”.
a b f
c a
h g d g
e f i
Part No. 57.4400.9209 GTH-4016 R - 4018 R - 5021 R 4-13
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January 2016 Section 4 • Repair Procedures
Operator's Compartment
2-1 4 Cut and remove any cable ties securing the
electrical harnesses. Disconnect the harness
Operator's Compartment connectors.
5 Disconnect the hydraulic hoses of the power
How to Remove the Operator's steering unit and of the heater.
Compartment WARNING Bodily injury hazard. Spraying
hydraulic oil can penetrate and
The operator's compartment is used to activate burn skin. Loosen hydraulic
machine functions while sitting in the operator's connections very slowly to allow
drivers seat. the oil pressure to dissipate
gradually. Do not allow oil to
Within the operator's compartment there is a squirt or spray.
transmission column shifter, steering selector,
4-way controller, accelerator pedal, brake 6 Disconnect the electrical and hydraulic
pedal and a differential lock switch. All of these connections from the brake pump.
components are replaceable.
WARNING Bodily injury hazard. Spraying
hydraulic oil can penetrate and
For further information or assistance, consult the burn skin. Loosen hydraulic
Genie Service Department. connections very slowly to allow
WARNING Bodily injury hazard. This the oil pressure to dissipate
procedure requires specific gradually. Do not allow oil to
repair skills, lifting equipment squirt or spray.
and a suitable workshop.
Attempting this procedure
7 Disconnect the wire from the throttle pedal:
without these skills and tools
- remove the locking clip;
could result in death or serious
- remove the fasteners securing the throttle rope.
injury and significant component
damage. Dealer service is
8 Disconnect the wire from the manual throttle:
required.
- disconnect the wire of the manual accelerator;
- remove the fasteners securing the throttle
1 Open the engine cover.
bracket.
2 Disconnect the battery from the machine.
9 Disconnect the power cables from the horn.
WARNING Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.
3 Open the access door above the hydraulic
tank.
Part No. 57.4400.9209 GTH-4016 R - 4018 R - 5021 R 4-23
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January 2016 Section 4 • Repair Procedures
Transmission
5-1 5-2
Gearbox Axle
How to Repair the Gearbox How to Remove the Axle
Repair procedures and additional transmission
information is available in the Carraro TB172/2
WARNING Bodily injury hazard. This
procedure requires specific
speed Transmission Repair Manual repair skills, lifting equipment
(Carraro part number CA270305). and a suitable workshop.
Attempting this procedure
Carraro TB172/2 speed Transmission Repair without these skills and tools
Manual could result in death or serious
Genie part number 57.4700.0010 injury and significant component
damage. Dealer service is
required.
1 Chock the wheels.
2 Remove the fasteners securing the driveshaft
to the transmission. Lower the end of the
driveshaft to the ground.
3 Remove the fasteners securing the driveshaft
to the axle. Remove the driveshaft from the
machine.
4 Tag and remove the hydraulic hoses from the
axle.
WARNING Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
5 Loosen the lug nuts of both wheels on the axle
to be removed. Do not remove the lug nuts.
Part No. 57.4400.9209 GTH-4016 R - 4018 R - 5021 R 4-33
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January 2016 Section 4 • Repair Procedures
HYDRAULIC PUMPS
How to Install the Hydrostatic 8 Connect the hoses to the pump.
Transmission Pump WARNING Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
WARNING Bodily injury hazard. This the oil pressure to dissipate
procedure requires specific
repair skills, lifting equipment gradually. Do not allow oil to
and a suitable workshop. squirt or spray.
Attempting this procedure
without these skills and tools 10 Connect the harness to the transmission pump.
could result in death or serious
injury and significant component 11 Install the auxiliary gear pump on the
damage. Dealer service is hydrostatic transmission pump.
strongly recommended.
12 Install the retaining fasteners securing the
Note: When removing a hose assembly or fitting, battery disconnect switch mounting plate.
the fitting and/or hose end must be torqued to
specification during installation. Refer to Section 2, 13 Start the engine and prime the pump. See 6-3,
Hydraulic Hose and Fitting Torque Specifications. How to Prime the Hydrostatic Transmission
Pump.
Note: Perform this procedure with the engine off
and cool to the touch. 14 Inspect for leaks.
1 Open the engine compartment. 15 Adjust the pump pressure. See 6-3, How to test
the Hydrostatic Transmission Pump.
2 Remove the front cover of the engine housing.
3 Remove the cover that is under engine.
4 Attach a lifting strap and lift the transmission
pump using a overhead crane.
5 Install the hydrostatic transmission pump on the
engine.
6 Remove the fitting caps from the hydrostatic
transmission pump.
7 Remove the hoses caps.
Part No. 57.4400.9209 GTH-4016 R - 4018 R - 5021 R 4-43
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January 2016 Section 4 • Repair Procedures
OUTRIGGERS
How to Remove an Outrigger
Foot Raise/Retract Cylinder -
GTH-4018R/GTH-5021R
Note: When removing a hose assembly or fitting,
the fitting and/or hose end must be torqued to
specification during installation. Refer to Section 2,
Hydraulic Hose and Fitting Torque Specifications.
1 Tag, disconnect and plug the two hydraulic
supply hoses at the foot cylinder. Cap the
fittings.
WARNING Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
NOTICE Component damage hazard.
Hoses can be damaged if they
are kinked or pinched.
2 Attach a lifting strap from an overhead crane to
the barrel end of the foot cylinder. Support the
cylinder. Do not apply any lifting pressure.
3 Remove the fasteners securing the outrigger
foot barrel-end to the machine.
4 Remove the cylinder from the machine.
WARNING Crushing hazard. The cylinder
will fall if not properly supported
when the fasteners are removed
from the machine.
Part No. 57.4400.9209 GTH-4016 R - 4018 R - 5021 R 4-53
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January 2016 Section 5 Settings
SETTINGS
34 Press the ARROW UP key or the ARROW 51 CLOCK.
DOWN key to highlight “ANGLE”.
52 Press ENTER to confirm.
35 Press ENTER to confirm.
53 Press the PLUS (+) or MINUS (-) key to select
36 Raise the boom to a horizontal position. Using “MODIF”.
a digital level, adjust the boom to 0°.
54 Press ENTER to confirm.
37 Press the PLUS (+) or MINUS (-) key to select
“ZERO”. 55 Blinking cursor passes to year field: enter the
correct year using the PLUS (+) or MINUS (-)
38 Press ENTER to confirm. key.
39 Press the PLUS (+) or MINUS (-) key to select 56 Press ENTER to confirm.
“SAVE”.
57 Blinking cursor passes to month field: enter the
40 Press ENTER to confirm. correct month using the PLUS (+) or MINUS (-)
key.
41 Press the PLUS (+) or MINUS (-) key to select
“EXIT”. 58 Press ENTER to confirm.
42 Press ENTER to confirm. 59 Blinking cursor passes to to day field: enter the
correct day using the PLUS (+) or MINUS (-)
43 TILT SENSOR (if equipped). key.
44 Press ENTER to confirm. 60 Press the PLUS (+) or MINUS (-) key to select
“SAVE”.
45 Press the PLUS (+) or MINUS (-) key to select
“ZERO”. 61 Press ENTER to confirm.
46 Press ENTER to confirm. 62 Press the PLUS (+) or MINUS (-) key to select
“EXIT”.
47 Press the PLUS (+) or MINUS (-) key to select
“SAVE”. 63 Press ENTER to confirm.
48 Press ENTER to confirm. 64 Press the ARROW UP key or the ARROW
DOWN key to highlight “ENABLING
49 Press the PLUS (+) or MINUS (-) key to select IMPLEMENTS”.
“EXIT”.
65 Press ENTER to confirm.
50 Verify the Machine Levelled Warning Light is
on.
Part No. 57.4400.9209 GTH-4016 R - 4018 R - 5021 R 5-5
--- Page 16 ---
January 2016 Section 6 Fault Codes
FAULT CODES
How to Troubleshoot the
Perkins 854E-E34TA Engine
Troubleshooting procedures and additional engine
information is available in the
Perkins 854E Troubleshooting Manual
(Perkins part number UENR0612-06).
Perkins 854E Troubleshooting Manual
Genie part number 57.4700.0016
Part No. 57.4400.9209 GTH-4016 R - 4018 R - 5021 R 6-9
--- Page 17 ---
January 2016 Section 7 • Schematics
Electrical Schematic
GTH-4016R/GTH-4018R Stage IIIB EN280 (from GTH4016R15M-105 & from GTH4018R15M-105) Sheet 1 of 20