Terex Genie GTH4016 SR User manual

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

ii GTH-4016SR • GTH-4018SR Part No. 57.4400.9203
March 2010
Introduction
Important
Read, understand and obey the safety rules and
operating instructions in the appropriate Operator's
Manual on your machine before attempting any
maintenance or repair procedure.
This manual provides detailed scheduled
maintenance information for the machine owner
and user. It also provides troubleshooting
and repair procedures for qualified service
professionals.
Basic mechanical, hydraulic and electrical
skills are required to perform most procedures.
However ,several procedures require specialized
skills, tools, lifting equipment and a suitable
workshop. In these instances, we strongly
recommend that maintenance and repair be
performed at an authorized Genie dealer
service center.
Technical Publications
Genie Industries has endeavored to deliver the
highest degree of accuracy possible. However,
continuous improvement of our products is a
Genie policy. Therefore, product specifications are
subject to change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.
©Copyright 2010 TEREXLIFT srl - All rights reserved
Produced by:
TEREXLIFT Technical Literature Dept.
Umbertide (PG) Italy
57.4400.9203 Rev A March 2010
First Edition, First Printing
For the electronic version of this manual visit
http://www.genielift.com/parts_service_manuals.asp
Introduction
Contact us:
Genie Service Dept:
Area Phone
UK [phone]
France [phone]
Germany [phone]
Italy [phone]
Iberica [phone]
Scandinavia [phone]
Middle East [phone]
[phone]
All other
locations [phone]

Part No. 57.4400.9203 GTH-4016SR • GTH-4018SR iii
March 2010
Machine Identification
Chassis Serial Number
The chassis serial number is punched on the front right part of the chassis side member.
Machine Data Plate
The identification plate contains the main identification data of the machine like model, serial number and
year of manufacture.
Identification Plates Of The Main Parts
The plates of the main components, not directly manufactured by TEREXLIFT srl (for instance, engines,
pumps, etc.), are located where originally applied by the manufacturers.
INTRODUCTION
GTH-4016 P 10 20000
MODEL
ENGINE
TYPE
YEAR OF
MANUFACTURER
SERIAL
NUMBER
Model Year:
Manufacturer:
Terexlift srl z.i.Buzzacchero
06019 Umbertide, Italy
MMMMMMMMMMMMMMMMMMMMMMMMMMMMMM
AAAA
MMMMMMMMMMMMMMMMMMMMMMMMMMMMMM
AAAAAAAAAA
AAAA
AAAAAAAAA
AAAAAAAAA
AAAAAAAAA
AAAAAAAAA
AAAAAAAAA
Country of Manufacture: ITALY
Max vertical load provided for on the coupling hook (N):
Max drawbar pull provided for at the coupling hook (N):
Nominal Power (kW):
Rated Capacity (Kg):
Mass with Forks (Kg):
Manufacture Year:
Serial Number:
Designation:
Model:
MMMMMMMMMMMMMMMMMMMMMMMMMMMMMM

iv GTH-4016SR • GTH-4018SR Part No. 57.4400.9203
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March 2010 Section 1 • Safety Rules
Part No. 57.4400.9203 GTH-4016SR • GTH-4018SR v
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..
Do Not Perform Maintenace Unless:
You are trained and qualified to perform
maintenace on this machine.
You read, understand and obey:
- manufacturer's instructions and safety rules
- employer's safety rules and worksite regulations
- applicable governmental regulations
You have the appropriate tools, lifting equipment
and a suitable workshop.

vi GTH-4016SR • GTH-4018SR Part No. 57.4400.9203
March 2010Section 1 • Safety Rules
Personal Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Read each procedure thoroughly. This
manual and the decals on the machine,
usesignalwordstoidentifythefollowing:
Safety alert symbol: used to
alert you to potential personal
injury hazards. Obey all safety
messages that follow this
symbol to avoid possible injury
or death
DANGER
Red: indicates a hazardous
situation which, if not avoided, will
result in death or serious injury.
WARNING
Orange: indicates a hazardous
situation which, if not avoided,
could result in death or serious
injury.
CAUTION
Yellow : indicates a hazardous
situation which, if not avoided,
could result in minor or moderate
injury.
NOTICE
Blue:indicatesapropertydamage
message.
PROTECT THE
ENVIRONMENT
Green: used to draw the attention
to important information on
environment protection.
Be sure to wear protective eye wear and
other protective clothing if the situation
warrants it.
Be aware of potential crushing hazards
such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved
steel-toed shoes.
Workplace Safety
Be sure to keep sparks, flames and
lighted tobacco away from flammable
and combustible materials like battery
gases and engine fuels. Always have
an approved fire extinguisher within
easy reach.
Be sure that all tools and working areas
are properly maintained and ready for
use. Keep work surfaces clean and free
of debris that could get into machine
components and cause damage.
Be sure any forklift, overhead crane or
other lifting or supporting device is fully
capable of supporting and stabilizing the
weight to be lifted. Use only chains or
straps that are in good condition and of
ample capacity.
Be sure that fasteners intended for one
time use (i.e., cotter pins and self-locking
nuts) are not reused. These components
may fail if they are used a second time.
Be sure to properly dispose of old oil or
other fluids. Use an approved container.
Please be environmentally safe.
Be sure that your workshop or work
area is
properly ventilated and well lit.
SAFETY RULES

Part No. 57.4400.9203 GTH-4016SR • GTH-4018SR vii
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Table of Contents
Introduction
Important Information........................................................................................... ii
Machine Identification..........................................................................................iii
Section 1 Safety Rules
Personal Safety Rules ......................................................................................... v
Section 2 Rev Specifications
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

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TABLE OF CONTENTS
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

Part No. 57.4400.9203 GTH-4016SR • GTH-4018SR ix
March 2010
TABLE OF CONTENTS
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

x GTH-4016SR • GTH-4018SR Part No. 57.4400.9203
March 2010
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
TABLE OF CONTENTS

Part No. 57.4400.9203 GTH-4016SR • GTH-4018SR xi
March 2010
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
TABLE OF CONTENTS

xii GTH-4016SR • GTH-4018SR Part No. 57.4400.9203
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March 2010 Section 2 • Specification
REV A
Part No. 57.4400.9203 GTH-4016SR • GTH-4018SR 1
GTH-4016SR & GTH-4018SR
Operation Description
The system layout of this machine consists of two
main sections: an undercarriage and a slewing
turret; these two main subassemblies incorporate
all the components of the machine.
The source of mechanical power of this machine
is a Perkins turbocharged diesel engine (1), model
1104D-44T without intercooler, which supplies a
power of 74 kW at 2300 rev/min and is capable of a
max torque of 392 Nm at 1400 rpm.
On the flywheel housing of the engine, and linked to
its flywheel through a PTO (gear ratio 1:1) provided
with an elastic joint, is installed a Rexroth closed-
loop hydrostatic transmission pump (2), model
A4VG71, equipped with a DA hydraulic automotive
control valve.
The max displacement of this swash-plate pistons
type pump is 71 cm3and its max working pressure
is 430 bar.
This pump transforms most of the mechanical power
(torque*rotational speed) received from the diesel
engine into hydraulic power (pressure*flow rate)
of the hydraulic fluid contained in the transmission
closed loop.
This power is then used to move the machine.
This piston pump is equipped with an internal gear
pump acting as a charge pump for the transmission
closed circuit, to generate pressure for the pump
piloting lines and for other external purposes.
In particular in this machine, the low pressure
generated by this charge pump is used to power,
through the port G, the low pressure circuits which
will be described later.
The standard setting pressure for this circuit is 25
bar.
The transmission pump is provide with a passing
through PTO on its back side which is used to
drive an open circuit type gear pump (3), having a
displacement of 43 cm3.
The function of this pump is to provide hydraulic
power to most of the functional subsystems of the
machine: the steering, the telescopic boom, the
turret slewing and the stabilizers.
Another open circuit type gear pump (4), having
a displacement of 14 cm3, is installed on the PTO
provided on the diesel engine distribution side.
The function of this pump is to provide hydraulic
power to the braking systems (service and parking)
and to the air conditioning system compressor
(optional).
When the work platform attachment (optional) is
installed, the additional emergency powerpack (5)
is provided with the aim to allow the work platform
recovery in case of failure on the main power
generation system and controls.
This powerpack mainly consists of a 12 VDC
electrical motor, powered by the machine battery,
and of a small gear pump, having a displacement of
2.6 cm3and driven by the electrical motor directly.
The maximum pressure on the emergency hydraulic
line is controlled by the pressure relief valve (6)
which is set to 150 bar.
The two check valves (7) having a cracking
pressure of 0.5 bar, are installed on the open circuit
main and emergency pressure lines, to prevent
any interference between these two lines and any
flow loss to the tank, considering that these pumps
normally work separately.
All the pumps described before receive oil from
a steel tank (8) installed on the left side of the
undercarriage and having a nominal capacity of
220 liters.
In particular, the gear pumps (3), (4) and (5) receive
oil from a dedicated suction line provided with a
mechanical shutoff valve (9), installed immediately
downstream of the tank and used during the
maintenance operations on the hydraulic system.
Inside the tank and on the same suction line, a
dedicated hydraulic screen (10) is installed with the
aim reduce the contamination level of the oil before
it enters into the suction line.
The transmission pump (2) receives oil from the
special filter (11) which has a double function: to
filter most of the return oil of all the open type circuits
of the machine and to provide a filtered, cooled and
pressurized suction line for any pump requiring a
good level of oil filtration on the suction line.
In particular the minimum pressure of 0.5 bar
guaranteed on the suction line for the transmission
pump, reduce the risk of oil cavitation during
the engine starting phase at very low ambient
Specification

2 GTH-4016SR • GTH-4018SR Part No. 57.4400.9203
March 2010Section 2 • Specification
SPECIFICATION REV A
temperatures.
This filter package, which is flanged directly on the
top side of the tank, is provided with a electrical
pressure switch (12) indicating when the filter
cartridge is clogged and then has to be replaced.
The maximum pressure on the brake circuit line is
controlled by the pressure relief valve (13) which is
set to 180 bar.
The mechanical shutoff valve (14) when closed,
allows the pressure relief valve setting pressure
can be checked and adjusted as necessary.
In the normal machine working conditions this
shutoff valve must be placed in its fully open
position.
The hydrostatic pump (2) hydraulically powers the
Rexroth hydrostatic motor closed loop, piston bent
axis type (15), model A6VM80 which transforms
the hydraulic power (pressure*flow rate) of the oil
contained in the hydrostatic transmission closed
loop circuit into mechanical power (torque*rotational
speed) to be used for the machine displacement.
The low pressure line, which is part of the
hydrostatic transmission, is also used to cool the
hydrostatic pump a motor through a drain case line
routed between the pump and the motor and finally
connected to the tank where the warm oil is finally
sent.
This drain case flow rate is controlled by the check
valve (16) having a cracking pressure of 2.5 bar.
When the pressure in the drain case line exceeds
2.5 bar, the flow rate in excess can be directly
discharged to the tank so preventing any damage
at the pump and motor sealing gaskets.
The hydrostatic motor is directly flanged on a
Carraro two-speed gear box (17) installed on the
central part of the undercarriage.
The speed shifting phase is activated by the
hydraulic actuator (18), which is part of the gearbox
itself, and controlled by the 4 ways/3 positions
electrical selector valve (19).
This selector valve is powered by the low pressure
generated by the hydrostatic transmission charge
pump.
The gearbox is mechanically linked, through two
distinct drive shafts, to the front axle (20) and to the
rear axle (21), both manufactured by Carraro, so
transmitting to the wheels the torque generated by
the hydrostatic motor.
The front axle, provided with an embedded steering
cylinder (22) and articulation, is rigidly secured
on the front area of the undercarriage whilst the
rear axle, provided with an embedded steering
cylinder (23) and articulation, is floating around its
pivoting axle in most of the machine displacement
conditions.
The floating condition of the rear axle is controlled
by the single effect right and left rear axle pivoting
cylinders (24) and (25) which, when the rear axle
is floating, are completely free to extend/retract
exchanging oil between their piston chambers
and giving a negligible resistance to the rear axle
floating movement.
The free flow between the two cylinder is allowed
by the two 2 ways/2 positions electrical rear axle
pivoting lockout valves (26) which are energized
when the rear axle is floating free.
These valves are directly embedded in the cylinder
body and, when not energized, close the line
between the two cylinders piston chamber so
locking the floating movement of the rear axle.
The two air bleeding valves (27), embedded one
for each cylinder, are used to eliminate air from the
cylinders after the first machine installation or in
occasion of maintenance operations.
The oil used to fill the rear axle pivoting cylinders
is provided by the low pressure line, powered by
the hydrostatic transmission charge pump, and is
controlled through the rear axle lockout cylinders
control valve (28).
The scope of this valve is to provide a free flow of
oil when this is requested by the rear axle pivoting
cylinders (check valve opens) and to prevent any
pressure surges and peaks on the low pressure
line when the quantity of oil in the rear axle pivoting
cylinders is in excess (damping effect due to the
calibrated restrictor).
The machine open circuits are linked to the tank
through the heat exchanger (29) which cools the oil
before it is filtered through the special filter package
(11) already described.

Part No. 57.4400.9203 GTH-4016SR • GTH-4018SR 3
March 2010 Section 2 • Specification
SPECIFICATIONREV A
When the pressure upstream of the heat exchanger
exceeds 8 bar, the flow rate in excess is directly
discharged to the tank through the check valve (30)
having a cracking pressure of 8 bar indeed.
The scope of this valve is to prevent any risk of
heat exchanger damage due to excessive pressure
(machine start-up at very low temperatures).
This heat exchanger is part of the main machine
radiator (cooling also the engine) and is installed
inside the engine compartment.
The gear pump (4) feeds the hydraulically powered
service/emergency brakes pedal pump (31) which
is installed underneath the cabin bottom in such
a way the operator can easily control the service
brake circuit by a mechanical pedal which is a part
of the pump itself.
The main function of this pump is to use the
pressurized oil available from the gear pump (4) to
maintain two hydraulic accumulators (32) and (33)
charged at a pressure not exceeding 150 bar.
The first accumulator (32), having a capacity of 0.5
liters and a nitrogen pre-charge pressure of 50 bar,
feeds the service brake line whilst the second one
(33), having a capacity of 1.5 liters and a nitrogen
pre-charge pressure of 35 bar, feeds the parking
brake line.
The electrical pressure switch (34), installed on
the service brake pressure line, signals when the
pressure is applied to the service brake line.
The electrical pressure switch (35), installed on
the parking brake pressure line, signals when the
pressure charging the accumulators is too low and
then the pump (31) is expected to recharge them
using the flow coming from the gear pump (4).
The service brake output line is linked, through the
electrical 3 ways/2 positions selector valve (36),
to the wet type brake disks packages, which are
installed inside the axles.
When the selector valve (36) is not energized, the
brake pump (31) is directly linked to the brakes
disks so producing the requested braking effect
when the operator in the cabin pushes on the brake
pedal.
When the selector valve (36) is energized, the
service brakes ports of the front axle, receive a
pressure of 10 bar which makes stronger the effect
of the anti-slipping device, device which is installed
inside the front axle.
This low pressure is generated by a pressure
reducing valve (37) fed by the low pressure
generated by the transmission charge pump.
The brakes pedal pump (31) is also linked, through
the port “R”, to the parking brake handle selector
valve (38) controlling the parking brake function.
When the handle of this valve, which is located in
the cabin on left of the operator’s seat, is placed in
the parking brake “on” position, the parking brake
hydraulic line, connected to the front axle (20), is
vented to the tank.
This condition allows the parking brake package,
installed inside the axle, to be self-activated,
through an internal mechanism energized by disk
springs, so maintaining the machine in the parking
condition.
On the other position of the lever, the parking
brake hydraulic line is pressurized at 30 bar so
maintaining the parking brake disks released and
then allowing the machine to move without any
braking effect.
Two electrical pressure switches (39) signals when
the parking brake is activated.
After the flow rate generated by the gear pump (4)
and used by the brakes pedal pump (31) to maintain
the accumulators (32) and (33) charged, leaves the
brakes pedal pump itself, this is available to power
the air condition compressor hydraulic gear motor
(40) which can be installed on the machine as an
option.
The gear pump (3) powers two distinct and
separated circuits: the steering circuit (priority
circuit) and the circuit driving the boom functions,
the slewing turret and the stabilizers operations
(secondary circuit).
The flow rate coming from this pump is controlled
by the load sensing priority valve (41) which is
controlled by the steering load sense line “LS”.
The principle of this valve is to ensure that all the
necessary flow rate is available to the steering
circuit when requested by the steering operation
and to give the exceeding flow rate to the secondary

4 GTH-4016SR • GTH-4018SR Part No. 57.4400.9203
March 2010Section 2 • Specification
SPECIFICATION REV A
circuit. Off course, when the steering is not used,
most of the flow rate is available for the secondary
circuit.
The priority line of the valve (41) powers the steering
rotating actuator (42) which is mechanically linked
to the steering wheel.
The scope of this actuator is to send a flow rate
to the steering cylinders which is proportional, in
addition to the actuator displacement, also to the
steering wheel rotational speed.
The actuator is also provided with a pressure relief
valve, which is adjusted to 190 bar, and two anti-
shock relief valves, which are adjusted to 260 bar.
The machine is provide with 3 distinct steering
modes (2 wheel, 4 wheels and crab steering) which
are implemented in the circuit by the 4 ways/3
positions electrical selector valve (43).
When the valve is not energized the 2 wheels
steering mode is selected, when one solenoid of
the valve is energized the 4 wheels is selected
and when the other solenoid is energized the crab
steering model is selected.
The secondary line of the valve (41) is linked to the
telescopic boom, turret and undercarriage main
valve (44).
This valve is a pressure compensated, modular,
flow sharing type valve controlling the boom and
attachments functions, the slewing turret and the
stabilizers operations. It mainly consists of one
inlet manifold, containing the main 3 ways pressure
compensator, the maximum pressure relief valve,
adjusted to 280 bar, the pressure reducing valve
feeding the spools actuators and the 2 enabling
function electrical valves, of 5 modules having
electro-proportional controls and of one module
having electrical on/off type control.
The first section of the valve, pressure compensated,
controls the boom up/down functions and is linked
to the telescopic boom lift cylinder (45) through the
single over-center safety valve (46).
The hydraulic accumulator (47), having a capacity
of 0.5 liters and a nitrogen pre-charge pressure of
35 bar, is installed on the boom down hydraulic line
to prevent any oscillation of the boom during the
boom-down movement.
The second section of the valve, not pressure
compensated, controls the forks tilt up/down
functions and is linked to the forks tilt cylinder (48)
through the double over-center safety valve (49).
On the same line of the forks tilt cylinder (48)
is installed, in parallel, the forks self-leveling
articulation slave cylinder (50) provided with a
double over-center safety valve (51).
This cylinder, which is linked to the boom and to
the turret, works as a pump and maintain leveled
the forks articulation when the boom is moved up
and down.
The output lines of the valve second section are
protected by 2 pressure relief valves, adjusted to
320 bar.
The third section of the valve, pressure
compensated, controls the boom telescoping in/out
functions and is linked to the second section boom
telescopic cylinder (52) through the double over-
center safety valve (53).
On the GTH-4016 SR only, the second section
boom telescopic cylinder (52) is linked to the third
section boom telescopic cylinder (70), provided
with a single over-center safety valve (71).
The fourth section of the valve, not pressure
compensated, controls the attachment quick
coupling device (optional) and is used to power
optional attachments requiring an hydraulic flow to
work.
This section is linked to the forks attachment quick
coupling cylinder (56) through the double piloted
safety valve (57) and the quick coupling hydraulic
ports (58).
The fifth section of the valve, pressure compensated,
controls the turret slewing functions and is linked to
the turret rotation hydraulic motor (54) through the
special double over-center safety valve (55).
The hydraulic motor is installed on a planetary type
gear, for the turret slewing, provided by an internal
negative type brake which is capable to maintain
the turret locked when no pressure is applied to the
hydraulic motor.
The sixth section of the valve, provided by an
electrical on/off type control, drives the stabilizers
through the stabilizers electrical selector valves

Part No. 57.4400.9203 GTH-4016SR • GTH-4018SR 5
March 2010 Section 2 • Specification
SPECIFICATIONREV A
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.
On the GTH-4018 SR only, the four valves of
the block (59) feed in parallel the four stabilizers
telescope lockout cylinders (73) through the
four stabilizers electrical lockout valve 2 ways/2
positions (72).
On the stabilizers selector valves block (59) inlet
line, linked to the stabilizers up movements, a
pressure relief valve (74), adjusted to 100 bar, is
installed.
The scope of this relief valve is to limit the
loads against the stabilizers telescope lockout
mechanisms, in case of failure of the stabilizers
telescope arm and rotating foot sequence control.
The scope of this additional circuit, which is installed
on the GTH-4018 SR only, is to give the right
functioning sequence to the stabilizers telescope
arms and rotating feet, since each of them is moved
by the same cylinder.
In order to reduce the number of hoses linking the
undercarriage and the turret sections of the hydraulic
circuit, a tank lines collector (68) is installed on the
turret receiving a number of tank lines coming from
several valves installed on the turret itself.
In order to improve the life of the hoses passing
through the slewing ring and connecting the
undercarriage and turret sections of the machine,
hydraulic circuit, single rotating joints (69) are
installed on each of these hoses and grouped
together on a single panel mounted on the central
section of the machine undercarriage.

6 GTH-4016SR • GTH-4018SR Part No. 57.4400.9203
March 2010Section 2 • Specification
SPECIFICATION REV A
GTH-4016SR Hydraulic Schematic
M
X2 MH S
A
T1 PS Fa Fa1 Fe MB
T2
R
B
MA
FS
Diesel engine
Auxiliary circuit max pressure relief valve
Hydrostatic transmission pump
max displacement: 71 cc rev/
Auxiliary gear pump
brakes circuit
displacement: 14 cc/rev
Suction screen
Anticavitation valve
cracking pressure
5 bar
Check valve
cracking pressure:
2.5 bar
Check valve
cracking pressure:
0.5 bar (optional)
Oil tank
capacity
220 liters
Telescopic boom
lift cylinder
Double overcenter safety valve
piloting ratio: 7.6 1
cracking pressure: 350 bar
/
Double overcenter safety valve
piloting ratio: 4/1
cracking pressure: 350 bar
Sing 4/ le overcenter safety valve
piloting ratio: 1
cracking pressure: 350 bar
25 bar 430 bar
450 bar
450 bar
Tp2
Tp4
Tp3
Tp1
capacity:
0.5 Litri
precharge
pressure
35 bar
Hydrostatic transmission
high pressure test port
Telescopic boom,
turret and
undercarriage
functions hydraulic
circuit test port
Telescopic boom, turret and
undercarriage
functions main valve
T2
Hydrostatic transmission motor
max displacement: 80 cc rev/
TP
A
B
Mechanical gear speed
selector valve
4 ways/3 positions
Emergency electrical
motor driven pump set
2.6 cc/rev (optional)
Mechanical gear speed
selector actuator
Boom functions gear pump
displacement: 43 cc/rev
Mechanical gear (2 speeds)
X1 G
Forks attachment quick
coupling cylinder (optional)
Heat exchanger
Hydrostatic transmission
boost pressure test port
C
Ev1 Ev2
Ev5 Ev6
A
M1
X1
X2
T
G
B
U
Flushing valve Return filter
with suction line
pressurized at 0,5 bar
Check valve
cracking pressure:
8 bar
Shutoff valve
Shutoff valve
280 bar
320 bar
320 bar
A1
Pp
LS1
LS2
TP
A2
A3
A4
A5
A6
B1
B2
B3
B4
B5
B6
Forks tilt cylinder
Forks self-levelling
articulation slave
cylinder
Second section boom
telescoping cylinder
Double overcenter safety valve
piloting ratio: 4/1
cracking pressure: 350 bar
Quick coupling
hydraulic ports
Hydraulically piloted
double check valve
piloting ratio: 4 1/
TURRET -UNDERCARRIAGE BOUNDAR Y TURRET -UNDERCARRIAGE BOUNDAR Y
N
R
F
P
B
N’
R1
T1
T1’
Capacity:
0.5 litres
precharge
pressure
50 bar
Capacity:
1.5 litres
precharge
pressure
35 bar
Pressure
switch
activating
pressure
70 bar
Pressure
switch
activating
pressure
5 bar
Pressure
switch
activating
pressure
2-10 bar
Hydraulically powered
service/emergency brakes
pedal pump
Air condition compressor
hydraulic motor
displacement 16 cc/rev
(optional)
Tank lines collector
150 bar
Pressure
switch
activating
pressure
10 bar-20
R
T
N
30 bar
Parking brake
handle selector
valve
190 bar
260 bar
LS
LS
L
R
T
P
Steering rotating
actuator
displacement:
200 cc rev/
Priority valve
load sensing type
T
P
A
B
CT
P
Differential lock
selector valve
3 ways / 2 positions
Front axle
steering cylinder
Rear axle pivoting
cylinder (right)
Rear axle pivoting
cylinder (left)
Rear axle
steering cylinder
Front axle
Rear axle
Steering modes
selector valve
4 ways / 3 positions
Rear axle pivoting
lockout valves
2 ways/2 positions
Rear axle lockout cylinders control valve
orifice dia.: 2 mm cracking pressure: 0.5 bar
HYDRAULIC CIRCUIT
COLORS LEGENDA
Functions lines
Low pressure lines
Load sensing and piloting lines
Open circuits pressure lines
Closed circuits high pressure lines
Suction lines
Tank lines
180 bar
Unlocking
pressure
15/50 bar
Turret rotation
hydraulic motor
Turret rotation hydraulic motor
double overcenter safety valve
piloting ratio: 3/1
cracking pressure: 150 bar
TP
A
A
A
A
B
B
B
B
Outriggers selector
valves block
Auxiliary circuit
pressure test port
Front right
outrigger cylinder
Rear right outrigger cylinder
Rear left outrigger cylinder
Hydraulically piloted
double check valve
piloting ratio: 4 1/
Hydraulically piloted
double check valve
piloting ratio: 4 1/
Hydraulically piloted
double check valve
piloting ratio: 4 1/
Hydraulically piloted
double check valve
piloting ratio: 4 1/
Boom lift
Forks tilt
Telescoping
Attachments
Turret
Stabilizers
V2
V1
C1
C2 C3
T
Third section boom
telescoping cylinder Sing 4/
le overcenter safety valve
piloting ratio: 1
cracking pressure: 350 bar
Tp6
Emergency line max pressure
relief valve (optional)
Emergency line
test port (optional)
150 bar
Air bleeding
valve
Air bleeding
valve
Front left
outrigger cylinder
Tp7
Test port
T
P
PR
Pressure reducing valve
setting pressure: 10 bar
TURRET -UNDERCARRIAGE BOUNDAR Y
Rotating joint Rotating joint Rotating joint
Steering modes
selector valve
4 ways / 3 positions
48
49 70
54
71
57
58
56
55
53
44
52
74
51
50
47
45 46
33
35
32
38
34
31
39
41
42
40
68
69
26 21
27
27
25
24 23
43
20
36
22
37
69
59
62
60
61
63
65
67
66 64
6
5
12
29
30
11
8
15
17
9
3
10
18
19
7
2
1
13
4
28
14 16

Part No. 57.4400.9203 GTH-4016SR • GTH-4018SR 7
March 2010 Section 2 • Specification
SPECIFICATIONREV A
GTH-4018SR Hydraulic Schematic
M
X2 MH S
A
T1 PS Fa Fa1 Fe MB
T2
R
B
MA
FS
Diesel engine
Auxiliary circuit max pressure relief valve
Hydrostatic transmission pump
max displacement: 71 cc rev/
Auxiliary gear pump
brakes circuit
displacement: 14 cc/rev
Suction screen
Anticavitation valve
cracking pressure
5 bar
Check valve
cracking pressure:
2.5 bar
Check valve
cracking pressure:
0.5 bar (option)
Oil tank
capacity
220 liters
Telescopic boom
lift cylinder
Double overcenter safety valve
piloting ratio: 7.6 1
cracking pressure: 350 bar
/
Double overcenter safety valve
piloting ratio: 4/1
cracking pressure: 350 bar
Sing 4/ le overcenter safety valve
piloting ratio: 1
cracking pressure: 350 bar
25 bar 430 bar
450 bar
450 bar
Tp3
Tp7
Tp4
Tp5
Tp2
Tp1
capacity:
0.5 Litri
precharge
pressure
35 bar
Hydrostatic transmission
high pressure test port
Telescopic boom,
turret and
undercarriage
functions hydraulic
circuit test port
Telescopic boom, turret and
undercarriage
functions main valve
T2
Hydrostatic transmission motor
max displacement: 80 cc rev/
TP
A
B
Mechanical gear speed
selector valve
4 ways/3 positions
Emergency electrical
motor driven pump set
2.6 cc/rev (option)
Mechanical gear speed
selector actuator
Boom functions gear pump
displacement: 43 cc/rev
Mechanical gear (2 speeds)
X1 G
Forks attachment
quick coupling cylinder
(optional)
Heat exchanger
Hydrostatic transmission
boost pressure test port
M
C
Ev1 Ev2
Ev5 Ev6
A
M1
X1
X2
T
G
B
U
Flushing valve Return filter
with suction line
pressurized at 0,5 bar
Check valve
cracking pressure:
8 bar
Shutoff valve
Shutoff valve
280 bar
320 bar
320 bar
A1
Pp
LS1
LS2
TP
A2
A3
A4
A5
A6
B1
B2
B3
B4
B5
B6
Forks tilt cylinder
Forks self-levelling
articulation slave
cylinder
Second section boom
telescoping cylinder
Double overcenter safety valve
piloting ratio: 4/1
cracking pressure: 350 bar
Quick coupling
hydraulic ports
Hydraulically piloted
double check valve
piloting ratio: 4 1/
TURRET -UNDERCARRIAGE BOUNDAR Y TURRET -UNDERCARRIAGE BOUNDAR Y
N
R
F
P
B
N’
R1
T1
T1’
Capacity:
0.5 litres
precharge
pressure
50 bar
Capacity:
1.5 litres
precharge
pressure
35 bar
Pressure
switch
activating
pressure
70 bar
Pressure
switch
activating
pressure
2-10 bar
Hydraulically powered
service/emergency brakes
pedal pump
Air condition compressor
hydraulic motor
displacement 16 cc/rev
(optional)
Tank lines collector
150 bar
Pressure
switch
activating
pressure
10 bar-20
R
T
N
30 bar
Parking brake
handle selector
valve
190 bar
260 bar
LS
LS
L
R
T
P
Steering rotating
actuator
displacement:
200 cc rev/
Priority valve
load sensing type
T
P
A
B
CT
P
Differential lock
selector valve
3 ways / 2 positions
Front axle
steering cylinder
Rear axle pivoting
cylinder (right)
Rear axle pivoting
cylinder (left)
Rear axle
steering cylinder
Air bleeding
valve
Air bleeding
valve Front axle
Rear axle
Rotating joint Rotating joint Rotating joint
Steering modes
selector valve
4 ways / 3 positions
Rear axle pivoting
lockout valves
2 ways/2 positions
Outriggers
lockout valve
2 ways/2 positions
Outriggers telescope
lockout cylinder Outriggers retraction line
max pressure relief valve
Outriggers retraction
line test port
Outriggers telescope
lockout cylinder
Rear axle lockout cylinders control valve
orifice dia.: 2 mm - cracking pressure: 0.5 bar
HYDRAULIC CIRCUIT
COLORS LEGENDA
Functions lines
Low pressure lines
Load sensing and piloting lines
Open circuits pressure lines
Closed circuits high pressure lines
Suction lines
Tank lines
180 bar
100 bar
Unlocking
pressure
15/50 bar
Turret rotation
hydraulic motor
Turret rotation hydraulic motor
double overcenter safety valve
piloting ratio: 3/1
cracking pressure: 150 bar
TP
A
A
A
A
B
B
B
B
Outriggers selector
valves block
Auxiliary circuit
pressure test port
Front right
outrigger cylinder
Rear right outrigger cylinder
Front left
outrigger cylinder
Rear left outrigger cylinder
Hydraulically piloted
double check valve
piloting ratio: 4 1/
Hydraulically piloted
double check valve
piloting ratio: 4 1/
Hydraulically piloted
double check valve
piloting ratio: 4 1/
Hydraulically piloted
double check valve
piloting ratio: 4 1/
Boom lift
Forks tilt
Telescoping
Attachments
Turret
Stabilizers
V2
V1
C1
C2 C3
T
Pressure
switch
activating
pressure
5 bar
Rear right outrigger cylinder
Rear left outrigger cylinder
Tp6 Emergency line max pressure
relief valve (optional)
Emergency line
test port (optional)
150 bar
Test port
T
P
PR
Pressure reducing valve
setting pressure: 10 bar
39
68
48
49
56
57
58
54
55
53
52
44
74
50
51
47
46
45
33
35
32
38
34
31
40
42
41
74
73
72 62
60
12
11
8
30
29
64
6
15
61
63
67 65
66
5
17
10
19
9
18
3
7
73
59
69
43 36
20
22
37
28
23
21
69
26
25
27
27
24
16
1
14
4
2
13

8 GTH-4016SR • GTH-4018SR Part No. 57.4400.9203
March 2010Section 2 • Specification
SPECIFICATION REV A
Performance Specifications
Fluid capacities
Fuel tank 205 L
Hydraulic tank 220 L
Tires and wheels
Tire size 18-19.5
Tire pressure 5.5 bar
Tire ply rating 16
Wheel diameter 1104 mm
Wheel width 460 mm
Lug pattern 14x19.5
Lug nut torque, dry 630 Nm
Continuous improvement of our products is
a Genie policy. Product specifications are
subject to change without notice.
Drive speed, maximum
GTH-4016SR & GTH-4018SR 35 km/h
Towing capacity at dinamometer
max load 7,000 kg
without load 6,900 kg
Lift capacity, maximum
GTH-4016SR & GTH-4018SR 4,000 kg