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Genie GTH-1048 Service Manual

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See also: Operator's Manual
Service Manual
Parts Manual
GTH-1048
GTH-1056
Serial Number Range
Serial Number Range
from GTH1007A-11697
from GTH1007B-7101
from GTH1010-14001
from GTH1014E-10001
Part No. 123701
Rev F2
May 2015

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Summary of Contents for Genie GTH-1048

  • Page 1 Parts Manual Service Manual Serial Number Range Serial Number Range GTH-1048 from GTH1007A-11697 from GTH1007B-7101 from GTH1010-14001 GTH-1056 from GTH1014E-10001 Part No. 123701 Rev F2 May 2015...

  • Page 2: Introduction

    Machine Design Life Unrestricted with proper operation, inspection and scheduled maintenance. Technical Publications Genie 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.
  • Page 3 Telematics Connector Legend, Electrical Schematic Harness Maps, 6-3 3/2015 2 - Repair 4-55, Electrical Schematics, Hydraulic Schematics 5/2015 6- Schem. 6-5, 6-40 Electronic Version Click on any procedure or page number highlighted in blue to view the update. Part No. 123701 GTH-1048 • GTH-1056...
  • Page 4 May 2015 REVISION HISTORY, CONTINUED Revision Date Section Procedure / Schematic Page / Description Electronic Version Click on any procedure or page number highlighted in blue to view the update. GTH-1048 • GTH-1056 Part No. 123701...

  • Page 5: Serial Number Legend

    ASME B56.6-2002 SAFETY STD FOR Facility code ROUGH TERRAIN FORKLIFT TRUCK Serial label (located inside fork frame) (models with quick attach frame) Serial label Serial number (located inside chassis at tank side of machine) (stamped on chassis) Part No. 123701 GTH-1048 • GTH-1056...
  • Page 6 May 2015 This page intentionally left blank. GTH-1048 • GTH-1056 Part No. 123701...

  • Page 7: Safety Rules

    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. Part No. 123701 GTH-1048 • GTH-1056...

  • Page 8: Personal Safety

    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. viii GTH-1048 • GTH-1056 Part No. 123701...

  • Page 9: Table Of Contents

    SAE and Metric Fasteners Torque Charts ..........2 - 16 Section 3 Scheduled Maintenance Procedures Introduction ....................3 - 1 Pre-delivery Preparation Report ..............3 - 3 Maintenance Inspection Report ..............3 - 5 Part No. 123701 GTH-1048 • GTH-1056...
  • Page 10 Inspect the Fuel and Hydraulic Tank Cap Venting Systems ....3 - 16 Check the Boom Wear Pads ............. 3 - 17 Lubricate the Driveshafts ..............3 - 18 B-10 Perform Engine Maintenance - John Deere Models ......3 - 18 GTH-1048 • GTH-1056 Part No. 123701...
  • Page 11 Perform Engine Maintenance - Perkins Models ......... 3 - 33 Perform Engine Maintenance - John Deere Models ......3 - 33 Perform Engine Maintenance - Deutz Models ........3 - 34 Perform Engine Maintenance - Perkins Models ......... 3 - 34 Part No. 123701 GTH-1048 • GTH-1056...
  • Page 12 Fuel and Hydraulic Tanks ..............4 - 29 Engines Engines .................... 4 - 30 Engine Fault Codes ................4 - 32 Transmission Transmission ..................4 - 33 Hydraulic Pumps Hydraulic Pump ................4 - 35 GTH-1048 • GTH-1056 Part No. 123701...
  • Page 13 AC Hydraulic Manifold Components ..........4 - 56 Valve Adjustments - Secondary Function Manifold ......4 - 58 Valve Coils ..................4 - 62 Axle Components Axles ....................4 - 64 Outriggers Outriggers ..................4 - 65 xiii Part No. 123701 GTH-1048 • GTH-1056...
  • Page 14 (before serial number GTH1012-16292) ............6 - 6 Electrical Component & Wire Color Legend (from serial number GTH1012-16292) ............6 - 7 Telematics Connector Legend ..............6 - 9 Electrical and Hydraulic Symbols Legends ..........6 - 10 GTH-1048 • GTH-1056 Part No. 123701...
  • Page 15 (from serial number GTH1012-16292 to GTH1014-19340) Electrical Schematic .................. 6 - 44 (from serial number GTH1014-19341, GTH1014E-10001) Hydraulic Schematic - Models with Single Joystick ............... 6 - 48 Hydraulic Schematic - Models with Dual Joysticks ................ 6 - 49 Part No. 123701 GTH-1048 • GTH-1056...

  • Page 16: Part

    May 2015 TABLE OF CONTENTS This page intentionally left blank. GTH-1048 • GTH-1056 Part No. 123701...

  • Page 17: Specifications

    10 x 13.189 Wheel diameter 24 in 60.1 cm Wheel width 9 in 22.9 cm Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. Part No. 123701 GTH-1048 • GTH-1056 2 - 1...

  • Page 18: Performance Specifications

    14 to 16 seconds Boom retract 13 to 15 seconds Fork rotate 3 to 6 seconds Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. 2 - 2 GTH-1048 • GTH-1056 Part No. 123701...
  • Page 19 Hydraulic fluids may be imcompatible due to the Hydraulic Fluid Specifications differences in base additive Genie specifications require hydraulic oils which are chemistry. When incompatible designed to give maximum protection to hydraulic fluids are mixed, insoluble systems, have the ability to perform over a wide...
  • Page 20 32°F / 0°C may result in component damage. Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. 2 - 4 GTH-1048 • GTH-1056 Part No. 123701...
  • Page 21 Flash Point None Pour Point -81°F / -63°C Maximum continuous operating 189°F / 87°C temperature Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. Part No. 123701 GTH-1048 • GTH-1056 2 - 5...

  • Page 22: Hydraulic Component Specifications

    (measured at test port TR) 3.4 bar Outrigger Manifold Flow regulator, 6 gpm Outrigger circuit 22.7 L/min Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. 2 - 6 GTH-1048 • GTH-1056 Part No. 123701...

  • Page 23: Manifold Component Specifications

    Solenoid valve, 3 position 4 way 7.3Ω 12V DC with diode (schematic items DA and DB) Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. Part No. 123701 GTH-1048 • GTH-1056 2 - 7...

  • Page 24: John Deere 4045Th485 Engine

    (warm, at rated speed with full load) 4.13±1.7 bar Continuous improvement of our products is a Oil pressure 15 psi Genie policy. Product specifications are (warm, at low idle) 1 bar subject to change without notice. Oil capacity 14 quarts (including filter) 13.2 liters...

  • Page 25: Deutz Tcd3.6 L4 Engine

    For oil requirements, refer to the Engine Operator's Manual on your machine. Reserve capacity @ 25A rate 200 minutes Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. Part No. 123701 GTH-1048 • GTH-1056 2 - 9...

  • Page 26: Perkins 1104D-E44Ta Engine

    Group Quantity Cold cranking ampere @ 0°F 1000A Continuous improvement of our products is a Genie policy. Product specifications are subject Reserve capacity @ 25A rate 200 minutes to change without notice. 2 - 10 GTH-1048 • GTH-1056 Part No. 123701...

  • Page 27: Perkins 1204E-E44Ta Engine

    Engine Operation and Maintenance Manual on your Reserve capacity @ 25A rate 200 minutes machine. Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. Part No. 123701 GTH-1048 • GTH-1056 2 - 11...

  • Page 28: Dana T20000 Transmission

    ZF 4 WG-98 TC Operating Manual Genie part number 115025 Genie part number 1258405 Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. 2 - 12 GTH-1048 • GTH-1056 Part No. 123701...

  • Page 29: Dana Planetary 213 Drive Axle

    (Dana part number 0243). Dana 213 Axle Maintenance and Repair Manual Genie part number 115026 Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. Part No. 123701 GTH-1048 • GTH-1056 2 - 13...

  • Page 30: Hydraulic Hose And Fitting Torque Specifications

    Your machine is equipped with Parker Seal-Lok ® SAE Dash size Torque fittings and hose ends. Genie specifications require that fittings and hose ends be torqued to 14 ft-lbs / 19 Nm specification when they are removed and installed 23 ft-lbs / 31.2 Nm or when new hoses or fittings are installed.
  • Page 31 Figure 1 fittings and hose ends are custom-size O-rings. They are not standard SAE size O-rings. They are hex nut available in the O-ring field service kit (Genie part reference mark body hex fitting number 49612). 3 Working clockwise on the body hex fitting, make 2 Lubricate the O-ring before installation.
  • Page 32 5 Operate all machine functions and inspect the hoses and fittings and related components to confirm that there are no leaks. 2 - 16 GTH-1048 • GTH-1056 Part No. 123701...
  • Page 33 50.5 39.9 54.1 53.2 72.2 46.7 63.3 62.3 84.4 18.9 25.6 25.1 34.1 48.6 64.9 69.7 94.5 92.2 30.1 40.8 54.3 77.4 46.9 63.6 62.5 84.8 64.5 87.5 86.2 1055 1233 Part No. 123701 GTH-1048 • GTH-1056 2 - 17...
  • Page 34 Section 2 • Specifications September 2014 SPECIFICATIONS This page intentionally left blank. 2 - 18 GTH-1048 • GTH-1056 Part No. 123701...

  • Page 35: Scheduled Maintenance Procedures

    Repair any machine damage or malfunction injury. before operating the machine. Indicates a potentially hazardous Use only Genie approved replacement parts. situation which, if not avoided, Machines that have been out of service for a may result in property damage.

  • Page 36: Pre-Delivery Preparation Report

    Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection. Make copies of the Maintenance Inspection Report to use for each inspection. Store completed forms for three years. 3 - 2 GTH-1048 • GTH-1056 Part No. 123701...
  • Page 37 500 Oak Wood Road The Maltings, Wharf Road PO Box 1150 Grantham, Lincolnshire Watertown, SD 57201-6150 NG31- 6BH England (605) 882-4000 (44) 1476-584333 Copyright © 2011 Terex Corporation. Genie® is a registered trademark of Terex South Dakota, Inc. 133192 Rev D...
  • Page 38 Section 3 • Scheduled Maintenance Procedures September 2014 This page intentionally left blank. 3 - 4 GTH-1048 • GTH-1056 Part No. 123701...

  • Page 39: Maintenance Inspection Report

    N = no, remove from service E-8 Engine maintenance - Deutz models R = repaired Deutz models C-5 Engine maintenance - Perform every 12,000 hours: Perkins models Comments E-9 Engine maintenance - Perkins models Part No. 123701 GTH-1048 • GTH-1056 3 - 5...

  • Page 40: Checklist A Procedures

    Inspect the Manuals and Decals Result: The operator's manual is appropriate for Genie specifications require that this procedure be the machine and all manuals are legible and in performed every 8 hours or daily, whichever good condition.

  • Page 41: Perform Pre-Operation Inspection

    Section 3 • Scheduled Maintenance Procedures CHECKLIST A PROCEDURES Perform Pre-operation Inspection Perform Function Tests Genie specifications require that this procedure be Genie specifications require that this procedure be performed every 8 hours or daily, whichever performed every 8 hours or daily, whichever comes first.

  • Page 42: Lubricate The Boom

    CHECKLIST A PROCEDURES Lubricate the Boom Perform Engine Maintenance - All Models Genie specifications require that this procedure be performed every 8 hours or daily, whichever Note: Engine specifications require that this comes first. procedure be performed every 8 hours or daily, Greasing the specified locations is essential for whichever comes first.

  • Page 43: Perform Transmission Maintenance- All Models

    Perkins and Deutz models: ZF 4 WG-98 TC Operating Manual · B-5 Inspect the Tires, Wheels and Genie part number 1258405 Lug Nut Torque · D-2 Replace the Hydraulic Tank Return Filter Element Part No. 123701 GTH-1048 • GTH-1056 3 - 9...

  • Page 44: Perform Axle Maintenance

    John Deere 4045HF485 Operator's Manual (Dana part number 0243). (John Deere part number OMRG36852) Dana 213 Axle Maintenance and Repair Manual John Deere 4045HF485 Operator's Manual Genie part number 115026 Genie part number 123703 3 - 10 GTH-1048 • GTH-1056 Part No. 123701...

  • Page 45: Perform Axle Maintenance

    Dana 213 Axle Maintenance and Repair Manual (Dana part number 0243). (Dana part number 0243). Dana 213 Axle Maintenance and Repair Manual Genie part number 115026 Dana 213 Axle Maintenance and Repair Manual Genie part number 115026 Part No. 123701 GTH-1048 • GTH-1056 3 - 11...

  • Page 46: Checklist B Procedures

    September 2014 Checklist B Procedures Inspect the Battery Inspect the Electrical Wiring Genie requires that this procedure be performed Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes every 250 hours or quarterly, whichever comes first.

  • Page 47: Check The Exhaust System

    Do Genie requires that this procedure be performed not stand or work beneath a boom every 250 hours or quarterly, whichever comes that is not properly supported.

  • Page 48: Inspect The Engine Air Filter

    Inspect the Engine Air Filter Inspect the Tires, Wheels and Lug Nut Torque Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes Genie requires that this procedure be performed first. Perform this procedure more often if dusty every 250 hours or quarterly, whichever comes conditions exist.

  • Page 49: Perform Hydraulic Oil Analysis

    5 Check the air pressure in the tire. Refer to Section 2, Specifications . Result: The air pressure meets specification. Genie requires that this procedure be performed The tire is at the correctly filled level. every 250 hours or quarterly, whichever comes first.

  • Page 50: Inspect The Fuel And Hydraulic Tank Cap Venting Systems

    4 Install the fuel tank cap onto the fuel tank. 5 Remove the breather cap from the hydraulic tank. Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes 6 Check for proper venting. first. Perform this procedure more often if dusty Result: Air passes through the fuel tank cap.

  • Page 51: Check The Boom Wear Pads

    Result: Some of the wear indicator of both wear pads is visible. The wear pads are good. Result: All of the wear indicator of one or both Genie specifications require that this procedure be wear pads is not visible. Replace both wear performed every 250 hours of operation.

  • Page 52: Lubricate The Driveshafts

    CHECKLIST B PROCEDURES B-10 Lubricate the Driveshafts Perform Engine Maintenance - John Deere Models Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes Engine specifications require that this procedure be first. performed every 250 hours of operation.

  • Page 53: Part No. 123701 Gth-1048 •

    Deutz DQC III LA approved oil in extreme conditions Required maintenance procedures and additional engine information is available in the Deutz TCD3.6 Operation Manual (Deutz part number 0312 3907). Deutz TCD3.6 Operation Manual Genie part number 218707 Part No. 123701 GTH-1048 • GTH-1056 3 - 19...

  • Page 54: Checklist C Procedures

    John Deere 4045HF485 Operator's Manual Dana 213 Axle Maintenance and Repair Manual (John Deere part number OMRG36852) Genie part number 115026 John Deere 4045HF485 Operator's Manual Genie part number 123703 3 - 20 GTH-1048 • GTH-1056 Part No. 123701...

  • Page 55: Perform Transmission Maintenance - Dana Models

    Dana T20000 Maintenance Manual engine information is available in the Genie part number 115025 Deutz TCD3.6 Operation Manual (Deutz part number 0312 3907). Deutz TCD3.6 Operation Manual Genie part number 218707 Part No. 123701 GTH-1048 • GTH-1056 3 - 21...

  • Page 56: Perform Engine Maintenance - Perkins Models

    117765 Perkins 1204 Operation and Maintenance Manual Perkins 1104 Operation and Maintenance Manual Genie part number 218726 Genie part number 117765 Perkins 1204 Operation and Maintenance Manual Genie part number 218726 3 - 22 GTH-1048 • GTH-1056 Part No. 123701...

  • Page 57: Inspect And Lubricate The Sequencing Chains

    1 Park the machine on a firm level surface, level the boom and engage the parking brake. 2 Fully extend the boom. Genie specifications require that this procedure be performed every 500 hours or semi-annually, 3 Inspect the chains for the following conditions: whichever comes first.

  • Page 58: Adjust The Sequencing Chains

    5%. · Cracked plates Check link side plates for any cracks. These are generally a sign of chain fatigue. Note: Genie specifications require that this procedure be performed every 500 hours or · Turning pins semi-annually, whichever comes first.

  • Page 59: Perform Axle Maintenance

    8 Fully retract the boom. 9 Measure the gap between the washer and the spacer. The gap should be between 0.125 to 0.25 inch / 3.2 mm to 6.35 mm. Part No. 123701 GTH-1048 • GTH-1056 3 - 25...

  • Page 60: Perform Axle Maintenance

    Required maintenance procedures and additional axle information is available in the Dana 213 Axle Maintenance and Repair Manual (Dana part number 0243). Dana 213 Axle Maintenance and Repair Manual Genie part number 115026 3 - 26 GTH-1048 • GTH-1056 Part No. 123701...

  • Page 61: Checklist D Procedures

    Checklist D Procedures Inspect the Forks Replace Hydraulic Tank Return Filter Element Genie specifications require that this procedure be performed every 1000 hours or annually, Genie specifications require that this procedure be whichever comes first OR whenever permanent performed every 1000 hours or annually, deformation of the forks is suspected.

  • Page 62: Perform Transmission Maintenance- Dana Models

    Dana T20000 Maintenance Manual Dana 213 Axle Maintenance and Repair Manual (Dana part number 0202). Genie part number 115026 Dana T20000 Maintenance Manual Genie part number 115025 3 - 28 GTH-1048 • GTH-1056 Part No. 123701...

  • Page 63: Perform Engine Maintenance - Deutz Models

    (Deutz part number 0312 3907). Perkins 1104 Operation and Maintenance Manual Genie part number 117765 Deutz TCD3.6 Operation Manual Genie part number 218707 Perkins 1204 Operation and Maintenance Manual Genie part number 218726 Part No. 123701 GTH-1048 • GTH-1056 3 - 29...

  • Page 64: Perform Transmission Maintenance- Zf Models

    Required maintenance procedures and additional transmission information is available in the ZF 4 WG-98 TC Maintenance Manual (ZF part number 5872 134 002). ZF 4 WG-98 TC Operating Manual Genie part number 1258405 3 - 30 GTH-1048 • GTH-1056 Part No. 123701...

  • Page 65: Checklist E Procedures

    Bodily injury hazard. Beware of hot oil. Contact with hot oil may cause severe burns. 5 Rinse out the inside of the tank using a mild Genie specifications require that this procedure be solvent. performed every 2000 hours or two years, whichever comes first 6 Install the drain plug and securely tighten.

  • Page 66: Perform Engine Maintenance - John Deere Models

    OR the, Perkins 1204 Operation and Maintenance Manual (Perkins part number SEBU8605-01). Perkins 1104 Operation and Maintenance Manual Genie part number 117765 Perkins 1204 Operation and Maintenance Manual Genie part number 218726 3 - 32 GTH-1048 • GTH-1056 Part No. 123701...

  • Page 67: E-4 Perform Engine Maintenance - Deutz Models

    OR the, Perkins 1204 Operation and Maintenance Manual (Perkins part number SEBU8605-01). Perkins 1104 Operation and Maintenance Manual Genie part number 117765 Perkins 1204 Operation and Maintenance Manual Genie part number 218726 Part No. 123701 GTH-1048 • GTH-1056 3 - 33...

  • Page 68: E-6 Perform Engine Maintenance - Perkins Models

    (John Deere part number OMRG36852) Perkins 1204 Operation and Maintenance Manual (Perkins part number SEBU8605-01). John Deere 4045HF485 Operator's Manual Genie part number 123703 Perkins 1204 Operation and Maintenance Manual Genie part number 218726 3 - 34 GTH-1048 • GTH-1056 Part No. 123701...

  • Page 69: E-8 Perform Engine Maintenance - Deutz Models

    OR the, Perkins 1204 Operation and Maintenance Manual (Perkins part number SEBU8605-01). Perkins 1104 Operation and Maintenance Manual Genie part number 117765 Perkins 1204 Operation and Maintenance Manual Genie part number 218726 Part No. 123701 GTH-1048 • GTH-1056 3 - 35...
  • Page 70 Be sure that all necessary tools and parts are situation which, if not avoided, available and ready for use. could result in death or serious Use only Genie approved replacement parts. injury. Read each procedure completely and adhere Indicates a potentially hazardous to the instructions.

  • Page 71: Boom Components

    60° or higher and the boom is extended to greater than 43 feet / 13.1 m. 4 - 2 GTH-1048 • GTH-1056 Part No. 123701...
  • Page 72 The proximity switch is properly calibrated. Result: The light of the proximity switch assembly is illuminated. The proximity switch is not calibrated correctly. Repeat this procedure beginning with step 4. Part No. 123701 GTH-1048 • GTH-1056 4 - 3...

  • Page 73: Boom

    Note: Do not lubricate the side wear pads. when the lock pin is removed from the machine. 4 Install the wear pads. Install and securely tighten the fasteners. Do not over tighten. 4 - 4 GTH-1048 • GTH-1056 Part No. 123701...
  • Page 74 1. Remove the hose roller cylinder and auxiliary connections (if equipped). assembly from the boom. The three-section boom on the GTH-1048 does 5 Working at the fork end of the boom, remove not require the use of a cable bridge.
  • Page 75 Refer to Illustration 1. 1 Start the engine and allow the engine to idle. 8 GTH-1048: Working at the fork end of the 2 Raise the boom to a horizontal position. boom, loosen the fasteners securing the single-chain tensioners to the top of boom tube 3 Fully retract the boom.
  • Page 76 2 and 3. Refer to Illustration 3. 12 Using a strap from an overhead crane, support GTH-1048: Locate the chain anchor of the the extend cylinder. Do not apply any lifting boom retraction chain where it attaches to the...
  • Page 77 Refer to Illustration 1. tensioners to the top of the boom tube until they are securely tightened. 25 GTH-1048: Install the chain tensioners into the tensioner mount at the fork end of boom tube number 1. Install the mounting components, removed in step 8.
  • Page 78 9 Repeat this procedure, beginning with step 8, boom. Refer to Illustration 1. for the other chains. 7 GTH-1048: Working at the fork end of the 10 Working at the fork end of the boom, select a boom, loosen the fasteners securing the chain.
  • Page 79 Section 4 • Repair Procedures March 2015 BOOM COMPONENTS 15 Install the chain anchor, pin and clip onto the 24 GTH-1048: Install the chain tensioners into the new chain. tensioner mount at the fork end of boom tube number 1. Install the mounting components, 16 Remove the rope from the end of the old chain removed in step 7.
  • Page 80 8 Select a lift cylinder. Tag, disconnect and plug when placing the boom assembly the hydraulic hoses at the lift cylinder manifold. onto a structure capable of Cap the fittings on the cylinder manifold. supporting it. Part No. 123701 GTH-1048 • GTH-1056 4 - 11...
  • Page 81 6 Repeat this procedure beginning with step 3 for Note: The hose keepers ensure that the hoses do the other lift cylinder. not jump off the hose rollers. 4 - 12 GTH-1048 • GTH-1056 Part No. 123701...
  • Page 82 1. Note: During removal, the overhead crane strap will need to be adjusted for proper balancing. Part No. 123701 GTH-1048 • GTH-1056 4 - 13...
  • Page 83 6 Repeat this procedure beginning with step 3 for the other lift cylinder. Note: The hose keepers ensure that the hoses do not jump off the hose rollers. 4 - 14 GTH-1048 • GTH-1056 Part No. 123701...
  • Page 84 2. bracket to boom tube number 3. Remove the chain rollers from the boom. Part No. 123701 GTH-1048 • GTH-1056 4 - 15...
  • Page 85 Note: During removal, the overhead crane strap the fasteners securing the chain roller to boom will need to be adjusted for proper balancing. tube number 2. Remove the chain roller from the boom. 4 - 16 GTH-1048 • GTH-1056 Part No. 123701...

  • Page 86: Boom Lift Cylinder

    3 Attach a lifting strap from an overhead crane to the rod end of the lift cylinder. Support the cylinder. Do not apply any lifting pressure. 4 Remove the fasteners securing the lift cylinder barrel-end pivot pin to the chassis. Part No. 123701 GTH-1048 • GTH-1056 4 - 17...

  • Page 87: Boom Extension Cylinder

    Do not allow oil to squirt or spray. Component damage hazard. Hoses can be damaged if they are kinked or pinched. 4 - 18 GTH-1048 • GTH-1056 Part No. 123701...

  • Page 88: Fork Level Cylinder

    Support when the pivot pin is removed the cylinder. Do not apply any lifting pressure. from the machine. Part No. 123701 GTH-1048 • GTH-1056 4 - 19...
  • Page 89 6 Working near the center of the boom assembly, tag, disconnect and plug the hydraulic hoses from the hydraulic hard lines under boom tube number number 1. Cap the hard lines. 4 - 20 GTH-1048 • GTH-1056 Part No. 123701...
  • Page 90 Hoses can be damaged if they are tighten. kinked or pinched. 16 Remove the lifting strap from the fork frame. 17 Install the cover onto the rear of the boom. Install and securely tighten the retaining fasteners. Part No. 123701 GTH-1048 • GTH-1056 4 - 21...
  • Page 91 Securely tighten all fasteners. Do not over tighten. 20 Install the cover onto the rear of the boom. Install and securely tighten the retaining fasteners. 4 - 22 GTH-1048 • GTH-1056 Part No. 123701...

  • Page 92: Operator's Compartment

    For further information or assistance, consult the at the operator's compartment side of the Genie Industries Service Department. machine. Tag, disconnect and plug the hydraulic hose. Cap the fitting. Bodily injury hazard. This...
  • Page 93 Bolt torque specification 16 Working inside the chassis, tag and disconnect Operator's cab mounting bolts 750 ft-lbs the wire harnesses at the connectors next to 1017 Nm the operator's compartment. 4 - 24 GTH-1048 • GTH-1056 Part No. 123701...

  • Page 94: Machine Controls

    8 Loosen the two lower fasteners securing the dash frame to the operator's compartment. 9 Remove the two upper fasteners securing the dash frame to the operator's compartment. Part No. 123701 GTH-1048 • GTH-1056 4 - 25...
  • Page 95 SULS of the primary function manifold. Cap the fitting. 6 Slowly move the steer orbitral away from the dash frame while feeding all loose hoses through the opening of the chassis. Joystick port orientation 4 - 26 GTH-1048 • GTH-1056 Part No. 123701...
  • Page 96 Remove the joystick. assembly away from the dash frame while feeding all loose hoses through the opening of the chassis. Joystick port orientation Part No. 123701 GTH-1048 • GTH-1056 4 - 27...
  • Page 97 4 Tag and disconnect the wire harness from the diagnostic display. Remove the diagnostic 5 Tag and disconnect the wire harness from the display from the machine. dash cluster. Remove the dash cluster from the machine. 4 - 28 GTH-1048 • GTH-1056 Part No. 123701...

  • Page 98: Fuel And Hydraulic Tanks

    4 Tag and disconnect the wire harness from the unbalanced and fall if not properly fuel level terminals. supported when removed from the machine. 5 Remove the filler cap from the hydraulic tank. Part No. 123701 GTH-1048 • GTH-1056 4 - 29...

  • Page 99: Engines

    Deutz TD3.6 L4 and TCD3.6 L4 Workshop Manual (Deutz part number 0312 3965en). Deutz TCD3.6 Operation Manual Genie part number 218707 Deutz TD3.6 and TCD3.6 Workshop Manual Genie part number 1251788 4 - 30 GTH-1048 • GTH-1056 Part No. 123701...
  • Page 100 8 John Deere models: Open the engine access 19 Remove the engine tray from the machine. cover at the tank side of the machine. Locate the fuel supply line where it is attached to the fuel filter/water separator. Part No. 123701 GTH-1048 • GTH-1056 4 - 31...

  • Page 101: Engine Fault Codes

    Section 5, Fault Codes . Perkins 1104D-E44TA engine oil pressure sensor coolant temperature sender intake temperature sensor crank speed sensor John Deere 4045HF485 engine coolant temperature sender oil pressure sender starter relay 4 - 32 GTH-1048 • GTH-1056 Part No. 123701...

  • Page 102: Transmission

    '2' Hoses can be damaged if they are (gear reduction) (green wire) transmission shift coil '1' (gear reduction) (yellow wire) Note: refer to electrical schematic for additional transmission shift coil information. Part No. 123701 GTH-1048 • GTH-1056 4 - 33...
  • Page 103 12 Remove the fasteners securing the transmission mounting flange to the chassis. Remove the transmission from the machine. Crushing hazard. The transmission will fall if not properly supported when removed from the machine. 4 - 34 GTH-1048 • GTH-1056 Part No. 123701...

  • Page 104: Hydraulic Pumps

    3 Hold the manual fuel shut-off lever on the connections very slowly to allow engine in the closed position. the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Part No. 123701 GTH-1048 • GTH-1056 4 - 35...
  • Page 105 Do not lower the open end of the case drain hose to below the fluid level of the hydraulic tank until the hose is plugged. 4 - 36 GTH-1048 • GTH-1056 Part No. 123701...
  • Page 106 Refer to Section 2, Specifications . 7 Securely install the wire harness onto the pump. 8 Check the level of the hydraulic fluid in the hydraulic tank. Add fluid if needed. Part No. 123701 GTH-1048 • GTH-1056 4 - 37...
  • Page 107 5 Check for hydraulic leaks and clean up any oil case drain filler plug that may have spilled. case drain hose hydraulic supply line (from tank) 4 - 38 GTH-1048 • GTH-1056 Part No. 123701...
  • Page 108 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. Part No. 123701 GTH-1048 • GTH-1056 4 - 39...
  • Page 109 Loosen hydraulic not adjust the pressure connections very slowly to allow compensator higher than the oil pressure to dissipate specified. gradually. Do not allow oil to squirt or spray. 4 - 40 GTH-1048 • GTH-1056 Part No. 123701...
  • Page 110 March 2015 Section 4 • Repair Procedures This page intentionally left blank. Part No. 123701 GTH-1048 • GTH-1056 4 - 41...

  • Page 111: Primary Function Manifold Components - Models With Single Joystick

    2 gpm / 7.6 L/min ......AN ..Sway left/right circuit ........20 ft-lbs / 27 Nm Check valve, 5 psi / 0.3 bar ..... AO ..Sway left circuit ......... 12-14 ft-lbs / 16-19 Nm 4 - 42 GTH-1048 • GTH-1056 Part No. 123701...
  • Page 112 MANIFOLDS Y72B Y72A View A View A Y72A Y72B Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic; alphanumeric callouts refer to the electrical schematic View B View B Part No. 123701 GTH-1048 • GTH-1056 4 - 43...
  • Page 113 ....... 20 ft-lbs / 27 Nm Solenoid valve, 2 position 2 way ..AAC ..Function select - sway left/right ....20 ft-lbs / 27 Nm 4 - 44 GTH-1048 • GTH-1056 Part No. 123701...
  • Page 114 MANIFOLDS Y72B Y72A View A View A Y72A Y72B Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic; alphanumeric callouts refer to the electrical schematic View B View B Part No. 123701 GTH-1048 • GTH-1056 4 - 45...

  • Page 115: Primary Function Manifold Components - Models With Dual Joysticks

    Check valve, 5 psi / 0.3 bar ..... BN ..Sway left circuit ......... 12-14 ft-lbs / 16-19 Nm Priority flow regulator valve, 2 gpm / 7.6 L/min ......BO ..Sway left/right circuit ........20 ft-lbs / 27 Nm 4 - 46 GTH-1048 • GTH-1056 Part No. 123701...
  • Page 116 Section 4 • Repair Procedures MANIFOLDS Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic; alphanumeric callouts refer to the electrical schematic View A View A View B View B Part No. 123701 GTH-1048 • GTH-1056 4 - 47...
  • Page 117 2 position 2 way, pilot operated ..BX ..Fork tilt circuit ..........25 ft-lbs / 34 Nm Diagnostic nipple ......BZ ..Test port 'TP' Solenoid valve, 2 position 2 way ..BAA ..Function select - sway left/right ....20 ft-lbs / 27 Nm 4 - 48 GTH-1048 • GTH-1056 Part No. 123701...
  • Page 118 Section 4 • Repair Procedures MANIFOLDS Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic; alphanumeric callouts refer to the electrical schematic View A View A View B View B Part No. 123701 GTH-1048 • GTH-1056 4 - 49...

  • Page 119: Secondary Function Manifold Components

    Solenoid valve, 2 position 3 way ..CP ..Differential lock-up select ......20 ft-lbs / 27 Nm Diagnostic nipple ......CQ ..Test port 'TJ' Diagnostic nipple ......CR ..Test port 'TS' Diagnostic nipple ......CS ..Test port 'TR' 4 - 50 GTH-1048 • GTH-1056 Part No. 123701...
  • Page 120 Section 4 • Repair Procedures MANIFOLDS View A View A Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic; alphanumeric callouts refer to the electrical schematic View B View B Part No. 123701 GTH-1048 • GTH-1056 4 - 51...

  • Page 121: Outrigger Manifold Components

    Check valve, 5 psi / 0.3 bar ..... DG ..Left outrigger retract circuit ....12-14 ft-lbs / 16-19 Nm Check valve, 5 psi / 0.3 bar ..... DH ..Right outrigger retract circuit ..... 12-14 ft-lbs / 16-19 Nm 4 - 52 GTH-1048 • GTH-1056 Part No. 123701...
  • Page 122 Section 4 • Repair Procedures MANIFOLDS Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic; alphanumeric callouts refer to the electrical schematic View A View A View B View B Part No. 123701 GTH-1048 • GTH-1056 4 - 53...

  • Page 123: Auxiliary Manifold Components (Option)

    Check valve, 5 psi / 0.3 bar ..... ED ..Auxiliary 'A2' circuit ......12-14 ft-lbs / 16-19 Nm Y77A Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic; alphanumeric callouts refer Y77B to the electrical schematic 4 - 54 GTH-1048 • GTH-1056 Part No. 123701...

  • Page 124: Brake Manifold Components

    50 psi / 3.4 bar ......... PS5 ..Brake light pressure (option) ....11 ft-lbs / 14.9 Nm TO REAR AXLE Note: 'alphanumeric' callouts refer to corresponding notes on th electrical and hydraulic schematics TO FRONT AXLE TO BRAKE PEDAL Part No. 123701 GTH-1048 • GTH-1056 4 - 55...

  • Page 125: Ac Hydraulic Manifold Components

    Flow control valve, 3 gpm/ 11.3 lpm ........ FB ..Regulates flow ........33-37 ft-lbs / 45-50 Nm Note: 'alphanumeric' callouts refer to corresponding notes on the electrical and hydraulic schematics 4 - 56 GTH-1048 • GTH-1056 Part No. 123701...
  • Page 126 March 2015 Section 4 • Repair Procedures MANIFOLDS This page intentionally left blank. Part No. 123701 GTH-1048 • GTH-1056 4 - 57...

  • Page 127: Valve Adjustments - Secondary Function Manifold

    Do not allow oil to squirt burn skin. Loosen hydraulic or spray. connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 4 - 58 GTH-1048 • GTH-1056 Part No. 123701...
  • Page 128 Do not allow oil to squirt burn skin. Loosen hydraulic or spray. connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Part No. 123701 GTH-1048 • GTH-1056 4 - 59...
  • Page 129 Do not allow oil to squirt burn skin. Loosen hydraulic or spray. connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 4 - 60 GTH-1048 • GTH-1056 Part No. 123701...
  • Page 130 Do not allow oil to squirt burn skin. Loosen hydraulic or spray. connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Part No. 123701 GTH-1048 • GTH-1056 4 - 61...

  • Page 131: Valve Coils

    (Ω). Refer to the Valve Coil (schematic items DA and DB) Resistance Specification table. Result: If the resistance is not within the adjusted specification, plus or minus 10%, replace the coil. 4 - 62 GTH-1048 • GTH-1056 Part No. 123701...
  • Page 132 How to Test a Coil Diode 4 Connect the negative lead to the other terminal on the coil. Genie incorporates spike suppressing diodes in all Note: If testing a single-terminal coil, connect the of its coils. Properly functioning coil diodes protect negative lead to the internal metallic ring at either the electrical circuit by suppressing voltage spikes.

  • Page 133: Axles

    Place blocks under the chassis for support. Crushing hazard. The chassis will fall if not properly supported. 6 Remove the lug nuts. Remove the tire and wheel assembly from both ends of the axle. 4 - 64 GTH-1048 • GTH-1056 Part No. 123701...

  • Page 134: Outriggers

    Lower the cylinder onto the outrigger. Crushing hazard. The cylinder may become unbalanced and fall if not properly supported when the pivot pin is removed from the machine. Part No. 123701 GTH-1048 • GTH-1056 4 - 65...
  • Page 135 3 Attach a lifting strap from an overhead crane to the barrel end of the outrigger cylinder. Support the cylinder. Do not apply any lifting pressure. 4 Remove the fasteners securing the outrigger cylinder barrel-end pivot pin to the chassis. 4 - 66 GTH-1048 • GTH-1056 Part No. 123701...
  • Page 136 · Key switch in the off position with the key connections very slowly to allow removed the oil pressure to dissipate · Wheels chocked gradually. Do not allow oil to squirt or spray. Part No. 123701 GTH-1048 • GTH-1056 5 - 1...

  • Page 137: Diagnostic Display

    WARNING message. Also on display are the (before Serial Number GTH1012-16292) SPN and FMI codes which are combined to show an engine fault code. amber warning light red stop engine light menu key arrow/scroll keys enter key 5 - 2 GTH-1048 • GTH-1056 Part No. 123701...
  • Page 138 For additional information, refer to the engine operator's manual which came with your machine. Gauge Cluster (from Serial Number GTH1012-16292) FMI Code SPN Code or ASPN Code amber warning light red stop engine light Part No. 123701 GTH-1048 • GTH-1056 5 - 3...

  • Page 139: Engine Fault Codes - Models With John Deere Power

    Range - Low Engine Coolant Temperature High-Least Severe Check Cooling System, Reduce Power Engine Coolant Temperature Check Cooling System, Reduce Power High - Moderately Severe Engine Coolant Temperature Low-Least Severe Check Cooling System 5 - 4 GTH-1048 • GTH-1056 Part No. 123701...
  • Page 140 000641 Turbocharger Actuator Current Low or Open Circuit Contact Servicing Dealer Contact Servicing Dealer Turbocharger Actuator Communication Error Turbocharger Learn Error Contact Servicing Dealer Turbocharger Temperature High-Moderately Severe Contact Servicing Dealer Part No. 123701 GTH-1048 • GTH-1056 5 - 5...
  • Page 141 Contact Servicing Dealer Out of Range High Turbo Compressor Inlet Temperature Input Voltage Contact Servicing Dealer Out of Range Low Turbo Compressor Inlet Temperature Contact Servicing Dealer High - Moderately Severe 5 - 6 GTH-1048 • GTH-1056 Part No. 123701...
  • Page 142 Sensor Supply Voltage #5 Out of Range Low Contact Servicing Dealer 523229 Sensor Supply Voltage #4 Out of Range High Sensor Supply Voltage #4 Out of Range Low Contact Servicing Dealer Part No. 123701 GTH-1048 • GTH-1056 5 - 7...

  • Page 143: Engine Fault Codes - Models With Deutz Power

    Target range to low for ambient air pressure sensor Coolant temperature is out of target range; system reaction generated Target range to high for coolant temperature sensor Target range to low for coolant temperature sensor 5 - 8 GTH-1048 • GTH-1056 Part No. 123701...
  • Page 144 SRC high for EGR cooler downstream temperature sensor SRC low for EGR cooler downstream temperature sensor Timeout Error of CAN-Receive-Frame TSC1TR Break Lever Main switch and Break Lever Redundancy switch status not plausible Part No. 123701 GTH-1048 • GTH-1056 5 - 9...
  • Page 145 Short circuit on low side starter relay No load error starter relay Over load ECU power stage for Starter (overtemp.) Air Heater not connected. 1079 Sensor supply voltage monitor error 1109 Engine off request ignored 5 - 10 GTH-1048 • GTH-1056 Part No. 123701...
  • Page 146 Target range to high for urea pump module pressure sensor before pressure build up Physical range check low for urea pump module pressure sensor 4343 General pressure check error (SCR) 4345 General backflow line plausibility error (SCR) Part No. 123701 GTH-1048 • GTH-1056 5 - 11...
  • Page 147 Exhaust gas temperature sensor signal downstream (DOC) not plausible Target range to high for exhaust gas temperature sensor downstream (DOC) Target range to low for exhaust gas temperature sensor downstream (DOC) 5 - 12 GTH-1048 • GTH-1056 Part No. 123701...
  • Page 148 11 Pressure Relief Valve (PRV) error; Rail pressure out of tolerance range Rail pressure out of tolerance range 12 Pressure Relief Valve (PRV) forced to open; system reaction initiated 14 Pressure Relief Valve (PRV) is open Part No. 123701 GTH-1048 • GTH-1056 5 - 13...
  • Page 149 4 SCR main relay (primary side); short circuit to ground SCR mainrelay; short circuit to ground (only CV56B) 5 SCR main relay (primary side); open load SCR mainrelay; open load (only CV56B) 12 SCR mainrelay; powerstage over temperature (only CV56B) 5 - 14 GTH-1048 • GTH-1056 Part No. 123701...
  • Page 150 13 check of missing injector adjustment value programming (IMA) injector 2 (in firing order) 23896 65144 13 check of missing injector adjustment value programming (IMA) injector 3 (in firing order) 23897 65145 Part No. 123701 GTH-1048 • GTH-1056 5 - 15...
  • Page 151 4 Sensor error burner dosing valve (DV2) downstream pressure sensor; signal range check low 23913 65161 3 Sensor error glow plug control diagnostic line voltage; signal range check high 4 Sensor error glow plug control diagnostic line voltage; signal range check low 5 - 16 GTH-1048 • GTH-1056 Part No. 123701...
  • Page 152 2 Sensor DV1 & DV2 upstream temperature; plausibility error 3 Sensor error DV1 & DV2 upstream temperature; signal range check high 4 Sensor error DV1 & DV2 upstream temperature; signal range check low Part No. 123701 GTH-1048 • GTH-1056 5 - 17...
  • Page 153 1 Fuel Balance Control integrator injector 1 (in firing order); minimum value exceeded 23930 65178 0 Fuel Balance Control integrator injector 2 (in firing order); maximum value exceeded 1 Fuel Balance Control integrator injector 2 (in firing order); minimum value exceeded 5 - 18 GTH-1048 • GTH-1056 Part No. 123701...
  • Page 154 & Sensorcalibration for NOX Sensor (SCR-system upstream cat; DPF- system downstream cat) 9 Timeout Error (PCK2PCK) for CAN-Receive-Frame AT1IGCVol1 information; factors 23940 65188 & Sensorcalibration for NOX Sensor (SCR-system upstream cat; DPF-system downstream cat) Part No. 123701 GTH-1048 • GTH-1056 5 - 19...
  • Page 155 Exhaust gas temperature EGR downstream; out of range, system reaction initiated 14 SCR Tamper detection; derating timer below limit 1 23973 65221 14 SCR Tamper detection; derating timer below limit 2 23974 65222 5 - 20 GTH-1048 • GTH-1056 Part No. 123701...
  • Page 156 65243 13 check of missing injector adjustment value programming (IMA) injector 7 (in firing order) 23996 65244 13 check of missing injector adjustment value programming (IMA) injector 8 (in firing order) Part No. 123701 GTH-1048 • GTH-1056 5 - 21...
  • Page 157 5 DPF system; operating voltage error 14 Particulate filter; regeneration not succesful 24028 65276 2 CAN message PROEGRActr; plausibility error 2 Timeout Error of CAN-Receive-Frame ComEGRActr - exhaust gas recirculation 24029 65277 positioner 5 - 22 GTH-1048 • GTH-1056 Part No. 123701...
  • Page 158 9 Timeout error of CAN-Receive-Frame ComMS_Sys5TO (error memory Slave); Master- Slave internal CAN message 24043 65291 9 Timeout error of CAN-Receive-Frame ComMS_Sys6TO (error memory Slave); Master- Slave internal CAN message 9 CAN message ComMS_Sys7 not received from slave 24044 65292 Part No. 123701 GTH-1048 • GTH-1056 5 - 23...
  • Page 159 65349 9 Timeout error of CAN-Transmit-Frame ComDPFTstMon 24102 65350 9 Timeout error of CAN-Receive-Frame ComRxDPFBrnAirPmpCtl 9 Timeout error of CAN-Receive-Frame ComRxDPFBrnAirPmp 24103 65351 24104 65352 9 Timeout error of CAN-Receive-Frame ComRxDPFCtl 5 - 24 GTH-1048 • GTH-1056 Part No. 123701...
  • Page 160 65370 9 Timeout error of CAN-Receive-Frame ComRxUQSens 24123 65371 9 Timeout error of CAN-Receive-Frame ComSCRHtCtl 24124 65372 9 Timeout error of CAN-Receive-Frame ComTxAT1IMG 24125 65373 9 Timeout error of CAN-Receive-Frame ComTxTrbChActr Part No. 123701 GTH-1048 • GTH-1056 5 - 25...

  • Page 161: Engine Fault Codes - Models With Perkins Power

    Fuel temperature sensor: data erratic/intermittent or incorrect Engine speed signal abnormal Engine speed: overspeed WARNING Engine overspeed Ether start aid current low Ether start aid current high System parameters incorrect Personality module mismatch Engine timing calibration invalid 5 - 26 GTH-1048 • GTH-1056 Part No. 123701...
  • Page 162 5V DC power supply sensor short to ground For further engine fault code troubleshooting and diagnostic information, refer to the Perkins 1100 Troubleshooting Manual (Perkins part number SENR9982-01). Perkins 1100 Troubleshooting Manual Genie part number 123583 Part No. 123701 GTH-1048 • GTH-1056 5 - 27...
  • Page 163 Section 5 • Fault Codes September 2014 This page intentionally left blank. 5 - 28 GTH-1048 • GTH-1056 Part No. 123701...
  • Page 164 Be sure that all necessary tools and test equipment are available and ready for use. Malfunction Identify Troubleshoot discovered symptoms problem still exists Return to Inspect Perform service and test repair problem solved Part No. 123701 GTH-1048 • GTH-1056 6 - 1...

  • Page 165: Proximity Switch Layout

    Section 6 • Schematics May 2015 Proximity Switch Layout Boom Extend Proximity Switch PX1 (under plate at top of boom tube) (GTH-1056 only) Boom Angle Proximity Switch PX2 (under boom pivot pin) 6 - 2 GTH-1048 • GTH-1056 Part No. 123701...

  • Page 166: Fuse Box Layout

    CR22 or CR34 FUSE PANEL F20.1 F20.7 F20.2 F20.8 MACHINE OPTIONS F20.3 F20.9 (REFER TO ELECTRICAL SCHEMATIC) F20.4 F20.10 F20.5 F20.11 F20.6 F20.12 PCB Board Fuse Panel located in the Cab Part No. 123701 GTH-1048 • GTH-1056 6 - 3...

  • Page 167: Fuse Box Layout (From Serial Number Gth1012-16292)

    ANGLE MAIN OPTIONS SERVICE POWER POWER HORN CAP1 50 Amp JOYSTICK CB 1 HARNESS PCB Board Fuse Panel located in the Cab John Deere Engine Circuit Breakers Located in Tank Assembly 6 - 4 GTH-1048 • GTH-1056 Part No. 123701...

  • Page 168: Fuse Box Layout (From Serial Number Gth1014E-10353)

    ENABLE CR10 BOOM FORWARD REVERSE EXTEND ENABLE ENABLE LIGHTS SWAY BOOM OPTION ENABLE ANGLE MAIN OPTIONS SERVICE POWER POWER HORN CAP1 JOYSTICK HARNESS PCB Board Fuse Panel located in the Cab Part No. 123701 GTH-1048 • GTH-1056 6 - 5...

  • Page 169: Electrical Component Legend (Before Serial Number Gth1012-16292)

    Y79 = Crab steer select S12 = Transmission oil pressure Y80 = Transmission "D" S13 = Fuel level Y81 = Transmission "E" Y82 = Sway enable Y83 = Rear axle oscillate fast 6 - 6 GTH-1048 • GTH-1056 Part No. 123701...

  • Page 170: (From Serial Number Gth1012-16292)

    Windshield Wiper Motor Switch S18B Windshield Washer Switch Dome Light Switch Enclosed Cab Fan Switch Road / Work Light Switch Brake Pressure Warning Switch Transmission Oil Pressure Switch Transmission Oil Temp. Switch Part No. 123701 GTH-1048 • GTH-1056 6 - 7...
  • Page 171 Red/White 4Wheel Steer SVD1A Orange Crab Steer SVD1B OR/BK Orange/Black Left Stabilizer Down Left Stabilizer Up OR/RD Orange/Red Right Stabilizer Down White Right Stabilizer Up WH/BK White/Black AC Control WH/RD White/Red 6 - 8 GTH-1048 • GTH-1056 Part No. 123701...

  • Page 172: Telematics Connector Legend

    Monitor machine utilization    *12V = active, 0V = inactive Remote Machine Disable  6  Digital Input 1  12 VDC  Remote Engine Shutdown  ** Configurable Active High or Active  Low via wiring at the Disable Relay  7  CAN HIGH  J1939  Databus HIGH J1939  Receive J1939 Engine data  8  CAN LOW  J1939  Databus LOW J1939  Receive J1939 Engine data    Remote Disable Relay Configuration  Telematic device software should monitor that Pin 3 is at 0V before activating Disable Relay    A Deutsch plug p/n DT06‐08SA mates with the Genie Telematics connector   Wireless Certifications  Telematic device(s) should comply with specific wireless carrier certifications where applicable and comply with  the following:  N. America – PTCRB, FCC/IC  Europe – CE, R&TTE  Part No. 123701 GTH-1048 • GTH-1056 6 - 9...

  • Page 173: Electrical And Hydraulic Symbols Legends

    Valve coil with diode 2 position 2 way 2 position 4 way solenoid valve solenoid valve Diode Switch Joystick Proximity switch Limit switch Counterbalance valve Temperature switch Fuel level sender Pressure switch Battery 6 - 10 GTH-1048 • GTH-1056 Part No. 123701...

  • Page 174: Harness Map - Control System Power Single Joystick

    Section 6 • Schematics May 2015 Harness Map - Control System Power Single Joystick 6 - 12 6 - 11...
  • Page 175 Section 6 • Schematics May 2015 Harness Map - Control System Power Single Joystick HARNESS LEGEND SJ NUM. PART DESCRIPTION 823054 HARNESS, DASHBOARD 214539 HARNESS, SECONDARY MANIFOLD 219457 HARNESS, BACKUP ALARM 162065 HARNESS, TRANSMISSION 123588 HARNESS, BOOM EXT SW, 1056 217207 HARNESS, THROTTLE PEDAL 214443...

  • Page 176: Harness Map - Control System Ground Single Joystick

    May 2015 Section 6 • Schematics Harness Map - Control System Ground Single Joystick STABILIZER MANIFOLD HARNESS LEGEND GND_SJ NUM. PART DESCRIPTION 823054 HARNESS, DASHBOARD 214539 HARNESS, SECONDARY MANIFOLD 162065 HARNESS, TRANSMISSION 161444 ASSEMBLY, GROUND BUSS 214538 HARNESS, PRIMARY MANIFOLD SJ 1255981 HARNESS, HERTZ TELEMATICS ES0462F...
  • Page 177 May 2015 Section 6 • Schematics Harness Map - Control System Ground Single Joystick 6 - 13 6 - 14...

  • Page 178: Harness Map - Control System Power Dual Joysticks

    Section 6 • Schematics May 2015 Harness Map - Control System Power Dual Joystick 6 - 16 6 - 15...
  • Page 179 Section 6 • Schematics May 2015 Harness Map - Control System Power Dual Joystick HARNESS LEGEND DJ NUM. PART DESCRIPTION 823054 HARNESS, DASHBOARD 214539 HARNESS, SECONDARY MANIFOLD 219457 HARNESS, BACKUP ALARM 162065 HARNESS, TRANSMISSION 123588 HARNESS, BOOM EXT SW, 1056 217207 HARNESS, THROTTLE PEDAL 214443...

  • Page 180: Harness Map - Control System Ground Dual Joysticks

    May 2015 Section 6 • Schematics Harness Map - Control System Ground Dual Joystick STABILIZER MANIFOLD HARNESS LEGEND GND_DJ NUM. PART DESCRIPTION 823054 HARNESS, DASHBOARD 214539 HARNESS, SECONDARY MANIFOLD 162065 HARNESS, TRANSMISSION 161444 ASSEMBLY, GROUND BUSS 214446 HARNESS, PRIMARY MANIFOLD DJ 1255981 HARNESS, HERTZ TELEMATICS ES0462F...
  • Page 181 May 2015 Section 6 • Schematics Harness Map - Control System Ground Dual Joystick 6 - 17 6 - 18...
  • Page 182 Section 6 • Schematics May 2015 Harness Map - Deutz TCD3.6 Engine Battery Power and Ground 6 - 20 6 - 19...

  • Page 183: Harness Map - Deutz 3.6Tcd Engine Battery Power And Ground

    Section 6 • Schematics May 2015 Harness Map - Deutz 3.6TCD Engine Battery Power and Ground HARNESS LEGEND DEUTZ TCD3.6 NUM. PART DESCRIPTION 227493 HARNESS, TRANSMISSION 229033 CABLE, BATTERY, RED 3/0 130719 CABLE, BATTERY BLACK 000 237933 HARNESS, POWER LEAD 7-319-17 GROUND STRAP, 12 IN 237933...

  • Page 184: Harness Map - Perkins 1104D Engine Battery Power And Ground

    May 2015 Section 6 • Schematics Harness Map - Perkins 1104D Engine Battery Power and Ground HARNESS LEGEND PERKINS 1104D NUM. PART DESCRIPTION 227493 HARNESS, TRANSMISSION 229033 CABLE, BATTERY, RED 3/0 130719 CABLE, BATTERY BLACK 000 237933 HARNESS, POWER LEAD 7-319-17 GROUND STRAP, 12 IN 237933...
  • Page 185 May 2015 Section 6 • Schematics Harness Map - Perkins 1104D Engine Battery Power and Ground 6 - 21 6 - 22...

  • Page 186: Harness Map - Perkins 854E Engine Battery Power And Ground

    Section 6 • Schematics May 2015 Harness Map - Perkins 854E Engine Battery Power and Ground 6 - 24 6 - 23...
  • Page 187 Section 6 • Schematics May 2015 Harness Map - Perkins 854E Engine Battery Power and Ground HARNESS LEGEND PERKINS 1204E NUM. PART DESCRIPTION 227493 HARNESS, TRANSMISSION 229033 CABLE, BATTERY, RED 3/0 130719 CABLE, BATTERY BLACK 000 237933 HARNESS, POWER LEAD 237933 HARNESS, PCB GROUND 161444...

  • Page 188: Harness Map - Options

    May 2015 Section 6 • Schematics Harness Map - Options Auxiliary Hydraulics, Beacon and 3rd Gear Lockout HARNESS LEGEND AUX, BEA, LKOT OPTIONS NUM. PART DESCRIPTION 161444 ASSEMBLY, GROUND BUSS 215332 HARNESS, AUXILIARY HYDRAULICS 229683 HARNESS, BEACON POWER 229862 HARNESS, POWER, BEACON LIGHT 826879 HARNESS, TOP GEAR LOCKOUT 1255981...
  • Page 189 May 2015 Section 6 • Schematics Harness Map - Options Auxiliary Hydraulics, Beacon and 3rd Gear Lockout 6 - 25 6 - 26...

  • Page 190: Harness Map - Options Work Lights

    Section 6 • Schematics May 2015 Harness Map - Options Work Lights 6 - 28 6 - 27...
  • Page 191 Section 6 • Schematics May 2015 Harness Map - Options Work Lights HARNESS LEGEND WORK LIGHT OPTION NUM. PART DESCRIPTION 161444 ASEMBLY, GROUND BUSS 233989 HARNESS, CAB LIGHT 214334 HARNESS, CAB LIGHT POWER 229677 HARNESS, TAIL LIGHT LED 229678 HARNESS, BACKUP LIGHT LED 215331 HARNESS, WORK LIGHTS ES0462F...

  • Page 192: Harness Map - Options Road Lights

    May 2015 Section 6 • Schematics Harness Map - Options Road Lights HARNESS LEGEND ROAD LIGHT OPTION NUM. PART DESCRIPTION 161444 ASSEMBLY, GROUND BUSS 233989 HARNESS, CAB LIGHT 214334 HARNESS, CAB LIGHT POWER 229677 HARNESS, TAIL LIGHT LED 123929 ROAD LIGHT BLINKER 215329 HARNESS, ROAD LIGHTS 123925...
  • Page 193 May 2015 Section 6 • Schematics Harness Map - Options Road Lights 6 - 29 6 - 30...

  • Page 194: Harness Map - Options Enclosed Cab With Heater

    Section 6 • Schematics May 2015 Harness Map - Options Enclosed Cab with Heater 6 - 32 6 - 31...
  • Page 195 Section 6 • Schematics May 2015 Harness Map - Options Enclosed Cab with Heater HARNESS LEGEND CAB W/HEATER OPTION NUM. PART DESCRIPTION 161444 ASSEMBLY, GROUND BUSS 233812 HARNESS, ENCLOSED CAB 234859 HARNESS, CAB FAN 233940 HARNESS, POWER, DOME LIGHT 123817 DOME LIGHT WITH CONNECTORS 234861 HARNESS, CAB HEATER...

  • Page 196: Harness Map - Options Enclosed Cab With Hvac

    May 2015 Section 6 • Schematics Harness Map - Options Enclosed Cab with HVAC HARNESS LEGEND CAB W/HVAC OPTION NUM. PART DESCRIPTION 161444 ASSEMBLY, GROUND BUSS 233812 HARNESS, ENCLOSED CAB 234859 HARNESS, CAB FAN 233940 HARNESS, POWER, DOME LIGHT 123817 DOME LIGHT WITH CONNECTORS 238126 HARNESS, CAB A/C...
  • Page 197 May 2015 Section 6 • Schematics Harness Map - Options Enclosed Cab with HVAC 6 - 33 6 - 34...

  • Page 198: Electrical Schematic

    Section 6 • Schematics May 2015 Electrical Schematic - View 1 (before serial number GTH1012-16292) 6 - 36 6 - 35...
  • Page 199 Section 6 • Schematics May 2015 Electrical Schematic - View 1 (before serial number GTH1012-16292) DOME LIGHT STROBE LIGHT OPTION OPTION BELOW BELOW F20.2 F20.3 F20.4 F20.5 F20.7 F20.6 F20.8 F20.1 CR88 5 AMP 15 AMP 10 AMP 10 AMP 5 AMP 5 AMP 10 AMP...
  • Page 200 May 2015 Section 6 • Schematics Electrical Schematic - View 2 (before serial number GTH1012-16292) AIR CONDITIONING HEATER/DEFROSTER FAN WINDSHIELD WINDSHIELD WASH DOME LIGHT STROBE LIGHT WORK LIGHT ROAD LIGHT (OPTION) OPTION OPTION WIPER OPTION OPTION OPTION HEAT VALVE A/C SWITCH BLOWER SWITCH POTENTIOMETER (ON/OFF)
  • Page 201 May 2015 Section 6 • Schematics Electrical Schematic - View 2 (before serial number GTH1012-16292) 6 - 37 6 - 38...

  • Page 202: From Serial Number Gth1012-16292 To

    Section 6 • Schematics May 2015 Electrical Schematic - View 1 (from serial number GTH1012-16292 to 19340) 6 - 40 6 - 39...

  • Page 203: Electrical Schematic

    Section 6 • Schematics May 2015 Electrical Schematic - View 1 (from serial number GTH1012-16292 to 19340) Ω ES0462D 6 - 40 GTH-1056 Part No. 123701...
  • Page 204 May 2015 Section 6 • Schematics Electrical Schematic - View 2 (from serial number GTH1012-16292 to 19340) Ω Ω Ω Ω ES0462D Part No. 123701 GTH-1056 6 - 41...
  • Page 205 May 2015 Section 6 • Schematics Electrical Schematic - View 2 (from serial number GTH1012-16292 to 19340) 6 - 41 6 - 42...

  • Page 206: From Serial Number Gth1014-19341,

    Section 6 • Schematics May 2015 Electrical Schematic - View 1 (from serial number GTH1014-19341, GTH1014E-1001) 6 - 44 6 - 43...

  • Page 207: Electrical Schematic

    Section 6 • Schematics May 2015 Electrical Schematic - View 1 (from serial number GTH1014-19341, GTH1014E-1001) ES0462G 6 - 44 GTH-1056 Part No. 123701...
  • Page 208 May 2015 Section 6 • Schematics Electrical Schematic - View 2 (from serial number GTH1014-19341, GTH1014E-1001) Ω Ω Ω Ω ES0462G Part No. 123701 GTH-1056 6 - 45...
  • Page 209 May 2015 Section 6 • Schematics Electrical Schematic - View 2 (from serial number GTH1014-19341, GTH1014E-1001) 6 - 45 6 - 46...

  • Page 210: Hydraulic Schematic Models With Single Joystick

    Section 6 • Schematics May 2015 Hydraulic Schematic Models with Single Joystick 6 - 48 6 - 47...
  • Page 211 Section 6 • Schematics May 2015 Hydraulic Schematic Models with Single Joystick Y77A Y77B Note: 'alpha' callouts refer to components shown in the manifold illustrations. FR50 Refer to the Repair Section. SV08 3 gpm 11.4 L/min HS0201E 6 - 48 GTH-1056 Part No.

  • Page 212: Models With Dual Joysticks

    May 2015 Section 6 • Schematics Hydraulic Schematic Models with Dual Joystick Y77A Y77B SWAY ENABLE PRESS (50 PSI) 50 PSI FR50 SV08 3 gpm 11.4 L/min Note: 'alpha' callouts refer to components shown in the manifold illustrations. HS0202E Refer to the Repair Section. Part No.
  • Page 213 May 2015 Section 6 • Schematics Hydraulic Schematic Models with Dual Joystick 6 - 49 6 - 50...

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