Genie GTH-1048 Service Manual
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Genie GTH-1048 Service Manual

Serial number range from gth1007a-11443 to gth1009a-14000/from gth1007b-7101 to gth1007b-7251
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Download this manual See also: Service Manual, Operator's Manual
Service Manual
GTH-1048
GTH-1056
Serial Number Range
from GTH1007A-11443 to
GTH1009A-14000
from GTH1007B-7101 to
GTH1007B-7251
Part No. 123701
Rev G
March 2016
Courtesy of Crane.Market

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Summary of Contents for Genie GTH-1048

  • Page 1 Service Manual Serial Number Range from GTH1007A-11443 to GTH-1048 GTH1009A-14000 from GTH1007B-7101 to GTH-1056 GTH1007B-7251 Part No. 123701 Rev G March 2016 Courtesy of Crane.Market...

  • Page 2: Introduction

    Copyright © 2011 by Terex Corporation 123701 Rev G, March 2016 Second Edition, Seventh Printing Genie is a registered trademark of Terex South Dakota, Inc. in the U.S.A. and many other countries. "GTH" is a trademark of Terex South Dakota, Inc.

  • Page 3: Revision History

    Schem Electrical and Hydraulic 5/2015 Schem Fuse Box Layout / Electrical 3/2016 Ending SN for GTH-1048 Ending SN for GTH-1056 for MM/SRM Reference Examples: Section – Maintenance, B-3 Electronic Version Section – Repair Procedure, 4-2 Click on any content or procedure in the Table of Contents to view Section –...

  • Page 4: Serial Number Legend

    2 Model year 3 Facility code (for models manufactured in multiple facilities) 4 Sequence number 5 Serial label 6 Serial number (stamped on chassis) 7 Serial label (located inside fork frame) GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 5: 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. GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...
  • Page 6 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. GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 7: Table Of Contents

    Hydraulic Hose and Fitting Torque Specifications ..........11 Torque Procedure ....................12 Section 3 Scheduled Maintenance Procedures ............... 13 Introduction ......................13 Pre-Delivery Preparation Report ................16 Maintenance Inspection Report................17 Maintenance Inspection Report................18 GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...
  • Page 8 C-5 Perform Engine Maintenance - Perkins Models..........36 C-6 Perform Engine Maintenance - Perkins Models..........36 C-7 Adjust the Boom Sequencing Chains ............37 C-8 Perform Axle Maintenance ................38 C-9 Perform Axle Maintenance ................38 GTH-1048 • GTH-1056 viii Part No. 123701 Courtesy of Crane.Market...
  • Page 9 How to Replace the Retraction Chain ............. 52 How to Replace the Extension Chains ............55 How to Remove the Boom ................57 How to Disassemble the Boom - GTH-1048 ........... 59 How to Disassemble the Boom - GTH-1056 ........... 61 1-3 Boom Lift Cylinder ..................64 GTH-1048 •...
  • Page 10 1-5 Fork Level Cylinder ..................66 1-6 Hydraulic Hoses ..................... 67 How to Replace the Fork Level and/or Auxiliary Cylinder Hoses, GTH-1048 ............67 How to Replace the Fork Level and/or Auxiliary Cylinder Hoses, GTH-1056 ............68 Operator's Compartment ................... 71 2-1 Operator's Compartment ................
  • Page 11 How to Remove the Axle ................109 How to Repair the Axle ................. 109 Outriggers ......................110 9-1 Outriggers..................... 110 How to Remove an Outrigger ................ 110 How to Remove an Outrigger Cylinder ............111 GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...
  • Page 12 Hydraulic Symbols Legend ................132 Electrical Schematics ..................133 Electrical Schematic ................... 134 Hydraulic Schematics ..................137 Hydraulic Schematic - Models with Single Joystick ........... 138 Hydraulic Schematic - Models with Dual Joystick ..........139 GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 13: Specifications

    50 psi (models with air-filled tires) 3.45 bar Lug nut torque 465 ft-lbs 630 Nm Lug Pattern 10 x 13.189 Wheel diameter 24 in 60.1 cm Wheel width 9 in 22.9 cm GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 14: Performance Specifications

    GTH-1056 Boom up 17 to 19 seconds Boom down 23 to 25 seconds Boom extend 14 to 16 seconds Boom retract 13 to 15 seconds Fork rotate 3 to 6 seconds GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 15: Hydraulic Specification

    Hydraulic fluids may be incompatible 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 16 @ 149°F / 65°C cSt @ 104°F / 40°C cSt @ 0°F / -18°C 1300 Flash point None Pour point -81°F / -63°C Maximum continuous operating 189°F / 87°C temperature GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...
  • Page 17 5606A hydraulic fluid, or ambient temperature is below -20°F / -29°C with equivalent, when ambient Rando HD Premium MV. temperatures are consistently above 32°F / 0°C may result in component damage GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 18: Hydraulic Component Specifications

    (measured at test port TJ) 27.5 bar Rear lock-up relief valve pressure, 50 psi maximum 3.4 bar (measured at test port TR) Outrigger Manifold Flow regulator, Outrigger circuit 6 gpm 22.7 L/min GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 19: Manifold Component Specifications

    SAE No. 6 18 ft-lbs / 24 Nm SAE No. 8 50 ft-lbs / 68 Nm SAE No. 10 55 ft-lbs / 75 Nm SAE No. 12 75 ft-lbs / 102 Nm GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 20: John Deere 4045Hf485 Engine Specifications

    Break-In Oil as needed to maintain the specified oil level. Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator's Manual on your machine. GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 21: Perkins 1104D-E44Ta Engine Specifications

    85A @ 14V DC Unit ships with 15W-40. Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Manual for your engine. GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 22: Dana T20000 Transmission Specifications

    Planetary ends Chevron Supreme 80W90 LS For additional axle information, refer to the Dana 213 Axle Maintenance and Repair Manual Dana 213 Axle Maintenance and Repair Manual Genie part number 115026 GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 23: Hydraulic Hose And Fitting Torque Specifications

    Your machine is equipped with Parker Seal-Lok™ SAE Dash Size Torque ORFS or 37° JIC fittings and hose ends. Genie specifications require that fittings and hose ends 14 ft-lbs / 19 Nm be torqued to specification when they are removed 23 ft-lbs / 31.2 Nm...

  • Page 24: Torque Procedure

    O-rings. They are not 1 hex nut standard size O-rings. They are available in the 2 reference mark O-ring field service kit (Genie part number 49612). 3 body hex fitting Lubricate the O-ring before installation. Working clockwise on the body hex fitting,...

  • Page 25: Scheduled Maintenance Procedures

     Repair any machine damage or malfunction before operating the machine.  Use only Genie approved replacement parts.  Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection.

  • Page 26: About This Section

    Indicates that a specific result is expected after performing a series of steps. Indicates that an incorrect result has occurred after performing a series of steps. GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...
  • Page 27 Make copies of the Maintenance Inspection Report to use for each inspection. Maintain completed forms for a minimum of 4 years or in compliance with your employer, jobsite and governmental regulations and requirements. GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 28: Pre-Delivery Preparation Report

    Service Manual March 2016 Pre-Delivery Preparation Report Pre-Deliv ery Prepar ati on Repor t Fundamentals Instructions It is the responsibility of the owner or dealer to Use the operator’s manual on your machine. perform the Pre-delivery Preparation. The Pre-delivery Preparation consists of The Pre-delivery Preparation is performed prior to completing the Pre-operation Inspection, the each delivery.

  • Page 29: Maintenance Inspection Report

    After repair, place a check in the "R" box. Driveshaft B-10 Engine Maintenance Legend Y = yes, acceptable N = no, remove from service R = repaired GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 30: Maintenance Inspection Report

    After repair, place a check in the "R" box. Legend Y = yes, acceptable N = no, remove from service R = repaired GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 31: Checklist A Procedures

    Carefully and thoroughly Inspect the Manuals and Decals inspect all decals on the machine for legibility and damage. Genie specifications require that this procedure be performed every 8 hours or daily, whichever Result: The machine is equipped with all comes first.

  • Page 32: Perform Pre-Operation Inspection

    A-3 Per form F uncti on Tes ts 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 33: Lubricate The Boom

    A-5 Per form Engi ne M ai ntenance - All M odels Lubricate the Boom Perform Engine Maintenance - All Models Genie specifications require that this procedure be performed every 8 hours or daily, whichever Engine specifications require that this procedure comes first.

  • Page 34: Perform Transmission Maintenance

    Dana T20000 Service Manual John Deere Models Genie part number 115025 All models: • B-5 Inspect the Tires, Wheels and Lug Nut Torque • D-2 Replace the Hydraulic Tank Return Filter Element GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 35: Perform Axle Maintenance

    John Deere 4045HF485 Operator's Manual. Dana 213 Axle Maintenance and Repair Manual Genie part number 115026 John Deere 4045HF485 Operator's Manual Genie part number 123703 GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 36: Perform Axle Maintenance

    Dana 213 Axle Maintenance and Repair Manual. Maintenance and Repair Manual. Dana 213 Axle Maintenance and Repair Manual Dana 213 Axle Maintenance and Repair Manual Genie part number 115026 Genie part number 115026 GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 37: Checklist B Procedures

    Note: Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion Genie requires that this procedure be performed on the battery terminals and cables. every 250 hours or quarterly, whichever comes Be sure that the battery retainers and cable first.

  • Page 38: Inspect The Electrical Wiring

    11 Check the ambient air temperature and adjust the specific gravity reading for each cell as follows: Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes • Add 0.004 to the reading of each cell for first.

  • Page 39: Check The Exhaust System

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

  • Page 40: Inspect The Engine Air Filter

    B-5 Ins pect the Tir es, Wheels and Lug N ut T orque 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 specifications require that this procedure be first.

  • Page 41: Perform Hydraulic Oil Analysis

    B-7 Ins pect the F uel and Hy draulic T ank C ap Venting Systems Perform Hydraulic Oil Analysis Inspect the Fuel and Hydraulic Tank Cap Venting Systems Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever Genie specifications require that this procedure be comes first.

  • Page 42: Check The Boom Wear Pads

    Check the Boom Wear Pads compressed air. Repeat this procedure beginning with step 2. Install the fuel tank cap onto the fuel tank. Genie specifications require that this procedure be Remove the breather cap from the hydraulic performed every 250 hours of operation. tank.

  • Page 43: Lubricate The Driveshaft

    Lubricate the Driveshaft Measure each side wear pad. Result: The measurement is within specification. Genie requires that this procedure be performed Result: The measurement is less than every 250 hours or quarterly, whichever comes specification. Replace all side wear pads.

  • Page 44: Perform Engine Maintenance - John Deere Models

    • Engine oil and filter - change Required maintenance procedures and additional engine information is available in the John Deere 4045HF485 Operator's Manual. John Deere 4045HF485 Operator's Manual Genie part number 123703 GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 45: Checklist C Procedures

    Sequencing Chains Inspect the chains for the following conditions: • Elongation • BL666 chain - Measure 16 pitches of the Genie specifications require that this procedure be extend chain for machines using performed every 500 hours or semi-annually, BL666 chain.

  • Page 46: Perform Engine Maintenance - John Deere Models

    All excess lubricant should be wiped away from the external surfaces. Note: Do not use solvents to remove excess lubricant. GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 47: Perform Axle Maintenance

    Required maintenance procedures and additional transmission information is available in the Dana Dana 213 Axle Maintenance and Repair Manual T20000 Maintenance Manual. Genie part number 115026 Dana T20000 Service Manual Genie part number 115025 GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 48: Perform Engine Maintenance - Perkins Models

    • Radiator - clean Required maintenance procedures and additional engine information is available in the Perkins 1104 Operation and Maintenance Manual. Perkins 1104 Operation and Maintenance Manual Genie part number 117765 GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 49: Adjust The Boom Sequencing Chains

    Repeat this procedure beginning with step 4 until the gap is between 0.25 to 0.5 inch / Genie specifications require that this procedure be 6.35 to 12.7 mm. performed every 500 hours or six months, Note: If the adjusting bolt runs out of threads whichever comes first.

  • Page 50: Perform Axle Maintenance

    Dana 213 Axle Maintenance and Repair Manual. Maintenance and Repair Manual. Dana 213 Axle Maintenance and Repair Manual Dana 213 Axle Maintenance and Repair Manual Genie part number 115026 Genie part number 115026 GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 51: Checklist D Procedures

    D-1 Inspec t the F orks Perform Transmission Inspect the Forks Maintenance - Dana Models Genie specifications require that this procedure be performed every 1000 hours or annually, Transmission specifications require that this whichever comes first OR whenever permanent procedure be performed every 1000 hours or deformation of the forks is suspected.

  • Page 52: Replace Hydraulic Tank Return Filter Element

    Perform Axle Maintenance Filter Element Axle specifications require that this procedure be performed every 1000 hours of operation. Genie specifications require that this procedure be performed every 1000 hours or annually, Required maintenance procedures and additional whichever comes first. axle information is available in the Dana 213 Axle Maintenance and Repair Manual.

  • Page 53: Perform Engine Maintenance - Perkins Models

    • Engine valve lash - inspect/adjust Required maintenance procedures and additional engine information is available in the Perkins 1104 Operation and Maintenance Manual. Perkins 1104 Operation and Maintenance Manual Genie part number 117765 GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 54: Checklist E Procedures

    Remove oil cap from top of hydraulic tank. Using an approved hand-operated pump, drain the hydraulic tank into a suitable container. Refer to Specifications, Hydraulic Genie specifications require that this procedure be Specifications. performed every 2000 hours or every two years, Bodily injury hazard. Beware of whichever comes first.

  • Page 55: Perform Engine Maintenance - John Deere Models

    • Water pump - inspect Required maintenance procedures and additional engine information is available in the Perkins 1104 Operation and Maintenance Manual. Perkins 1104 Operation and Maintenance Manual Genie part number 117765 GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 56: Perform Engine Maintenance - Perkins Models

    John Deere 4045HF485 Operator's Manual engine information is available in the Perkins 1104 Genie part number 123703 Operation and Maintenance Manual. Perkins 1104 Operation and Maintenance Manual Genie part number 117765 GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 57: Perform Engine Maintenance - Perkins Models

    • Cooling System Coolant (Extended life coolant) - change Required maintenance procedures and additional engine information is available in the Perkins 1104 Operation and Maintenance Manual. Perkins 1104 Operation and Maintenance Manual Genie part number 117765 GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 58: Repair Procedures

     Be sure that all necessary tools and parts are available and ready for use.  Use only Genie approved replacement parts.  Read each procedure completely and adhere to the instructions. Attempting shortcuts may produce hazardous conditions.
  • Page 59 Indicates that a specific result is expected after performing a series of steps. Indicates that an incorrect result has occurred after performing a series of steps. GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 60: Boom Components

    The boom proximity switch is a component of the drive circuit and the chassis sway circuit. Both the drive and the chassis sway functions are disabled when the boom is raised to 60° or higher. GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 61: How To Adjust The Boom Angle Proximity Switch

    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. GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 62: Boom

    Note: Do not lubricate the side wear pads. supported when the lock pin is removed from the machine. Install the wear pads. Install and securely tighten the fasteners. Do not over tighten. GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 63: How To Remove The Cable Bridge Assembly , Gth-1056

    (if equipped). bracket to boom tube number 3. The three-section boom on the GTH-1048 does Working at the fork end of the boom, remove not require the use of a cable bridge.

  • Page 64: How To Replace The Retraction Chain

    0. After noting the orientation and assembly order of the components, remove the fasteners and pull the tensioners free of the boom. GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...
  • Page 65 March 2016 Service Manual Boom Components GTH-1048: Working at the fork end of the Remove the inspection cover from the pivot boom, loosen the fasteners securing the end of the boom. single-chain tensioners to the top of boom 10 GTH-1056: Locate the two chain anchors of tube number 1.
  • Page 66 17 Remove the rope from the end of the chain 25 GTH-1048: Install the chain tensioners into and securely attach the rope to the new chain. the tensioner mount at the fork end of boom tube number 1.

  • Page 67: How To Replace The Extension Chains

    0. After noting the orientation and assembly order of the components, remove the fasteners and pull the tensioners free of the boom. GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...
  • Page 68 Service Manual March 2016 Boom Components 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. Securely connect a 30 foot / 10 m single-chain tensioners to the top of boom length of rope to the end of the chain.

  • Page 69: How To Remove The Boom

    Attach a lifting strap from an overhead 10 ton / 24 GTH-1048: Install the chain tensioners into 10,000 kg crane to the fork end of the boom. the tensioner mount at the fork end of boom Support the boom.
  • Page 70 Crushing hazard. The lift cylinder will fall if not properly supported when the boom is raised. 15 Remove the fasteners securing the boom pivot pin to the chassis. GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 71: How To Disassemble The Boom - Gth-1048

    March 2016 Service Manual Boom Components How to Dis ass embl e the Boom - GTH-1048 How to Disassemble the Boom - Remove the fastener securing the fork level cylinder rod-end pivot pin to the fork frame GTH-1048 mount. Bodily injury hazard. This...
  • Page 72 3. 16 Working at the fork end of the boom, remove the clamps securing the hoses to the inside of boom tube number 3. GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 73: How To Disassemble The Boom - Gth-1056

    Crushing hazard. The cylinder could become unbalanced and fall if not properly supported when removed from the machine. Repeat this procedure beginning with step 3 for the other lift cylinder. GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...
  • Page 74 Remove the bracket from the boom. 16 Working at the pivot end of the boom, tag, disconnect and plug the hydraulic hoses at the hard lines of the cable bridge. Cap the fittings. GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...
  • Page 75 Remove the chain rollers from the boom. 29 Working at the pivot end of the boom, remove the fasteners securing the retraction chain block pivot pin to boom tube number 2. Remove the pivot pin. GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 76: Boom Lift Cylinder

    0 if not properly supported and attached to the overhead crane. Note: During removal, the overhead crane strap will need to be adjusted for proper balancing. GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 77: Boom Extension Cylinder

    Hoses can be damaged if they are kinked or pinched. Attach a lifting strap from an overhead crane to the center point of the boom extension cylinder. Support the cylinder. Do not apply any lifting pressure. GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 78: Fork Level Cylinder

    Use a soft metal drift to remove the pivot pin. Attach a lifting strap from an overhead crane to the barrel end of the fork level cylinder. Support the cylinder. Do not apply any lifting pressure. GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 79: Hydraulic Hoses

    Hydraulic Hoses Cap the fittings. How to R eplac e the F ork Lev el and/or Auxiliary Cylinder Hoses , GTH-1048 How to Replace the Fork Level Bodily injury hazard. Spraying hydraulic oil can penetrate and and/or Auxiliary Cylinder Hoses, burn skin.

  • Page 80: How To Replace The Fork Level And/Or Auxiliary Cylinder Hoses, Gth-1056

    How to R eplac e the F ork Lev el and/or Auxiliary Cylinder Hoses , GTH-1056 gradually. Do not allow oil to squirt or spray. Component damage hazard. Hoses can be damaged if they are kinked or pinched. GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...
  • Page 81 Cap the tighten. fittings. 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. GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...
  • Page 82 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. GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 83: Operator's Compartment

    J1, J2, J3 and J4 of the primary disconnect and plug the hydraulic hoses at function manifold. Cap the fittings. ports BP and BT of the secondary function manifold. Cap the fittings. Refer to Secondary Function Manifold Components. GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...
  • Page 84 Component damage hazard. connectors next to the operator's Hoses, cables and wires can be compartment. damaged if they are kinked or pinched. Bolt torque specification Operator's cab mounting bolts 750 ft-lbs 1017 Nm GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 85: Machine Controls

    11 Support and secure the steer orbitral to the dash frame. 12 Remove the fasteners securing the steer column and steer orbitral to the dash frame. 13 Lower the steer orbitral and remove the steer column from the machine. GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 86: How To Remove The Steer Orbitral

    Remove the fasteners securing the joystick to the mount panel. Remove the joystick. Slowly move the steer orbitral away from the dash frame while feeding all loose hoses through the opening of the chassis. GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 87: How To Remove The Joystick - Models With Dual Joysticks

    Remove the fasteners securing the joystick to the mount panel. Remove the joystick. GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 88: How To Remove The Gauge Cluster Assembly

    Tag and disconnect the wire harness from the diagnostic display. Remove the diagnostic Tag and disconnect the wire harness from the display from the machine. dash cluster. Remove the dash cluster from the machine. GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 89: Fuel And Hydraulic Tanks

    Tag and disconnect the wire harness from the Crushing hazard. The tank fuel level terminals. assembly could become unbalanced and fall if not Remove the filler cap from the hydraulic tank. properly supported when removed from the machine. GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 90: Engines

    Perkins 1100 Operation and Maintenance Manual at the fuel filter/water separator. Cap the Genie part number 123702 fitting. Perkins 1104 Service Manual Genie part number 117764 Perkins 1100 Troubleshooting Manual Genie part number 123583 GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 91: Engine Fault Codes

    11 Remove the fasteners securing the engine tray to the chassis. 12 Support and secure the engine tray to a forklift of adequate capacity. 13 Remove the engine tray from the machine. GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 92: Transmission

    Hoses can be damaged if they 6 transmission shift coil '1' (gear reduction) are kinked or pinched. (yellow wire) Note: refer to electrical schematic for additional transmission shift coil information. How to R emove the Transmission GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...
  • Page 93 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. GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 94: Hydraulic Pump

    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. GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 95: How To Remove The Function Pump

    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. GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 96: How To Install The Function

    Procedures, How to Adjust the Function Pump Standby Pressure and How to Adjust the Function Pump Pressure Pressure Compensator. 1 case drain filler plug 2 case drain hose 3 hydraulic supply line (from tank) GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 97: How To Adjust The Function Pump Standby Pressure

    ±25 psi / 31 ±1.7 bar. The pump is functioning correctly. Proceed to step 6. Result: The pressure gauge fails to read 450 ±25 psi / 31 ±1.7 bar. The pressure setting needs to be adjusted. Proceed to step 4. GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 98: How To Adjust The Function Pump Pressure Compensator

    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. GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...
  • Page 99 Do not allow oil to squirt or spray. 1 pressure compensator adjustment screw 2 set screw 3 hydraulic supply line (from tank) GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 100: Manifolds

    Priority flow regulator valve, 2 gpm Sway left/right circuit 20 ft-lbs / 27 Nm / 7.6 L/min Check valve, 5 psi / 0.3 bar Sway left circuit 12-14 ft-lbs / 16-19 Nm GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...
  • Page 101 March 2016 Service Manual Manifolds GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...
  • Page 102 Solenoid valve, 2 position 4 way Function select -boom extend 20 ft-lbs / 27 Nm and sway right Solenoid valve, 2 position 2 way Function select - sway left/right 20 ft-lbs / 27 Nm GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...
  • Page 103 March 2016 Service Manual Manifolds GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 104: Primary Function Manifold Components - Models With Dual Joysticks

    Check valve, 5 psi / 0.3 bar Sway left circuit 12-14 ft-lbs / 16-19 Nm Priority flow regulator valve, 2 gpm / 7.6 Sway left/right circuit 20 ft-lbs / 27 Nm L/min GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...
  • Page 105 March 2016 Service Manual Manifolds GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...
  • Page 106 Directional valve, 2 position 2 way, pilot Fork tilt circuit 25 ft-lbs / 34 Nm operated Diagnostic nipple Test port 'TP' Solenoid valve, 2 position 2 way Function select - sway 20 ft-lbs / 27 Nm left/right GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...
  • Page 107 March 2016 Service Manual Manifolds GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 108: Secondary Function Manifold Components

    20 ft-lbs / 27 Nm select Solenoid valve, 2 position 3 way Differential lock-up select 20 ft-lbs / 27 Nm Diagnostic nipple Test port 'TJ' Diagnostic nipple Test port 'TS' Diagnostic nipple Test port 'TR' GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...
  • Page 109 March 2016 Service Manual Manifolds GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 110: Outrigger Manifold Components

    Check valve, 5 psi / 0.3 bar Left outrigger retract circuit 12-14 ft-lbs / 16-19 Nm Check valve, 5 psi / 0.3 bar Right outrigger retract 12-14 ft-lbs / 16-19 Nm circuit GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...
  • Page 111 March 2016 Service Manual Manifolds GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 112: Auxiliary Manifold Components (Option)

    60 in-lbs / 6.8 Nm Flow regulator valve Function speed control 25 ft-lbs / 34 Nm Check valve, 5 psi / 0.3 bar Auxiliary 'A2' circuit 12-14 ft-lbs / 16-19 Nm GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 113: Brake Manifold Components

    Pressure switch, 450 psi / 31 bar Clutch cut-off pressure 11 ft-lbs / 14.9 Nm Pressure switch, 50 psi / 3.4 bar Brake light pressure (option) 11 ft-lbs / 14.9 Nm GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 114: Ac Hydraulic Manifold Components

    Description Function Torque Item Solenoid valve, 2 position 2 way Controls motor 20 ft-lbs / 27.1 Nm Flow control valve, 3 gpm/ 11.3 lpm Regulates flow 33-37 ft-lbs / 45-50 Nm GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 115: Valve Adjustments - Secondary Function Manifold

    Install a 0 to 3500 psi / 0 to 250 bar pressure gauge into test port 'TS' at the top of the secondary function manifold. Refer to Secondary Function Manifold Components. GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 116: How To Set The Parking Brake System Pressure

    Install a 0 to 1000 psi / 0 to 100 bar pressure gauge into test port 'TPB' at the top of the secondary function manifold, Refer to Secondary Function Manifold Components. GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 117: How To Set The Differential Lock/Joystick System Pressure

    Install a 0 to 1000 psi / 0 to 100 bar pressure gauge into test port 'TJ' at the top of the secondary function manifold, Refer to Secondary Function Manifold Components. GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 118: How To Set The Rear Lock-Up System Pressure

    Install a 0 to 500 psi / 0 to 50 bar pressure gauge into test port 'TR' at the top of the secondary function manifold, Refer to Secondary Function Manifold Components. GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 119: Valve Coils

    (schematic items DA and DB) Test the coil resistance. Result: The resistance should be within specification, plus or minus 30%. Result: If the resistance is not within specification, plus or minus 30%, replace the coil. GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...
  • Page 120 6. Resistor 10Ω Set a multimeter to read DC current. Genie part number 27287 Note: The multimeter, when set to read DC current, should be capable of reading up to 800 mA. Note: The battery should read 9V DC or more when measured across the terminals.

  • Page 121: Axle

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

  • Page 122: Outriggers

    Support the cylinder. Do not apply any lifting pressure. Remove the fasteners securing the outrigger cylinder barrel-end pivot pin to the machine. GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 123: How To Remove An Outrigger Cylinder

    Hoses can be damaged if they are kinked or pinched. 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. GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...
  • Page 124 Service Manual March 2016 This page intentionally left blank. GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 125: Fault Codes

    • Machine parked on a firm, level surface • Boom in the stowed position • Key switch in the off position with the key removed • Wheels chocked GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 126: Diagnostic Display

    1 amber warning light display are the SPN and FMI codes which are 2 red stop engine light combined to show an engine fault code. 3 menu key 4 arrow/scroll keys 5 enter key GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...
  • Page 127 For additional information, refer to the engine operator's manual which came with your machine. 1 FMI Code 2 SPN Code 3 amber warning light 4 red stop engine light GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 128: John Deere 4045Hf485 Engine Fault Codes

    Contact Servicing Dealer Turbocharger Harness Open Circuit Contact Servicing Dealer Turbocharger Harness Shorted To Ground Contact Servicing Dealer Turbocharger Speed Signal In-Range Failure Contact Servicing Dealer Turbocharger Speed Signal Missing Contact Servicing Dealer GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...
  • Page 129 Fuel Temperature Voltage Out of Range Low Check Senor and Wiring Fuel Temperature High-Moderately Severe Add Fuel or Switch Fuel Tanks 000189 Engine Speed Derate Check Fault Codes or Contact Servicing Dealer GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...
  • Page 130 Contact Servicing Dealer Grounded Circuit Crank/Camshaft Position Out of Sync Check Sensor and Wiring Crank Position Input Missing Check Sensor and Wiring Crank Position Input Pattern Error Check Sensor and Wiring GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...
  • Page 131 Cylinder #5 Electronic Injector Circuit Shorted Check Injector Wiring or Injector Solenoid Cylinder #5 Electronic Injector Fuel Flow Low Injector Failed or Flow Limiter Closed Cylinder #5 Injector QR Code String Error Contact Servicing Dealer GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...
  • Page 132 Turbo Compressor Inlet Temperature High - Contact Servicing Dealer Moderately Severe 001180 Turbo Turbine Inlet Temperature High-Most Severe Contact Servicing Dealer Turbo Turbine Inlet Temperature High - Moderately Contact Servicing Dealer Severe GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...
  • Page 133 Exhaust Gas Recirculation Flow Rate Above Normal Contact Servicing Dealer Exhaust Gas Recirculation Flow Rate Below Normal Contact Servicing Dealer 002790 Turbocharger Compressor Outlet Temperature High - Contact Servicing Dealer Most Severe GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...
  • Page 134 Sensor Supply Voltage #5 Out of Range Low Contact Servicing Dealer 523229 Sensor Supply Voltage #4 Out of Range High Contact Servicing Dealer Sensor Supply Voltage #4 Out of Range Low Contact Servicing Dealer GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 135: Perkins 1104 Engine Fault Codes

    Cylinder #1 injector short Engine coolant temperature short to Cylinder #1 injector not responding ground Cylinder #2 injector data incorrect Cylinder #2 injector open circuit Cylinder #2 injector short Cylinder #2 injector not responding GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...
  • Page 136 Mode selector switch: data erratic/intermittent or incorrect 3509 5V DC power supply sensor short to battery positive (+) 5V DC power supply sensor short to ground Perkins 1100 Troubleshooting Manual Genie part number 123583 GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...
  • Page 137 March 2016 Service Manual This page intentionally left blank. GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 138: Schematics

    Read, understand and obey the safety rules and operating instructions in the appropriate operator's manual on your machine.  Be sure that all necessary tools and test equipment are available and ready for use. GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 139: Proximity Switch Legend

    Proximity Switch Legend Proximity Switc h Legend 1 Boom Angle Proximity Switch PX2 (under boom pivot pin) 2 Boom Extend Proximity Switch PX1 (under plate at top of boom tube, GTH-1056 only) GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 140: Fuse Panel Layout

    Fuse Panel Layout Fus e Panel Lay out FUSE PANEL F20.9, F20.10, F20.11 and F20.11 are for machine options, refer to electrical schematics. PCB Board Fuse Panel located in the Cab GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 141: Electrical Component Legend

    Fuel level Proximity switch Tachometer Boom extend Horn Boom angle Auto-style horn Sensor Multifunction alarm Engine coolant temperature Key switch Engine oil pressure Transmission oil temperature Transmission oil pressure Fuel level GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 142: Wire Color Legend

    Sway right enable Tilt Right outrigger extend Right outrigger retract Left outrigger extend Left outrigger retract Auxiliary 4-wheel steer select Crab steer select Transmission "D" Transmission "E" Sway enable Rear axle oscillate fast GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 143: Electrical Symbol Legend

    Oil temperature switch Coolant temperature Oil pressure switch Control relay contact Diode starting aid, glow normally open switch - normally open normally closed normally open plug or flame ignitor GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 144: Hydraulic Symbols Legend

    Solenoid operated Solenoid operated Counterbalance valve with 3 position, 4 way 2 position, 2 way solenoid 3 position, 4 way directional pressure and pilot ratio proportional directional valve valve valve GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 145: Electrical Schematics

    March 2016 Service Manual Electrical Schematics Electrical Schematic Courtesy of Crane.Market...

  • Page 146: Electrical Schematic

    Service Manual March 2016 Elec trical Schem atic Electrical Schematic GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...
  • Page 147 March 2016 Service Manual Electrical Schematic GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...
  • Page 148 Service Manual March 2016 Electrical Schematic Courtesy of Crane.Market...

  • Page 149: Hydraulic Schematics

    March 2016 Service Manual Hydr aulic Schematics Hydraulic Schematic - Models with Single Joystick Courtesy of Crane.Market...

  • Page 150: Hydraulic Schematic - Models With Single Joystick

    Service Manual March 2016 Hydraulic Schem atic - M odels with Si ngl e J oys tick Hydraulic Schematic - Models with Single Joystick GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...

  • Page 151: Hydraulic Schematic - Models With Dual Joystick

    March 2016 Service Manual Hydraulic Schem atic - M odels with Dual J oys tick Hydraulic Schematic - Models with Dual Joystick GTH-1048 • GTH-1056 Part No. 123701 Courtesy of Crane.Market...
  • Page 152 Service Manual March 2016 Hydraulic Schematic - Models with Dual Joystick GTH-1048 • GTH-1056 Part No. 123701 Servic e M anual March 2016 Courtesy of Crane.Market...
  • Page 153 Courtesy of Crane.Market...

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