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GTH-1048
Genie GTH-1048 Manuals
Manuals and User Guides for Genie GTH-1048. We have
4
Genie GTH-1048 manuals available for free PDF download: Service Manual, Operator's Manual
Genie GTH-1048 Service Manual (196 pages)
Brand:
Genie
| Category:
Front End Loaders
| Size: 4.32 MB
Table of Contents
Table of Contents
7
Introduction
2
Serial Number Legend
3
Safety Rules
5
Personal Safety
6
Table of Contents
7
Machine Specifications
15
Performance Specifications
17
Hydraulic Specifications
18
Manifold Component Specifications
20
John Deere 4045TF270 Engine
21
John Deere 4045TF275 Engine
22
Deutz BF4 2012 Engine
23
Perkins 1104C-44T Engine
24
Perkins 1104C-44TA Engine
25
Dana T12000 Transmission
26
Dana T20000 Transmission
26
Dana Planetary 212 Drive Axle
27
Dana Planetary 213 Drive Axle
27
Specifications
27
Hydraulic Hose and Fitting Torque Specifications
28
About this Section
31
Observe and Obey
31
Pre-Delivery Preparation Report
32
Maintenance Inspection Report
35
C Checklist a Procedures
37
Inspect the Manuals and Decals
37
Perform Pre-Operation Inspection
38
Perform Function Tests
38
Lubricate the Machine
39
Perform Engine Maintenance - John Deere and Perkins Models
41
Perform Transmission Maintenance
41
Perform Engine Maintenance - Deutz Models
42
Perform 30 Day Service
42
Perform Transmission Maintenance
43
And GTH-844 Models
43
Perform Engine Maintenance - Perkins Models
43
Perform Axle Maintenance
44
Perform Engine Maintenance - John Deere Models
44
And GTH-844 Models
44
Perform Transmission Maintenance
45
A-15 Perform Axle Maintenance
46
B Checklist B Procedures
47
Inspect the Battery
47
Inspect the Electrical Wiring
47
Check the Exhaust System
48
Inspect the Engine Air Filter
49
Inspect the Tires, Wheels and Lug Nut Torque
49
Perform Hydraulic Oil Analysis
50
Inspect the Fuel and Hydraulic Tank Cap Venting Systems
51
Check the Boom Wear Pads
52
Lubricate the Driveshafts
53
Perform Engine Maintenance - John Deere Models
53
B Checklist C Procedures
54
Perform Engine Maintenance - Deutz Models
54
Perform Engine Maintenance - John Deere Models
54
Perform Axle Maintenance
55
Perform Transmission Maintenance
55
Perform Engine Maintenance - Perkins Models
56
Perform Axle Maintenance
56
Perform Axle Maintenance
57
B Checklist D Procedures
58
Inspect the Forks
58
Adjust the Boom Sequencing Chains
58
Replace the Hydraulic Tank Return Filter Element
61
Perform Engine Maintenance - Deutz Models
62
Perform Transmission Maintenance
62
Perform Axle Maintenance
63
Perform Engine Maintenance - Perkins Models
63
Perform Engine Maintenance - Deutz Models
64
C Checklist E Procedures
65
Test or Replace the Hydraulic Oil
65
Perform Engine Maintenance - John Deere Models
66
Perform Engine Maintenance - Perkins Models
66
Perform Engine Maintenance - Perkins Models
67
Perform Engine Maintenance - John Deere Models
68
Perform Engine Maintenance - Perkins Models
68
Perform Engine Maintenance - Deutz Models
69
Perform Engine Maintenance - Perkins Models
69
Repair Procedures
71
Boom Components
72
Boom Angle Limit Switch (All Models Except GTH-636)
72
Boom
73
Bodily Injury Hazard. Spraying
76
Boom Lift Cylinder
85
Boom Extension Cylinder
87
Fork Level Cylinder
88
Fork Rotate Cylinder (Option)
90
Operator's Compartment
93
Electrocution Hazard. Contact with Electrically Charged Circuits Could Result in Death or Serious Injury
93
Machine Controls
102
Fuel and Hydraulic Tanks
108
Fuel Tank
108
Hydraulic Tank
109
Gradually. Do Not Allow Oil to Squirt
109
Engines
110
Engine Fault Codes - John Deere 4045TF275 Engine
111
Transmission
112
Hydraulic Pumps
114
Hydraulic Pump
114
Or Spray
116
Main Valve Manifold Components
118
Tilt Limiter Manifold Components
119
Dual Pilot Check Manifold Components
120
Boom Activated Rear Lock-Up Manifold Components
121
Fork Rotate Speed Manifold Components (Option)
122
Control Block Manifold Components
123
Fork Tilt Manifolds Components
124
Rear Lock-Up Manifold Components
125
Parking Brake Manifold Components
126
Differential Lock-Up Manifold Components (Optional on GTH-636 and GTH-644)
127
Sway Manifold Components
128
Fork Rotate Manifold Components (Option)
129
Sway Directional Manifold Components
130
Outrigger Manifold Components - GTH-1048 and GTH-1056
131
Controller Relief (Drop Block) Manifold
132
GTH-636, GTH-1048 and GTH-1056
132
Boom Lift and Boom Extension Cylinders Manifold Components
133
Fork Level Cylinder Manifold Components
134
Fork Rotate Cylinder Manifold Components (Option)
135
Pump Destroke Manifold Components
136
GTH-636, GTH-1048 and GTH-1056
137
Boom Activated Sway Lock-Up Manifold Components
138
Valve Adjustments - Control Block Manifold
139
Valve Adjustments - Tilt Limiter Manifold
141
Valve Coils
142
Remove All Rings, Watches and Other Jewelry
142
Axles
143
To Adjust Front Axle Service Brakes
144
To Adjust Parking Brakes
144
Outriggers
146
Immediately Tag and Remove from Service a Damaged or Malfunctioning Machine
149
Repair any Machine Damage or Malfunction before Operating the Machine
149
Troubleshooting and Repair Procedures Shall be Completed by a Person Trained and Qualified on the Repair of this Machine
149
Before Troubleshooting
149
Be Sure that All Necessary Tools and Test Equipment Are Available and Ready for Use
149
Read, Understand and Obey the Safety Rules and Operating Instructions in the Appropriate Operator's Manual on Your Machine
149
Malfunction Discovered
149
Return to Service
149
General Repair Process
149
Identify Symptoms
149
Engine Fault Codes - GTH-1048 and GTH-1056
150
Hydraulic Pump
152
Boom Functions
154
Drive Functions
161
Steer Functions
162
Brake Functions
165
Sway Functions
166
Connections very Slowly to Allow
169
Hydraulic Oil Can Penetrate and Burn Skin. Loosen Hydraulic
169
The Oil Pressure to Dissipate
169
Schematics
171
Electrical Component and Limit Switch Legends
172
Section 6 • Schematics
172
Electrical and Hydraulic Symbols Legends
173
Electrical Schematics
173
Hydraulic Schematics
173
Electrical Schematic - GTH-636 with John Deere Power
174
C Electrical Schematic
176
And GTH-844 with John Deere Power
178
Electrical Schematic - GTH-636 with Perkins Power
176
Electrical Schematic - GTH-644, GTH-842 and GTH-844 with Perkins Power
180
Electrical Schematic - GTH-644, GTH-842 and GTH-844 with Deutz Power
182
Electrical Schematic - GTH-1048 and GTH-1056 with John Deere Power
184
Electrical Schematic - GTH-1048 and GTH-1056 with Perkins Power
186
With Single Joystick
186
A Hydraulic Schematic
188
Hydraulic Schematic GTH-636 with Single Joystick
188
GTH-636 with Dual Joysticks
189
B Hydraulic Schematic
189
Hydraulic Schematic GTH-636 with Dual Joysticks
189
And GTH-844 with Single Joystick
190
A Hydraulic Schematic
190
Hydraulic Schematic GTH-644, GTH-842 and GTH-844 with Single Joystick
190
GTH-644, GTH-842 and GTH-844 with Dual Joysticks
191
A Hydraulic Schematic
192
GTH-1048 and GTH-1056 with Dual Joysticks
193
Hydraulic Schematic - GTH-1048 and GTH-1056 with Single Joystick
192
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Genie GTH-1048 Service Manual (214 pages)
Brand:
Genie
| Category:
Ranges
| Size: 10.14 MB
Table of Contents
Introduction
2
Serial Number Legend
5
Safety Rules
7
Personal Safety
8
Table of Contents
9
Part
16
Specifications
17
Machine Specifications
17
Performance Specifications
18
Hydraulic Component Specifications
22
Manifold Component Specifications
23
AC Refrigerant Specification
23
Valve Coil Resistance Specifications
23
John Deere 4045TH485 Engine
24
Deutz TCD3.6 L4 Engine
25
Perkins 1104D-E44TA Engine
26
Perkins 1204E-E44TA Engine
27
Dana T20000 Transmission
28
Dana Planetary 213 Drive Axle
29
Hydraulic Hose and Fitting Torque Specifications
30
Scheduled Maintenance Procedures
35
Pre-Delivery Preparation Report
36
Maintenance Inspection Report
39
Checklist a Procedures
40
Inspect the Manuals and Decals
40
Perform Pre-Operation Inspection
41
Perform Function Tests
41
Lubricate the Boom
42
Perform Engine Maintenance
42
Perform Transmission Maintenance- All Models
43
Perform 30 Day Service
43
Perform Axle Maintenance
44
Perform Engine Maintenance - John Deere Models
44
Perform Axle Maintenance
45
Checklist B Procedures
46
Inspect the Battery
46
Inspect the Electrical Wiring
46
Check the Exhaust System
47
Inspect the Engine Air Filter
48
Inspect the Tires, Wheels and Lug Nut Torque
48
Perform Hydraulic Oil Analysis
49
Inspect the Fuel and Hydraulic Tank Cap Venting Systems
50
Check the Boom Wear Pads
51
Lubricate the Driveshafts
52
Perform Engine Maintenance - John Deere Models
52
Part No. 123701 GTH-1048 •
53
Checklist C Procedures
54
Perform Engine Maintenance - John Deere Models
54
Perform Axle Maintenance
54
Perform Transmission Maintenance - Dana Models
55
Perform Engine Maintenance
55
Perform Engine Maintenance - Perkins Models
56
Inspect and Lubricate the Sequencing Chains
57
Adjust the Sequencing Chains
58
Perform Axle Maintenance
59
Perform Axle Maintenance
60
Checklist D Procedures
61
Inspect the Forks
61
Replace the Hydraulic Tank Return Filter Element
61
Perform Transmission Maintenance- Dana Models
62
Perform Axle Maintenance
62
Perform Engine Maintenance - Deutz Models
63
Perform Engine Maintenance - Perkins Models
63
Perform Transmission Maintenance- ZF Models
64
Checklist E Procedures
65
Test or Replace the Hydraulic Oil
65
Perform Engine Maintenance - John Deere Models
66
Perform Engine Maintenance - Perkins Models
66
E-4 Perform Engine Maintenance - Deutz Models
67
E-6 Perform Engine Maintenance - Perkins Models
68
E-8 Perform Engine Maintenance - Deutz Models
69
Repair Procedures
71
Boom Components
71
Boom Proximity Switches
71
Boom
73
Boom Lift Cylinder
86
Boom Extension Cylinder
87
Fork Level Cylinder
88
Operator's Compartment
92
Machine Controls
94
Fuel and Hydraulic Tanks
98
Engines
99
Engine Fault Codes
101
Transmission
102
Hydraulic Pumps
104
Hydraulic Pump
104
Manifolds
111
Repair Procedures, Continued
111
Primary Function Manifold Components - Models with Single Joystick
111
Primary Function Manifold Components - Models with Dual Joysticks
115
Secondary Function Manifold Components
119
Outrigger Manifold Components
121
Auxiliary Manifold Components (Option)
123
Brake Manifold Components
124
AC Hydraulic Manifold Components
125
Valve Adjustments - Secondary Function Manifold
127
Valve Coils
131
Axle Components
133
Axles
133
Outriggers
134
Fault Codes
137
Diagnostic Display
137
Engine Fault Codes - Models with John Deere Power
139
Engine Fault Codes - Models with Deutz Power
143
Engine Fault Codes - Models with Perkins Power
161
Schematics
165
Proximity Switch Layout
165
Fuse Box Layout
166
(Before Serial Number GTH1012-16292)
166
Fuse Box Layout (from Serial Number GTH1012-16292)
167
Fuse Box Layout (from Serial Number GTH1014E-10353)
168
Electrical Component Legend (before Serial Number GTH1012-16292)
169
(From Serial Number GTH1012-16292)
170
Telematics Connector Legend
172
Electrical and Hydraulic Symbols Legends
173
Schematics, Continued
174
Harness Map - Control System Power Single Joystick
174
Harness Map - Control System Ground Single Joystick
176
Harness Map - Control System Power Dual Joysticks
178
Harness Map - Control System Ground Dual Joysticks
180
Harness Map - Deutz 3.6TCD Engine Battery Power and Ground
183
Harness Map - Perkins 1104D Engine Battery Power and Ground
184
Harness Map - Perkins 854E Engine Battery Power and Ground
186
Harness Map - Options
188
Auxiliary Hydraulics, Beacon and 3Rd Gear Lockout
188
Harness Map - Options Work Lights
190
Harness Map - Options Road Lights
192
Harness Map - Options Enclosed Cab with Heater
194
Harness Map - Options Enclosed Cab with HVAC
196
Electrical Schematic
198
(Before Serial Number GTH1012-16292)
198
From Serial Number GTH1012-16292 to
202
Electrical Schematic
203
From Serial Number GTH1014-19341
206
Electrical Schematic
207
Hydraulic Schematic Models with Single Joystick
210
Hydraulic Schematic
210
Models with Dual Joysticks
212
Hydraulic Schematic Models with Dual Joysticks
212
Genie GTH-1048 Service Manual (153 pages)
Serial Number Range from GTH1007A-11443 to GTH1009A-14000/from GTH1007B-7101 to GTH1007B-7251
Brand:
Genie
| Category:
Lifting Systems
| Size: 8.52 MB
Table of Contents
Table of Contents
7
Introduction
2
Find a Manual for this Model
2
Revision History
3
Serial Number Legend
4
Safety Rules
5
Table of Contents
7
Specifications
13
Machine Specifications
13
Performance Specifications
14
Hydraulic Specification
15
Hydraulic Component Specifications
18
Manifold Component Specifications
19
Air Conditioner Refrigerant Specifications
19
John Deere 4045HF485 Engine Specifications
20
Perkins 1104D-E44TA Engine Specifications
21
Dana T20000 Transmission Specifications
22
Dana Planetary 213 Drive Axle Specifications
22
Hydraulic Hose and Fitting Torque Specifications
23
Torque Procedure
24
Scheduled Maintenance Procedures
25
Introduction
25
Observe and Obey
25
About this Section
26
Pre-Delivery Preparation Report
28
Maintenance Inspection Report
29
Maintenance Inspection Report
30
Checklist a Procedures
31
Inspect the Manuals and Decals
31
Perform Pre-Operation Inspection
32
Perform Function Tests
32
Lubricate the Boom
33
Perform Engine Maintenance - All Models
33
Perform Transmission Maintenance
34
Perform 30 Day Service
34
Perform Axle Maintenance
35
Perform Engine Maintenance - John Deere Models
35
Perform Axle Maintenance
36
Checklist B Procedures
37
B-1 Inspect the Batteries
37
Electrocution/Burn Hazard
37
Inspect the Electrical Wiring
38
Check the Exhaust System
39
Inspect the Engine Air Filter
40
Inspect the Tires, Wheels and Lug Nut Torque
40
Perform Hydraulic Oil Analysis
41
Inspect the Fuel and Hydraulic Tank Cap Venting Systems
41
Check the Boom Wear Pads
42
Lubricate the Driveshaft
43
Perform Engine Maintenance - John Deere Models
44
Checklist C Procedures
45
Inspect and Lubricate the Sequencing Chains
45
Perform Engine Maintenance - John Deere Models
46
Perform Axle Maintenance
47
Perform Transmission Maintenance - Dana Models
47
Perform Engine Maintenance - Perkins Models
48
Adjust the Boom Sequencing Chains
49
Perform Axle Maintenance
50
Checklist D Procedures
51
Inspect the Forks
51
Perform Transmission Maintenance - Dana Models
51
Replace Hydraulic Tank Return Filter Element
52
Perform Axle Maintenance
52
Perform Engine Maintenance - Perkins Models
53
Checklist E Procedures
54
Test or Replace the Hydraulic Oil
54
Perform Engine Maintenance - John Deere Models
55
Perform Engine Maintenance - Perkins Models
55
Perform Engine Maintenance - Perkins Models
56
Perform Engine Maintenance - John Deere Models
56
Perform Engine Maintenance - Perkins Models
57
Repair Procedures
58
Introduction
58
Boom Components
60
Boom Proximity Switch
60
How to Test a Proximity Switch
60
How to Adjust the Boom Angle Proximity Switch
61
How to Adjust the Boom Extend Proximity Switch
61
Boom
62
How to Replace the Boom Wear Pads
62
How to Remove the Lifting Fork Frame
62
How to Remove the Cable Bridge Assembly , GTH-1056
63
How to Replace the Retraction Chain
64
How to Replace the Extension Chains
67
How to Remove the Boom
69
How to Disassemble the Boom - GTH-1048
71
Bodily Injury Hazard. Spraying
71
How to Disassemble the Boom - GTH-1056
73
Boom Lift Cylinder
76
Boom Extension Cylinder
77
Fork Level Cylinder
78
Hydraulic Hoses
79
How to Replace the Fork Level And/Or
79
Auxiliary Cylinder Hoses, GTH-1048
79
How to Replace the Fork Level And/Or Auxiliary Cylinder Hoses, GTH-1056
80
Operator's Compartment
83
Machine Controls
85
How to Remove the Steering Column
85
How to Remove the Steering Wheel
85
How to Remove the Steer Orbitral
86
How to Remove the Joystick - Models with Single Joystick
86
How to Remove the Joystick - Models with Dual Joysticks
87
How to Remove the Brake Pedal Assembly
87
How to Remove the Gauge Cluster Assembly
88
How to Remove the Diagnostic Display
88
Fuel and Hydraulic Tanks
89
Engines
90
How to Repair the John Deere 4045T Engine
90
How to Repair the Perkins 1104D-E44TA Engine
90
How to Remove the Engine
90
Engine Fault Codes
91
Transmission
92
How to Repair the Transmission
92
How to Remove the Transmission
92
Hydraulic Pump
94
How to Test the Function Pump
94
How to Remove the Function Pump
95
How to Install the Function
96
How to Prime the Function Pump
96
How to Adjust the Function Pump Standby Pressure
97
How to Adjust the Function Pump Pressure Compensator
98
Manifolds
100
Primary Function Manifold Components - Models with Single Joystick
100
Primary Function Manifold Components - Models with Dual Joysticks
104
Secondary Function Manifold Components
108
Outrigger Manifold Components
110
Auxiliary Manifold Components (Option)
112
Brake Manifold Components
113
AC Hydraulic Manifold Components
114
Valve Adjustments - Secondary Function Manifold
115
How to Set the Steer System Pressure
115
How to Set the Parking Brake System Pressure
116
How to Set the Differential Lock/Joystick System Pressure
117
How to Set the Rear Lock-Up System Pressure
118
Valve Coils
119
Axle
121
Axles
121
How to Remove the Axle
121
How to Repair the Axle
121
Outriggers
122
How to Remove an Outrigger
122
How to Remove an Outrigger Cylinder
123
Hydraulic Oil Can Penetrate and Burn Skin. Loosen Hydraulic
123
Connections very Slowly to Allow
123
The Oil Pressure to Dissipate
123
Gradually. Do Not Allow Oil to
123
Squirt or Spray
123
Fault Codes
125
Introduction
125
Troubleshooting and Repair Procedures Shall be Completed by a Person Trained and Qualified on the Repair of this Machine
125
Immediately Tag and Remove from Service a Damaged or Malfunctioning Machine
125
Repair any Machine Damage or Malfunction before Operating the Machine
125
Before Troubleshooting
125
Read, Understand and Obey the Safety Rules and Operating Instructions in the Appropriate Operator's Manual on Your Machine
125
Be Sure that All Necessary Tools and Test
125
Equipment Are Available and Ready for Use
125
Contact with Electrically Charged Circuits Could Result in Death or Serious Injury. Remove All Rings, Watches and Other Jewelry
125
Diagnostic Display
126
John Deere 4045HF485 Engine Fault Codes
128
Perkins 1104 Engine Fault Codes
135
Schematics
138
Introduction
138
Proximity Switch Legend
139
Fuse Panel Layout
140
Electrical Schematics
140
Electrical Component Legend
141
Wire Color Legend
142
Electrical Symbol Legend
143
Hydraulic Symbols Legend
144
Electrical Schematics
145
Electrical Schematic
146
Hydraulic Schematics
149
Hydraulic Schematic - Models with Single Joystick
150
Hydraulic Schematic - Models with Dual Joystick
151
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Genie GTH-1048 Operator's Manual (64 pages)
ROUGH TERRAIN FORK LIFT
Brand:
Genie
| Category:
Boom Lifts
| Size: 4.37 MB
Table of Contents
Operator's Manual Gth-1048
2
Table of Contents
2
Introduction
5
Standards and Symbols
6
Safety
7
Training and Knowledge
7
Operator's Responsibilities
8
Management's Responsibilities
9
Maintenance and Repair
10
Operation Safety
11
Section 2 General Safety
15
General Safety Procedures
17
General Safety
18
Jump Starting
22
Proper Load Chart Use
23
Section 3 Controls and Instruments
25
Section 3 Controls and Instruments
26
Operator's Compartment
27
Joystick Control Functions
28
Joystick Control Functions (Button Pushed)
29
Parking Brake
30
Service Brakes
30
Frame Sway Control
31
Gauges
32
Hydraulic Pump Destroke Button
32
Steering
33
Transmission
33
Front Axle Differential Lock
34
Front Stabilizers
35
Engine Electronic Control Unit (ECU)
36
Section 4 Operation
39
Section 4 Operation
40
Operation and Safety Guidelines
41
Before Starting the Engine
42
Starting the Engine
43
Before Operating the Forklift
45
Transporting a Load
49
Placing a Load
51
Section 5 Maintenance Procedures
55
General Safety Practices
57
Maintenance Procedures
58
Daily Maintenance
59
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