Genie GTH-1056 Service And Repair Manual
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Genie GTH-1056 Service And Repair Manual

From gth1016e-11305 to gth1016e-11799 includes gth1016e-11281 gth1016e-11282 gth1016e-11286 from gth10e-11800
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See also: Service Manual , Maintenance Manual
Service and Repair Manual
GTH-1056
Serial Number Range
from GTH1016E-11305 to
GTH1016E-11799
includes GTH1016E-11281
GTH1016E-11282
GTH1016E-11286
from GTH10E-11800
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
Part No. 1278145
Rev A1
April 2017

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Summary of Contents for Genie GTH-1056

  • Page 1 Service and Repair Manual Serial Number Range GTH-1056 from GTH1016E-11305 to This manual includes: GTH1016E-11799 Repair procedures includes GTH1016E-11281 GTH1016E-11282 Fault Codes GTH1016E-11286 Electrical and from GTH10E-11800 Hydraulic Schematics For detailed maintenance procedures, refer to the appropriate Maintenance Manual for your machine.

  • Page 2: Find A Manual For This Model

    Copyright © 2016 by Terex Corporation 1278145 Rev A1, April 2016 First Edition, First 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: Hydraulic Schematics

    Reference Examples: Electronic Version Section – Repair Procedure, 4-2 Click on any content or procedure in the Table of Contents to view Section – Fault Codes, All charts the update. Section – Schematics, Legends and schematics Part No. 1278145 GTH-1056...

  • Page 4: Serial Number Legend

    3 Serial label (located inside fork frame) 4 Sequence number From September 1, 2016 1 Model 1 Serial label 2 Facility code 2 Serial number (stamped on chassis) 3 Sequence number 3 Serial label (located inside fork frame) GTH-1056 Part No. 1278145...

  • 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. Part No. 1278145 GTH-1056...
  • Page 6 Be sure to properly dispose of old oil or other fluids. Use an approved container. Please be environmentally safe. Be sure that your workshop or work area is properly ventilated and well lit. GTH-1056 Part No. 1278145...

  • Page 7: Table Of Contents

    How to Adjust the Boom Extend Proximity Switch .......... 19 1-2 Boom ......................20 How to Replace the Boom Wear Pads ............20 How to Remove the Lifting Fork Frame ............20 How to Remove the Cable Bridge Assembly ..........21 Part No. 1278145 GTH-1056...
  • Page 8 1-4 Boom Extension Cylinder ................32 1-5 Fork Level Cylinder ..................33 1-6 Hydraulic Hoses ..................... 34 How to Replace the Fork Level and/or Auxiliary Cylinder Hoses, GTH-1056 . 34 Operator's Compartment ................... 36 2-1 Operator's Compartment ................36 2-2 Machine Controls ................... 38 How to Remove the Steering Column .............
  • Page 9 8-1 Axles ....................... 75 How to Remove the Axle ................. 75 How to Repair the Axle ................... 75 Outriggers ......................76 9-1 Outriggers....................... 76 How to Remove an Outrigger ................76 How to Remove an Outrigger Cylinder ............77 Part No. 1278145 GTH-1056...
  • Page 10 Harness Map - Auxiliary Hydraulics, Beacon and Top Gear Lockout ....133 Electrical Schematics ..................135 Electrical Schematic ................... 136 Hydraulic Schematics ..................139 Hydraulic Schematic - Models with Single Joystick..........140 Hydraulic Schematic - Models with Dual Joystick ..........141 GTH-1056 Part No. 1278145...

  • Page 11: Specifications

    459 ±16 kg Tire pressure 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 Part No. 1278145 GTH-1056...

  • Page 12: Performance Specifications

    Hydraulic Oil Specifications Drive speed, maximum 18 mph Hydraulic Fluid Specifications 29 km/h Genie specifications require hydraulic oils which are Draw bar pull 29,000 lbs designed to give maximum protection to hydraulic 13,154 kg systems, have the ability to perform over a wide...
  • Page 13 -20°F / -29°C with Rando HD Premium MV. Ambient air temperature 1 Chevron hydraulic oil 5606A 2 Petro-Canada Environ MV 46 3 UCON Hydrolube HP-5046D 4 Chevron Rando HD premium oil MV Part No. 1278145 GTH-1056...
  • Page 14 Brookfield Viscosity component damage cSt @ -4°F / -20°C cSt @ -13°F / -25°C 702.4 cSt @ -40°F / -40°C 2624 Flash point >100 Pour point -76°F / -60°C Maximum continuous operating 103°F / 75°C temperature GTH-1056 Part No. 1278145...

  • Page 15: Hydraulic Component Specifications

    @ 0°F / -18°C 1300 Pump pressure, maximum 3190 psi 220 bar Flash point None Pressure compensator 3190 psi Pour point -81°F / -63°C 220 bar Maximum continuous operating 189°F / 87°C Standby pressure 464 psi temperature 32 bar Part No. 1278145 GTH-1056...

  • Page 16: Manifold Component Specifications

    Diff lock relief valve pressure, maximum 400 psi (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-1056 Part No. 1278145...

  • Page 17: Air Conditioner Refrigerant Specifications

    April 2017 Service and Repair Manual Specifications Air Conditioner Refrigerant Specifications System Full Charge R134a 1 lb 14 oz Part No. 1278145 GTH-1056...

  • Page 18: Deutz Tcd3.6 L4 Engine Specifications

    Extreme operating temperatures may require the use of Reserve capacity @ 25A rate 200 Minutes alternative engine oils. For oil requirements, refer to the Engine Operator Manual for your engine. Alternator output 95A @ 12V DC GTH-1056 Part No. 1278145...

  • Page 19: Deutz Tcd3.6 L4 T4F Engine Specifications

    Unit ships with 15W-40 API CJ4 low ash oil. 120A @ 12V DC Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Manual for your engine. Part No. 1278145 GTH-1056...

  • Page 20: Perkins 1104D-E44Ta Engine Specifications

    Oil viscosity requirements Alternator output 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-1056 Part No. 1278145...

  • Page 21: Perkins 1204E-E44Ta Engine Specifications

    Units ship with 15W-40 API CJ4 low ash oil. Alternator output 120A @ 12V DC Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operation and Maintenance Manual on your machine. Part No. 1278145 GTH-1056...

  • Page 22: Zf 4 Wg-98 Tc Transmission Specifications

    ZF 4 WG-98 TC Maintenance Manual. Oil viscosity requirements ZF 4 WG-98 TC Operating Manual Differential Chevron Supreme 80W90 LS Genie part number 1258405 Planetary ends Chevron Supreme 80W90 LS For additional axle information, refer to the Dana 213...

  • Page 23: Hydraulic Hose And Fitting Torque Specifications

    SAE O-ring Boss Port (tube fitting - installed into Aluminum) Your machine is equipped with Parker Seal-Lok™ (all types) ORFS or 37° JIC fittings and hose ends. Genie SAE Dash Size Torque specifications require that fittings and hose ends be...

  • Page 24: Torque Procedure

    Refer to Illustration 1. hose end are custom-size O-rings. They are not standard size O-rings. They are available in the O-ring field service kit (Genie part number 49612). Lubricate the O-ring before installation. Be sure the O-ring face seal is seated and retained properly.
  • Page 25 Tighten the hex nut until the mark on the hex nut is aligned with the second mark on the body hex fitting. Operate all machine functions and inspect the hose, fittings and related components to confirm there are no leaks. Part No. 1278145 GTH-1056...

  • Page 26: 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 27: 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. Part No. 1278145 GTH-1056...

  • Page 28: 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-1056 Part No. 1278145...

  • Page 29: How To Adjust The Boom Angle Proximity Switch

    Result: The light of the proximity switch assembly is not illuminated. 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. 1278145 GTH-1056...

  • Page 30: Boom

    Lubricate the Boom. when the lock pin is removed Note: Do not lubricate the side wear pads. from the machine. Install the wear pads. Install and securely tighten the fasteners. Do not over tighten. GTH-1056 Part No. 1278145...

  • Page 31: How To Remove The Cable Bridge Assembly

    1 cable bridge mount bracket 2 cable track mount bracket 3 cable bridge slider 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. Part No. 1278145 GTH-1056...

  • Page 32: 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. Remove the inspection cover from the pivot end of the boom. GTH-1056 Part No. 1278145...
  • Page 33 12 Working at the fork end of the boom, remove the fasteners securing the boom extend cylinder pivot pin to the boom. 13 Use a soft metal drift to remove the pivot pin. Lower the cylinder just enough for access to the chain anchor bolts. Part No. 1278145 GTH-1056...

  • Page 34: How To Replace The Extension Chains

    Boom Sequencing Chains. Component damage hazard. Chains can be damaged if the boom is used while the chains are out of adjustment. Do not return the machine to use until the chains have been correctly adjusted. GTH-1056 Part No. 1278145...
  • Page 35 0. and securely attach the rope to the new chain. After noting the orientation and assembly order of the components, remove the fasteners and pull the tensioners free of the boom. Part No. 1278145 GTH-1056...

  • Page 36: How To Remove The Boom

    Boom Sequencing Chains. Component damage hazard. Chains can be damaged if the boom is used while the chains are out of adjustment. Do not return the machine to use until the chains have been correctly adjusted. GTH-1056 Part No. 1278145...
  • Page 37 14 Using the overhead crane, raise the boom to a horizontal position. 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. Part No. 1278145 GTH-1056...

  • Page 38: How To Disassemble The Boom - Gth1056

    Service and Repair Manual April 2017 Boom Components How to Dis ass embl e the Boom - GTH-1056 How to Disassemble the Boom - Remove the fastener securing the fork level cylinder rod-end pivot pin to the fork frame GTH1056 mount.
  • Page 39 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. Part No. 1278145 GTH-1056...
  • Page 40 29 Working at the pivot end of the boom, remove Note: During removal, the overhead crane strap will the fasteners securing the retraction chain need to be adjusted for proper balancing. block pivot pin to boom tube number 2. Remove the pivot pin. GTH-1056 Part No. 1278145...

  • Page 41: Boom Lift Cylinder

    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. Remove the fasteners securing the lift cylinder barrel-end pivot pin to the chassis. Part No. 1278145 GTH-1056...

  • Page 42: 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-1056 Part No. 1278145...

  • Page 43: Fork Level Cylinder

    Attach a lifting strap from an overhead crane to supported when the pivot pin is the barrel end of the fork level cylinder. removed from the machine. Support the cylinder. Do not apply any lifting pressure. Part No. 1278145 GTH-1056...

  • Page 44: Hydraulic Hoses

    1. Cap the How to R eplac e the F or k Level and/or Auxili ar y C yli nder H oses, GTH-1056 How to Replace the Fork Level hard lines.
  • Page 45 Securely plug the auxiliary hoses at the fittings. Cap the tighten all fasteners. Do not over tighten. fittings. 20 Install the cover onto the rear of the boom. Install and securely tighten the retaining fasteners. Part No. 1278145 GTH-1056...

  • Page 46: Operator's Compartment

    Cap the fitting. For further information or assistance, consult the Bodily injury hazard. Spraying Genie Product Support. hydraulic oil can penetrate and burn skin. Loosen hydraulic Bodily injury hazard. This connections very slowly to allow...
  • Page 47 Component damage hazard. the wire harnesses at the connectors next to Hoses, cables and wires can be the operator's compartment. damaged if they are kinked or pinched. Bolt torque specification Operator's cab mounting bolts 750 ft-lbs 1017 Nm Part No. 1278145 GTH-1056...

  • Page 48: 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-1056 Part No. 1278145...

  • Page 49: How To Remove The Steer Orbitral

    Cap the fitting. Slowly move the steer orbitral away from the Remove the fasteners securing the joystick to dash frame while feeding all loose hoses the mount panel. Remove the joystick. through the opening of the chassis. Part No. 1278145 GTH-1056...

  • Page 50: How To Remove The Joystick - Models With Dual Joysticks

    Remove the fasteners securing the joystick to the mount panel. Remove the joystick. GTH-1056 Part No. 1278145...

  • Page 51: How To Remove The Gauge Cluster Assembly

    Tag and disconnect the wire harness from the Tag and disconnect the wire harness from the diagnostic display. Remove the diagnostic dash cluster. Remove the dash cluster from display from the machine. the machine. Part No. 1278145 GTH-1056...

  • Page 52: Fuel And Hydraulic Tanks

    Crushing hazard. The tank Tag and disconnect the wire harness from the assembly could become fuel level terminals. unbalanced and fall if not properly supported when removed from Remove the filler cap from the hydraulic tank. the machine. GTH-1056 Part No. 1278145...

  • Page 53: Engines

    Repair procedures and additional engine information is available in the John Deere Deutz TCD3.6 Operation Manual 4045HF485 Operator's Manual, John Deere 4045T Genie part number 218707 Workshop Manual, John Deere 4045T Alternator Deutz TD3.6 and TCD3.6 Workshop Manual Manual and the John Deere 4045T Fuel Systems...
  • Page 54 Open the engine access cover at the operator's compartment side of the machine. Locate the fuel return hose at the fuel pump. Tag, disconnect and plug the fuel return hose at the fuel pump. Cap the fitting. GTH-1056 Part No. 1278145...

  • Page 55: Engine Fault Codes

    23 To learn the specifics of and how to use the fault codes, refer to, Fault Codes Section. Part No. 1278145 GTH-1056...

  • Page 56: How To Repair The Transmission

    Transmission Maintenance and Repair Manual and tank. the Dana T20000 Maintenance Manual. Disconnect the battery from the machine. Dana T12000 Service Manual Electrocution/burn hazard. Genie part number 97489 Contact with electrically charged Dana T20000 Service Manual circuits could result in death or Genie part number 115025 serious injury.
  • Page 57 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. Part No. 1278145 GTH-1056...

  • Page 58: Hydraulic Pump

    Loosen hydraulic 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-1056 Part No. 1278145...

  • Page 59: 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. Part No. 1278145 GTH-1056...

  • Page 60: How To Install The Function

    12 Adjust the pump pressure. Refer to Repair 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-1056 Part No. 1278145...

  • Page 61: How To Adjust The Function Pump Standby Pressure

    / 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. Part No. 1278145 GTH-1056...

  • Page 62: How To Adjust The Function Pump Pressure Compensator

    Turn the engine off and remove the pressure gauge. 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-1056 Part No. 1278145...
  • Page 63 Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 1 pressure compensator adjustment screw 2 set screw 3 hydraulic supply line (from tank) Part No. 1278145 GTH-1056...

  • Page 64: Manifolds

    20 ft-lbs / 27 Nm Priority flow regulator valve, 2 gpm Sway left/right circuit 33-37 ft-lbs / 45-50 Nm / 7.6 L/min Check valve, 5 psi / 0.3 bar Sway left circuit 20 ft-lbs / 27 Nm GTH-1056 Part No. 1278145...
  • Page 65 April 2017 Service and Repair Manual Manifolds Part No. 1278145 GTH-1056...
  • Page 66 Test port 'TP' Solenoid valve, 2 position 4 way Function select -boom extend 40 ft-lbs / 54 Nm and sway right Solenoid valve, 2 position 2 way Function select - sway left/right 40 ft-lbs / 54 Nm GTH-1056 Part No. 1278145...
  • Page 67 April 2017 Service and Repair Manual Manifolds Part No. 1278145 GTH-1056...

  • Page 68: Primary Function Manifold Components - Models With Dual Joysticks

    33-37 ft-lbs / 44.9-50.3 Nm circuit Check valve, 5 psi / 0.3 bar Sway left circuit 20 ft-lbs / 27.1 Nm Priority flow regulator valve, 2 gpm / 7.6 Sway left/right circuit 33-37 ft-lbs / 44.9-50.3 Nm L/min GTH-1056 Part No. 1278145...
  • Page 69 April 2017 Service and Repair Manual Manifolds Part No. 1278145 GTH-1056...
  • Page 70 Directional valve, 2 position 2 way, pilot Fork tilt circuit 50 ft-lbs / 68 Nm operated Diagnostic nipple Test port 'TP' Solenoid valve, 2 position 2 way Function select - sway 40 ft-lbs / 54 Nm left/right GTH-1056 Part No. 1278145...
  • Page 71 April 2017 Service and Repair Manual Manifolds Part No. 1278145 GTH-1056...

  • Page 72: Secondary Function Manifold Components

    20 ft-lbs / 27 Nm enable select Solenoid valve, 2 position 3 way Differential lock-up 20 ft-lbs / 27 Nm select Diagnostic nipple Test port 'TJ' Diagnostic nipple Test port 'TS' Diagnostic nipple Test port 'TR' GTH-1056 Part No. 1278145...
  • Page 73 April 2017 Service and Repair Manual Manifolds Part No. 1278145 GTH-1056...

  • Page 74: Outrigger Manifold Components

    13 ft-lbs / 17.6 Nm circuit Check valve, 5 psi / 0.3 bar Left outrigger retract 13 ft-lbs / 17.6 Nm circuit Check valve, 5 psi / 0.3 bar Right outrigger retract 13 ft-lbs / 17.6 Nm circuit GTH-1056 Part No. 1278145...
  • Page 75 April 2017 Service and Repair Manual Manifolds Part No. 1278145 GTH-1056...

  • Page 76: Auxiliary Manifold Components (Option)

    DO3 valve, 3 position 4 way Auxiliary function enable 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-1056 Part No. 1278145...

  • Page 77: Brake Manifold Components

    Schematic Description Function Torque Item 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 Part No. 1278145 GTH-1056...

  • Page 78: Ac Hydraulic Manifold Components

    The AC Hydraulic manifolds are located under the manifold inspection cover. Index Schematic 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-1056 Part No. 1278145...

  • Page 79: 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. Part No. 1278145 GTH-1056...

  • Page 80: 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-1056 Part No. 1278145...

  • Page 81: 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. Part No. 1278145 GTH-1056...

  • Page 82: 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-1056 Part No. 1278145...

  • Page 83: 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. Part No. 1278145 GTH-1056...
  • Page 84 6. Resistor 10Ω Set a multimeter to read DC current. Genie part number 27287 Note: The multimeter, when set to read DC current, Note: The battery should read 9V DC or more when should be capable of reading up to 800 mA.

  • Page 85: Axle

    Loosen the lug nuts of both wheels on the axle Dana 213 Axle Maintenance and Repair Manual to be removed. Do not remove the lug nuts. Genie part number 115026 Raise the end of the machine until the tires are off the ground.

  • Page 86: Outriggers

    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. Remove the fasteners securing the outrigger cylinder barrel-end pivot pin to the machine. GTH-1056 Part No. 1278145...

  • Page 87: How To Remove An Outrigger Cylinder

    Component damage hazard. 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. Part No. 1278145 GTH-1056...

  • Page 88: April

    Service and Repair Manual April 2017 This page intentionally left blank. GTH-1056 Part No. 1278145...

  • Page 89: Fault Codes

    Note: Two persons will be required to safely • Machine parked on a firm, level surface perform some troubleshooting procedures. • Boom in the stowed position • Key switch in the off position with the key removed • Wheels chocked Part No. 1278145 GTH-1056...

  • Page 90: Diagnostic Display

    3 amber warning light 4 red stop engine light Active Codes vs Stored Codes Active fault codes, indicating an engine condition or conditions which have not been corrected, are displayed at the moment the fault is detected. GTH-1056 Part No. 1278145...

  • Page 91: Deutz Tcd3.6 Engine Fault Codes

    Sensor error charged air pressure; signal range check high Sensor error charged air pressure; signal range check low Charged air cooler temperature; system reaction initiated Sensor error charged air temperature; signal range check high Sensor error charged air temperature; signal range check low Part No. 1278145 GTH-1056...
  • Page 92 Sensor error intake air; signal range check high Sensor error intake air sensor; signal range check low Sensor ambient air temperature; plausibility error High Low fuel temperature; shut off threshold exceeded High low fuel temperature; warning threshold exceeded GTH-1056 Part No. 1278145...
  • Page 93 Break lever mainswitch and break lever redundancyswitch status not plausible SVS lamp; short circuit to battery SVS lamp; short circuit to ground SVS lamp; open load SVS lamp; powerstage over temperature Access error EEPROM CAN-Bus 0 "BusOff-Status" Part No. 1278145 GTH-1056...
  • Page 94 Starter relay; short circuit Starter relay; no load error Starter relay; powerstage over temperature Engine running lamp; short circuit to battery Engine running lamp; short circuit to ground Engine running lamp; open load Engine running lamp; powerstage over temperature GTH-1056 Part No. 1278145...
  • Page 95 Sensor error exhaust gas temperature upstream turbine; signal range check low Sensor exhaust gas temperature upstream turbine; plausibility error Exhaust gas temperature upstream turbine; out of range, system reaction initiated Exhaust gas temperature upstream turbine; out of range, system reaction initiated Part No. 1278145 GTH-1056...
  • Page 96 Physical range check low for EGR exhaust gas mass flow AGS sensor temperature exhaust gas mass flow; plausibility error Exhaust gas recirculation; AGS sensor has "burn off" not performed Exhaust gas recirculation AGS sensor; plausibility error GTH-1056 Part No. 1278145...
  • Page 97 NOx Sensor; CAN DLC error NOx Sensor; CAN Timeout Nox Sensor downstream of SCR Catalysator; plausibility error "stuk in range" 3241 Sensor SCR catalyst upstream temperature too high; plausibility error Sensor SCR catalyst upstream temperature too low; plausibility error Part No. 1278145 GTH-1056...
  • Page 98 DPF differential pressure sensor and a further sensor or actuator CRT system defective Maximum stand-still-duration reached; oil exchange required Temperature sensor us. and ds. DOC simultaneously defect 3711 Regeneration temperature (PFltRgn LigtOff) not reached; regeneration aborted 3936 Standstill request ignored too long GTH-1056 Part No. 1278145...
  • Page 99 SCR Tank heating valve; short circuit to ground SCR main relay (secondary side): open load SCR-heater relay urea tank powerstage output; over temperature SCR main relay; short circuit SCR Tank heating valve; open load 4374 Pressure stabilisation error dosing valve (SCR) Part No. 1278145 GTH-1056...
  • Page 100 Actuator EGR-Valve (2.9; 3.6); Open load on ECU output is detected Actuator error EGR-Valve; signal range check high Actuator position for EGR-Valve (2.9; 3.6) Power stage over temperature due to high current 20521 Actuator error EGR-Valve (2.9;3.6) Signal range check low GTH-1056 Part No. 1278145...
  • Page 101 Multiple Stage Switch engine speed control parameter; short circuit to ground 23452 64700 2 Multiple Stage Switch engine torque limitation curve; plausibility error Multiple Stage Switch engine torque limitation curve; short circuit to battery Multiple Stage Switch engine torque limitation curve; short circuit to ground Part No. 1278145 GTH-1056...
  • Page 102 Pressure overload of SCR-System Pressure build-up error SCR-System Metering control is not performed in time error Pump pressure SCR metering unit too high Pump pressure SCR metering unit too low 23633 64881 11 Nox conversion rate insufficient GTH-1056 Part No. 1278145...
  • Page 103 Urea supply module heater temperature; signal disrupted 23721 64969 2 Urea supply module heater temperature; plausibility error Urea supply module temperature; signal disrupted Urea supply module temperature measurement not available 23722 64970 8 Urea supply module PWM signal; signal disrupted Part No. 1278145 GTH-1056...
  • Page 104 23910 65158 0 Air Pump; internal error Air Pump; over current Air pump; CAN communication interrupted no purge function available Air Pump; CAN communication lost Air Pump; internal error Air pump doesn´t achieve air mass flow setpoint GTH-1056 Part No. 1278145...
  • Page 105 Physical range check low for HCI dosing valve (DV1) downstream pressure; shut off regeneration Sensor HCI dosing valve (DV1) downstream pressure; plausibility error Sensor error HCI dosing valve (DV1) downstream pressure; signal range check high Sensor error HCI dosing valve (DV1) downstream pressure; signal range check low Part No. 1278145 GTH-1056...
  • Page 106 23922 65170 3 Burner shut of valve; short circuit to battery Burner shut of valve; short circuit to ground Burner shut off valve; open load Shut off valve: blocked Over temperature error on burner shut of valve GTH-1056 Part No. 1278145...
  • Page 107 Sensorcalibration for NOX Sensor (SCR-system downstream cat; DPF- system downstream cat) 23942 65190 9 Timeout Error (BAM to BAM) for CAN-Receive-Frame AT1OGCVol2 information; factors & Sensorcalibration for NOX Sensor (SCR-system downstream cat; DPF- system downstream cat) Part No. 1278145 GTH-1056...
  • Page 108 Urea tank level; derating timer below limit 2 23980 65228 14 Bad quality of reduction agent detected 23981 65229 11 Urea-tank without heating function (heating phase) 23982 65230 0 Powerstage diagnosis disabled; high battery voltage Powerstage diagnosis disabled; low battery voltage GTH-1056 Part No. 1278145...
  • Page 109 High side to low side short circuit in the injector 8 (in firing order) Injector 8 (in firing order); interruption of electric connection 24004 65252 12 Too many recognized misfires in cylinder 7 (in firing order) 24005 65253 12 Too many recognized misfires in cylinder 8 (in firing order) Part No. 1278145 GTH-1056...
  • Page 110 EGR actuator; status message "EGRCust" is missing 24033 65281 7 EGR actuator; due to overload in Save Mode 24034 65282 3 Disc separator; short circuit to battery Disc separator; short circuit to ground Disc Separator; open load Disc Separator; powerstage over temperature GTH-1056 Part No. 1278145...
  • Page 111 SCR or SCR relay for suction line not connected or SCR heater supply module; open load or SCR heater tank; open loac DEF supply module, time for defrosting too long or DEF tank, time for defrosting too long Part No. 1278145 GTH-1056...
  • Page 112 NOx sensor upstream SCR-CAT, lambda value above upper physical threshold 24081 NOx sensor upstream SCR-CAT, lambda value below lower physical threshold 24083 NOx sensor downstream SCR-CAT, NOx value below minimum value 24085 NOx sensor upstream SCR-CAT, NOx value below lower physical threshold GTH-1056 Part No. 1278145...
  • Page 113 24111 65359 9 Timeout error of CAN-Receive-Frame ComRxETVActr 24112 65360 9 Timeout ComITVActr 24113 65361 9 Timeout error of CAN-Receive-Frame ComRxITVActr 24114 65362 9 Timeout error of CAN-Transmit-Frame A1DOC 24115 65363 9 Timeout error of CAN-Transmit-Frame AT1S Part No. 1278145 GTH-1056...
  • Page 114 The standstill-regeneration mode time exceeds the short limit threshold; Vehicle was too long or too often within a short time in standstill mode; Change oil and reset counter 24195 Standstill request due to crystalization ignored too long GTH-1056 Part No. 1278145...

  • Page 115: Perkins 1104 Engine Fault Codes

    Cylinder #1 injector short battery positive (+) Cylinder #1 injector not responding Engine coolant temperature short to ground Cylinder #2 injector data incorrect Cylinder #2 injector open circuit Cylinder #2 injector short Cylinder #2 injector not responding Part No. 1278145 GTH-1056...
  • Page 116 2882 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-1056 Part No. 1278145...

  • Page 117: 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. Part No. 1278145 GTH-1056...

  • Page 118: Proximity Switch Legend

    Service and Repair Manual April 2017 Proximity Switch 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-1056 Part No. 1278145...

  • Page 119: Fuse Panel Layout

    April 2017 Service and Repair Manual Fuse Panel Layout Perkins Engine Circuit Breakers Located in Tank Assembly PCB Board Fuse Panel located in the Cab Part No. 1278145 GTH-1056...

  • Page 120: Electrical Component Legend

    Forward Enable HVAC Control Panel CR10 Reverse Enable CR11 Parking Brake Latch CR12 Sway Left/Right Enable CR13 Tilt Up/Down Enable CR15 HVAC Blower L CR16 HVAC Blower M CR17 HVAC Blower H Diode Engine Control Unit GTH-1056 Part No. 1278145...

  • Page 121: Service And Repair Manual

    Forward Shift ON Enclosed Cab Fan Switch Parking Brake Release OFF Road / Work Light Switch Brake Light Power ON Brake Pressure Warning Switch Hazard Power ON Transmission Oil Pressure Switch Not Used Transmission Oil Temp. Switch Part No. 1278145 GTH-1056...

  • Page 122: Wire Color Legend

    E Transmission Orange Transmission Forward OR/BK Orange/Black Transmission Reverse OR/RD Orange/Red 4Wheel Steer SVD1A White Crab Steer SVD1B WH/BK White/Black Left Stabilizer Down WH/RD White/Red Left Stabilizer Up Right Stabilizer Down Right Stabilizer Up AC Control GTH-1056 Part No. 1278145...

  • Page 123: Telematics Connector Pin Legend

    April 2017 Service and Repair Manual Telematics Connector Pin Legend Genie installed Telematics connector is wired with an Active High digital input. Circuit Type Circuit Properties Genie Machine Function(s) Telematics Use Case System Power 12 VDC Battery Positive – constant power Supply power to device 5 Amp Max.
  • Page 124 Telematics with Active High input Telematics with Active Low input 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 GTH-1056 Part No. 1278145...

  • Page 125: Electrical Symbol Legend

    Battery separator Gauge sending unit open normally closed 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 Part No. 1278145 GTH-1056...

  • Page 126: Hydraulic Symbols Legend

    (mechanically activated) 3 way shuttle valve valve Solenoid operated Solenoid operated Counterbalance valve with 3 position, 4 way Solenoid valve, 2 position 3 position 4 way directional pressure and pilot ratio proportional directional 2 way valve valve GTH-1056 Part No. 1278145...

  • Page 127: Harness Map - Control System- Single Joystick

    April 2017 Service and Repair Manual Harness Map - Control System - Single Joystick Part No. 1278145 GTH-1056...
  • Page 128 Service and Repair Manual April 2017 Harness Map - Control System Ground Single Joystick...
  • Page 129 April 2017 Service and Repair Manual Harness Map - Control System - Dual Joystick...

  • Page 130: Harness Map - Control System- Dual Joystick

    Service and Repair Manual April 2017 Harness Map - Control System - Dual Joystick GTH-1056 Part No. 1278145...

  • Page 131: Harness Map - Deutz 3.6Tcd T4F Engine

    April 2017 Service and Repair Manual Harness Map - Deutz TCD3.6 T4F Engine Part No. 1278145 GTH-1056...
  • Page 132 Service and Repair Manual April 2017 Harness Map - Deutz 3.6TCD T4F Engine...
  • Page 133 April 2017 Service and Repair Manual Harness Map - Perkins 1204 T4F Engine...

  • Page 134: Harness Map - Perkins 1204 T4F Engine

    Service and Repair Manual April 2017 Harness Map - Perkins 1204 T4F Engine GTH-1056 Part No. 1278145...

  • Page 135: Harness Map - Work Lights

    April 2017 Service and Repair Manual Harness Map - Work Lights Part No. 1278145 GTH-1056...
  • Page 136 Service and Repair Manual April 2017 Harness Map - Work Lights...
  • Page 137 April 2017 Service and Repair Manual Harness Map - Road Lights...

  • Page 138: Harness Map - Road Lights

    Service and Repair Manual April 2017 Harness Map - Road Lights GTH-1056 Part No. 1278145...

  • Page 139: Harness Map - Enclosed Cab With Heat

    April 2017 Service and Repair Manual Harness Map - Enclosed Cab with Heat Part No. 1278145 GTH-1056...
  • Page 140 Service and Repair Manual April 2017 Harness Map - Enclosed Cab with Heat...
  • Page 141 April 2017 Service and Repair Manual Harness Map - Enclosed Cab with HVAC...

  • Page 142: Harness Map - Enclosed Cab With Hvac

    Service and Repair Manual April 2017 Harness Map - Enclosed Cab with HVAC GTH-1056 Part No. 1278145...

  • Page 143: Harness Map - Auxiliary Hydraulics, Beacon And Top Gear Lockout

    April 2017 Service and Repair Manual Harness Map - Auxiliary Hydraulics, Beacon and Top Gear Lockout Part No. 1278145 GTH-1056...
  • Page 144 Service and Repair Manual April 2017 Harness Map - Auxiliary Hydraulics, Beacon and Top Gear Lockout...

  • Page 145: Electrical Schematics

    April 2017 Service and Repair Manual Electrical Schematic...

  • Page 146: Electrical Schematic

    Service and Repair Manual April 2017 Electrical Schematic GTH-1056 Part No. 1278145...
  • Page 147 April 2017 Service and Repair Manual Electrical Schematic Part No. 1278145 GTH-1056...
  • Page 148 Service and Repair Manual April 2017 Electrical Schematic...

  • Page 149: Hydraulic Schematics

    April 2017 Service and Repair Manual Hydraulic Schematic - Models with Single Joystick...

  • Page 150: Hydraulic Schematic - Models With Single Joystick

    Service and Repair Manual April 2017 Hydraulic Schematic - Models with Single Joystick GTH-1056 Part No. 1278145...

  • Page 151: Hydraulic Schematic - Models With Dual Joystick

    April 2017 Service and Repair Manual Hydraulic Schematic - Models with Dual Joystick Part No. 1278145 GTH-1056...
  • Page 152 Service and Repair Manual April 2017 Hydraulic Schematic - Models with Dual Joystick GTH-1056 Part No. 1278145 Ser vic e and R epair M anual April 2017...

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