Genie GTH-1048 Manuale utente

Service Manual

Serial Number Range

GTH-1048

from GTH1007A-11443 to

GTH1009A-

14000

GTH-1056

from GTH1007B-7101 to

GTH1007B-

7251

Part No. 123701

Rev G

March 2016

Courtesy of Crane.Market

Service Manual March 2016

Introduction

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

Intr od ucti o n Intr od ucti o n

Impor ta nt In for m at i on

Important

Read, understand and obey the safety rules and

operating instructions in the appropriate Operator's

Manual on your machine before attempting any

maintenance procedure.

This manual provides detailed scheduled

maintenance information for the machine owner

and user. It also provides troubleshooting and

repair procedures for qualified service

professionals.

Basic mechanical, hydraulic and electrical skills

are required to perform most procedures. However,

several procedures require specialized skills, tools,

lifting equipment and a suitable workshop. In these

instances, we strongly recommend that

maintenance and repair be performed at an

authorized Genie dealer service center.

Compliance

Machine Design Life

Unrestricted with proper operation, inspection and

scheduled maintenance.

Technical Publications

Genie has endeavored to deliver the highest

degree of accuracy possible. However, continuous

improvement of our products is a Genie policy.

Therefore, product specifications are subject to

change without notice.

Readers are encouraged to notify Genie of errors

and send in suggestions for improvement. All

communications will be carefully considered for

future printings of this and all other manuals.

Internet: www.genielift.com

E-mail: awp.techpub@terex.com

Find a Manual for this Model

Go to http://www.genielift.com

Use the links to locate Service Manuals,

Maintenance Manuals, Service and Repair

Manuals, Parts Manuals and Operator's Manuals.

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.

Courtesy of Crane.Market

March 2016 Service Manual

Introduction

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

RevisionHistory

Revision History

Revision Date Section Procedure / Page / Description

C 7/2012

Spec, Maint, Repair, Fault and Schematics

C1 3/2013

Spec, Maint and Schematics

D 6/2013

Fault

E 8/2013

Maint

F 9/2014 Spec Hydraulic Oil

Maint ZF Transmission

Fault Deutz Fault Codes

Schem Telematics

F1 3/2015 Schem Electrical and Hydraulic

F2 5/2015 Schem Fuse Box Layout / Electrical

G 3/2016 All Ending SN for GTH-1048

Ending SN for GTH-1056 for MM/SRM

Reference Examples:

Section – Maintenance, B-3

Electronic Version

Click on any content or procedure in the Table of Contents to view

the update.

Section – Repair Procedure, 4-2

Section – Fault Codes, All charts

Section – Schematics, Legends and schematics

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Service Manual March 2016

Introduction

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

Serial Number Legend

1 Model

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)

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March 2016 Service Manual

Safety Rules

Part No. 123701 GTH-1048 • GTH-1056 v

Section 1 Safet y R ules Gener al Saf et y R ul es

Danger

Failure to obey the instructions and safety rules in

this manual and the appropriate Operator's Manual

on your machine will result in death or serious

injury.

Many of the hazards identified in the operator's

manual are also safety hazards when maintenance

and repair procedures are performed.

Do Not Perform Maintenance

Unless:

You are trained and qualified to perform

maintenance on this machine.

You read, understand and obey:

•manufacturer's instructions and safety rules

•employer's safety rules and worksite

regulations

•applicable governmental regulations

You have the appropriate tools, lifting

equipment and a suitable workshop.

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Service Manual March 2016

Safety Rules

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

Personal Safety

Any person working on or around a machine must

be aware of all known safety hazards. Personal

safety and the continued safe operation of the

machine should be your top priority.

Read each procedure thoroughly. This

manual and the decals on the machine,

use signal

words to identify the following:

Safety alert symbol

—used to

alert personnel to potential

personal injury hazards. Obey all

safety messages that follow this

symbol to avoid possible injury or

death.

Indicates a imminently hazardous

situation which,

if not avoided,

will result in death or serious

injury.

Indicates a potentially hazardous

situation which, if not avoided,

could result in death or serious

injury.

Indicates a potentially hazardous

situation which, if not avoided,

may cause minor or

moderate

injury.

Indicates a potentially hazardous

situation which, if not avoided,

may result in property damage.

Be sure to wear protective eye wear and

other protective clothing if the situation

warrants it.

Be aware of potential crushing

hazards

such as moving parts, free swinging or

unsecured components when lifting or

placing loads. Always wear approved

steel

-toed shoes.

Workplace Safety

Any person working on or around a machine must

be aware of all known safety hazards. Personal

safety and the continued safe operation of the

machine should be your top priority.

Be sure to keep sparks, flames and

lighted tobacco away from flammable and

combustible materials like battery gases

and engine fuels. Always have an

approved fire extingu

isher within easy

reach.

Be sure that all tools and working areas

are properly maintained and ready for

use. Keep work surfaces clean and free

of debris that could get into machine

components and cause damage.

Be sure any forklift, overhead crane or

other lifting or supporting device is fully

capable of supporting and stabilizing the

weight to be lifted. Use only chains or

straps that are in good condition and of

ample capacity.

Be sure that fasteners intended for one

time use (i.e., cotter pins an

d self-locking

nuts) are not reused. These components

may fail if they are used a second time.

Be sure to properly dispose of old oil or

other fluids. Use an approved container.

Please be environmentally safe.

Be sure that your workshop or work area

is properly ventilated and well lit.

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March 2016

Table of Contents

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

Introduction Introduction...........................................................................................................ii

Important Information ............................................................................................. ii

Find a Manual for this Model .................................................................................. ii

Revision History..................................................................................................... iii

Serial Number Legend .......................................................................................... iv

Section 1 Safety Rules ..........................................................................................................v

General Safety Rules ............................................................................................. v

Section 2Specifications .......................................................................................................1

Machine Specifications...........................................................................................1

Performance Specifications....................................................................................2

Hydraulic Specification ...........................................................................................3

Hydraulic Component Specifications......................................................................6

Manifold Component Specifications .......................................................................7

Air Conditioner Refrigerant Specifications .............................................................7

John Deere 4045HF485 Engine Specifications .....................................................8

Perkins 1104D-E44TA Engine Specifications ........................................................9

Dana T20000 Transmission Specifications ..........................................................10

Dana Planetary 213 Drive Axle Specifications.....................................................10

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

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March 2016

Table of Contents

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

Checklist A Procedures..................................................................................... 19

A-1 Inspect the Manuals and Decals ................................................................... 19

A-2 Perform Pre-operation Inspection ................................................................. 20

A-3 Perform Function Tests ................................................................................. 20

A-4 Lubricate the Boom ....................................................................................... 21

A-5 Perform Engine Maintenance - All Models.................................................... 21

A-6 Perform Transmission Maintenance ............................................................. 22

A-7 Perform 30 Day Service ................................................................................ 22

A-8 Perform Axle Maintenance ............................................................................ 23

A-9 Perform Engine Maintenance - John Deere Models ..................................... 23

A-10 Perform Axle Maintenance .......................................................................... 24

A-11 Perform Axle Maintenance .......................................................................... 24

Checklist B Procedures..................................................................................... 25

B-1 Inspect the Batteries...................................................................................... 25

B-2 Inspect the Electrical Wiring .......................................................................... 26

B-3 Check the Exhaust System ........................................................................... 27

B-4 Inspect the Engine Air Filter .......................................................................... 28

B-5 Inspect the Tires, Wheels and Lug Nut Torque............................................. 28

B-6 Perform Hydraulic Oil Analysis...................................................................... 29

B-7 Inspect the Fuel and Hydraulic Tank Cap Venting Systems......................... 29

B-8 Check the Boom Wear Pads ......................................................................... 30

B-9 Lubricate the Driveshaft ................................................................................ 31

B-10 Perform Engine Maintenance - John Deere Models ................................... 32

Checklist C Procedures..................................................................................... 33

C-1 Inspect and Lubricate the Sequencing Chains ............................................. 33

C-2 Perform Engine Maintenance - John Deere Models ..................................... 34

C-3 Perform Axle Maintenance............................................................................ 35

C-4 Perform Transmission Maintenance - Dana Models..................................... 35

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

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March 2016

Table of Contents

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

Checklist D Procedures .....................................................................................39

D-1 Inspect the Forks ...........................................................................................39

D-2 Perform Transmission Maintenance - Dana Models .....................................39

D-3 Replace Hydraulic Tank Return Filter Element .............................................40

D-4 Perform Axle Maintenance ............................................................................40

D-5 Perform Engine Maintenance - Perkins Models ............................................41

Checklist E Procedures .....................................................................................42

E-1 Test or Replace the Hydraulic Oil ..................................................................42

E-2 Perform Engine Maintenance - John Deere Models .....................................43

E-3 Perform Engine Maintenance - Perkins Models ............................................43

E-4 Perform Engine Maintenance - Perkins Models ............................................44

E-5 Perform Engine Maintenance - John Deere Models .....................................44

E-6 Perform Engine Maintenance - Perkins Models ............................................45

Section 4 Repair Procedures .............................................................................................46

Introduction...........................................................................................................46

Boom Components ............................................................................................48

1-1 Boom Proximity Switch ..................................................................................48

How to Test a Proximity Switch.......................................................................48

How to Adjust the Boom Angle Proximity Switch............................................49

How to Adjust the Boom Extend Proximity Switch..........................................49

1-2 Boom ..............................................................................................................50

How to Replace the Boom Wear Pads ...........................................................50

How to Remove the Lifting Fork Frame ..........................................................50

How to Remove the Cable Bridge Assembly , GTH-1056 ..............................51

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

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March 2016

Table of Contents

x GTH-1048 • GTH-1056 Part No. 123701

1-4 Boom Extension Cylinder .............................................................................. 65

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 ............................................................................... 71

2-2 Machine Controls........................................................................................... 73

How to Remove the Steering Column ............................................................ 73

How to Remove the Steering Wheel .............................................................. 73

How to Remove the Steer Orbitral.................................................................. 74

How to Remove the Joystick - Models with Single Joystick ........................... 74

How to Remove the Joystick - Models with Dual Joysticks............................ 75

How to Remove the Brake Pedal Assembly................................................... 75

How to Remove the Gauge Cluster Assembly ............................................... 76

How to Remove the Diagnostic Display ......................................................... 76

Fuel and Hydraulic Tanks ................................................................................. 77

3-1 Fuel and Hydraulic Tanks .............................................................................. 77

Engines ............................................................................................................... 78

4-1 Engines .......................................................................................................... 78

How to Repair the John Deere 4045T Engine ................................................ 78

How to Repair the Perkins 1104D-E44TA Engine.......................................... 78

How to Remove the Engine ............................................................................ 78

4-2 Engine Fault Codes ....................................................................................... 79

Transmission...................................................................................................... 80

5-1 Transmission.................................................................................................. 80

How to Repair the Transmission..................................................................... 80

How to Remove the Transmission.................................................................. 80

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