John Deere

Par ts Manual
Service Manual
Serial Number
Serial Range
Number Range
GTH-1048 from GTH1007B-7101
GTH-1056 from GTH1007B-7101
Part No. 123701

Rev A2
August 2007
Introduction May 2007
Introduction
Important
Read, understand and obey the safety rules and
operating instructions in the appropriate Operator's
Manual on your machine before attempting any
maintenance or repair 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.
Technical Publications
Genie Industries 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.
Copyright 2006 by Genie Industries

Contact Us:
123701 Rev A May 2007
PO Box 97030 Second Edition, First Printing
Redmond, WA 98073-9730 USA
"Genie" is a registered trademark of Genie
www.genieindustries.com Industries in the USA and many other countries.
"GTH" is a trademark of Genie Industries.
e-mail: techsup@genieind.com
Printed on recycled paper
Printed in U.S.A.
ii GTH-1048 GTH-1056 Part No. 123701

May 2007
INTRODUCTION
Serial Number Legend
A TEREX COMPANY
Genie Industries
18340 NE 76th S treet
Redmond, WA 98052
USA
MODEL: GTH1048
SERIAL NUMBER: GTH1007B-7101
ATTACHMENT:
MANUFACTURE DATE: 04/12/07
TOTAL TRUCK WEIGHT(LBS): 29,000lbs / 13,182kg
MAX LIFT CAPACITY(LBS):

10000 LBS
GTH10 07 B - 7101
LIFT CAPACITY(LBS)
AT MAX LIFT HEIGHT: 6000 LBS Model
OUTRIGGERS UP: N/A Sequence
OUTRIGGERS DOWN: N/A number
Year of
manufacture
THIS FORKLIFT TRUCK COMPLIES
WITH:
ASME B56.6-2002 SAFETY STD FOR Facility code
ROUGH TERRAIN FORKLIFT TRUCK
Serial label
(located inside fork frame)
(models with quick attach frame)
Serial label Serial number
(located inside chassis at tank side of machine) (stamped on chassis)
Part No. 123701 GTH-1048 GTH-1056 iii

May 2007
This page intentionally left blank.
iv GTH-1048 GTH-1056 Part No. 123701

May 2007 Section 1 Safety Rules
Safety Rules
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
operators 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:
- manufacturers instructions and safety rules
- employers safety rules and worksite
regulations
- applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.
Part No. 123701 GTH-1048 GTH-1056 v

Section 1 Safety Rules May 2007
SAFETY RULES
Personal Safety Workplace Safety

Any person working on or around a machine must Be sure to keep sparks, flames and
be aware of all known safety hazards. Personal lighted tobacco away from flammable and
safety and the continued safe operation of the combustible materials like battery gases
machine should be your top priority. and engine fuels. Always have an
approved fire extinguisher within easy
Read each procedure thoroughly. This reach.
manual and the decals on the machine,
use signal words to identify the following: Be sure that all tools and working areas
are properly maintained and ready for
Safety alert symbolused to alert use. Keep work surfaces clean and free of
personnel to potential personal debris that could get into machine
injury hazards. Obey all safety components and cause damage.
messages that follow this symbol
to avoid possible injury or death. Be sure any forklift, overhead crane or
other lifting or supporting device is fully
Indicates an imminently hazardous
capable of supporting and stabilizing the
situation which, if not avoided, will
weight to be lifted. Use only chains or
result in death or serious injury.
straps that are in good condition and of
Indicates a potentially hazardous ample capacity.
situation which, if not avoided,
could result in death or serious Be sure that fasteners intended for one
injury. time use (i.e., cotter pins and self-locking
nuts) are not reused. These components
Indicates a potentially hazardous may fail if they are used a second time.
may cause minor or moderate Be sure to properly dispose of old oil or
injury. other fluids. Use an approved container.
Please be environmentally safe.
Indicates a potentially hazardous
situation which, if not avoided, Be sure that your workshop or work area
may result in property damage. is properly ventilated and well lit.
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.
vi GTH-1048 GTH-1056 Part No. 123701

May 2007
Table of Contents
Introduction
Important Information ......................................................................................... ii
Serial Number Legend ...................................................................................... iii
Section 1 Safety Rules

General Safety Rules ........................................................................................ v
Section 2 Rev Specifications

A Machine Specifications ................................................................................ 2 - 1
Performance Specifications ......................................................................... 2 - 2
Hydraulic Specifications ............................................................................... 2 - 3
Hydraulic Component Specifications ........................................................... 2 - 4
Manifold Component Specifications ............................................................. 2 - 5
Valve Coil Resistance Specifications ........................................................... 2 - 5
John Deere 4045TH485 Engine ................................................................... 2 - 6
Perkins 1104D-E44TA Engine ..................................................................... 2 - 7
Dana T20000 Transmission ......................................................................... 2 - 8
Dana Planetary 213 Drive Axle .................................................................... 2 - 8
Hydraulic Hose and Fitting Torque Specifications ........................................ 2 - 9
SAE and Metric Fasteners Torque Charts ................................................. 2 - 10
Section 3 Rev Scheduled Maintenance Procedures

Introduction .................................................................................................. 3 - 1
Pre-delivery Preparation Report .................................................................. 3 - 3
Maintenance Inspection Report ................................................................... 3 - 5
Part No. 123701 GTH-1048 GTH-1056 vii

May 2007
TABLE OF CONTENTS
Section 3 Rev Scheduled Maintenance Procedures, continued

A Checklist A Procedures
A-1 Inspect the Manuals and Decals ......................................................... 3 - 6
A-2 Perform Pre-operation Inspection ....................................................... 3 - 7
A-3 Perform Function Tests ...................................................................... 3 - 7
A-4 Lubricate the Boom ............................................................................ 3 - 8
A-5 Perform Engine Maintenance ............................................................. 3 - 8
A-6 Perform Transmission Maintenance ................................................... 3 - 9
A-7 Perform 30 Day Service ..................................................................... 3 - 9
A-8 Perform Engine Maintenance - Perkins Models ................................ 3 - 10
A-9 Perform Axle Maintenance ............................................................... 3 - 10
A-10 Perform Engine Maintenance - John Deere Models ......................... 3 - 11
A Checklist B Procedures
B-1 Inspect the Battery ........................................................................... 3 - 12
B-2 Inspect the Electrical Wiring ............................................................. 3 - 12
B-3 Check the Exhaust System .............................................................. 3 - 13
B-4 Inspect the Engine Air Filter .............................................................. 3 - 14
B-5 Inspect the Tires, Wheels and Lug Nut Torque ................................. 3 - 14
B-6 Perform Hydraulic Oil Analysis ......................................................... 3 - 15
B-7 Inspect the Fuel and Hydraulic Tank Cap Venting Systems ............. 3 - 16
B-8 Check the Boom Wear Pads ............................................................ 3 - 17
B-9 Lubricate the Driveshafts .................................................................. 3 - 18
B-10 Perform Engine Maintenance - John Deere Models ......................... 3 - 18
viii GTH-1048 GTH-1056 Part No. 123701

May 2007
TABLE OF CONTENTS
Section 3 Rev Scheduled Maintenance Procedures, continued

A Checklist C Procedures
C-1 Perform Engine Maintenance - John Deere Models ......................... 3 - 19
C-2 Perform Axle Maintenance ............................................................... 3 - 19
C-3 Perform Transmission Maintenance ................................................. 3 - 19
C-4 Perform Engine Maintenance - Perkins Models ................................ 3 - 20
A Checklist D Procedures
D-1 Inspect the Forks .............................................................................. 3 - 21
D-2 Adjust the Boom Sequencing Chains ............................................... 3 - 21
D-3 Replace the Hydraulic Tank Return Filter Element ........................... 3 - 22
D-4 Perform Transmission Maintenance ................................................. 3 - 23
D-5 Perform Axle Maintenance ............................................................... 3 - 23
D-6 Perform Engine Maintenance - Perkins Models ................................ 3 - 23
A Checklist E Procedures
E-1 Test or Replace the Hydraulic Oil ..................................................... 3 - 24
E-2 Perform Engine Maintenance - John Deere Models ......................... 3 - 25
E-3 Perform Engine Maintenance - Perkins Models ................................ 3 - 25
E-6 Perform Engine Maintenance - John Deere Models ......................... 3 - 26
Part No. 123701 GTH-1048 GTH-1056 ix

August 2007
TABLE OF CONTENTS
Section 4 Rev Repair Procedures

Introduction .................................................................................................. 4 - 1
B Boom Components
1-1 Boom Proximity Switches ................................................................... 4 - 2
1-2 Boom ................................................................................................. 4 - 4
1-3 Boom Lift Cylinder ............................................................................ 4 - 17
1-4 Boom Extension Cylinder ................................................................. 4 - 18
1-5 Fork Level Cylinder .......................................................................... 4 - 19
A Operator's Compartment
2-1 Operator's Compartment .................................................................. 4 - 23
2-2 Machine Controls ............................................................................. 4 - 25
A Fuel and Hydraulic Tanks
3-1 Fuel and Hydraulic Tanks ................................................................ 4 - 29
A Engines
4-1 Engines ............................................................................................ 4 - 30
4-2 Engine Fault Codes - John Deere 4045TF275 Engine ..................... 4 - 32
A Transmission
5-1 Transmission .................................................................................... 4 - 33
A Hydraulic Pumps
6-1 Hydraulic Pump ................................................................................ 4 - 35
x GTH-1048 GTH-1056 Part No. 123701

August 2007
TABLE OF CONTENTS
Section 4 Rev Repair Procedures, continued

C Manifolds
7-1 Primary Function Manifold Components -
Models with Single Joystick ............................................................. 4 - 42
7-2 Primary Function Manifold Components -
Models with Dual Joysticks .............................................................. 4 - 46
7-3 Secondary Function Manifold Components ...................................... 4 - 50
7-4 Outrigger Manifold Components ....................................................... 4 - 52
7-5 Auxiliary Manifold Components (option) ........................................... 4 - 54
7-6 Brake Manifold Components ............................................................ 4 - 55
7-7 Valve Adjustments - Secondary Function Manifold .......................... 4 - 56
7-8 Valve Coils ....................................................................................... 4 - 60
A Axle Components
8-1 Axles ................................................................................................ 4 - 62
A Outriggers
9-1 Outriggers ........................................................................................ 4 - 63
Part No. 123701 GTH-1048 GTH-1056 xi

August 2007
TABLE OF CONTENTS
Section 5 Rev Fault Codes

Introduction .................................................................................................. 5 - 1
A Diagnostic Display ....................................................................................... 5 - 2
A Engine Fault Codes - Models with John Deere Power ................................. 5 - 4
A Engine Fault Codes - Models with Perkins Power ....................................... 5 - 8
Section 6 Rev Schematics

Introduction .................................................................................................. 6 - 1
B Electrical Component Legend ...................................................................... 6 - 2
B Proximity Switch Layout ............................................................................... 6 - 3
B Fuse Box Layout .......................................................................................... 6 - 4
B Electrical and Hydraulic Symbols Legends .................................................. 6 - 5
B Electrical Schematic .................................................................................... 6 - 6
C Hydraulic Schematic -
Models with Single Joystick ....................................................................... 6 - 10
C Hydraulic Schematic -
Models with Dual Joysticks ........................................................................ 6 - 14
xii GTH-1048 GTH-1056 Part No. 123701

May 2007 Section 2 Specifications
REV A
Specifications
Machine Specifications Tires and wheels
Tire size 14.00 x 24

Fluid capacities
Tire ply rating 12
Fuel tank 35 gallons
132.5 liters Weight, rough terrain tire 315 lbs
Hydraulic tank 44 gallons (air filled) 142.9 kg
166.5 liters Weight, rough terrain tire 967 35 lbs
Hydraulic system 55 gallons (foam filled) 439 16 kg
(including tank) 208.2 liters
Weight, rock lug tire 1013 35 lbs
(foam filled) 459 16 kg
Tire pressure 50 psi

For operational specifications, refer to the (models with air-filled tires) 3.45 bar
Operator's Manual.
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
Continuous improvement of our products is a

Genie policy. Product specifications are
Part No. 123701 GTH-1048 GTH-1056 2-1

Section 2 Specifications May 2007
SPECIFICATIONS REV A
Performance Specifications Boom function speeds, maximum
Drive speed, maximum 18 mph GTH-1048

29 km/h Boom up 12 to 14 seconds
Draw bar pull 29,000 lbs Boom down 13 to 15 seconds
13,154 kg
Boom extend 16 to 18 seconds
Lift capacity, maximum 10,000 lbs
4545 kg Boom retract 15 to 17 seconds
Fork rotate 19 to 21 seconds
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

2-2 GTH-1048 GTH-1056 Part No. 123701

REV A SPECIFICATIONS
Hydraulic Specifications Optional Fluids
Hydraulic Oil Specifications Biodegradable Petro Canada Environ MV46

(all oils except fire resistant) Statoil Hydra Way Bio Pa 32
BP Biohyd SE-S
Hydraulic oil type Chevron Rykon MV equivalent
ISO viscosity grade Mult-viscosity Fire resistant UCON Hydrolube HP-5046
Viscosity index 200 Quintolubric 822
Cleanliness level, minimum 15/13 Mineral based Chevron Rykon MV

Shell Tellus T32
Water content, maximum 200 ppm Shell Tellus T46
Chevron Aviation A
Genie specifications require hydraulic oils which

are designed to give maximum protection to Continued use of Chevron
hydraulic systems, have the ability to perform over Aviation A hydraulic fluid when
a wide temperature range, and have a minimum ambient temperatures are
viscosity index rating of 140. They should provide consistently above 32F / 0C may
excellent antiwear, oxidation, corrosion inhibition, result in component damage.
seal conditioning, and foam and aeration Note: Use Chevron Aviation A hydraulic fluid when
suppression properties. ambient temperatures are consistently below
0F / -17C.
Note: Use Shell Tellus T46 hydraulic oil when oil

temperatures consistently exceed 205F / 96C.
Note: Genie specifications require additional
equipment and special installation instructions for
the approved optional fluids. Consult the Genie
Industries Service Department before use.

Part No. 123701 GTH-1048 GTH-1056 2-3

Hydraulic Components Primary Function Manifold

Specifications System relief valve pressure, maximum 3500 psi
(measured at test port TP) 241 bar
Function Pump
Boom extend relief valve pressure, maximum 3500 psi
Type: variable displacement piston pump 241 bar
Displacement 0 to 3.66 cu in Fork tilt relief valve pressure, maximum 3500 psi
0 to 60 cc 241 bar
Flow rate @ 2400 rpm 38 gpm Flow regulator, 14 gpm

144 L/min Fork tilt circuit 53 L/min
Pump pressure, maximum 3190 psi Flow regulator, 2 gpm

220 bar Sway circuit 7.5 L/min
Pressure compensator 3190 psi Flow regulator, 0.1 gpm

220 bar Pilot pressure bleed circuit 1.4 L/min
Standby pressure 464 psi Secondary Function Manifold
32 bar
Steer relief valve pressure, maximum 2500 psi
(measured at test port TS) 172 bar
Parking brake relief valve pressure, maximum 400 psi

(measured at test port TPB) 27.5 bar
Diff lock relief valve pressure, maximum 400 psi

(measured at test port TJ) 27.5 bar
Rear lock-up relief valve pressure, maximum 50 psi

(measured at test port TR) 3.4 bar
Outrigger Manifold
Flow regulator, 6 gpm

Outrigger circuit 22.7 L/min

2-4 GTH-1048 GTH-1056 Part No. 123701

REV A
Manifold Component Valve Coil Resistance

Specifications Specifications
Plug torque Note: The following coil resistance specifications
are at an ambient temperature of 68F / 20C. As
SAE No. 2 50 in-lbs / 6 Nm valve coil resistance is sensitive to changes in air
temperature, the coil resistance will typically
SAE No. 4 13 ft-lbs / 18 Nm
increase or decrease by 4% for each 18F / 20C
SAE No. 6 18 ft-lbs / 24 Nm that your air temperature increases or decreases
from 68F / 20C.
SAE No. 8 50 ft-lbs / 68 Nm
SAE No. 10 55 ft-lbs / 75 Nm Description Specification
SAE No. 12 75 ft-lbs / 102 Nm Solenoid valve, 2 position 4 way 8.9

12V DC with diode
(schematic items AA, AD, AY, AAB and BAA)
Solenoid valve, 2 position 2 way 8.9

12V DC with diode
(schematic items AAC)
DO3 valve, 3 position 4 way 5.6

12V DC with diode
(schematic items CA and EB)

12V DC with diode
(schematic items CF, CO and CP)

12V DC with diode
(schematic items CG )

12V DC with diode
(schematic items DA and DB)

Part No. 123701 GTH-1048 GTH-1056 2-5

John Deere 4045HF485 Engine Injection system
Displacement 275 cu in Injection pump make Stanadyne

4.5 liters Peak injection pressure 10,000 psi
Number of cylinders 4 690 bar
Bore & stroke 4.19 x 5 inches Fuel requirement

106 x 127 mm For fuel requirements, refer to the engine Operator's
Horsepower 125 @ 2400 rpm Manual on your machine.
93.2 kw @ 2400 rpm Engine coolant
Firing order 1-3-4-2 Capacity 7 gallons
Low idle 800 rpm 26.5 liters
Frequency 160 Hz Alternator
High idle 2400 rpm Output 95 A, 14V DC
Frequency 480 Hz
Battery
Compression ratio 17:1
Type 12V DC
Valve clearances, cold
Group C31
Intake 0.14 in
0.36 mm Quantity 1
Exhaust 0.18 in Cold cranking ampere @ 0F 1000A
0.46 mm
Reserve capacity @ 25A rate 200 minutes
Lubrication system
Oil pressure 6025 psi

(warm, at rated speed with full load) 4.131.7 bar
Oil pressure 15 psi

(warm, at low idle) 1 bar Genie policy. Product specifications are
Oil capacity 14 quarts
(including filter) 13.2 liters
Oil viscosity requirements
Units ship with John Deere Engine Break-In Oil.

During the break-in period, add John Deere Engine
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.
2-6 GTH-1048 GTH-1056 Part No. 123701

Perkins 1104D-E44TA Engine Injection system
Displacement 269 cu in Injection pump make Delphi

4.4 liters Injector pressure, minimum 2500 psi
Number of cylinders 4 172 bar
Bore and stroke 4.13 x 5 inches Lift (transfer)pump pressure 45-55 psi
105 x 127 mm 3.1-3.8 bar
Horsepower 125 @ 2400 rpm Fuel requirement

93.2 kW @ 2400 rpm For fuel requirements, refer to the engine Operation
Firing order 1-3-4-2 Manual on your machine.
Compression ratio 16.2:1 Engine coolant
Low idle 1000 rpm Capacity 9.75 gallons

Frequency 200 Hz 36.9 liters
High idle 2400 rpm Alternator

Frequency 480 Hz Output 85 A, 14V DC
Valve clearance, cold Fan belt tension 90 ft-lb
Intake 0.013 in 400 N
0.35 mm Alternator bolt torque 16 ft-lb
Exhaust 0.013 in 22 Nm
0.35 mm Battery
Lubrication system Type 12V DC
Oil pressure at operating temperature 43-58 psi Group C31
2.96-4 bar
Quantity 1
Oil capacity 7.4 quarts
(including filter) 7 liters Cold cranking ampere @ 0F 1000A
Oil viscosity requirements Reserve capacity @ 25A rate 200 minutes
Units ship with 15W-40.
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operation and Maintenance Manual on your Continuous improvement of our products is a
machine.
Part No. 123701 GTH-1048 GTH-1056 2-7

Dana T20000 Transmission Dana Planetary 213 Drive Axle

Transmission Type 3 speed powershift converter Steering Intergrated steer cylinder
Speeds, Forward 3 Joints Heavy duty double U-joints
Speeds, Reverse 3 Steering angle, maximum 45
Torque Converter Front Axle Lubrication
Maximum input 3100 rpm Front differential 15 quarts

14.2 liters
Size 12 inches
Axle planetary end (each) 2 quarts
Lubrication 1.9 liters
Oil capacity 20 quarts Rear Axle Lubrication
18.9 liters
Rear differential 15 quarts
Oil viscosity requirements 14.2 liters
Units ship with Chevron RPM SAE 10W. Axle planetary end (each) 2 quarts
Extreme operating temperatures may require the use 1.9 liters
of alternative transmission oils. For oil requirements,
refer to the Dana T20000 Maintenance Manual Oil viscosity requirements
(Dana part number 0202).
Differential Chervron Supreme 80W90 LS
Dana 0202 Maintenance Manual
Genie part number 117155 Planetary ends Chervron 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 117154

2-8 GTH-1048 GTH-1056 Part No. 123701

Hydraulic Hose and Fitting Seal-Lok fittings

Torque Specifications 1 Replace the O-ring. The O-ring must be
replaced anytime the seal has been broken.
Your machine is equipped with Parker Seal-Lok The O-ring cannot be re-used if the fitting or
fittings and hose ends. Genie specifications require hose end has been tightened beyond finger
that fittings and hose ends be torqued to tight.
specification when they are removed and installed
or when new hoses or fittings are installed. Note: The O-rings used in the Parker Seal Lok
fittings and hose ends are custom-size O-rings.
They are not standard SAE size O-rings. They are
SAE O-ring Boss Port available in the O-ring field service kit (Genie part
(tube fitting - installed into Aluminum) number 49612).
SAE Dash size Torque 2 Lubricate the O-ring before installation.

-4 11 ft-lbs / 14.9 Nm 3 Be sure that the face seal O-ring is seated and
retained properly.
-6 23 ft-lbs / 31.2 Nm
4 Position the tube and nut squarely on the face
-8 40 ft-lbs / 54.2 Nm seal end of the fitting and tighten the nut finger
-10 69 ft-lbs / 93.6 Nm
tight.
5 Tighten the nut or fitting to the appropriate
-12 93 ft-lbs / 126.1 Nm
torque per given size as shown in the table.
-16 139 ft-lbs / 188.5 Nm
6 Operate all machine functions and inspect the
-20 172 ft-lbs / 233.2 Nm hoses and fittings and related components to
confirm that there are no leaks.
-24 208 ft-lbs / 282 Nm
SAE O-ring Boss Port Seal-Lok Fittings

(tube fitting - installed into Steel) (hose end)
SAE Dash size Torque SAE Dash size Torque
-4 16 ft-lbs / 21.7 Nm -4 18 ft-lbs / 24.4 Nm
-6 35 ft-lbs / 47.5 Nm -6 27 ft-lbs / 36.6 Nm
-8 60 ft-lbs / 81.3 Nm -8 40 ft-lbs / 54.2 Nm
-10 105 ft-lbs / 142.4 Nm -10 63 ft-lbs / 85.4 Nm
-12 140 ft-lbs / 190 Nm -12 90 ft-lbs / 122 Nm
-16 210 ft-lbs / 284.7 Nm -16 120 ft-lbs / 162.7 Nm
-20 260 ft-lbs / 352.5 Nm -20 140 ft-lbs / 190 Nm
-24 315 ft-lbs / 427.1 Nm -24 165 ft-lbs / 223.7 Nm
Part No. 123701 GTH-1048 GTH-1056 2-9

SAE FASTENER TORQUE CHART

This chart is to be used as a guide only unless noted elsewhere in this manual
A574 High Strength
SIZE THREAD Grade 5 Grade 8
Black Oxide Bolts
LUBED DRY LUBED DRY LUBED
in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm
1/4 20 80 9 100 11.3 110 12.4 140 15.8 130 14.7

28 90 10.1 120 13.5 120 13.5 160 18 140 15.8
LUBED DRY LUBED DRY LUBED
f t - lbs Nm f t - lbs Nm f t - lbs Nm f t - lbs Nm f t - lbs Nm
5/16 18 13 17.6 17 23 18 24 25 33.9 21 28.4

24 14 19 19 25.7 20 27.1 27 36.6 24 32.5
3/8 16 23 31.2 31 42 33 44.7 44 59.6 38 51.5
24 26 35.2 35 47.4 37 50.1 49 66.4 43 58.3
7/16 14 37 50.1 49 66.4 50 67.8 70 94.7 61 82.7
20 41 55.5 55 74.5 60 81.3 80 108.4 68 92.1
1/2 13 57 77.3 75 101.6 80 108.4 110 149 93 126
20 64 86.7 85 115 90 122 120 162 105 142
9/16 12 80 108.4 110 149 120 162 150 203 130 176
18 90 122 120 162 130 176 170 230 140 189
5/8 11 110 149 150 203 160 217 210 284 180 244
18 130 176 170 230 180 244 240 325 200 271
3/4 10 200 271 270 366 280 379 380 515 320 433
16 220 298 300 406 310 420 420 569 350 474
7/8 9 320 433 430 583 450 610 610 827 510 691
14 350 474 470 637 500 678 670 908 560 759
8 480 650 640 867 680 922 910 1233 770 1044
1
12 530 718 710 962 750 1016 990 1342 840 1139
7 590 800 790 1071 970 1315 1290 1749 1090 1477
1 1/8
12 670 908 890 1206 1080 1464 1440 1952 1220 1654
7 840 1138 1120 1518 1360 1844 1820 2467 1530 2074
1 1/4
12 930 1260 1240 1681 1510 2047 2010 2725 1700 2304
6 1460 1979 1950 2643 2370 3213 3160 4284 2670 3620
1 1/2
12 1640 2223 2190 2969 2670 3620 3560 4826 3000 4067
METRIC FASTENER TORQUE CHART

This chart is to be used as a guide only unless noted elsewhere in this manual
Size Class 4.6 4.6 Class 8.8 8.8 Class 10.9 10.9 Class 12.9 12.9
(m m ) LUBED DRY LUBED DRY LUBED DRY LUBED DRY

in- lbs Nm in-lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm
5 16 1.8 21 2.4 41 4.63 54 6.18 58 6.63 78 8.84 68 7.75 91 10.3
6 19 3.05 36 4.07 69 7.87 93 10.5 100 11.3 132 15 116 13.2 155 17.6
7 45 5.12 60 6.83 116 13.2 155 17.6 167 18.9 223 25.2 1.95 22.1 260 29.4
LUBED DRY LUBED DRY LUBED DRY LUBED DRY
f t - lbs Nm f t -lbs Nm f t - lbs Nm f t - lbs Nm f t - lbs Nm ft - lbs Nm f t - lbs Nm f t - lbs Nm
8 5.4 7.41 7.2 9.88 14 19.1 18.8 25.5 20.1 27.3 26.9 36.5 23.6 32 31.4 42.6
10 10.8 14.7 14.4 19.6 27.9 37.8 37.2 50.5 39.9 54.1 53.2 72.2 46.7 63.3 62.3 84.4
12 18.9 25.6 25.1 34.1 48.6 66 64.9 88 69.7 94.5 92.2 125 81 110 108 147
14 30.1 40.8 40 54.3 77.4 105 103 140 110 150 147 200 129 175 172 234
16 46.9 63.6 62.5 84.8 125 170 166 226 173 235 230 313 202 274 269 365
18 64.5 87.5 86.2 117 171 233 229 311 238 323 317 430 278 377 371 503
20 91 124 121 165 243 330 325 441 337 458 450 610 394 535 525 713
22 124 169 166 225 331 450 442 600 458 622 612 830 536 727 715 970
24 157 214 210 285 420 570 562 762 583 791 778 1055 682 925 909 1233
2 - 10 GTH-1048 GTH-1056 Part No. 123701

May 2007 Section 3 Scheduled Maintenance Procedures
Scheduled Maintenance Procedures

About This Section
This section contains detailed procedures for each
scheduled maintenance inspection.
Each procedure includes a description, safety

warnings and step-by-step instructions.
Observe and Obey: Symbols Legend
Maintenance inspections shall be completed by Safety alert symbolused to alert

a person trained and qualified on the personnel to potential personal
maintenance of this machine. injury hazards. Obey all safety
Scheduled maintenance inspections shall be to avoid possible injury or death.
completed daily, quarterly, semi-annually,
Indicates an imminently hazardous
annually and every 2 years as specified on the
situation which, if not avoided, will
Maintenance Inspection Report.
Failure to perform each procedure
as presented and scheduled could
result in death, serious injury or
could result in death or serious
substantial damage.
injury.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction may cause minor or moderate
before operating the machine. injury.
Use only Genie approved replacement parts. Indicates a potentially hazardous

Machines that have been out of service for a may result in property damage.
period longer than 3 months must complete the
quarterly inspection. Indicates that a specific result is expected after
performing a series of steps.
Unless otherwise specified, perform each
maintenance procedure with the machine in the Indicates that an incorrect result has occurred
following configuration: after performing a series of steps.
Machine parked on a firm, level surface

Boom in the stowed position
Key switch in the off position with the key
removed
Wheels chocked
Part No. 123701 GTH-1048 GTH-1056 3-1

Section 3 Scheduled Maintenance Procedures May 2007
SCHEDULED MAINTENANCE PROCEDURES
Maintenance Symbols Legend Pre-delivery Preparation Report

Note: The following symbols have been used in The pre-delivery preparation report contains
this manual to help communicate the intent of the checklists for each type of scheduled inspection.
instructions. When one or more of the symbols
appear at the beginning of a maintenance Make copies of the Pre-delivery Preparation report
procedure, it conveys the meaning below. to use for each inspection. Store completed forms
as required.
Maintenance Schedule
Indicates that tools will be required to
perform this procedure. There are five types of maintenance inspections
that must be performed according to a schedule
daily, quarterly, semi-annually, annually, and
two year. The Scheduled Maintenance Procedures
Indicates that new parts will be required
Section and the Maintenance Inspection Report
to perform this procedure.
have been divided into five subsectionsA, B, C,
D, and E. Use the following chart to determine
which group(s) of procedures are required to
Indicates that a cold engine will be perform a scheduled inspection.
required to perform this procedure.
Inspection Checklist
Indicates that a warm engine will be Daily or every 8 hours A

required to perform this procedure.
Quarterly or every 250 hours A+B
Semi-annually or every 500 hours A+B+C

Indicates that dealer service will be
required to perform this procedure. Annually or every 1000 hours A+B+C+D
Two year or every 2000 hours A+B+C+D+E
Maintenance Inspection Report
The maintenance inspection report contains

checklists for each type of scheduled inspection.
Make copies of the Maintenance Inspection Report
to use for each inspection. Store completed forms
for three years.
3-2 GTH-1048 GTH-1056 Part No. 123701

Pre-Delivery Preparation
Fundamentals Instructions
It is the responsibility of the dealer to perform the Use the operators manual on your machine.
Pre-delivery Preparation.
The Pre-delivery Preparation consists of completing
The Pre-delivery Preparation is performed prior to the Pre-operation Inspection, the Maintenance items
each delivery. The inspection is designed to discover if and the Function Tests.
anything is apparently wrong with a machine before it
is put into service. Use this form to record the results. Place a check in
the appropriate box after each part is completed.
A damaged or modified machine must never be used. Follow the instructions in the operators manual.
If damage or any variation from factory delivered
condition is discovered, the machine must be tagged If any inspection receives an N, remove the machine
and removed from service. from service, repair and re-inspect it. After repair,
place a check in the R box.
Repairs to the machine may only be made by a
qualified service technician, according to the Legend
manufacturer's specifications. Y = yes, completed
Scheduled maintenance inspections shall be N = no, unable to complete
performed by qualified service technicians, according R = repaired
to the manufacturer's specifications and the Comments
requirements listed in the responsibilities manual.
Pre-Delivery Preparation Y N R
Pre-operation inspection
completed
Maintenance items completed
Function tests completed
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Genie Industries USA Genie UK

18340 NE 76th Street The Maltings, Wharf Road
PO Box 97030 Grantham, Lincolnshire
Redmond, WA 98073-9730 NG31- 6BH England
(425) 881-1800 (44) 1476-584333
Copyright 2002 by Genie Industries. Genie is a registered trademark of Genie
Industries. Rev B
3-4 GTH-1048 GTH-1056 Part No. 123701

Maintenance Inspection Report

Model Checklist A - Rev A Y N R Checklist C - Rev A Y N R
A-1 Manuals and decals C-1 Engine maintenance -
Serial number John Deere models
A-2 Pre-operation inspect
Date A-3 Function tests C-2 Axle maintenance
A-4 Lubricate boom C-3 Transmission
Hour meter maintenance
A-5 Engine maintenance
C-4 Engine maintenance -
Machine owner A-6 Transmission
Perkins models
maintenance
Perform every 700 hours:
Inspected by (print) Perform after 40 hours:
C-5 Axle maintenance
A-7 30 day service
Inspector signature Perform every 800 hours:
C-6 Axle maintenance
Inspector title A-8 Engine maintenance -
Perkins models
Inspector company A-9 Axle maintenance Checklist D - Rev A Y N R
Perform after 100 hours: D-1 Forks
Instructions A-10 Engine maintenance - D-2 Sequencing chains
Make copies of this report to use for John Deere models D-3 Hydraulic return filter
each inspection.
A-11 Axle maintenance D-4 Transmission
Select the appropriate checklist(s) for maintenance
the type of inspection to be performed.
A-12 Axle maintenance D-5 Axle maintenance
Daily or 8 hour D-6 Engine maintenance -
Inspection: A Perkins models
Checklist B - Rev A Y N R
Quarterly or 250 hour
B-1 Battery
Inspection: A+B Checklist E - Rev A Y N R
B-2 Electrical wiring
Semi-annually or 500 hour E-1 Hydraulic oil
B-3 Exhaust system
Inspection: A+B+C E-2 Engine maintenance -
B-4 Engine air filter
Annually or 1000 hour John Deere models
Inspection: A+B+C+D B-5 Tires and wheels
E-3 Engine maintenance -
2 Year or 2000 hour B-6 Hydraulic oil Perkins models
Inspection: A+B+C+D+E B-7 Tank venting systems Perform every 3000 hours:
B-8 Boom wear pads E-4 Engine maintenance -
Place a check in the appropriate box
after each inspection procedure is B-9 Lubricate driveshafts Perkins models
completed. B-10 Engine maintenance - Perform every 4000 hours:
Use the step-by-step procedures in John Deere models E-5 Engine maintenance -
this section to learn how to perform Perkins models
these inspections. Comments Perform every 4500 hours:
If any inspection receives an N, tag E-6 Engine maintenance -
and remove the machine from service, John Deere models
repair and re-inspect it. After repair,
place a check in the R box.
Legend Perkins models
Y = yes, acceptable
Perform every 12,000 hours:
N = no, remove from service
R = repaired
Perkins models
Part No. 123701 GTH-1048 GTH-1056 3-5

Checklist A Procedures REV A
A-1 2 Examine the pages of each manual to be sure

that they are legible and in good condition.
Inspect the Manuals and Decals
Result: The operator's manual is appropriate for
Genie specifications require that this procedure be the machine and all manuals are legible and in
performed every 8 hours or daily, whichever good condition.
comes first.
Result: The operator's manual is not
Maintaining the operators and safety manuals in appropriate for the machine or all manuals are
good condition is essential to safe machine not in good condition or is illegible. Remove the
operation. Manuals are included with each machine from service until the manual is
machine and should be stored in the container replaced.
provided in the operator's compartment. An
illegible or missing manual will not provide safety 3 Open the operator's manual to the decals
and operational information necessary for a safe inspection section. Carefully and thoroughly
operating condition. inspect all decals on the machine for legibility
and damage.
In addition, maintaining all of the safety and
instructional decals in good condition is mandatory Result: The machine is equipped with all
for safe machine operation. Decals alert operators required decals, and all decals are legible and
and personnel to the many possible hazards in good condition.
associated with using this machine. They also Result: The machine is not equipped with all
provide users with operation and maintenance required decals, or one or more decals are
information. An illegible decal will fail to alert illegible or in poor condition. Remove the
personnel of a procedure or hazard and could machine from service until the decals are
result in unsafe operating conditions. replaced.
1 Check to make sure that the operator's and 4 Always return the manuals to the storage
safety manuals are present and complete in the container after use.
storage container in the operator's
compartment. Note: Contact your authorized Genie distributor or
Genie Industries if replacement manuals or decals
are needed.
3-6 GTH-1048 GTH-1056 Part No. 123701

REV A CHECKLIST A PROCEDURES
A-2 A-3
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. comes first.
Completing a Pre-operation Inspection is essential Completing the function tests is essential to safe
to safe machine operation. The Pre-operation machine operation. Function tests are designed to
Inspection is a visual inspection performed by the discover any malfunctions before the machine is
operator prior to each work shift. The inspection is put into service. A malfunctioning machine must
designed to discover if anything is apparently never be used. If malfunctions are discovered, the
wrong with a machine before the operator performs machine must be tagged and removed from
the function tests. The Pre-operation Inspection service.
also serves to determine if routine maintenance
procedures are required. Complete information to perform this procedure is
available in the appropriate operator's manual.
Complete information to perform this procedure is Refer to the Operator's Manual on your machine.
available in the appropriate operator's manual.
Refer to the Operator's Manual on your machine.
Part No. 123701 GTH-1048 GTH-1056 3-7

CHECKLIST A PROCEDURES REV A
A-4 A-5
Lubricate the Boom Perform Engine Maintenance
Genie specifications require that this procedure be

Engine specifications require that this procedure
performed every 8 hours or daily, whichever
be performed every 8 hours or daily, whichever
comes first.
comes first.
Greasing the specified locations is essential for
Required maintenance procedures and additional
good machine performance and service life.
engine information is available in the
Operating the machine with little or no grease
John Deere 4045HF485 Operator's Manual
may cause the machine to perform poorly and
(John Deere part number OMRG36852) OR the
continued use could cause component damage.
Perkins 1100D Operation and Maintenance
1 Fully extend the boom. Raise the boom as Manual (Perkins part number SEBU8172-00).
needed.
2 Lubricate the top and bottom boom tube wear John Deere 4045HF485 Operator's Manual
pads.
Note: Do not lubricate the side wear pads. Perkins 1100D Operation and Maintenance Manual
3 Return the boom to the stowed position.
Grease Specification
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)

or equivalent
3-8 GTH-1048 GTH-1056 Part No. 123701

A-6 A-7
Perform Transmission Perform 30 Day Service
Maintenance
The 30 day maintenance procedure is a one-time

sequence of procedures to be performed after the
Transmission specifications require that this
first 30 days or 40 hours of usage. After this
procedure be performed every 8 hours or daily,
interval, refer to the maintenance checklists for
whichever comes first.
continued scheduled maintenance.
1 Perform the following maintenance procedures:
Transmission information is available in the
Dana T20000 Maintenance Manual John Deere models:
(Dana part number 0202). A-10 Perform Engine Maintenance -
John Deere Models
Dana T20000 Maintenance Manual
B-5 Inspect the Tires, Wheels and
Lug Nut Torque
D-3 Replace the Hydraulic Tank
Return Filter Element
Perkins models:
B-5 Inspect the Tires, Wheels and

Lug Nut Torque
D-3 Replace the Hydraulic Tank
Return Filter Element
Part No. 123701 GTH-1048 GTH-1056 3-9

CHECKLIST A PROCEDURES REV A
A-8 A-9
Perform Engine Maintenance - Perform Axle Maintenance
Perkins Models
Axle specifications require that this procedure be

Engine specifications require that this procedure performed every 50 hours or monthly, whichever
be performed every 50 hours or weekly, whichever comes first.
comes first. Required maintenance procedures and additional
Required maintenance procedures and additional axle information is available in the
engine information is available in the Dana 213 Axle Maintenance and Repair Manual
Perkins 1100D Operation and Maintenance (Dana part number 0243).
Manual (Perkins part number SEBU8172-00).
Perkins 1100D Operation and Maintenance Manual
3 - 10 GTH-1048 GTH-1056 Part No. 123701

A-10 A-11
John Deere Models
Axle specifications require that this one-time

Engine specifications requires that this one-time procedure be performed after 100 hours of
procedure be performed after 100 hours of operation.
operation. Required maintenance procedures and additional
Required maintenance procedures and additional axle information is available in the
engine information is available in the Dana 213 Axle Maintenance and Repair Manual
John Deere 4045HF485 Operator's Manual (Dana part number 0243).
(John Deere part number OMRG36852)
A-12
Perform Axle Maintenance
Axle specifications requires that this procedure be

performed every 200 hours of operation.

axle information is available in the

Part No. 123701 GTH-1048 GTH-1056 3 - 11

Checklist B Procedures REV A
B-1 B-2
Inspect the Battery Inspect the Electrical Wiring
Genie requires that this procedure be performed Genie requires that this procedure be performed
every 250 hours or quarterly, whichever comes every 250 hours or quarterly, whichever comes
first. first.
Proper battery condition is essential to good Maintaining electrical wiring in good condition is
engine performance and operational safety. essential to safe operation and good machine
Damaged cables and connections can result in performance. Failure to find and replace burnt,
engine component damage and hazardous chafed, corroded or pinched wires could result in
conditions. unsafe operating conditions and may cause
component damage.
Electrocution hazard. Contact with
hot or live circuits could result in Electrocution hazard. Contact with
death or serious injury. Remove all hot or live circuits could result in
rings, watches and other jewelry. death or serious injury. Remove all
rings, watches and other jewelry.
Bodily injury hazard. Batteries
contain acid. Avoid spilling or 1 Inspect the following areas for burnt, chafed,
contacting battery acid. Neutralize corroded and loose wires:
battery acid spills with baking soda
Inside of the operator's compartment
and water.
Inside of the chassis
1 Put on protective clothing and eye wear.
2 Inspect for a liberal coating of dielectric grease
2 Be sure that the battery cable connections are in the following locations:
free of corrosion.
All harness connectors
Note: Adding terminal protectors and a corrosion
3 Start the engine and raise the boom so there is
preventative sealant will help eliminate corrosion
enough room to access and remove all the
on the battery terminals and cables.
covers attached to the chassis.
3 Be sure that the battery hold-downs and cable 4 Attach a lifting strap from an overhead crane to
connections are tight. the boom. Support the boom. Do not apply any
lifting pressure.
3 - 12 GTH-1048 GTH-1056 Part No. 123701

REV A CHECKLIST B PROCEDURES
5 Remove all engine covers, tank covers and B-3

chassis covers.
Check the Exhaust System
Crushing hazard. Death or serious
injury could result if the boom
should unexpectedly fall while
working underneath the boom. Do
not stand or work beneath a boom Genie requires that this procedure be performed
that is not properly supported. every 250 hours or quarterly, whichever comes
first.
6 Inspect the following areas for burnt, chafed,
corroded, pinched and loose wires: Maintaining the exhaust system is essential to
good engine performance and service life. Running
Engine the engine with a damaged or leaking exhaust
Transmission system can cause component damage and unsafe
operating conditions.
Manifolds
Chassis Bodily injury hazard. Do not
inspect while the engine is
7 Inspect for a liberal coating of dielectric grease
running. Remove the key to
in all connections between the engine,
secure from operation.
transmission and the operator's compartment.
Bodily injury hazard. Beware of
8 Install all covers removed in step 5.
hot engine components. Contact
9 Remove the lifting strap from the overhead with hot engine components may
crane. cause severe burns.
10 Start the engine and lower the boom to the 1 Remove the center engine cover and set aside.
stowed position. Turn the machine off.
2 Open the right side engine access cover.
3 Be sure that all fasteners are tight.
4 Inspect all welds for cracks.
5 Inspect for exhaust leaks; i.e., carbon buildup
around seams and joints.
6 Close the right side engine access cover. Install
the center engine access cover.
Part No. 123701 GTH-1048 GTH-1056 3 - 13

CHECKLIST B PROCEDURES REV A
B-4 B-5
Inspect the Engine Air Filter Inspect the Tires, Wheels and
Lug Nut Torque
Genie requires that this procedure be performed

every 250 hours or quarterly, whichever comes Genie requires that this procedure be performed
first. Perform this procedure more often if dusty every 250 hours or quarterly, whichever comes
conditions exist. first.
Maintaining the engine air filter in good condition is Maintaining the tires and wheels in good
essential to good engine performance and service condition, including proper wheel fastener torque,
life. Failure to perform this procedure can lead to is essential to safe operation and good
poor engine performance and component damage. performance. Tire and/or wheel failure could result
Note: Perform this procedure with the engine off. in a machine tip-over. Component damage may
also result if problems are not discovered and
1 Release the latches on the front cover of the air repaired in a timely fashion.
cleaner assembly. Remove the cover.
Bodily injury hazard. An
2 Gently twist and pull out the external or primary overinflated tire can explode and
filter element. could result in death or serious
3 Remove the inner or secondary filter element. injury.
4 Clean the inside of the canister and the gasket Tip over hazard. Do not use
with a damp cloth. temporary flat tire repair products.
5 Inspect the primary and secondary air filter Note: The tires on some machines are foam filled
elements. If needed, blow from the inside and do not need air added to them.
out using low pressure dry compressed air, 1 Check all tire treads and sidewalls for cuts,
or carefully tap out dust. cracks, punctures and unusual wear.
6 Install the secondary filter element first, then 2 Check each wheel for damage, bends and
install the primary filter element. cracks.
7 Install the front cover onto the air cleaner 3 Check each lug nut for proper torque. Refer to
assembly and secure the latches. Section 2, Specifications.
3 - 14 GTH-1048 GTH-1056 Part No. 123701

Models with air-filled tires: B-6

4 Put on protective clothing and eye wear. Perform Hydraulic Oil Analysis
5 Check the air pressure in the tire. Refer to
Section 2, Specifications.
Result: The air pressure meets specification.
The tire is at the correctly filled level.
every 250 hours or quarterly, whichever comes
Result: The air pressure does not meet first.
specification. Add air until the air pressure
Replacement or testing of the hydraulic oil is
meets specification.
essential for good machine performance and
6 Repeat this procedure beginning with step 5 for service life. Dirty oil may cause the machine to
each remaining tire. perform poorly and continued use may cause
component damage. Extremely dirty conditions
may require oil changes to be performed more
often. Refer to Section 2, Specifications.
Note: Before replacing the hydraulic oil, the oil may

be tested by an oil distributor for specific levels of
contamination to verify that changing the oil is
necessary. If the hydraulic oil is not replaced at
the two year inspection, test the oil quarterly.
Replace the oil when it fails the test. See E-1,
Test or Replace the Hydraulic Oil.
Part No. 123701 GTH-1048 GTH-1056 3 - 15

B-7 3 Using a mild solvent, carefully wash the cap

venting system. Dry using low pressure
Inspect the Fuel and Hydraulic compressed air. Repeat this procedure
Tank Cap Venting Systems beginning with step 2.
4 Install the fuel tank cap onto the fuel tank.
5 Remove the breather cap from the hydraulic
tank.
every 250 hours or quarterly, whichever comes 6 Check for proper venting.
first. Perform this procedure more often if dusty
Result: Air passes through the fuel tank cap.
conditions exist.
Proceed to step 8.
Free-breathing fuel and hydraulic tank caps are
Result: If air does not pass through the cap,
essential for good machine performance and
clean or replace the cap. Proceed to step 7.
service life. A dirty or clogged tank cap may cause
the machine to perform poorly and continued use Note: When checking for positive tank cap venting,
may cause component damage. Extremely dirty air should pass freely through the cap.
conditions may require that the caps be inspected
more often. 7 Using a mild solvent, carefully wash the cap
venting system. Dry using low pressure
Explosion and fire hazard. Engine compressed air. Repeat this procedure
fuels are combustible. Perform this beginning with step 6.
procedure in an open, well-
8 Install the breather cap onto the hydraulic tank.
ventilated area away from heaters,
sparks, flames and lighted
tobacco. Always have an
approved fire extinguisher within
easy reach.
Note: Perform this procedure with the engine off.
1 Remove the cap from the fuel tank.
2 Check for proper venting.
Result: Air passes through the fuel tank cap.
Proceed to step 4.
Result: If air does not pass through the cap,
clean or replace the cap. Proceed to step 3.
Note: When checking for positive tank cap venting,
air should pass freely through the cap.
3 - 16 GTH-1048 GTH-1056 Part No. 123701

B-8 3 Visually inspect each lower wear pad at the fork

end of the boom.
Check the Boom Wear Pads
Result: Some of the wear indicator of both wear
pads is visible. The wear pads are good.
Genie specifications require that this procedure be Result: All of the wear indicator of one or both
performed every 250 hours of operation. wear pads is not visible. Replace both wear
pads. Refer to Repair Procedure 1-2, How to
1 Select a boom tube. Visually inspect both upper Replace the Boom Wear Pads.
wear pads at the fork end of the boom.
Note: Steps 4 through 6 do not apply for the large
Result: Some of the wear indicator of both wear outside boom tube with external hard lines.
4 Visually inspect both upper wear pads at the
Result: All of the wear indicator of one or both pivot end of the boom.
wear pads is not visible. Replace both wear
Replace the Boom Wear Pads.
Result: All of the wear indicator of one or both
5 Visually inspect both side wear pad at the pivot
Wear Pad with Wear Pad with end of the boom.
wear indicator visible wear indicator not visible
2 Visually inspect both side wear pads at the fork
end of the boom.
pads is visible. The wear pads are good. pads. Refer to Repair Procedure 1-2, How to
Result: All of the wear indicator of one or both Replace the Boom Wear Pads.
wear pads is not visible. Replace both wear 6 Visually inspect both lower wear pads at the
pads. Refer to Repair Procedure 1-2, How to pivot end of the boom.
7 Repeat this procedure, beginning with step 1,
for each remaining boom tube.
Part No. 123701 GTH-1048 GTH-1056 3 - 17

B-9 B-10
Lubricate the Driveshafts Perform Engine Maintenance -
John Deere Models

every 250 hours or quarterly, whichever comes Engine specifications require that this procedure
first. be performed every 250 hours of operation.
Greasing the specified locations is essential for Required maintenance procedures and additional
good machine performance and service life. engine information is available in the
Operating the machine with little or no grease John Deere 4045HF485 Operator's Manual
may cause the machine to perform poorly and (John Deere part number OMRG36852)
continued use may cause component damage.
1 Using a grease gun, thoroughly grease the John Deere 4045HF485 Operator's Manual
driveshafts at each of the locations indicated in Genie part number 123703
the illustration.
Grease Specification
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)

or equivalent
b b b a a a
a rear driveshaft
b front driveshaft
3 - 18 GTH-1048 GTH-1056 Part No. 123701

REV A
Checklist C Procedures
C-1 C-2
John Deere Models

Engine specifications require that this procedure performed after 500 hours of operation.
be performed every 500 hours or semi-annually, Required maintenance procedures and additional
whichever comes first. axle information is available in the
Required maintenance procedures and additional Dana 213 Axle Maintenance and Repair Manual
engine information is available in the (Dana part number 0243).
(John Deere part number OMRG36852) Dana 213 Axle Maintenance and Repair Manual
C-3
Perform Transmission
Maintenance

procedure be performed every 500 hours or
semi-annually, whichever comes first.

transmission information is available in the

Part No. 123701 GTH-1048 GTH-1056 3 - 19

CHECKLIST C PROCEDURES REV A
C-4 C-5
Perkins Models

Engine specifications require that this procedure performed every 700 hours of operation.
be performed every 500 hours or annually, Required maintenance procedures and additional
whichever comes first. axle information is available in the
Required maintenance procedures and additional Dana 213 Axle Maintenance and Repair Manual
engine information is available in the (Dana part number 0243).
Perkins 1104 Operation and Maintenance Manual
(Perkins part number SEBU8172-00). Dana 213 Axle Maintenance and Repair Manual
Perkins 1104 Operation and Maintenance Manual
C-6
Perform Axle Maintenance


axle information is available in the

3 - 20 GTH-1048 GTH-1056 Part No. 123701

REV A
Checklist D Procedures
D-1 D-2
Inspect the Forks Adjust the Boom Sequencing
Chains
Genie specifications require that this procedure be

performed every 1000 hours or annually, Genie specifications require that this procedure be
whichever comes first OR whenever permanent performed every 1000 hours or annually,
deformation of the forks is suspected. whichever comes first.
Maintaining the lifting forks in good condition is GTH-1048:
essential to safe operation and good machine
performance. Failure to detect damage to the forks 1 Raise the boom to the horizontal position.
could result in a hazardous operating condition.
2 Extend the boom fully, then fully retract the
1 Thoroughly clean the lifting forks. boom.
2 Inspect the forks for the following: 3 Measure the distance between the washer and
the 1.5 inch / 38 mm steel spacer. Refer to
Surface cracks Illustration 1.
Straightness of the blade and shank
Result: The distance between the washer and
Fork angle at 90 3 degrees spacer is 0.125 to 0.25 inch / 3.2 to 6.3 mm. No
Relative height of fork tips shall not differ adjustment to the chain is necessary.
more than 3% of blade length
Result: The distance between the washer and
Excessive wear to the forks, fork mount or spacer is less than 0.125 inch / 3.2 mm OR is
legible markings greater than 0.25 inch / 6.3 mm. The chain
Result: If any of the above criteria are not met, requires adjustment. Tighten or loosen the nut
the fork shall be removed from service until it is until the distance meets specification.
repaired or replaced.
a b
a shank
b blade
Illustration 1
a washer
b spacer
Part No. 123701 GTH-1048 GTH-1056 3 - 21

CHECKLIST D PROCEDURES REV A
GTH-1056: D-3
1 Raise the boom to the horizontal position. Replace Hydraulic Tank Return
2 Extend the boom fully, then fully retract the Filter Element
boom.
3 Working at boom tube number 0, measure the
distance between the washer and the 1.5 inch /
38 mm steel spacer. Refer to Illustration 1. Genie specifications require that this procedure be
performed every 1000 hours or annually,
Result: The distance between the washer and whichever comes first
spacer is 0.125 to 0.25 inch / 3.2 to 6.3 mm. No
adjustment to the chain is necessary. Replacing the hydraulic return filter element is
essential to good machine performance and
Result: The distance between the washer and service life. A dirty or clogged filter element may
spacer is less than 0.125 inch / 3.2 mm OR is cause the machine to perform poorly and
greater than 0.25 inch / 6.3 mm. The chain continued use may cause component damage.
requires adjustment. Tighten or loosen the nut Extremely dirty conditions may require that the
until the distance meets specification. filter element be replaced more often.
4 Working at boom tube number 1, measure the Bodily injury hazard. Beware of
distance between the washer and face of the hot oil. Contact with hot oil may
spring pocket. Refer to Illustration 2. cause severe burns.
Result: The distance between the washer and 1 Start the engine. Retract the boom and lower
face of the spring pocket is 0.125 to the forks to the ground. Shut off the engine.
0.25 inch / 3.2 to 6.3 mm. No adjustment to the
chain is necessary. 2 Open the hydraulic tank cover.
Result: The distance between the washer and 3 Remove the hydraulic tank filler cap.
face of the spring pocket is less than 4 Using a wrench, loosen the hydraulic tank
0.125 inch / 3.2 mm OR is greater than return filter element cap.
0.25 inch / 6.3 mm. The chain requires
adjustment. Tighten or loosen the nut until the 5 Remove and properly discard the filter element.
distance meets specification. Note: To reduce the amount of oil spilled, it may be
a b helpful to drain the element into the tank during
replacement.
6 Install the new filter element. Install and
securely tighten the cap.
7 Clean up any oil that may have spilled.
Illustration 2
a washer
b spring pocket face
3 - 22 GTH-1048 GTH-1056 Part No. 123701

REV A CHECKLIST D PROCEDURES
D-4 D-5
Perform Transmission Perform Axle Maintenance
Maintenance

procedure be performed every 1000 hours or Required maintenance procedures and additional
annually, whichever comes first. axle information is available in the
transmission information is available in the
(Dana part number 0202). Dana 213 Axle Maintenance and Repair Manual

D-6
Perform Engine Maintenance -
Perkins Models

be performed every 1000 hours.


Part No. 123701 GTH-1048 GTH-1056 3 - 23

Checklist E Procedures REV A
E-1 4 Remove the drain plug from the hydraulic tank

and completely drain the tank.
Test or Replace the Hydraulic Oil
hot oil. Contact with hot oil may
cause severe burns.
Genie specifications require that this procedure be 5 Rinse out the inside of the tank using a mild
performed every 2000 hours or two years, solvent.
whichever comes first 6 Install the drain plug and securely tighten. Do
Replacement or testing of the hydraulic oil is not over tighten.
essential for good machine performance and 7 Fill the tank with hydraulic oil until the fluid level
service life. Dirty oil may cause the machine to is in the center of the sight glass at the rear of
perform poorly and continued use may cause the tank.
component damage. Extremely dirty conditions
may require oil changes to be performed more 8 Clean up any oil that may have spilled.
frequently. Refer to Section 2, Specifications.
Component damage hazard. The

work area and surfaces where this
procedure will be performed must
be clean and free of debris that
could get into the hydraulic
system.
Note: Before replacing the hydraulic oil, the oil may
be tested by an oil distributor for specific levels of
contamination to verify that changing the oil is
necessary. If the hydraulic oil is not replaced at
the two year inspection, test the oil quarterly.
Replace the oil when it fails the test.
1 Lower the boom to the stowed position.

2 Remove the filler cap from the hydraulic tank.
3 Place a drain pan or other suitable container
under the hydraulic tank. Refer to Section 2,
Specifications.
3 - 24 GTH-1048 GTH-1056 Part No. 123701

REV A CHECKLIST E PROCEDURES
E-2 E-3
Perform Engine Maintenance - Perform Engine Maintenance -
John Deere Models Perkins Models
Engine specifications require that this procedure Engine specifications require that this procedure
be performed every 2000 hours or two years, be performed every 2000 hours.
Required maintenance procedures and additional engine information is available in the
engine information is available in the Perkins 1100D Operation and Maintenance
John Deere 4045HF485 Operator's Manual Manual (Perkins part number SEBU8172-00).
(John Deere part number OMRG36852)
John Deere 4045HF485 Operator's Manual Genie part number 123702
E-4
Perform Engine Maintenance -
Perkins Models

be performed every 3000 hours or two years,


Part No. 123701 GTH-1048 GTH-1056 3 - 25

CHECKLIST E PROCEDURES REV A
E-5 E-7
Perform Engine Maintenance - Perform Engine Maintenance -
Perkins Models Perkins Models
Engine specifications require that this procedure Engine specifications require that this procedure
be performed every 4000 hours. be performed every 6000 hours or every three
years, whichever comes first.
engine information is available in the Required maintenance procedures and additional
Perkins 1100D Operation and Maintenance engine information is available in the
Manual (Perkins part number SEBU8172-00). Perkins 1100D Operation and Maintenance
Genie part number 123702 Perkins 1100D Operation and Maintenance Manual
E-6
Perform Engine Maintenance - E-8
John Deere Models Perform Engine Maintenance -
Perkins Models

be performed every 4500 hours or 60 months, Engine specifications require that this procedure
whichever comes first. be performed every 12,000 hours or every six
years, whichever comes first.
engine information is available in the Required maintenance procedures and additional
John Deere 4045HF485 Operator's Manual engine information is available in the
(John Deere part number OMRG36852) Perkins 1100D Operation and Maintenance
Genie part number 123703 Perkins 1100D Operation and Maintenance Manual
3 - 26 GTH-1048 GTH-1056 Part No. 123701

May 2007 Section 4 Repair Procedures
Repair Procedures
About This Section
Most of the procedures in this section should only
be performed by a trained service professional
in a suitably equipped workshop. Select the
appropriate repair procedure after troubleshooting
the problem.
Observe and Obey: Perform disassembly procedures to the point
where repairs can be completed. Then to
Repair procedures shall be completed by a
re-assemble, perform the disassembly steps in
person trained and qualified on the repair of this
reverse order.
machine.
Immediately tag and remove from service a Symbols Legend
damaged or malfunctioning machine. Safety alert symbolused to alert
Repair any machine damage or malfunction personnel to potential personal
before operating the machine. injury hazards. Obey all safety
Before Repairs Start: to avoid possible injury or death.
Read, understand and obey the safety rules Indicates an imminently hazardous
and operating instructions in the appropriate situation which, if not avoided, will
operators manual on your machine. result in death or serious injury.
Be sure that all necessary tools and parts are Indicates a potentially hazardous
available and ready for use. situation which, if not avoided,
Use only Genie approved replacement parts. injury.
Read each procedure completely and adhere Indicates a potentially hazardous
to the instructions. Attempting shortcuts may situation which, if not avoided,
produce hazardous conditions. may cause minor or moderate
Unless otherwise specified, perform each injury.
repair procedure with the machine in the Indicates a potentially hazardous
following configuration: situation which, if not avoided,
Machine parked on a firm, level surface may result in property damage.
Boom in the stowed position Note: Used to indicate additional operation or
Key switch in the off position with the key procedure information.
removed Indicates that a specific result is expected after
Wheels chocked performing a series of steps.
Indicates that an incorrect result has occurred
after performing a series of steps.
Part No. 123701 GTH-1048 GTH-1056 4-1

Section 4 Repair Procedures August 2007
Boom Components REV B
1-1 How to Test a Proximity Switch

Boom Proximity Switches 1 Remove the switch from the machine. Do not
disconnect the switch wire harness from the
Both the boom angle proximity switch and the machine.
boom extend proximity switch are proximity
switches. These switches function by sensing a 2 Start the engine.
change in the electromagnetic field of the switch, 3 Move the switch away from any ferrous or
due to the introduction of metal into the field. A metallic object
proximity switch is, simply, a metal detector.
Result: The light of the limit switch assembly is
The switch generates an electromagnetic field at not illuminated.
the face of the switch. This field senses when steel
has been moved close to the switch as well as 4 Move the switch close to any ferrous or metallic
when the steel has been moved away, which is object
how the switch contacts open and close. Result: The light of the proximity switch
assembly turns on. The switch is functioning
These switches are of a fail-safe design. Should
correctly.
the switch or the switch wire circuit be faulty, the
machine will not function outside its designed
range of use.
The boom proximity switches are components 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
and the boom is extended to greater than
43 feet / 13.1 m.
4-2 GTH-1048 GTH-1056 Part No. 123701

August 2007 Section 4 Repair Procedures
REV B BOOM COMPONENTS
How to Adjust the Boom Angle How to Adjust the Boom Extend
Proximity Switch Proximity Switch
The boom angle proximity switch is attached to a The boom extend proximity switch assembly, used
mounting bracket, located between the boom and only on the GTH-1056, is secured to the top
the chassis directly beneath the boom pivot pin. surface of the number 0 boom tube at the center of
The switch location is adjustable. the boom. The proximity switch assembly is fixed
in position and is not adjustable.
1 Start the engine.
2 Raise the boom to 60. Confirm with a digital a b
level.
3 Working at the pivot end of the boom, locate the
boom angle proximity switch. Loosen the
fasteners, securing the proximity switch
assembly to the chassis, just enough to allow
the bracket to move.
4 Move the proximity switch assembly until the
light of the proximity switch turns on, then move
the proximity switch assembly until the light of
the proximity switch just turns off.
5 Securely tighten the fasteners. Do not over a boom angle proximity switch
b boom extend proximity switch (GTH-1056)
tighten.
6 Lower the machine to 55.
Result: The light of the proximity switch
assembly is illuminated.
7 Raise the boom to 60. Confirm with a digital
level.
assembly is not illuminated. The proximity
switch is properly calibrated.
assembly is illuminated. The proximity switch is
not calibrated correctly. Repeat this procedure
beginning with step 4.
Part No. 123701 GTH-1048 GTH-1056 4-3

BOOM COMPONENTS REV B
1-2 How to Remove the Lifting Fork

Boom Frame
1 With the boom in the stowed position, attach a
How to Replace the lifting strap from an overhead crane to the top
Boom Wear Pads of the lifting fork frame at the front of the boom.
Support the frame. Do not apply any lifting
1 Lower wear pads: Using a lifting strap from an pressure.
overhead crane or a fork lift of sufficient
capacity, lift the boom tube just enough to 2 Working from the rear of the frame, lift the
remove the weight from the pads. spring-assisted handle of the lock securing the
lower fork frame lock pin to the fork frame
2 Remove the wear pad mounting fasteners and mount. Use a soft metal drift to remove the pin.
remove the wear pads from the boom.
3 Using the overhead crane, lift and remove the
3 Lubricate the wear surface of the new pads. fork frame from the boom.
Refer to Maintenance Procedure A-4, Lubricate
the Boom. Crushing hazard. The fork frame
could fall if not properly supported
Note: Do not lubricate the side wear pads. when the lock pin is removed from
the machine.
4 Install the wear pads. Install and securely
tighten the fasteners. Do not over tighten.
4-4 GTH-1048 GTH-1056 Part No. 123701

How to Remove the Cable Bridge 3 Working at the pivot end of the boom, tag,
disconnect and plug the hydraulic hoses at the
Assembly , GTH-1056 hard lines of the cable bridge. Cap the fittings.
Inside the four-section boom of the GTH-1056, a 4 Working at the pivot end of the boom, remove
cable bridge is used to route hydraulic lines the fasteners securing the hose roller assembly
through the boom assembly to the fork level to boom tube number 1. Remove the hose roller
cylinder and auxiliary connections (if equipped). assembly from the boom.
The three-section boom on the GTH-1048 does
not require the use of a cable bridge. 5 Working at the fork end of the boom, remove
the fasteners securing the cable track mount
1 Remove the inspection cover at the pivot end of bracket to boom tube number 3.
the boom.
6 Working at the fork end of the boom, remove
2 Working at the pivot end of the boom, remove the fasteners securing the cable bridge slider to
the fasteners securing the cable bridge rear the cable bridge. Remove the slider from the
mount bracket to the boom assembly. Remove boom.
the bracket from the boom.
Note: Pay attention to how the hoses are routed
before removing the slider from the boom.
Note: During reassembly, it may be helpful to use

tape to secure the bolts to the cable bridge when
installing the cable bridge slider.
7 Working at the fork end of the boom, securely

attach the loose end of the cable track to the
cable bridge using a cable tie or similar device.
8 Working at the pivot end of the boom, carefully
remove the cable bridge from the boom.
a b c
a cable bridge mount bracket

b cable track mount bracket
c cable bridge slider
Part No. 123701 GTH-1048 GTH-1056 4-5

How to Replace the Retraction 7 GTH-1056: Working at the fork end of the
boom, loosen evenly the fasteners securing the
Chains single-chain tensioners to the top of boom tube
Note: Perform this procedure on a firm, level number 0. After noting the orientation and
surface with the boom in the stowed position and assembly order of the components, remove the
the wheels chocked. fasteners and pull the tensioners free of the
boom. Refer to Illustration 1.
1 Start the engine and allow the engine to idle.
8 GTH-1048: Working at the fork end of the
2 Raise the boom to a horizontal position. boom, loosen the fasteners securing the
single-chain tensioners to the top of boom tube
3 Fully retract the boom.
number 1. After noting the orientation and
4 Extend the boom approximately 1 inch / 2.5 cm. assembly order of the components, remove the
fasteners and pull the tensioners free of the
5 Turn the machine off and remove the key from boom. Refer to Illustration 2.
the key switch.
a b
boom, loosen the fasteners securing the
dual-chain tensioner to the top of boom tube
assembly order of the components, remove the
fasteners and pull the tensioner free of the
a b c d
e d c
Illustration 2
a extension chains
b single-chain tensioner
c boom tube number 1
d boom tube number 2
e boom tube number 3
h g f e
Illustration 1
a tube 3 extension chains

b dual-chain tensioner
c tube 2 extension chains
d single-chain tensioner
f boom tube number 1
g boom tube number 2
h boom tube number 3
4-6 GTH-1048 GTH-1056 Part No. 123701

9 Remove the inspection cover from the pivot end 11 Select a chain anchor. Remove the fasteners
of the boom. securing the chain anchor pivot pin to the
anchor mount of the boom tube. Remove the
10 GTH-1056: Locate the two chain anchors of the
pivot pin and pull the chain anchor free of the
boom retraction chains where they attach to the
mount.
chain anchor mount at the lower side of boom
tube 2 and 3. Refer to Illustration 3. 12 Using a strap from an overhead crane, support
GTH-1048: Locate the chain anchor of the the extend cylinder. Do not apply any lifting
boom retraction chain where it attaches to the pressure
chain anchor mount at the lower side of boom
tube 3. Refer to Illustration 4.
the fasteners securing the boom extend
cylinder pivot pin to the boom.
a
14 Use a soft metal drift to remove the pivot pin.
b Lower the cylinder just enough for access to the
chain anchor bolts.
15 Working at the fork end of the boom, securely
connect a 30 foot / 10 m length of rope to the
end of the chain. Securely tie off the other end
of the rope to the boom structure.
16 Working at the pivot end of the boom, pull the
Illustration 3 chain out of the boom.
a chain anchor - boom tube number 3 Note: Rope coming loose from the chain during
b chain anchor - boom tube number 2
removal may result in a difficult reassembly. Be
sure the rope is securely attached to the chain and
boom structure before pulling the chain out of the
boom.
17 Remove the rope from the end of the chain and
a
securely attach the rope to the new chain.
18 Working at the fork end of the boom, use the
rope to carefully pull the chain through the
boom just until the end of the chain is
accessible. Remove the rope from the chain.
19 Working at the pivot end of the boom, install the
chain anchor into the chain anchor mount.
Illustration 4
Secure the chain anchor to the mount using the
a chain anchor pivot pin and fasteners removed in step 11.
Securely tighten the fasteners. Do not over
tighten.
Part No. 123701 GTH-1048 GTH-1056 4-7

20 Working at the pivot end of the boom, route the How to Replace the Extension
chain over the roller and install the chain onto
the boom assembly using the pivot pin removed Chains
in step 11. Securely tighten the fasteners. Do Note: Perform this procedure on a firm, level
not over tighten. surface with the boom in the stowed position and
21 GTH-1056: Repeat this procedure, beginning the wheels chocked.
with step 11, for the remaining chain anchor.
1 Start the engine and allow the engine to idle.
22 Install the inspection cover, removed in step 9,
2 Raise the boom to a horizontal position.
onto the boom. Install and securely tighten the
fasteners. Do not over tighten. 3 Fully retract the boom.
23 GTH-1056: Working at the fork end of boom 4 Turn the machine off and remove the key from
tube number 1, install the dual-chain tensioner the key switch.
into the tensioner mount. Install the mounting
components, removed in step 6, and securely
tighten the fasteners.
dual-chain tensioner to the top of boom tube
24 GTH-1056: Install the chain tensioners into the number 1. After noting the orientation and
tensioner mount at the fork end of boom tube assembly order of the components, remove the
number 0. Install the mounting components, fasteners and pull the tensioner free of the
removed in step 7. Evenly tighten the chain boom. Refer to Illustration 1.
tensioners to the top of the boom tube until they a b c d
are securely tightened.
25 GTH-1048: Install the chain tensioners into the
tensioner mount at the fork end of boom tube
number 1. Install the mounting components,
removed in step 8. Evenly tighten the chain
tensioners to the top of the boom tube until they
26 Adjust the chains. Refer to Maintenance
Procedure D-2, Adjust the 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
h g f e
have been correctly adjusted.
Illustration 1
a tube 3 extension chains

b dual-chain tensioner
c tube 2 extension chains
d single-chain tensioner
f boom tube number 1
g boom tube number 2
h boom tube number 3
4-8 GTH-1048 GTH-1056 Part No. 123701

6 GTH-1056: Working at the fork end of the 8 Select a chain tensioner. Remove the bow tie
boom, loosen evenly the fasteners securing the clip securing the chain anchor pin to the chain
single-chain tensioners to the top of boom tube assembly. Remove the chain anchor pin from
number 0. After noting the orientation and the assembly and remove the chain anchor
assembly order of the components, remove the from the tensioner assembly.
fasteners and pull the tensioners free of the
for the other chains.
10 Working at the fork end of the boom, select a
chain. Securely connect a 30 foot / 10 m length
single-chain tensioners to the top of boom tube
of rope to the end of the chain. Securely tie off
the other end of the rope to the boom structure.
assembly order of the components, remove the
fasteners and pull the tensioners free of the 11 GTH-1056: Remove the inspection cover from
boom. Refer to Illustration 2. the pivot end of the boom and locate the chain
anchors of the extension chains at the top of
a b
boom tubes 2 and 3.
GTH-1048: Remove the inspection cover from
the pivot end of the boom and locate the chain
anchors of the extension chains at the top of
boom tube 3.
12 Remove the fasteners securing the extension
chain anchors to the boom tubes.
13 Working at the pivot end of the boom, pull the
chain out of the boom.
Note: Rope coming loose from the chain during
removal may result in a difficult reassembly. Be
sure the rope is securely attached to the chain and
boom structure before pulling the chain out of the
boom.
e d c 14 On a workbench, remove the bow tie clip
securing the chain anchor pin to the chain
Illustration 2 assembly. Remove the pin and chain anchor
pin from the assembly.
a extension chains
b single-chain tensioner
c boom tube number 1
d boom tube number 2
Part No. 123701 GTH-1048 GTH-1056 4-9

15 Install the chain anchor, pin and clip onto the 24 GTH-1048: Install the chain tensioners into the
new chain. tensioner mount at the fork end of boom tube
16 Remove the rope from the end of the old chain
and securely attach the rope to the new chain.
17 Working at the fork end of the boom, use the are securely tightened.
rope to carefully pull the chain through the
25 Adjust the chains. Refer to Maintenance
boom just until the end of the chain is
Procedure D-2, Adjust the Boom Sequencing
accessible.
Chains.
18 Working at the pivot end of the boom and using
the fasteners removed in step 12, install the
Chains can be damaged if the
chain anchor onto the boom tube. Securely
boom is used while the chains are
tighten the fasteners. Do not over tighten.
out of adjustment. Do not return
19 Remove the rope from the chain and install the the machine to use until the chains
chain into the chain anchor of the tensioner have been correctly adjusted.
assembly. Secure the chain to the chain anchor
using the pin and clip removed in step 8.
for the other chains.
21 Install the inspection cover, removed in step 8,
onto the boom. Install and securely tighten the
fasteners. Do not over tighten.
22 GTH-1056: Working at the fork end of boom
tube number 1, install the dual-chain tensioner
into the tensioner mount. Install the mounting
components, removed in step 5, and securely
tighten the fasteners.
23 GTH-1056: Install the chain tensioners into the
tensioner mount at the fork end of boom tube
4 - 10 GTH-1048 GTH-1056 Part No. 123701

How to Remove the Boom 9 Remove the fasteners securing the lift cylinder
barrel-end pivot pin to the chassis.
Bodily injury hazard. This
procedure requires specific repair 10 Support and secure the barrel end of the lift
skills, lifting equipment and a cylinder to the boom.
suitable workshop. Attempting this 11 Use a soft metal drift to remove the lift cylinder
procedure without these skills and pivot pin.
tools could result in death or
serious injury and significant 12 Repeat this procedure beginning with step 8 for
component damage. Dealer the other lift cylinder.
service is strongly recommended. 13 Tag, disconnect and plug the hydraulic hoses at
Note: When removing a hose assembly or fitting, the hydraulic hard line connections at the pivot
the O-ring on the fitting and/or hose end must be end of the boom. Cap the fittings.
replaced and then torqued to specification during 14 Using the overhead crane, raise the boom to a
installation. Refer to Section 2, Hydraulic Hose and horizontal position.
Fitting Torque Specifications.
Crushing hazard. The lift cylinders
1 Remove the lifting fork and frame. See 1-2, will fall if not properly supported
How to Remove the Lifting Fork Frame. when the boom is raised.
2 Attach a lifting strap from an overhead 15 Remove the fasteners securing the boom pivot
10 ton / 10,000 kg crane to the fork end of the pin to the chassis.
boom. Support the boom. Do not apply any
lifting pressure. 16 Use a soft metal drift to remove the boom pivot
pin.
3 Select a fork level cylinder. Remove the
fasteners securing the fork level cylinder Crushing hazard. The boom will
rod-end pivot pin to the boom. fall if not properly supported when
the pivot pin is removed from the
4 Using a lifting strap from another overhead machine.
crane, support the rod-end of the fork level
cylinder. Do not apply any lifting pressure. 17 Carefully remove the boom assembly from the
machine and place it on a structure capable of
5 Use a soft metal drift to remove the fork level supporting it.
cylinder pivot pin.
Crushing hazard. The boom could
6 Lower the fork level cylinder onto the chassis. become unbalanced and fall if not
properly supported when removed
Crushing hazard. Keep hands
from the machine.
clear of the cylinder manifold when
lowering the cylinder. Component damage hazard. The
weight of the boom assembly may
7 Repeat this procedure beginning with step 3 for
crush the hydraulic hard lines
the other fork level cylinder.
under the boom. Use caution
8 Select a lift cylinder. Tag, disconnect and plug when placing the boom assembly
the hydraulic hoses at the lift cylinder manifold. onto a structure capable of
Cap the fittings on the cylinder manifold. supporting it.
Part No. 123701 GTH-1048 GTH-1056 4 - 11

How to Disassemble the Boom, 7 Remove the fastener securing the fork level
cylinder rod-end pivot pin to the fork frame
GTH-1048 mount.
Bodily injury hazard. This 8 Use a soft metal drift to remove the rod-end
procedure requires specific repair pivot pin.
skills, lifting equipment and a
suitable workshop. Attempting this 9 Attach a lifting strap from an overhead crane to
procedure without these skills and the barrel end of the fork level cylinder. Support
tools could result in death or the cylinder. Do not apply any lifting pressure.
serious injury and significant 10 Tag, disconnect and plug the fork level cylinder
component damage. Dealer hoses from the cylinder manifolds. Cap the
service is strongly recommended. fittings.
Note: When removing a hose assembly or fitting, Bodily injury hazard. Spraying
the O-ring on the fitting and/or hose end must be hydraulic oil can penetrate and
replaced and then torqued to specification during burn skin. Loosen hydraulic
installation. Refer to Section 2, Hydraulic Hose and connections very slowly to allow
Fitting Torque Specifications. the oil pressure to dissipate
1 Remove the extension cylinder. See 1-4, How gradually. Do not allow oil to
to Remove the Extension Cylinder. squirt or spray.
2 Remove the boom. See 1-2, How to Remove Component damage hazard.
the Boom. Hoses can be damaged if they are
kinked or pinched
3 Select a lift cylinder. Remove the fasteners
securing the lift cylinder rod-end pivot pin to the 11 Remove the fasteners securing the fork level
boom. cylinder barrel-end pivot pin to the boom.
4 Using a lifting strap from an overhead crane, 12 Use a soft metal drift to remove the pivot pin.
support the lift cylinder. Do not apply any lifting Remove the cylinder from the boom.
pressure. Crushing hazard. The cylinder
5 Use a soft metal drift to remove the lift cylinder could fall if not properly supported
rod-end pivot pin. Remove the cylinder from the when the pivot pin is removed
boom. from the machine.
Crushing hazard. The cylinder 13 Remove the inspection cover at the pivot end of
could become unbalanced and fall the boom.
if not properly supported when 14 Remove the hose keepers from the hose roller
removed from the machine. assembly.
6 Repeat this procedure beginning with step 3 for Note: The hose keepers ensure that the hoses do
the other lift cylinder. not jump off the hose rollers.
4 - 12 GTH-1048 GTH-1056 Part No. 123701

a 20 Working at the fork end of the boom, remove

the fasteners securing the extension chain
rollers to the top of boom tube number 2.
Remove the chain rollers from the boom.
21 Working at the pivot end of the boom, remove
the fasteners securing the retraction chain
block pivot pin to boom tube number 3. Remove
the pivot pin. Remove the chain from the roller.
the fasteners securing the retraction chain roller
to boom tube number 2. Remove the chain
roller from the boom.
the wear pads from boom tube number 2.
24 Support and slide boom tube number 3 out of
d c b boom tube number 2. Place boom tube number
3 on a structure capable of supporting it.
Crushing hazard. Boom tube
a extension chains
b boom tube number 1 number 3 could become
c boom tube number 2 unbalanced and fall when
d boom tube number 3 removed from the boom tube
number 2 if not properly supported
and attached to the overhead
the clamps securing the hoses to the inside of
crane.
boom tube number 3.
Note: During removal, the overhead crane strap
will need to be adjusted for proper balancing.
the clamps securing the hoses to the inside of
boom tube number 3. 25 Working at the fork end of the boom, remove
17 Working at the pivot end of the boom, pull the the wear pads from boom tube number 1.
fork level hydraulic hoses from the boom and 26 Support and slide boom tube number 2 out of
lay them to the side. boom tube number 1. Place boom tube number
18 Working at the pivot end of the boom, remove 2 on a structure capable of supporting it.
the fasteners securing the hose roller assembly Crushing hazard. Boom tube
to boom tube number 2. Remove the hose roller number 2 could become
assembly from the boom. unbalanced and fall when
19 Working at the fork end of the boom, loosen removed from the boom tube
evenly, then remove, the fasteners securing the number 1 if not properly supported
chain tensioners to the top of boom tube and attached to the overhead
number 1. crane.
Part No. 123701 GTH-1048 GTH-1056 4 - 13

How to Disassemble the Boom, 7 Remove the fastener securing the fork level
GTH-1056 mount.
Bodily injury hazard. This 8 Use a soft metal drift to remove the rod-end
procedure requires specific repair pivot pin.
skills, lifting equipment and a
suitable workshop. Attempting this 9 Attach a lifting strap from an overhead crane to
procedure without these skills and the barrel end of the fork level cylinder. Support
tools could result in death or the cylinder. Do not apply any lifting pressure.
serious injury and significant 10 Tag, disconnect and plug the fork level cylinder
component damage. Dealer hoses from the cylinder manifolds. Cap the
service is strongly recommended. fittings.
1 Remove the extension cylinder. See 1-4, How gradually. Do not allow oil to
to Remove the Extension Cylinder. squirt or spray.
2 Remove the boom. See 1-2, How to Remove Component damage hazard.
the Boom. Hoses can be damaged if they are
kinked or pinched
3 Select a lift cylinder. Remove the fasteners
securing the lift cylinder rod-end pivot pin to the 11 Remove the fasteners securing the fork level
boom. cylinder barrel-end pivot pin to the boom.
4 Using a lifting strap from an overhead crane, 12 Use a soft metal drift to remove the pivot pin.
support the lift cylinder. Do not apply any lifting Remove the cylinder from the machine.
pressure. Crushing hazard. The cylinder
5 Use a soft metal drift to remove the lift cylinder could fall if not properly supported
rod-end pivot pin. Remove the cylinder from the when the pivot pin is removed
boom. from the machine.
Crushing hazard. The cylinder 13 Remove the inspection cover at the pivot end of
could become unbalanced and fall the boom.
if not properly supported when 14 Working at the pivot end of the boom, remove
removed from the machine. the hose keepers from the hose roller
6 Repeat this procedure beginning with step 3 for assembly.
the other lift cylinder. Note: The hose keepers ensure that the hoses do
not jump off the hose rollers.
4 - 14 GTH-1048 GTH-1056 Part No. 123701

a b
a b c
a cable bridge mount bracket

b cable track mount bracket
c cable bridge slider
f e d c 19 Working at the fork end of the boom, remove

the fasteners securing the cable bridge slider to
the cable bridge. Remove the slider from the
a tube 3 extension chains boom.
b tube 2 extension chains
c boom tube number 0 Note: Pay attention to how the hoses are routed
d boom tube number 1 before removing the slider from the boom.
f boom tube number 3 Note: During reassembly, it may be helpful to use
tape to secure the bolts to the cable bridge when
installing the cable bridge slider.
the fasteners securing the cable bridge rear
mount bracket to the boom assembly. Remove 20 Working at the fork end of the boom, securely
the bracket from the boom. attach the loose end of the cable track to the
cable bridge using a cable tie or similar device.
16 Working at the pivot end of the boom, tag,
disconnect and plug the hydraulic hoses at the 21 Working at the pivot end of the boom, carefully
hard lines of the cable bridge. Cap the fittings. remove the cable bridge from the boom.
17 Working at the pivot end of the boom, remove 22 Working at the fork end of the boom, remove
the fasteners securing the hose roller assembly the fasteners securing the dual-chain tensioner
to boom tube number 1. Remove the hose roller to the top of boom tube number 1.
assembly from the boom.
18 Working at the fork end of the boom, remove the fasteners securing the extension chain
the fasteners securing the cable track mount rollers to the top of boom tube number 2.
bracket to boom tube number 3. Remove the chain rollers from the boom.
Part No. 123701 GTH-1048 GTH-1056 4 - 15

24 Working at the pivot end of the boom, remove 31 Working at the fork end of the boom, remove
the fasteners securing the retraction chain the wear pads from boom tube number 1.
block pivot pin to boom tube number 3. Remove
the pivot pin.
boom tube number 1. Place boom tube number
25 Working at the fork end of the boom, remove 2 on a structure capable of supporting it.
the wear pads from boom tube number 2.
26 Support and slide boom tube number 3 out of number 2 could become
boom tube number 2. Place boom tube number unbalanced and fall when
3 on a structure capable of supporting it. removed from the boom tube
number 1 if not properly supported
number 3 could become
crane.
unbalanced and fall when
removed from the boom tube Note: During removal, the overhead crane strap
number 2 if not properly supported will need to be adjusted for proper balancing.
crane. 33 Working at the pivot end of the boom, remove
the fasteners securing the chain roller to boom
Note: During removal, the overhead crane strap tube number 1. Remove the chain roller from
will need to be adjusted for proper balancing. the boom.
27 Working at the fork end of the boom, loosen 34 Working at the fork end of the boom, remove
evenly, then remove, the fasteners securing the the wear pads from boom tube number 0.
chain tensioners to the top of boom tube
number 0.
boom tube number 0. Place boom tube number
28 Working at the fork end of the boom, remove 1 on a structure capable of supporting it.
the fasteners securing the extension chain
rollers to the top of boom tube number 1.
number 1 could become
Remove the chain rollers from the boom.
unbalanced and fall when
29 Working at the pivot end of the boom, remove removed from the boom tube
the fasteners securing the retraction chain number 0 if not properly supported
block pivot pin to boom tube number 2. Remove and attached to the overhead
the pivot pin. crane.
30 Working at the pivot end of the boom, remove Note: During removal, the overhead crane strap
the fasteners securing the chain roller to boom will need to be adjusted for proper balancing.
tube number 2. Remove the chain roller from
the boom.
4 - 16 GTH-1048 GTH-1056 Part No. 123701

1-3 5 Use a soft metal drift to remove the pivot pin.

Boom Lift Cylinder 6 Remove the fasteners securing the lift cylinder
rod-end pivot pin to the boom.
How to Remove a Lift Cylinder 7 Use a soft metal drift to remove the pivot pin.
Note: When removing a hose assembly or fitting, Crushing hazard. The boom will
the O-ring on the fitting and/or hose end must be fall if not properly supported when
replaced and then torqued to specification during the pivot pin is removed from the
installation. Refer to Section 2, Hydraulic Hose and machine.
8 Using the overhead crane, raise the boom to a
1 Attach a lifting strap from an overhead horizontal position. Remove the cylinder from
10 ton / 10,000 kg crane to the fork end of the the machine.
boom. Support the boom. Do not apply any Crushing hazard. The cylinder will
lifting pressure. fall if not properly supported when
2 Tag, disconnect and plug the hydraulic hoses at removed from the machine.
the lift cylinder manifold. Cap the fittings.
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.
Hoses can be damaged if they are
kinked or pinched.
3 Attach a lifting strap from an overhead crane to
the rod end of the lift cylinder. Support the
cylinder. Do not apply any lifting pressure.
4 Remove the fasteners securing the lift cylinder
barrel-end pivot pin to the chassis.
Part No. 123701 GTH-1048 GTH-1056 4 - 17

1-4 3 Attach a lifting strap from an overhead crane to

the center point of the boom extension cylinder.
Boom Extension Cylinder Support the cylinder. Do not apply any lifting
pressure.
How to Remove the Extension 4 Remove the extension cylinder support loop
Cylinder from the underside of the boom.
Note: When removing a hose assembly or fitting, Note: The extension cylinder support loop is
the O-ring on the fitting and/or hose end must be located at the fork end of the boom.
replaced and then torqued to specification during
installation. Refer to Section 2, Hydraulic Hose and 5 Remove the fasteners securing the extension
Fitting Torque Specifications. cylinder pivot pins to the boom.
6 Use a soft metal drift to remove both pivot pins.
1 Raise the boom to a horizontal position.
Remove the cylinder from the machine.
2 Tag, disconnect and plug the hydraulic hoses at
Crushing hazard. The boom will
the boom extension cylinder manifold. Cap the
fall if not properly supported when
fittings.
the pivot pins are removed from
Bodily injury hazard. Spraying the machine.
squirt or spray.
kinked or pinched.
4 - 18 GTH-1048 GTH-1056 Part No. 123701

1-5 5 Tag, disconnect and plug the fork level cylinder

hoses from the cylinder manifolds. Cap the
Fork Level Cylinder fittings.
How to Remove the Fork Level hydraulic oil can penetrate and
Cylinder burn skin. Loosen hydraulic
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
squirt or spray.
installation. Refer to Section 2, Hydraulic Hose and
Fitting Torque Specifications. Component damage hazard.
1 Remove the lifting fork frame. See 1-2, How to kinked or pinched
Remove the Lifting Fork Frame.
6 Remove the fasteners securing the fork level
2 Remove the fastener securing the fork level cylinder barrel-end pivot pin to the boom.
mount. 7 Use a soft metal drift to remove the pivot pin.
Remove the cylinder from the machine.
Crushing hazard. The cylinder
4 Attach a lifting strap from an overhead crane to could fall if not properly supported
the barrel end of the fork level cylinder. Support when the pivot pin is removed
the cylinder. Do not apply any lifting pressure. from the machine.
Part No. 123701 GTH-1048 GTH-1056 4 - 19

How to Replace the Fork Level 7 Securely connect a 30 feet / 10 m length of rope
to each end of the hoses disconnected in steps
and/or Auxiliary Cylinder Hoses, 5 and 6. Securely tie off the other end of each
GTH-1048 section of rope to the boom structure.
Note: When removing a hose assembly or fitting, 8 Working at the pivot end of the boom, select
the O-ring on the fitting and/or hose end must be one of the hoses. Pull the hose out of the boom.
replaced and then torqued to specification during Note: Rope coming loose from either end of the
installation. Refer to Section 2, Hydraulic Hose and hose or the boom during hose removal may result
Fitting Torque Specifications. in a difficult reassembly. Be sure each section of
1 Fully retract the boom. rope is securely attached to both the hose and the
boom structure before pulling the hose out of the
2 Fully lower the tips of the lifting forks. boom.
3 Remove the covers from the pivot end of the 9 Remove the rope from each end of the hose.
boom. Discard the hose.
4 Attach a lifting strap from an overhead crane to 10 Securely install a section of rope onto each end
the top of the lifting fork frame. Support the of the new hose assembly.
frame. Do not apply any lifting pressure.
11 Install the new hose assembly into the boom in
5 Tag, disconnect and plug the fork level cylinder the same manner the hose was removed.
supply hoses at the cylinder manifold. Cap the Using the rope, carefully pull the hose through
fittings. the boom until each end is accessible.
Bodily injury hazard. Spraying 12 Install both ends of the hose assembly onto the
hydraulic oil can penetrate and correct connection points. Torque to
burn skin. Loosen hydraulic specification. Refer to Section 2, Specifications.
the oil pressure to dissipate 13 Repeat this procedure for the remaining hose to
gradually. Do not allow oil to be replaced, beginning with step 8.
squirt or spray. 14 Remove the lifting strap from the fork frame.
Component damage hazard. 15 Install the cover onto the rear of the boom.
Hoses can be damaged if they are Install and securely tighten the retaining
kinked or pinched. fasteners.
6 Working near the center of the boom assembly,
tag, disconnect and plug the hydraulic hoses
from the hydraulic hard lines under boom tube
number number 1. Cap the hard lines.
4 - 20 GTH-1048 GTH-1056 Part No. 123701

How to Replace the Fork Level 7 Working near the center of the boom assembly,
tag, disconnect and plug the hydraulic hoses
and/or Auxiliary Cylinder Hoses, from the hydraulic hard lines under boom tube
GTH-1056 number number 1. Cap the hard lines.
Note: When removing a hose assembly or fitting, 8 Securely connect a 30 feet / 10 m length of rope
the O-ring on the fitting and/or hose end must be to the end of each hose disconnected in steps 6
replaced and then torqued to specification during and 7. Securely tie off the other end of each
installation. Refer to Section 2, Hydraulic Hose and section of rope to the boom structure.
Fitting Torque Specifications. 9 Working at the pivot end of the boom, select
Replace the lower hoses: one of the hoses. Pull the hose out of the boom.
Note: Rope coming loose from either end of the
hose or the boom during hose removal may result
2 Fully lower the tips of the lifting forks. in a difficult reassembly. Be sure each section of
rope is securely attached to both the hose and the
3 Remove the covers from the pivot end of the
boom structure before pulling the hose out of the
boom.
boom.
the top of the lifting fork frame. Support the 10 Remove the rope from the hose. Discard the
frame. Do not apply any lifting pressure. hose.
5 Working at the pivot end of the boom, remove 11 Securely install a section of rope onto the
the fasteners securing the cable bridge rear correct end of the new hose assembly.
mount bracket to the boom assembly. Remove 12 Install the new hose assembly into the boom by
the bracket from the boom. routing the hose under the roller at the pivot
6 Tag, disconnect and plug the hydraulic hoses at end of the boom. Using the rope, carefully pull
the hard lines of the cable bridge. Cap the the hose through the boom until the end is
fittings. accessible.
Bodily injury hazard. Spraying 13 Install both ends of the hose assembly onto the
hydraulic oil can penetrate and correct connection points. Torque to
burn skin. Loosen hydraulic specification. Refer to Section 2, Specifications.
connections very slowly to allow 14 Repeat this procedure for the remaining hose to
the oil pressure to dissipate be replaced, beginning with step 8.
squirt or spray. 15 Install the cable bridge rear mount bracket onto
the cable bridge and the boom assembly.
Component damage hazard. Securely tighten the fasteners. Do not over
Hoses can be damaged if they are tighten.
kinked or pinched.
16 Remove the lifting strap from the fork frame.
17 Install the cover onto the rear of the boom.
Install and securely tighten the retaining
fasteners.
Part No. 123701 GTH-1048 GTH-1056 4 - 21

Replace the upper hoses: 10 Working at the fork end of the boom, remove
the fasteners securing the cable bridge slider to
1 Fully retract the boom. the cable bridge. Remove the slider from the
2 Fully lower the tips of the lifting forks. boom.
3 Remove the covers from the pivot end of the Note: Pay attention to how the hoses are routed
boom. before removing the slider from the boom.
4 Attach a lifting strap from an overhead crane to Note: During reassembly, it may be helpful to use
the top of the lifting fork frame. Support the tape to secure the bolts to the cable bridge when
frame. Do not apply any lifting pressure. installing the cable bridge slider.
5 Working at the pivot end of the boom, remove 11 Remove the fasteners securing the cable track
the fasteners securing the cable bridge rear to the cable track mount bracket.
mount bracket to the boom assembly. Remove
12 Remove the fasteners securing the cable track
the bracket from the boom.
mount bracket to the cable bridge. Remove the
6 Tag, disconnect and plug the hydraulic hoses at bracket from the boom.
the hard lines of the cable bridge. Cap the
fittings. 13 Carefully pull the cable track through the
opening at the front of boom until the hose
Bodily injury hazard. Spraying connections are accessible.
burn skin. Loosen hydraulic 14 Tag, disconnect and plug the affected hoses.
connections very slowly to allow Cap the fitting. Remove the hose from the cable
the oil pressure to dissipate track.
gradually. Do not allow oil to 15 Install the new hose assembly and torque to
squirt or spray. specification. Refer to Section 2, Specifications.
Component damage hazard. 16 Install the cable bridge and cable track into the
Hoses can be damaged if they are boom.
kinked or pinched.
17 Install the cable track mount bracket and cable
7 Return the cable bridge to its original position. bridge slider. Securely tighten all fasteners. Do
not over tighten.
8 Working at the fork end of the boom, tag,
disconnect and plug the fork level cylinder 18 Working at the pivot end of the boom, install the
hoses at the cylinder manifolds. Cap the fittings. hydraulic hoses onto the hard lines of the cable
bridge and torque to specification. Refer to
9 Models with auxiliary function: Working at
Section 2, Specifications.
the fork end of the boom, tag, disconnect and
plug the auxiliary hoses at the fittings. Cap the 19 Install the cable bridge mount bracket onto the
fittings. cable bridge and the boom assembly. Securely
tighten all fasteners. Do not over tighten.
20 Install the cover onto the rear of the boom.
Install and securely tighten the retaining
fasteners.
4 - 22 GTH-1048 GTH-1056 Part No. 123701

REV A
Operator's Compartment
2-1 3 Locate the secondary function manifold under
the manifold inspection cover. Tag, disconnect
Operator's Compartment and plug the hydraulic hoses at ports BP and
BT of the secondary function manifold. Cap the
How to Remove the Operator's fittings. See 7-3, Secondary Function Manifold
Components.
Compartment
4 Locate the brake manifold under the manifold
The operator's compartment is used to activate
inspection cover. Tag, disconnect and plug the
machine functions while sitting in the operator's
hydraulic hose at the underside of the brake
drivers seat.
manifold. Cap the fitting. See 7-6, Brake
Within the operator's compartment there is a Manifold Components.
transmission column shifter, steering selector, 5 Working under the dashboard, locate the
4-way controller, accelerator pedal, brake pedal hydraulic hose at port L of the steering orbitral.
and a differential lock switch. All of these
components are replaceable. 6 Working at the front axle, locate the hydraulic
hose connected to the front axle steer cylinder
For further information or assistance, consult the at the operator's compartment side of the
Genie Industries Service Department. machine. Tag, disconnect and plug the
hydraulic hose. Cap the fitting.
procedure requires specific repair 7 Tag, disconnect and plug the hydraulic hoses at
skills, lifting equipment and a ports SUP, SUR and SUT of the secondary
suitable workshop. Attempting this function manifold. Cap the fitting.
procedure without these skills and
tools could result in death or Bodily injury hazard. Spraying
serious injury and significant hydraulic oil can penetrate and
component damage. Dealer burn skin. Loosen hydraulic
service is required. connections very slowly to allow
1 Open the access door above the hydraulic tank. gradually. Do not allow oil to
squirt or spray.
2 Disconnect the battery from the machine.
8 Tag, disconnect and plug the hydraulic hose at
port SULS of the primary function manifold.
electrically charged circuits could
Cap the fitting.
Remove all rings, watches and 9 Tag, disconnect and plug the hydraulic hose at
other jewelry. port JP of the secondary function manifold. Cap
the fitting.
squirt or spray.
Part No. 123701 GTH-1048 GTH-1056 4 - 23

Section 4 Repair Procedures May 2007
OPERATOR'S COMPARTMENT REV A
10 Tag, disconnect and plug the hydraulic hoses at 16 Working inside the chassis, tag and disconnect
ports J1, J2, J3 and J4 of the primary function the wire harnesses at the connectors next to
manifold. Cap the fittings. the operator's compartment.
11 Models with dual joystick: Tag, disconnect 17 Support and secure the operator's compartment
and plug the hydraulic hoses at ports JT2, JT4, to an adjustable table capable of supporting the
JS3 and JS1 of the primary function manifold. weight and that will allow the operator's
Cap the fittings. compartment to remain in an upright and stable
position.
12 Remove the fasteners securing the joystick
mount to the operator's compartment. Remove Note: Placing a wedge between the operator's
the joystick assembly. compartment and the adjustable table may be
required to keep the operator's compartment
13 Models with single joystick: With the base of
stable.
the joystick above the top of the hydraulic tank,
tag disconnect and plug the hydraulic hose at 18 Remove the lower fasteners securing the
port T of the joystick. Cap the fitting. operator's compartment to the chassis.
Note: Removing the hydraulic hose from port T of 19 Remove the upper fasteners securing the
the joystick with the joystick below the hydraulic oil operator's compartment to the chassis.
level in the hydraulic tank will result in excessive
hydraulic fluid leaking from the hose. Do not Crushing hazard. The operator's
disconnect the hose from the joystick if the joystick compartment will fall if not properly
is below the hydraulic oil level in the hydraulic tank. supported when the fasteners are
removed from the machine.
14 Models with dual joystick: Locate the tee
20 Slowly move the operator's compartment away
fitting which joins together the hydraulic hoses
from the chassis while feeding all loose hoses,
from port T of both joysticks to the tank return
cables and wires through the opening of the
hydraulic hose.
chassis.
15 Models with dual joystick: With the tee fitting
above the top of the hydraulic tank, tag,
Hoses, cables and wires can
disconnect and plug the tank return hydraulic
be damaged if they are kinked
hose from the tee fitting. Cap the fitting.
or pinched.
Note: Removing the hydraulic hose from the tee
fitting with the tee fitting below the hydraulic oil Bolt torque specification
Operator's cab mounting bolts 750 ft-lbs
hydraulic fluid leaking from the hose. Do not 1017 Nm
disconnect the hose from the tee fitting if the tee
fitting is below the hydraulic oil level in the
hydraulic tank.
4 - 24 GTH-1048 GTH-1056 Part No. 123701

REV A OPERATOR'S COMPARTMENT
2-2 10 Rotate the dash frame towards the seat of the

operator's compartment.Remove the dashboard
Machine Controls from the machine.
11 Tag and disconnect the ground wire of the steer
How to Remove the Steering column.
Column
12 Support and secure the steer orbitral to the
1 Open the access door above the hydraulic tank. dash frame.
2 Disconnect the battery from the machine. 13 Remove the fasteners securing the steer
column and steer orbitral to the dash frame.
electrically charged circuits could 14 Lower the steer orbitral and remove the steer
result in death or serious injury. column from the machine.
Remove all rings, watches and
other jewelry. How to Remove the Steering
3 Remove the fasteners securing the Wheel
transmission control lever to the column. 1 Open the access door above the hydraulic tank.
Carefully separate the lever from the column.
4 Remove the nut securing the key switch to the
dash panel. Gently push the key switch through Electrocution hazard. Contact with
the opening. electrically charged circuits could
5 Remove the fasteners securing the dash panel Remove all rings, watches and
to the dashboard. other jewelry.
6 Carefully pull the dash panel towards the seat 3 Remove the horn button from the steering
of the operator's compartment. wheel. Remove the nut securing the steering
7 Tag and disconnect the wire harness from the wheel to the column and remove the steering
componments of the dash panel. Remove the wheel.
dash panel from the machine.
8 Loosen the two lower fasteners securing the
dash frame to the operator's compartment.
9 Remove the two upper fasteners securing the
dash frame to the operator's compartment.
Part No. 123701 GTH-1048 GTH-1056 4 - 25

How to Remove the Steer Orbitral How to Remove the Joystick -

1 Remove the steering column. See 2-2, How to Models with Single Joystick
Remove the Steering Column. 1 Open the access door above the hydraulic tank.
2 Working under the dashboard, locate the 2 Disconnect the battery from the machine.
hydraulic hose at port L of the steering orbitral.
3 Follow the hydraulic hose from port L of the electrically charged circuits could
steer orbitral to its connection at the front axle result in death or serious injury.
of the machine. Tag, disconnect and plug the Remove all rings, watches and
hydraulic hose at the front axle. Cap the fitting. other jewelry.
3 Remove the fasteners securing the joystick
LS mount panel to the side console.
L R 4 Tag and disconnect the joystick wire harness
from the machine.
T P 5 Tag, disconnect and plug the hoses from ports
1, 2, 3, 4, P and T of the joystick. Cap the
fittings.
4 Tag, disconnect and plug the hydraulic hoses at
ports SUP, SUR and SUT of the secondary Note: Removing the hydraulic hose from port T of
function manifold. Cap the fitting. the joystick with the joystick below the hydraulic oil
Bodily injury hazard. Spraying hydraulic fluid leaking from the hose. Do not
hydraulic oil can penetrate and disconnect the hose from the port if the joystick is
burn skin. Loosen hydraulic below the hydraulic oil level in the hydraulic tank.
the oil pressure to dissipate 6 Remove the fasteners securing the joystick to
gradually. Do not allow oil to the mount panel. Remove the joystick.
squirt or spray.
5 Tag, disconnect and plug the hydraulic hose at
port SULS of the primary function manifold.
2 T
Cap the fitting.
6 Slowly move the steer orbitral away from the
dash frame while feeding all loose hoses
3 1
4
through the opening of the chassis.
P
Joystick port orientation
4 - 26 GTH-1048 GTH-1056 Part No. 123701

REV A OPERATOR'S COMPARTMENT
How to Remove the Joystick - How to Remove the Brake Pedal

Models with Dual Joysticks Assembly
1 Open the access door above the hydraulic tank. 1 Open the access door above the hydraulic tank.
2 Disconnect the battery from the machine. 2 Disconnect the battery from the machine.
Electrocution hazard. Contact with Electrocution hazard. Contact with
electrically charged circuits could electrically charged circuits could
result in death or serious injury. result in death or serious injury.
Remove all rings, watches and Remove all rings, watches and
other jewelry. other jewelry.
3 Remove the fasteners securing the joystick 3 Fully press and release the brake pedal a
mount panel to the side console. minimum of 10 times to release the hydraulic
pressure in the brake system.
4 Tag and disconnect the joystick wire harness
from the machine. 4 Tag, disconnect and plug the hydraulic hoses at
ports BP and BT of the secondary hydraulic
5 Tag, disconnect and plug the hoses from ports
manifold. Cap the fittings.
1, 2, 3, 4 and P of the joystick. Cap the fittings.
6 Locate the tee fitting which joins together the
hydraulic hoses from port T of both joysticks to
the tank return hydraulic hose.
7 With the tee fitting above the top of the the oil pressure to dissipate
hydraulic tank, tag, disconnect and plug the gradually. Do not allow oil to
tank return hydraulic hose from the tee fitting. squirt or spray.
Cap the fitting.
5 Follow the hydraulic hose from port A of the
Note: Removing the hydraulic hose from port T of brake pedal manifold to the brake manifold.
the joystick with the joystick below the hydraulic oil Tag, disconnect and plug this hydraulic hose at
level in the hydraulic tank will result in excessive the brake manifold. Cap the fitting.
hydraulic fluid leaking from the hose. Do not
6 Remove the fasteners securing the brake pedal
disconnect the hose from the port if the joystick is
assembly to the dash frame.
below the hydraulic oil level in the hydraulic tank.
7 Gentley rotate the brake pedal in an upwards
8 Remove the fasteners securing the joystick to direction and slowly move the brake pedal
the mount panel. Remove the joystick. assembly away from the dash frame while
feeding all loose hoses through the opening of
2 T the chassis.
3 1
4
P
Joystick port orientation
Part No. 123701 GTH-1048 GTH-1056 4 - 27

How to Remove the Dash Cluster How to Remove the Diagnostic

Assembly Display
1 Open the access door above the hydraulic tank. 1 Open the access door above the hydraulic tank.
2 Disconnect the battery from the machine. 2 Disconnect the battery from the machine.
Electrocution hazard. Contact with Electrocution hazard. Contact with
electrically charged circuits could electrically charged circuits could
result in death or serious injury. result in death or serious injury.
Remove all rings, watches and Remove all rings, watches and
other jewelry. other jewelry.
3 Remove the fasteners securing the 3 Reach under the dashboard and gently loosen
transmission control lever to the column. and remove the locknut securing the diagnostic
Carefully separate the lever from the column. display to the dashboard. Gently push the
diagnostic display through the opening in the
4 Reach under the dashboard and gently push
dashboard.
the dash cluster through the opening in the
dashboard. 4 Tag and disconnect the wire harness from the
diagnostic display. Remove the diagnostic
5 Tag and disconnect the wire harness from the
display from the machine.
dash cluster. Remove the dash cluster from the
machine.
4 - 28 GTH-1048 GTH-1056 Part No. 123701

REV A
Fuel and Hydraulic Tank
3-1 6 Place a drain pan or other suitable container
Fuel and Hydraulic Tank Specifications.
7 Remove the drain plug from the hydraulic tank
How to Remove the Fuel and and completely drain the tank.
Hydraulic Tank Assembly
Explosion and fire hazard. Engine hot oil. Contact with hot oil may
fuels are combustible. Remove the cause severe burns.
fuel tank in an open, well-
8 Remove the filler cap from the fuel tank.
ventilated area away from heaters,
sparks, flames and lighted 9 Using an approved hand-operated pump, drain
tobacco. Always have an the fuel tank into a container of suitable
approved fire extinguisher within capacity. Refer to Section 2, Specifications.
easy reach.
Explosion and fire hazard. When
Explosion and fire hazard. Never transferring fuel, connect a
drain or store fuel in an open grounding wire between the
container due to the possibility of machine and pump or container.
fire.
Note: Be sure to only use a hand operated pump
Explosion and fire hazard. When suitable for use with gasoline and/or diesel fuel.
transferring fuel, connect a
grounding wire between the 10 Tag, disconnect and plug the fuel supply and
machine and pump or container. return hoses. Cap the fittings.
1 Open the access door above the hydraulic tank. 11 Tag, disconnect and plug the supply and return
hoses from the hydraulic tank. Cap the fittings.
12 Support and secure the tank assembly to an
Electrocution hazard. Contact with appropriate lifting device.
result in death or serious injury. 13 Remove the fasteners securing the tank
Remove all rings, watches and assembly to the chassis. Remove the tank from
other jewelry. the machine.
3 Remove the battery from the machine. Crushing hazard. The tank
assembly could become
4 Tag and disconnect the wire harness from the unbalanced and fall if not properly
fuel level terminals. supported when removed from the
5 Remove the filler cap from the hydraulic tank. machine.
Part No. 123701 GTH-1048 GTH-1056 4 - 29

Engines REV A
4-1 How to Repair the

Engines Perkins 1104D-E44TA Engine
Repair procedures and additional engine
How to Repair the information is available in the
John Deere 4045T Engine Perkins 1100 Operation and Maintenance Manual
(Perkins part number SEBU8172-00) and the
Repair procedures and additional engine Perkins 1104 Service Manual
information is available in the (Perkins part number RENR9401) and the
John Deere 4045HF485 Operator's Manual Perkins 1100 Troubleshooting Manual
(John Deere part number OMRG36852) and the (Perkins part number SENR9982-01).
John Deere 4045T Workshop Manual
(John Deere part number CTM104) and the Perkins 1100 Operation and Maintenance Manual
John Deere 4045T Alternator Manual Genie part number 123702
(John Deere part number CTM77) and the
John Deere 4045T Fuel Systems Manual Perkins 1104 Service Manual
(John Deere part number CTM207). Genie part number 117764
Perkins 1100 Troubleshooting Manual

John Deere 4045HF485 Operator's Manual Genie part number 123583
John Deere 4045T Workshop Manual

John Deere 4045T Alternator Manual

John Deere 4045T Fuel Systems Manual

4 - 30 GTH-1048 GTH-1056 Part No. 123701

REV A ENGINES
How to Remove the Engine 9 John Deere models: Tag, disconnect and plug
the fuel supply hose at the fuel filter/water
Note: When removing a hose assembly or fitting, separator. Cap the fitting.
replaced and then torqued to specification during 10 John Deere models: Open the engine access
installation. Refer to Section 2, Hydraulic Hose and cover at the operator's compartment side of the
Fitting Torque Specifications. machine. Locate the fuel return hose at the fuel
pump.
1 Open the access door above the hydraulic tank.
11 John Deere models: Tag, disconnect and plug
2 Disconnect the battery from the machine. the fuel return hose at the fuel pump. Cap the
fitting.
electrically charged circuits could 12 Open the transmission access cover at the top
result in death or serious injury. of the machine. Locate the transmission cooler.
13 Tag, disconnect and plug the coolant hoses at
other jewelry.
the transmission cooler. Cap the fittings.
3 Remove the fasteners securing the engine
14 Tag and disconnect the engine wire harnesses
access cover from the rear of the machine.
near the operator's compartment.
Remove the cover from the machine.
15 Remove the air cleaner from the machine.
4 Perkins models: Open the engine access
Remove all intake and exhaust components
cover at the tank side of the machine. Locate
which would interfere with the removal of the
the fuel supply line where it is attached to the
engine from the chassis.
fuel filter/water separator.
16 Remove the fasteners securing the driveshaft to
5 Perkins models: Tag, disconnect and plug the
the transmission. Secure the bearing caps onto
fuel supply hose at the fuel filter/water
the universal joint of the driveshaft.
separator. Cap the fitting.
Note: Using adhesive tape to secure the caps to
6 Perkins models: Locate the fuel return hose
the universal joint may be helpful.
connection just above the fuel filter/water
separator. 17 Remove the fasteners securing the engine tray
7 Perkins models: Tag, disconnect and plug the to the chassis.
fuel return hose at the fuel filter/water 18 Support and secure the engine tray to a forklift
separator. Cap the fitting. of adequate capacity.
8 John Deere models: Open the engine access 19 Remove the engine tray from the machine.
cover at the tank side of the machine. Locate
the fuel supply line where it is attached to the
fuel filter/water separator.
Part No. 123701 GTH-1048 GTH-1056 4 - 31

ENGINES REV A
4-2 a b c d
Engine Fault Codes
How to Retrieve Engine Fault

Codes
When the engine Electronic Control Module (ECM)
detects an abnormal operating condition, a fault
code is immediately stored in the ECM memory. At
the same time, a colored warning lamp is
illuminated and the fault code is shown on the
engine diagnostic display, is located on the
dashboard in the operator's compartment.
To learn the specifics of and how to use the fault

codes, refer to Section 5, Fault Codes. Perkins 1104D-E44TA engine
a b c a oil pressure sensor
b coolant temperature sender
c intake temperature sensor
d crank speed sensor
John Deere 4045HF485 engine
a coolant temperature sender

b oil pressure sender
c starter relay
4 - 32 GTH-1048 GTH-1056 Part No. 123701

REV A
Transmission
5-1 How to Remove the Transmission
Transmission Note: When removing a hose assembly or fitting,
How to Repair the Transmission replaced and then torqued to specification during
installation. Refer to Section 2, Hydraulic Hose and
Repair procedures and additional transmission Fitting Torque Specifications.
information is available in the
Dana T12000 Transmission Maintenance and 1 Open the access door above the hydraulic tank.
Repair Manual (Dana part number 0109) and the
(Dana part number 0202). Electrocution hazard. Contact with
Dana T12000 Transmission Manual result in death or serious injury.
Genie part number 97489 Remove all rings, watches and
other jewelry.
Genie part number 115025 3 Place a drain pan or other suitable container
Specifications.
4 Remove the drain plug from the hydraulic tank
and completely drain the tank.
hot oil. Contact with hot oil may
cause severe burns.
5 Tag, disconnect and plug the transmission oil
cooler lines at the cooler. Cap the fittings.
a b c d e f hydraulic oil can penetrate and
Dana T20000 transmission connections very slowly to allow
a transmission temperature sender the oil pressure to dissipate
(located opposite side of trans) gradually. Do not allow oil to
b transmission pressure sender
c transmission shift coil 'F'
squirt or spray.
(drive forward function) (blue wire)
d transmission shift coil 'R'
(drive reverse function) (brown wire) Hoses can be damaged if they are
e transmission shift coil '2' kinked or pinched.
(gear reduction) (green wire)
f transmission shift coil '1'
(gear reduction) (yellow wire)
Note: refer to electrical schematic for additional

transmission shift coil information.
Part No. 123701 GTH-1048 GTH-1056 4 - 33

TRANSMISSION REV A
6 Tag, disconnect and plug the hydraulic pump

high pressure line at the function manifold. Cap
the fitting.
squirt or spray.
kinked or pinched.
7 Tag, disconnect and plug the hydraulic pump
supply line at the pump. Cap the orifice on the
pump.
8 Remove the fasteners securing the
transmission mounting flange to the chassis.
9 Tag and disconnect the driveshafts from the
transmission.
Note: To avoid damage to the driveshaft universal
joints, secure the driveshafts to the chassis.
10 Tag and disconnect the wiring harness from the
transmission.
the center point of the transmission.
12 Remove the fasteners securing the
transmission mounting flange to the chassis.
Remove the transmission from the machine.
Crushing hazard. The
transmission will fall if not properly
supported when removed from the
machine.
4 - 34 GTH-1048 GTH-1056 Part No. 123701

REV A
Hydraulic Pump
6-1 4 Observe the pressure gauge while cranking the
engine in one second intervals.
Hydraulic Pump
Result: If the pressure gauge reads
3190 psi / 220 bar, immediately stop. The pump
How to Test the Function Pump is good.
Note: When removing a hose assembly or fitting, Result: If the pressure fails to reach
the fitting and/or hose end must be torqued to 3190 psi / 220 bar, the pump needs to be
specification during installation. Refer to Section 2, adjusted OR or the pump or pump coupling is
Hydraulic Hose and Fitting Torque Specifications. faulty and will need to be serviced or replaced.
1 Tag, disconnect and plug the high pressure Component damage hazard.
hydraulic hose from the primary function There is no relief valve in the
manifold. Cap the fitting on the main valve. hydraulic pump and the pump can
Bodily injury hazard. Spraying be damaged if the pressure is
hydraulic oil can penetrate and allowed to exceed specification.
burn skin. Loosen hydraulic When testing the pump, crank the
connections very slowly to allow engine in one second intervals
the oil pressure to dissipate until the correct pressure is
gradually. Do not allow oil to squirt confirmed. Do not over-pressurize
or spray. the pump.
Note: The high pressure hose is the smaller of the 5 Remove the pressure gauge and install the high
two hoses. pressure hose onto the pump. Torque to
specification. Refer to Section 2, Specifications.
2 Connect a 0 to 5000 psi / 0 to 350 bar pressure
gauge to the high pressure hose disconnected
in step 1.
3 Hold the manual fuel shut-off lever on the connections very slowly to allow
engine in the closed position. the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
Part No. 123701 GTH-1048 GTH-1056 4 - 35

HYDRAULIC PUMP REV A
How to Remove the Function 5 Tag, disconnect and plug the large hydraulic
pump supply hose at the pump. Cap the fitting
Pump on the pump.
Bodily injury hazard. This Note: Placing the open end of the pump supply
procedure requires specific repair hose below the fluid level in the hydraulic tank will
skills, lifting equipment and a result in excessive hydraulic fluid leaking from the
suitable workshop. Attempting this hose. Do not lower the open end of the pump
procedure without these skills and supply hose to below the fluid level of the hydraulic
tools could result in death or tank until the hose is plugged.
serious injury and significant
component damage. Dealer 6 Tag, disconnect and plug the high pressure
service is strongly recommended. hose at the pump. Cap the fitting on the pump.
Note: Perform this procedure with the engine off or spray.
and cool.
7 Tag and disconnect the transmission cooler
1 Open the access door above the hydraulic tank. hoses at the transmission cooler. Cap the
fittings.
Burn hazard. Contact with hot
engine components may cause
severe burns.
Remove all rings, watches and 8 Remove the fasteners securing the pump to the
other jewelry. transmission. Remove the pump from the
machine.
3 Tag and disconnect the wire harness from the
pump.
4 Tag and disconnect the case drain hose at the
top of the pump. Cap the fitting on the pump.
Note: Placing the open end of the case drain hose
below the hydraulic oil level in the hydraulic tank
will result in excessive hydraulic fluid leaking from
the hose. Do not lower the open end of the case
drain hose to below the fluid level of the hydraulic
tank until the hose is plugged.
4 - 36 GTH-1048 GTH-1056 Part No. 123701

REV A HYDRAULIC PUMP
How to Install the Function Pump 9 Prime the pump. See 6-1, How to Prime the
Function Pump.
1 Carefully install the hydraulic pump onto the
transmission. Install the fasteners and tighten to 10 Start the engine and inspect for leaks.
finger tight. 11 Turn the machine off.
2 Torque the fasteners evenly to 12 Adjust the pump pressure. See 6-1, How to
85 ft-lbs / 115 Nm. Adjust the Function Pump Standby Pressure
3 Install the smaller high pressure hose onto the and How to Adjust the Function Pump Pressure
pump outlet. Torque the fasteners to Pressure Compensator.
27-37 ft-lbs / 37-50 Nm.
4 Install the larger low pressure hose onto the
pump outlet. Install the hose retaining rings and
fasteners. Torque the fasteners to
55-66 ft-lbs / 74-90 Nm.
5 Working at the case drain at the top of the
pump, fill the pump with hydraulic fluid until the
fluid is at the top of the case drain fitting.
6 Install the case drain hose onto the pump and
torque to specification. Refer to Section 2,
Specifications.
7 Securely install the wire harness onto the pump.
8 Check the level of the hydraulic fluid in the
hydraulic tank. Add fluid if needed.
Part No. 123701 GTH-1048 GTH-1056 4 - 37

How to Prime the Function Pump

Note: When removing a hose assembly or fitting,
installation. Refer to Section 2, Hydraulic Hose and a
1 Install all hoses onto the hydraulic pump.
Torque to specification. Refer to Section 2,
Hydraulic Hose and Fitting Torque b
Specifications.
2 Locate the case drain filler plug at the side of
the function pump.
3 Remove the plug and slowly fill the case drain
port of the pump with hydraulic fluid until the oil
c
level is even with the bottom of the hole. Install
the plug and torque to 40 ft-lbs / 54 Nm.
4 Start the engine, allow the engine to run at low
idle for 15 seconds then shut off the engine.
Wait 15 seconds, then start the engine again.
Allow the engine to run at low idle for 15
seconds and then shut off the engine.
5 Check for hydraulic leaks and clean up any oil a case drain filler plug
that may have spilled. b case drain hose
c hydraulic supply line (from tank)
4 - 38 GTH-1048 GTH-1056 Part No. 123701

REV A HYDRAULIC PUMP
How to Adjust the Function Pump

Standby Pressure
gauge to test port 'TP' on the primary function
manifold (schematic item AAA or BZ). See 7-1
or 7-2, Primary Function Manifold Components.
2 Start the engine and allow the engine to run at
low idle. a
3 Observe the pressure reading on the pressure
gauge. b
Result: The pressure gauge reads

450 25 psi / 31 1.7 bar. The pump is
functioning correctly. Proceed to step 6.
Result: The pressure gauge fails to read c
450 25 psi / 31 1.7 bar. The pressure setting
needs to be adjusted. Proceed to step 4.
4 Loosen the set screw for the standby pressure
adjustment screw.
5 Adjust the function pump standby pressure.
Turn the adjustment screw clockwise to
increase the pressure or counterclockwise to a standby pressure adjustment screw
decrease the pressure. Tighten the set screw. b set screw
c hydraulic supply line (from tank)
6 Turn the engine off and remove the pressure
gauge.
or spray.
Part No. 123701 GTH-1048 GTH-1056 4 - 39

How to Adjust the Function Pump

Pressure Compensator
Note: Two people will be required to perform this
procedure.

gauge to test port 'TP' on the primary function
manifold (schematic item AAA or BZ). See 7-1
or 7-2, Primary Function Manifold Components. a
2 Start the engine and allow the engine to run at

low idle. b

4 Continue to activate the boom retract function
and observe the pressure reading on the
c
pressure gauge.
319050 psi / 2203.4 bar. The pump is
functioning correctly. Proceed to step 7.
Result: The pressure gauge fails to read
319050 psi / 2203.4 bar. The pressure
setting needs to be adjusted. Proceed to step 5.
5 Loosen the set screw for the pressure a pressure compensator adjustment screw
b set screw
compensator adjustment screw. c hydraulic supply line (from tank)
6 Adjust the pressure compensator pressure.
Turn the adjustment screw clockwise to 7 Turn the engine off and remove the pressure
increase the pressure or counterclockwise to gauge.
decrease the pressure. Tighten the set screw. Bodily injury hazard. Spraying
Component damage hazard. Do hydraulic oil can penetrate and
not adjust the pressure burn skin. Loosen hydraulic
compensator higher than connections very slowly to allow
specified. the oil pressure to dissipate
or spray.
4 - 40 GTH-1048 GTH-1056 Part No. 123701

Part No. 123701 GTH-1048 GTH-1056 4 - 41

Manifolds REV C
7-1
Primary Function Manifold Components -
Models with Single Joystick
The primary function manifold is located under the manifold inspection cover.
Index Schematic
No. Description Item Function Torque
1 Solenoid valve, 2 position 4 way ...... AA .......... Function select -

boom extend and sway left ......................... 20 ft-lbs / 27 Nm
2 Directional valve,
3 position 4 way, pilot operated ........ AB .......... Boom extend/retract ........................ 65-75 ft-lbs / 88-101 Nm
3 position 4 way, pilot operated ....... AC .......... Boom up/down ................................ 65-75 ft-lbs / 88-101 Nm
4 Solenoid valve, 2 position 4 way ..... AD .......... Function select -
boom down and fork tilt down ..................... 20 ft-lbs / 27 Nm
3 position 4 way, pilot operated ........ AE .......... Fork tilt up/down ................................ 46-54 ft-lbs / 61-72 Nm
6 Relief valve, 3500 psi / 241 bar ........ AF .......... Fork tilt up relief .......................................... 20 ft-lbs / 27 Nm
7 Check valve, pilot operated
100 psi / 6.9 bar ............................... AG .......... Fork tilt down circuit .................................... 25 ft-lbs / 34 Nm
100 psi / 6.9 bar ............................... AH .......... Fork tilt up circuit ......................................... 25 ft-lbs / 34 Nm
9 Relief valve, 3500 psi / 241 bar ........ AI ........... Fork tilt down relief ...................................... 20 ft-lbs / 27 Nm
10 Relief valve, 3500 psi / 241 bar ........ AJ .......... System relief ............................................... 25 ft-lbs / 34 Nm
11 Diagnostic nipple .............................. AK .......... Test port 'LS'
12 Flow regulator valve,
0.1 gpm / 0.4 L/min ........................... AL .......... Load sense drain circuit .............................. 20 ft-lbs / 27 Nm
13 Check valve, 5 psi / 0.3 bar ............. AM .......... Sway right circuit ............................... 12-14 ft-lbs / 16-19 Nm
14 Priority flow regulator valve,
2 gpm / 7.6 L/min ............................. AN .......... Sway left/right circuit ................................... 20 ft-lbs / 27 Nm
15 Check valve, 5 psi / 0.3 bar ............. AO .......... Sway left circuit ................................. 12-14 ft-lbs / 16-19 Nm
4 - 42 GTH-1048 GTH-1056 Part No. 123701

REV C MANIFOLDS
AAC AA
28 1
AAB Y82 AB
27 Y70 2
AAA AC
26 3
Y71
AD
4
AY AE
25 Y72B 5
Y72A
AF
6
View A
AG
7
AH
8
Y72A
AI
9
Y72B
10
AJ
Y71
Note: 'alpha' callouts refer
Y70 to corresponding notes on
AX Y82 the hydraulic schematic;
24 alphanumeric callouts refer
to the electrical schematic
23
AW AK
11
AL
12
AM
13
View B AN
14
AO
15
AP
AV 16
22
AQ
AU 17
21
AR
18
AT
20 AS
19
Part No. 123701 GTH-1048 GTH-1056 4 - 43

MANIFOLDS REV C

Models with Single Joystick, continued
16 Check valve, 5 psi / 0.3 bar .............. AP .......... Boom extend circuit .......................... 12-14 ft-lbs / 16-19 Nm
17 Check valve, 5 psi / 0.3 bar ............. AQ .......... Boom down circuit ............................. 12-14 ft-lbs / 16-19 Nm
18 Check valve, 5 psi / 0.3 bar ............. AR .......... Fork tilt up circuit ............................... 12-14 ft-lbs / 16-19 Nm
19 Check valve, 5 psi / 0.3 bar .............. AS .......... Steer left/right circuit ......................... 12-14 ft-lbs / 16-19 Nm
20 Check valve, 5 psi / 0.3 bar .............. AT .......... Fork tilt down circuit .......................... 12-14 ft-lbs / 16-19 Nm
21 Check valve, 5 psi / 0.3 bar ............. AU .......... Boom up circuit ................................. 12-14 ft-lbs / 16-19 Nm
22 Check valve, 5 psi / 0.3 bar .............. AV .......... Boom retract circuit ........................... 12-14 ft-lbs / 16-19 Nm
3 position 4 way, pilot operated ....... AW ......... Sway left/right ................................... 33-37 ft-lbs / 45-50 Nm
14 gpm / 53 L/min ............................. AX .......... Fork tilt up/down circuit ............................... 20 ft-lbs / 27 Nm
25 Solenoid valve, 2 position 4 way ...... AY .......... Function select -
boom up and fork tilt up .............................. 20 ft-lbs / 27 Nm
26 Diagnostic nipple ............................ AAA ......... Test port 'TP'
27 Solenoid valve, 2 position 4 way .... AAB ......... Function select -
boom extend and sway right ....................... 20 ft-lbs / 27 Nm
28 Solenoid valve, 2 position 2 way .... AAC ......... Function select - sway left/right .................. 20 ft-lbs / 27 Nm
4 - 44 GTH-1048 GTH-1056 Part No. 123701

REV C MANIFOLDS
AAC AA
28 1
AAB Y82 AB
27 Y70 2
AAA AC
26 3
Y71
AD
4
AY AE
25 Y72B 5
Y72A
AF
6
View A
AG
7
AH
8
Y72A
AI
9
Y72B
10
AJ
Y71
Y70 to corresponding notes on
AX Y82 the hydraulic schematic;
24 alphanumeric callouts refer
23
AW AK
11
AL
12
AM
13
View B AN
14
AO
15
AP
AV 16
22
AQ
AU 17
21
AR
18
AT
20 AS
19
Part No. 123701 GTH-1048 GTH-1056 4 - 45

MANIFOLDS REV C
7-2
Models with Dual Joysticks
The primary function manifold is located under the manifold inspection cover.
Index Schematic
3 position 4 way, pilot operated ........ BA .......... Sway left/right ................................... 33-37 ft-lbs / 45-50 Nm
3 position 4 way, pilot operated ........ BB .......... Boom extend/retract ........................ 65-75 ft-lbs / 88-101 Nm
3 position 4 way, pilot operated ....... BC .......... Boom up/down ................................ 65-75 ft-lbs / 88-101 Nm
3 position 4 way, pilot operated ....... BD .......... Fork tilt up/down ................................ 46-54 ft-lbs / 61-72 Nm
5 Relief valve, 3500 psi / 241 bar ........ BE .......... Fork tilt up relief .......................................... 20 ft-lbs / 27 Nm
100 psi / 6.9 bar ................................ BF .......... Fork tilt down circuit .................................... 25 ft-lbs / 34 Nm
100 psi / 6.9 bar ............................... BG .......... Fork tilt up circuit ......................................... 25 ft-lbs / 34 Nm
8 Relief valve, 3500 psi / 241 bar ....... BH .......... Fork tilt down relief ...................................... 20 ft-lbs / 27 Nm
9 Relief valve, 3500 psi / 241 bar ........ BI ........... System relief ............................................... 25 ft-lbs / 34 Nm
10 Shuttle valve ..................................... BJ .......... Function select - sway left/right .................. 20 ft-lbs / 27 Nm
11 Diagnostic nipple .............................. BK .......... Test port 'LS'
14 gpm / 53 L/min ............................. BL .......... Fork tilt up/down circuit ............................... 20 ft-lbs / 27 Nm
0.1 gpm / 0.4 L/min .......................... BM .......... Pilot pressure drain circuit .......................... 20 ft-lbs / 27 Nm
14 Check valve, 5 psi / 0.3 bar ............. BN .......... Sway left circuit ................................. 12-14 ft-lbs / 16-19 Nm
15 Priority flow regulator valve,
2 gpm / 7.6 L/min ............................. BO .......... Sway left/right circuit ................................... 20 ft-lbs / 27 Nm
4 - 46 GTH-1048 GTH-1056 Part No. 123701

REV C MANIFOLDS
BAA BA
26 1
BB
to corresponding notes on 2
the hydraulic schematic; Y82
alphanumeric callouts refer
to the electrical schematic BC
3
BZ
25 BD
4
BX BE
24
5
View A
BF
6
BG
7
BH
8
9
BI
BJ
10
BK
11
BL
12
BM
13
BN
14
View B BO
15
BP
16
BQ
17
BW
23
BR
18
BV
22
BS
19
BU
21 BT
20
8
Part No. 123701 GTH-1048 GTH-1056 4 - 47

MANIFOLDS REV C

Models with Dual Joysticks, continued
16 Check valve, 5 psi / 0.3 bar .............. BP .......... Sway right circuit ............................... 12-14 ft-lbs / 16-19 Nm
17 Check valve, 5 psi / 0.3 bar ............. BQ .......... Boom extend circuit .......................... 12-14 ft-lbs / 16-19 Nm
18 Check valve, 5 psi / 0.3 bar ............. BR .......... Boom down circuit ............................. 12-14 ft-lbs / 16-19 Nm
19 Check valve, 5 psi / 0.3 bar .............. BS .......... Fork tilt down circuit .......................... 12-14 ft-lbs / 16-19 Nm
20 Check valve, 5 psi / 0.3 bar .............. BT .......... Steer left/right circuit ......................... 12-14 ft-lbs / 16-19 Nm
21 Check valve, 5 psi / 0.3 bar ............. BU .......... Fork tilt up circuit ............................... 12-14 ft-lbs / 16-19 Nm
22 Check valve, 5 psi / 0.3 bar .............. BV .......... Boom up circuit ................................. 12-14 ft-lbs / 16-19 Nm
23 Check valve, 5 psi / 0.3 bar ............. BW ......... Boom retract circuit ........................... 12-14 ft-lbs / 16-19 Nm
2 position 2 way, pilot operated ........ BX .......... Fork tilt circuit .............................................. 25 ft-lbs / 34 Nm
25 Diagnostic nipple .............................. BZ .......... Test port 'TP'
26 Solenoid valve, 2 position 2 way .... BAA ......... Function select - sway left/right .................. 20 ft-lbs / 27 Nm
4 - 48 GTH-1048 GTH-1056 Part No. 123701

REV C MANIFOLDS
BAA BA
26 1
BB
to corresponding notes on 2
the hydraulic schematic; Y82
to the electrical schematic BC
3
BZ
25 BD
4
BX BE
24
5
View A
BF
6
BG
7
BH
8
9
BI
BJ
10
BK
11
BL
12
BM
13
BN
14
View B BO
15
BP
16
BQ
17
BW
23
BR
18
BV
22
BS
19
BU
21 BT
20
8
Part No. 123701 GTH-1048 GTH-1056 4 - 49

MANIFOLDS REV C
7-3
Secondary Function Manifold Components
The secondary function manifold is located under the manifold inspection cover.
Index Schematic
1 DO3 valve, 3 position 4 way ............ CA .......... Steer left/right ............................................. 60 in-lbs / 6.8 Nm
2 Pressure reducing/relief valve,
50 psi / 3.4 bar ................................. CB .......... Rear lock-up circuit ........................... 25-27 ft-lbs / 34-37 Nm
400 psi / 27.5 bar ............................. CC .......... Differential lock-up circuit .................. 25-27 ft-lbs / 34-37 Nm
2500 psi / 172 bar ............................ CD .......... Steer circuit ....................................... 25-27 ft-lbs / 34-37 Nm
400 psi / 27.5 bar ............................. CE .......... Drive brake circuit ............................. 25-27 ft-lbs / 34-37 Nm
6 Solenoid valve, 2 position 3 way ...... CF .......... Parking brake select ................................... 20 ft-lbs / 27 Nm
7 Solenoid valve, 2 position 4 way ..... CG .......... Rear axle fast oscillate select ..................... 25 ft-lbs / 34 Nm
8 Check valve, 4 psi / 0.3 bar ............. CH .......... Rear lock-up extend circuit ......................... 20 ft-lbs / 27 Nm
9 Check valve, 25 psi / 1.7 bar ............ CI .......... Drive brake circuit ....................................... 20 ft-lbs / 27 Nm
10 Pressure switch,
350 psi / 24 bar ................................ PS7 ......... Low brake pressure ................................. 11 ft-lbs / 14.9 Nm
11 Pressure switch,
250 psi / 17.2 bar ............................. PS6 ......... Parking brake pressure ............................ 11 ft-lbs / 14.9 Nm
12 Orifice, 0.059 in / 1.5 mm ................. CJ .......... Rear lock-up extend circuit
13 Orifice, 0.051 in / 1.3 mm ................ CK .......... Rear lock-up retract circuit
14 Check valve, 4 psi / 0.3 bar .............. CL .......... Rear lock-up retract circuit .......................... 20 ft-lbs / 27 Nm
15 Diagnostic nipple ............................. CM ......... Test port 'TB'
16 Diagnostic nipple ............................. CN .......... Test port 'TPB'
17 Solenoid valve, 2 position 3 way ..... CO .......... Rear axle oscillate enable select ................ 20 ft-lbs / 27 Nm
18 Solenoid valve, 2 position 3 way ..... CP .......... Differential lock-up select ............................ 20 ft-lbs / 27 Nm
19 Diagnostic nipple ............................. CQ .......... Test port 'TJ'
20 Diagnostic nipple ............................. CR .......... Test port 'TS'
21 Diagnostic nipple ............................. CS .......... Test port 'TR'
4 - 50 GTH-1048 GTH-1056 Part No. 123701

REV C MANIFOLDS
CA
1
Y79
CS
21
CR Y78
20
CQ
19
CP
18
Y68
CO
17
CB
View A 2
CN
16 CC
Y55 3
CD
CM 4
15
Y78
Y67
CE
5
Y79
CF
CL 6
14
CK Note: 'alpha' callouts refer
13 to corresponding notes on
the hydraulic schematic;
Y83 alphanumeric callouts refer
CJ
12
CG
7
CH
8
View B CI
9
PS7
10
PS6 11
Part No. 123701 GTH-1048 GTH-1056 4 - 51

MANIFOLDS REV C
7-4
Outrigger Manifold Components
The outrigger manifold is located under the outrigger inspection cover.
Index Schematic
1 Solenoid valve, 3 position 4 way ..... DA .......... Left outrigger extend/retract ........................ 25 ft-lbs / 34 Nm
2 Solenoid valve, 3 position 4 way ..... DB .......... Right outrigger extend/retract ..................... 25 ft-lbs / 34 Nm
6 gpm / 22.7 L/min ........................... DC .......... Right outrigger circuit .................................. 25 ft-lbs / 34 Nm
6 gpm / 22.7 L/min ........................... DD .......... Left outrigger circuit .................................... 25 ft-lbs / 34 Nm
5 Check valve, 5 psi / 0.3 bar ............. DE .......... Left outrigger extend circuit .............. 12-14 ft-lbs / 16-19 Nm
6 Check valve, 5 psi / 0.3 bar .............. DF .......... Right outrigger extend circuit ............ 12-14 ft-lbs / 16-19 Nm
7 Check valve, 5 psi / 0.3 bar ............. DG .......... Left outrigger retract circuit ............... 12-14 ft-lbs / 16-19 Nm
8 Check valve, 5 psi / 0.3 bar ............. DH .......... Right outrigger retract circuit ............. 12-14 ft-lbs / 16-19 Nm
4 - 52 GTH-1048 GTH-1056 Part No. 123701

REV C MANIFOLDS
DA 1

to corresponding notes on
DB
2
Y74
View A
Y76
Y73
Y75
LS
R
Y76
RS
R
Y74 DC
LS 3
E
View B
Y75
RS
E
Y73
DH
8
DG
7
DF
6
DD
DE 4
5
Part No. 123701 GTH-1048 GTH-1056 4 - 53

MANIFOLDS REV C
7-5
Auxiliary Manifold Components (option)
The auxiliary manifold is located under the transmission inspection cover.
Index Schematic
1 Check valve, 5 psi / 0.3 bar .............. EA .......... Auxiliary 'A1' circuit ........................... 12-14 ft-lbs / 16-19 Nm
2 DO3 valve, 3 position 4 way ............. EB .......... Auxiliary function enable ............................ 60 in-lbs / 6.8 Nm
3 Flow regulator valve ........................ EC .......... Function speed control ............................... 25 ft-lbs / 34 Nm
4 Check valve, 5 psi / 0.3 bar ............. ED .......... Auxiliary 'A2' circuit ........................... 12-14 ft-lbs / 16-19 Nm
ED
4 EA
1
EC
3
2
EB
Y77A
to corresponding notes on
Y77B to the electrical schematic
4 - 54 GTH-1048 GTH-1056 Part No. 123701

REV C MANIFOLDS
7-6
Brake Manifold Components
The brake manifold is located under the manifold inspection cover.
Index Schematic
1 Pressure switch,
350 psi / 24 bar ................................ PS4 ......... Clutch cut-off pressure ............................. 11 ft-lbs / 14.9 Nm
2 Pressure switch,
50 psi / 3.4 bar ................................. PS5 ......... Brake light pressure (option) .................... 11 ft-lbs / 14.9 Nm
PS4
1
PS5
2
Note: 'alphanumeric' callouts refer

to corresponding notes on the
TO REAR AXLE electrical and hydraulic schematics
TO FRONT AXLE
TO BRAKE PEDAL (PORT A)
Part No. 123701 GTH-1048 GTH-1056 4 - 55

MANIFOLDS REV C
7-7 5 Install a 0 to 3500 psi / 0 to 250 bar pressure

gauge into test port 'TS' at the top of the
Valve Adjustments - secondary function manifold (schematic item
Secondary Function Manifold CR). See 7-3, Secondary Function Manifold
Components.
How to Set the Steer System 6 Start the engine. Allow the engine to idle.
Pressure 7 Fully turn and hold the steering wheel in the left
direction and allow the wheels to fully turn to
Note: Be sure that the hydraulic oil level is visible
the left. Continue holding the steering while
in the inspection glass of the hydraulic tank.
observing the pressure reading on the pressure
1 Install a 0 to 1000 psi / 0 to 100 bar pressure gauge.
gauge into test port 'TP' at the top of the
primary function manifold (schematic item AAA
2500 psi / 172 bar. The pressure setting is
or BZ). See 7-1 or 7-2, Primary Function
correct. Proceed to step 12.
Manifold Components.
2 Start the engine. Allow the engine to idle after
2500 psi / 172 bar. The pressure setting needs
warming the engine to operating temperature.
to be adjusted. Proceed to step 8.
3 Without operating any machine controls,
8 Turn the machine off. Hold the steer pressure
observe the reading on the pressure gauge.
reducing/relief valve with a wrench and remove
Result: The pressure gauge reads the cap (schematic item CD).
450 25 psi / 31 1.7 bar. The pump is
9 Adjust the internal hex socket. Turn it clockwise
functioning correctly.
to increase the pressure or counterclockwise to
Result: The pressure gauge fails to read decrease the pressure.
450 25 psi / 31 1.7 bar. The pressure setting
Component damage hazard. Do
needs to be adjusted. See Repair Procedure
not adjust the relief valve
6-1, How to Adjust the Function Pump
pressures higher than
Pressure.
specifications.
4 Turn the machine off. Remove the pressure
10 Install the relief valve cap.
gauge from the test port.
11 Repeat this procedure beginning with step 6.
hydraulic oil can penetrate and 12 Turn the machine off. Remove the pressure
burn skin. Loosen hydraulic gauge from the test port.
or spray.
or spray.
4 - 56 GTH-1048 GTH-1056 Part No. 123701

REV C MANIFOLDS
How to Set the Parking Brake 5 Install a 0 to 1000 psi / 0 to 100 bar pressure
gauge into test port 'TPB' at the top of the
System Pressure secondary function manifold (schematic item
Note: Be sure that the hydraulic oil level is visible CN). See 7-3, Secondary Function Manifold
in the inspection glass of the hydraulic tank. Components.
6 Start the engine. Allow the engine to idle.
1 Install a 0 to 1000 psi / 0 to 100 bar pressure
gauge into test port 'TP' at the top of the Result: The pressure gauge reads
primary function manifold (schematic item AAA 400 psi / 27.5 bar. The pressure setting is
or BZ). See 7-1 or 7-2, Primary Function correct. Proceed to step 11.
2 Start the engine. Allow the engine to idle after 400 psi / 27.5 bar. The pressure setting needs
warming the engine to operating temperature. to be adjusted. Proceed to step 7.
3 Without operating any machine controls, 7 Turn the machine off. Hold the steer pressure
observe the reading on the pressure gauge. reducing/relief valve with a wrench and remove
the cap (schematic item CE).
450 25 psi / 31 1.7 bar. The pump is 8 Adjust the internal hex socket. Turn it clockwise
functioning correctly. to increase the pressure or counterclockwise to
decrease the pressure.
450 25 psi / 31 1.7 bar. The pressure setting Component damage hazard. Do
needs to be adjusted. See Repair Procedure not adjust the relief valve
6-1, How to Adjust the Function Pump pressures higher than
Pressure. specifications.
4 Turn the machine off. Remove the pressure 9 Install the relief valve cap.
connections very slowly to allow Bodily injury hazard. Spraying
the oil pressure to dissipate hydraulic oil can penetrate and
gradually. Do not allow oil to squirt burn skin. Loosen hydraulic
or spray. connections very slowly to allow
or spray.
Part No. 123701 GTH-1048 GTH-1056 4 - 57

MANIFOLDS REV C
How to Set the Differential 5 Install a 0 to 1000 psi / 0 to 100 bar pressure
gauge into test port 'TJ' at the top of the
Lock/Joystick System Pressure secondary function manifold (schematic item
Note: Be sure that the hydraulic oil level is visible CQ). See 7-3, Secondary Function Manifold
primary function manifold (schematic item AAA 400 psi / 27.5 bar. The pressure setting is
or BZ). See 7-1 or 7-2, Primary Function correct. Proceed to step 11.
2 Start the engine. Allow the engine to idle after 400 psi / 27.5 bar. The pressure setting needs
warming the engine to operating temperature. to be adjusted. Proceed to step 7.
the cap (schematic item CC).
or spray.
4 - 58 GTH-1048 GTH-1056 Part No. 123701

REV C MANIFOLDS
How to Set the Rear Lock-up 5 Install a 0 to 500 psi / 0 to 50 bar pressure
gauge into test port 'TR' at the top of the
System Pressure secondary function manifold (schematic item
Note: Be sure that the hydraulic oil level is visible CS). See 7-3, Secondary Function Manifold
primary function manifold (schematic item AAA 50 psi / 3.4 bar. The pressure setting is correct.
or BZ). See 7-1 or 7-2, Primary Function Proceed to step 11.
2 Start the engine. Allow the engine to idle after 50 psi / 3.4 bar. The pressure setting needs to
warming the engine to operating temperature. be adjusted. Proceed to step 7.
the cap (schematic item CB).
or spray.
Part No. 123701 GTH-1048 GTH-1056 4 - 59

MANIFOLDS REV C
7-8 Valve Coil Resistance

Valve Coils Specification
Note: The following coil resistance specifications
How to Test a Coil are at an ambient temperature of 68F / 20C. As
A properly functioning coil provides an valve coil resistance is sensitive to changes in air
electromagnetic force which operates the solenoid temperature, the coil resistance will typically
valve. Critical to normal operation is continuity increase or decrease by 4% for each 18F / 20C
within the coil. Zero resistance or infinite resistance that your air temperature increases or decreases
indicates the coil has failed. from 68F / 20C.
Since coil resistance is sensitive to temperature, Description Specification

resistance values outside specification can
produce erratic operation. When coil resistance
12V DC with diode
decreases below specification, amperage (schematic items AA, AD, AY, AAB and BAA)
increases. As resistance rises above specification,
voltage increases. Solenoid valve, 2 position 2 way 8.9
12V DC with diode
While valves may operate when coil resistance is (schematic items AAC)
outside specification, maintaining coils within
specification will help ensure proper valve function DO3 valve, 3 position 4 way 5.6
over a wide range of operating temperatures. 12V DC with diode
(schematic items CA and EB)
12V DC with diode
result in death or serious injury. (schematic items CF, CO and CP)
other jewelry. Solenoid valve, 2 position 4 way 7.3
12V DC with diode
Note: If the machine has been in operation, allow (schematic items CG )
the coil to cool at least 3 hours before performing
this test. Solenoid valve, 3 position 4 way 7.3
12V DC with diode
1 Tag and disconnect the wiring from the coil to (schematic items DA and DB)
be tested.
2 Test the coil resistance using a multimeter set
to resistance (). Refer to the Valve Coil
Resistance Specification table.
Result: If the resistance is not within the
adjusted specification, plus or minus 10%,
replace the coil.
4 - 60 GTH-1048 GTH-1056 Part No. 123701

REV C MANIFOLDS
How to Test a Coil Diode 4 Connect the negative lead to the other terminal
on the coil.
Genie incorporates spike suppressing diodes in all
of its coils. Properly functioning coil diodes protect Note: If testing a single-terminal coil, connect the
the electrical circuit by suppressing voltage spikes. negative lead to the internal metallic ring at either
Voltage spikes naturally occur within a function end of the coil.
circuit following the interruption of electrical current
to a coil. Faulty diodes can fail to protect the
electrical system, resulting in a tripped circuit
COIL
breaker or component damage. a
MULTI
d METER
result in death or serious injury. c -
+
other jewelry. b
10 W 9V
RESISTOR BATTERY
1 Test the coil for resistance. See 7-8, How to
Test a Coil. c
b
+
2 Connect a 10 resistor to the negative terminal -
of a known good 9V DC battery. Connect the
other end of the resistor to a terminal on the a multimeter
b 9V DC battery
coil. c 10 resistor
d coil
Note: The battery should read 9V DC or more
when measured across the terminals. Note: Dotted lines in illustration indicate a
reversed connection as specified in step 6

Resistor, 10
5 Momentarily connect the positive lead from the
multimeter to the positive terminal on the 9V
battery. Note and record the current reading.
3 Set a multimeter to read DC amperage. 6 At the battery or coil terminals, reverse the
Note: The multimeter, when set to read DC connections. Note and record the current
amperage, should be capable of reading up to reading.
800 mA. Result: Both current readings are greater than
0 mA and are different by a minimum of 20%.
The coil is good.
Result: If one or both of the current readings are
0 mA, or if the two current readings do not differ
by a minimum of 20%, the coil and/or its
internal diode are faulty and the coil should be
replaced.
Part No. 123701 GTH-1048 GTH-1056 4 - 61

Axle REV A
8-1 7 Support and secure the axle to an appropriate

lifting device.
Axles
8 Remove the fasteners securing the sway
cylinder rod-end pivot pin to the chassis.
How to Remove the Axle
procedure requires specific repair 10 Remove the fasteners securing the axle to the
skills, lifting equipment and a chassis. Remove the axle from the machine.
suitable workshop. Attempting this
Crushing hazard. The axle will fall
procedure without these skills and
if not properly supported when the
tools could result in death or
fasteners are removed from the
serious injury and significant
machine.
component damage. Dealer
service is required. Bolt torque specification
1 Chock the wheels. Axle mounting bolts 380 ft-lbs
2 Remove the fasteners securing the driveshaft to 515 Nm
the transmission. Lower the end of the
driveshaft to the ground.
How to Repair the Axle
3 Remove the fasteners securing the driveshaft to
the axle. remove the driveshaft from the Repair procedures and additional axle information
machine. is available in the Dana 213 Axle Maintenance and
Repair Manual (Dana part number 0243).
4 Loosen the lug nuts of both wheels on the axle
to be removed. Do not remove the lug nuts.
5 Raise the end of the machine until the tires are Genie part number 115026
off the ground. Place blocks under the chassis
for support.
Crushing hazard. The chassis will
fall if not properly supported.
6 Remove the lug nuts. Remove the tire and
wheel assembly from both ends of the axle.
4 - 62 GTH-1048 GTH-1056 Part No. 123701

REV A
Outriggers
9-1 6 Attach a lifting strap from an overhead crane to
the outrigger assembly. Support the outrigger.
Outriggers Do not apply any lifting pressure.
7 Remove the fasteners securing the outrigger
How to Remove an Outrigger pivot pin to the machine.
1 Extend the outrigger until the pad just touches 8 Use a soft metal drift to remove the pivot pin.
the ground. Do not rest the weight of the Remove the outrigger assembly from the
machine on the outrigger. machine.
2 Tag, disconnect and plug the hydraulic supply Crushing hazard. The outrigger
hoses at the outrigger cylinder. Cap the fittings. will fall if not properly supported
Bodily injury hazard. Spraying when the pivot pin is removed
hydraulic oil can penetrate and from the machine.
squirt or spray.
kinked or pinched.
the barrel end of the fork level cylinder. Support
the cylinder. Do not apply any lifting pressure.
cylinder barrel-end pivot pin to the machine.
5 Use a soft metal drift to remove the outrigger
cylinder barrel-end pivot pin. Lower the cylinder
onto the outrigger.
Crushing hazard. The cylinder
may become unbalanced and fall
if not properly supported when the
pivot pin is removed from the
machine.
Part No. 123701 GTH-1048 GTH-1056 4 - 63

OUTRIGGERS REV A
How to Remove an Outrigger 5 Use a soft metal drift to remove the pivot pin.
Cylinder Crushing hazard. The cylinder will
fall if not properly supported when
Note: When removing a hose assembly or fitting, the pivot pin is removed from the
the O-ring on the fitting and/or hose end must be machine.
installation. Refer to Section 2, Hydraulic Hose and 6 Raise the cylinder to a vertical position.
Fitting Torque Specifications. 7 Remove the fasteners securing the outrigger
1 Extend the outrigger until the pad just touches cylinder rod-end pivot pin to the machine.
the ground. Do not rest the weight of the 8 Use a soft metal drift to remove the pivot pin.
machine on the outrigger. Remove the cylinder from the machine.
2 Tag, disconnect and plug the two hydraulic Crushing hazard. The cylinder will
supply hoses at the outrigger cylinder. Cap the fall if not properly supported when
fittings. the pivot pin is removed from the
Bodily injury hazard. Spraying machine.
squirt or spray.
kinked or pinched.
the barrel end of the outrigger cylinder. Support
the cylinder. Do not apply any lifting pressure.
cylinder barrel-end pivot pin to the chassis.
4 - 64 GTH-1048 GTH-1056 Part No. 123701

May 2007 Section 5 Fault Codes
Fault Codes
Before Troubleshooting:
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.
Observe and Obey:
Be aware of the following hazards and follow
Troubleshooting and repair procedures shall be generally accepted safe workshop practices.
completed by a person trained and qualified on
Crushing hazard. When testing
the repair of this machine.
or replacing any hydraulic
Immediately tag and remove from service a component, always support
damaged or malfunctioning machine. the structure and secure it
from movement.
Repair any machine damage or malfunction
before operating the machine. Electrocution hazard. Contact
with electrically charged circuits
Unless otherwise specified, perform each
repair procedure with the machine in the injury. Remove all rings, watches
following configuration: and other jewelry.
Machine parked on a firm, level surface
Boom in the stowed position hydraulic oil can penetrate and
Key switch in the off position with the key burn skin. Loosen hydraulic
removed connections very slowly to allow
Wheels chocked
squirt or spray.
General Repair Process
Malfunction Identify Troubleshoot

discovered symptoms
problem
still exists
Return to Inspect Perform

service problem and test repair
solved
Part No. 123701 GTH-1048 GTH-1056 5-1

Section 5 Fault Codes May 2007
Diagnostic Display
REV A
When the engine Electronic Control Module (ECM) Active Codes vs Stored Codes
detects an abnormal operating condition, a fault
code is immediately stored in the ECM memory. At Active fault codes, indicating an engine condition
the same time, this fault code is displayed on the or conditions which have not been corrected, are
engine diagnostic display which is located on the displayed at the moment the fault is detected.
dashboard in the operator's compartment. This Stored fault codes are the cumulative history of
backlit LCD display allows the operator to view fault codes which the ECM has detected. These
these fault codes, a description of the code and fault codes may be recalled by service personnel
corrective action needed. When not being used to at a later time even if the condition which caused
display fault codes, the display shows the many the engine fault has ceased to exist.
readouts of engine functions in both English and
metric units. Decoding Fault Codes
Located at the upper corners of the diagnostic The Suspect Parameter Number (SPN) and the
display are amber and red indicator lights. Failure Mode Identifier (FMI), when combined, are
Depending on the severity of a detected engine the basis for an engine fault code. The SPN
fault, one of these lights will illuminate indicating an number indicates the affected component; the FMI
active engine fault: number reveals the type of failure that has
occurred. Comparing the combination of numbers
Amber - WARNING to the fault code chart on the following pages will
An amber colored light signals an abnormal engine help to determine the exact engine fault and a
condition which should be corrected as soon as corrective course of action. For additional
possible. information, refer to the engine operator's manual
Red - STOP ENGINE which came with your machine.
A red colored light indicates an engine condition
exists which requires the operator to shut down the
engine as soon as possible. The ECM will, in some
cases, automatically shut down the engine when
the red light is displayed.
5-2 GTH-1048 GTH-1056 Part No. 123701

REV A DIAGNOSTIC DISPLAY
Access the Active Fault Codes Access the Stored Fault Codes:
Component damage hazard. 1 Turn the key switch to the on position. Do not
Ignoring active fault codes may start the engine.
result in engine damage.
2 Press the "Menu" key. Use the "Arrow" keys to
1 During normal operation, engine parameters scroll to "Stored Codes."
are visible in the diagnostic display. When an
3 Press the "Enter" key to view the stored code.
engine fault is detected, the engine parameters
on display are immediately replaced with a 4 If the word "Next" appears at the bottom of the
WARNING message. Also on display are the screen, there are additional codes being stored.
SPN and FMI codes which are combined to Use the "Arrow" key to scroll to the next stored
show an engine fault code. code.
2 If the word "Next" appears at the bottom of the 5 Press the "Menu" key to return to the main
display, this indicates that additional active fault menu.
codes exist. Use the arrow keys to scroll to the
next code.
3 Press the "Enter" key to acknowledge the active
code and return to the engine parameter
display.
a b
c d e
Diagnostic display
a amber warning light

b red stop engine light
c menu key
d arrow/scroll keys
e enter key
Part No. 123701 GTH-1048 GTH-1056 5-3

Engine Fault Codes -

Models with John Deere Power REV A
SPN FMI Description of Fault Corrective Action

000028 03 Throttle #3 Voltage Out of Range High Check Sensor and Wiring
04 Throttle #3 Voltage Out of Range Low Check Sensor and Wiring
14 Throttle #3 Voltage Out of Range Contact Servicing Dealer
000029 03 Throttle #2 Voltage Out of Range High Check Sensor and Wiring
04 Throttle #2 Voltage Out of Range Low Check Sensor and Wiring
14 Throttle #2 Voltage Out of Range Contact Servicing Dealer
000091 03 Throttle Voltage Out of Range High Check Switch and Wiring
04 Throttle Voltage Out of Range Low Check Switch and Wiring
14 Throttle Voltage Out of Range Check Sensor and Wiring
00094 03 Fuel Pressure Voltage Out of Range High Check Sensor and Wiring
04 Fuel Pressure Voltage Out of Range Low Check Sensor and Wiring
000097 03 Water in Fuel Voltage Out of Range High Check Sensor and Wiring
04 Water in Fuel Voltage Out of Range Low Check Sensor and Wiring
16 Water in Fuel Detected Stop and Drain Water Separator
000100 01 Engine Oil Pressure Low-Most Severe Check Oil Level
03 Engine Oil Pressure Voltage Out of Range High Check Sensor and Wiring
04 Engine Oil Pressure Voltage Out of Range Low Check Sensor and Wiring
18 Engine Oil Pressure Low-Moderately Severe Check Oil Level
31 Oil Pressure Detected with Zero Engine Speed Contact Servicing Dealer
000102 02 Manifold Air Pressure Sensor In-Range Failure Contact Servicing Dealer
03 Manifold Air Pressure Voltage Out of Range High Contact Servicing Dealer
04 Manifold Air Pressure Voltage Out of Range Low Contact Servicing Dealer
000103 00 Turbocharger Speed High -Most Severe Contact Servicing Dealer
02 Turbocharger Speed Data Incorrect Contact Servicing Dealer
05 Turbocharger Harness Open Circuit Contact Servicing Dealer
06 Turbocharger Harness Shorted To Ground Contact Servicing Dealer
08 Turbocharger Speed Signal In-Range Failure Contact Servicing Dealer
31 Turbocharger Speed Signal Missing Contact Servicing Dealer
000105 00 Exhaust Gas Recirculation Air Temperature Check Air Cleaner, Aftercooler, or
High - Most Severe Room Temperature
03 Exhaust Gas Recirculation Air Temperature Input
Voltage Out of Range High Check Sensor and Wiring
04 Exhaust Gas Recirculation Air Temperature Input
Voltage Out of Range Low Check Sensor and Wiring
15 Exhaust Gas Recirculation Air Temperature Check Air Cleaner, Aftercooler, or
High - LeastSevere Room Temperature
16 Exhaust Gas Recirculation Air Temperature Check Air Cleaner, Aftercooler, or
High-Moderately Severe Room Temperature
000108 02 Barometric Air Pressure Sensor Signal Invalid Contact Servicing Dealer
31 Barometric Air Pressure Sensor Signal Invalid Contact Servicing Dealer
000110 00 Engine Coolant Temperature High-Most Severe Check Cooling System, Reduce Power
03 Engine Coolant Temperature Input Voltage Out of
Range - High Check Sensor and Wiring
04 Engine Coolant Temperature Input Voltage Out of
Range - Low Check Sensor and Wiring
15 Engine Coolant Temperature High-Least Severe Check Cooling System, Reduce Power
16 Engine Coolant Temperature
High - Moderately Severe Check Cooling System, Reduce Power
17 Engine Coolant Temperature Low-Least Severe Check Cooling System
5-4 GTH-1048 GTH-1056 Part No. 123701

REV A ENGINE FAULT CODES -

MODELS WITH JOHN DEERE POWER

000111 01 Coolant Level Low Check Operator's Manual
000157 03 Fuel Rail Pressure Voltage Out of Range High Contact Servicing Dealer
04 Fuel Rail Pressure Voltage Out of Range Low Contact Servicing Dealer
10 Fuel Rail Pressure Drops Too Fast Contact Servicing Dealer
17 Fuel Rail Pressure Not Developed Contact Servicing Dealer
000158 17 Keyswitch Circuit Problem Contact Servicing Dealer
000174 00 Fuel Temperature High-Most Severe Add Fuel or Switch Fuel Tanks
03 Fuel Temperature Voltage Out of Range High Check Sensor and Wiring
04 Fuel Temperature Voltage Out of Range Low Check Senor and Wiring
16 Fuel Temperature High-Moderately Severe Add Fuel or Switch Fuel Tanks
000189 00 Engine Speed Derate Check Fault Codes or Contact
Servicing Dealer
000190 00 Engine Speed High-Most Severe Reduce Engine Speed
16 Engine Speed High-Moderately Severe Reduce Engine Speed
000412 00 Exhaust Gas Recirculation Temperature Input
Voltage High-Most Severe Contact Servicing Dealer
03 Exhaust Gas Recirculation Temperature Voltage
Out of Range High Contact Servicing Dealer
04 Exhaust Gas Recirculation Temperature Voltage
Out of Range Low Contact Servicing Dealer
16 Exhaust Gas Recirculation Temperature Moderately
Severe Contact Servicing Dealer
000611 03 Electronic Injector Wiring Shorted to Power Source Check Wiring
04 Electronic Injector Wiring Shorted to Ground Check Wiring
000620 03 5V Sensor Supply Voltage Out of Range High Check Wiring
04 5V Sensor Supply Voltage Out of Range Low Check Wiring
000627 01 Electronic Injector Supply Voltage Low Check Battery Voltage and Wiring
16 ECU Power Supply Voltage High Contact Servicing Dealer
18 ECU Power Supply Voltage Low Contact Servicing Dealer
000628 12 ECU Programming Error Contact Servicing Dealer
000629 12 ECU Programming Error Contact Servicing Dealer
13 ECU Error Contact Service Dealer
000636 02 Engine Position Sensor Noise Check Sensor and Wiring
05 Engine Position Sensor Current Low or Open Circuit Contact Servicing Dealer
06 Engine Position Sensor Current High or
Grounded Circuit Contact Servicing Dealer
08 Engine Position Sensor Input Missing Check Sensor and Wiring
10 Engine Position Sensor Pattern Error Check Sensor and Wiring
000637 02 Timing (Crank) Position Sensor Noise Check Sensor and Wiring
05 Timing (Crank) Position Sensor Current Low or Open
Circuit Contact Servicing Dealer
06 Timing (Crank) Position Sensor Current High or
07 Crank/Camshaft Position Out of Sync Check Sensor and Wiring
08 Crank Position Input Missing Check Sensor and Wiring
10 Crank Position Input Pattern Error Check Sensor and Wiring
000640 31 External Engine Protection Signal Not Recognized Engine External Protection Unknown.
Check Installation
000641 04 Turbocharger Actuator Disabled Contact Servicing Dealer
05 Turbocharger Actuator Current Low or Open Circuit Contact Servicing Dealer
12 Turbocharger Actuator Communication Error Contact Servicing Dealer
13 Turbocharger Learn Error Contact Servicing Dealer
16 Turbocharger Temperature High-Moderately Severe Contact Servicing Dealer
Part No. 123701 GTH-1048 GTH-1056 5-5

ENGINE FAULT CODES - REV A


000651 02 Cylinder #1 Injector Part Number Not Recognized Contact Servicing Dealer
05 Cylinder #1 Electronic Injector Circuit Open Check Injector Wiring or Injector Solenoid
06 Cylinder #1 Electronic Injector Circuit Shorted Check Injector Wiring or Injector Solenoid
07 Cylinder #1 Electronic Injector Fuel Flow Low Injector Failed or Flow Limiter Closed
13 Cylinder #1 Injector QR Code String Error Contact Servicing Dealer
000676 03 Glow Plug Relay Voltage High Check Relay and Wiring
04 Glow Plug Relay Voltage Low Check Relay and Wiring
000898 09 Vehicle Speed or Torque Message Invalid Contact Servicing Dealer
000970 31 Auxiliary Engine Shutdown Signal Non Engine Fault. Check Other
Shutdown Devices
000971 31 Auxiliary Engine Derate Signal Non Engine Fault. Check Other
Shutdown Devices
001079 03 Sensor Supply Voltage 3 Out of Range High Check Wiring
04 Sensor Supply Voltage 3 Out of Range Low Check Wiring
001080 03 Fuel Rail Pressure Sensor Supply Voltage 2 Out of
Range High Check Wiring
04 Fuel Rail Pressure Sensor Supply Voltage 2 Out of
Range Low Check Wiring
001109 31 Engine Protection System Approaching Shutdown Check Fault Codes
001110 31 Engine Protection System Shutdown Engine Check Fault Codes
001136 00 ECU Temperature High - Most Severe Contact Servicing Dealer
16 ECU Temperature High - Moderately Severe Contact Servicing Dealer
001172 03 Turbo Compressor Inlet Temperature Input Voltage
04 Turbo Compressor Inlet Temperature Input Voltage
16 Turbo Compressor Inlet Temperature Contact Servicing Dealer
High - Moderately Severe
5-6 GTH-1048 GTH-1056 Part No. 123701



001180 00 Turbo Turbine Inlet Temperature High-Most Severe Contact Servicing Dealer
16 Turbo Turbine Inlet Temperature
High - Moderately Severe Contact Servicing Dealer
001209 02 Exhaust Pressure Incorrect Contact Servicing Dealer
03 Exhaust Pressure Sensor Voltage Out of Range High Contact Servicing Dealer
04 Exhaust Pressure Sensor Voltage Out of Range Low Contact Servicing Dealer
001347 03 Fuel Pump Pressurizing Assembly #1 Sensor Voltage
High Contact Servicing Dealer
05 Fuel Pump Pressurizing Assembly #1 Sensor Circuit
Open, Shorted to Ground, or Overloaded Check Pump Wiring
07 Fuel Pump Assembly #1 Rail Pressure Contro Check Fuel Filter and Lines
Mismatch
001569 31 Engine Protection Derate Check Fault Codes
002630 00 Exhaust Gas Recirculation Fresh Air Temperature Contact Servicing Dealer
High-Most Severe
03 Exhaust Gas Recirculation Fresh Air Temperature Contact Servicing Dealer
Voltage Out of Range High
Voltage Out of Range Low
High-Least Severe
High-Moderately Severe
002659 02 Exhaust Gas Recirculation Flow/Temperature
Mismatch Contact Servicing Dealer
15 Exhaust Gas Recirculation Flow Rate Above Normal Contact Servicing Dealer
17 Exhaust Gas Recirculation Flow Rate Below Normal Contact Servicing Dealer
002790 16 Turbocharger Compressor Outlet Temperature
High - Most Severe Contact Servicing Dealer
002791 02 Exhaust Gas Recirculation Valve Sensor Voltage
Mismatch Contact Servicing Dealer
03 Exhaust Gas Recirculation Valve Sensor Voltage
04 Exhaust Gas Recirculation Valve Sensor Voltage
05 Exhaust Gas Recirculation Valve Current Low or
Open Circuit Contact Servicing Dealer
06 Exhaust Gas Recirculation Valve Current High or
07 Exhaust Gas Recirculation Valve Not Responding or
Out of Adjustment Contact Servicing Dealer
13 Exhaust Gas Recirculation Valve Out of Calibration Contact Servicing Dealer
14 Exhaust Gas Recirculation Valve Off Contact Servicing Dealer
31 Exhaust Gas Recirculation Valve Position Error Contact Servicing Dealer
002795 07 Turbocharger Actuator Not Responding or Out Of
Adjustment Contact Servicing Dealer
12 Turbocharger Actuator Bad Intelligent Device Or
Component Contact Servicing Dealer
523222 03 Sensor Supply Voltage #5 Out of Range High Contact Servicing Dealer
04 Sensor Supply Voltage #5 Out of Range Low Contact Servicing Dealer
523229 03 Sensor Supply Voltage #4 Out of Range High Contact Servicing Dealer
04 Sensor Supply Voltage #4 Out of Range Low Contact Servicing Dealer
Part No. 123701 GTH-1048 GTH-1056 5-7

Engine Fault Codes -

Models with Perkins Power REV A
SPN FMI Description of Fault

91 2 Incorrect throttle switch inputs
3 Throttle position sensor: voltage above normal or shorted high
4 Throttle position sensor: voltage below normal or shorted low
8 Throttle position sensor: abnormal frequency, pulse width or period
100 3 Engine oil pressure sensor: voltage above normal or shorted high
4 Engine oil pressure sensor :voltage below normal or shorted low
102 3 Boost pressure sensor voltage: voltage above normal or shorted high
4 Boost pressure sensor voltage: voltage below normal or shorted low
10 No 5V to sender
105 3 Intake manifold temperature sensor: temperature above normal or shorted high
4 Intake manifold temperature sensor: temperature below normal or shorted low
0105 3 Intake manifold air temperature open/short to battery positive (+)
4 Intake manifold air temperature short to ground
110 3 Engine coolant temperature open/short to battery positive (+)
4 Engine coolant temperature short to ground
157 3 Fuel rail pressure open/short to battery positive (+)
4 Fuel rail pressure short to ground
0168 0 System voltage high
1 System voltage low
2 ECM battery power intermittent/erratic
172 3 Air inlet temperature voltage high
4 Air inlet temperature voltage low
174 2 Fuel temperature sensor: data erratic/intermittent or incorrect
190 8 Engine speed signal abnormal
15 Engine speed: overspeed WARNING
0190 0 Engine overspeed
626 5 Ether start aid current low
6 Ether start aid current high
630 2 System parameters incorrect
0631 2 Personality module mismatch
637 11 Engine timing calibration invalid
0637 139 Engine timing calibration required
0639 9 J1939 data link communications
12 J1939 data link malfunction
How to Troubleshoot the

Perkins 1104D-E44TA Engine
Troubleshooting procedures and additional engine
(Perkins part number SENR9982-01).

5-8 GTH-1048 GTH-1056 Part No. 123701


MODELS WITH PERKINS POWER
SPN FMI Description of Fault

651 2 Cylinder #1 injector data incorrect
5 Cylinder #1 injector open circuit
6 Cylinder #1 injector short
7 Cylinder #1 injector not responding
678 3 8V DC supply short to battery positive (+)
4 8V DC supply shorted to ground
723 8 Secondary engine speed signal abnormal
1188 5 Turbo wastegate drive current low
1196 9 Machine security system module non-communication
1347 5 Fuel rail pump output current low
6 Fuel rail pump output current high
7 Fuel rail pressure valve solenoid not responding
2882 2 Mode selector switch: data erratic/intermittent or incorrect
3509 3 5V DC power supply sensor short to battery positive (+)
4 5V DC power supply sensor short to ground
How to Troubleshoot the

Perkins 1104D-E44TA Engine
Troubleshooting procedures and additional engine
(Perkins part number SENR9982-01).

Part No. 123701 GTH-1048 GTH-1056 5-9

5 - 10 GTH-1048 GTH-1056 Part No. 123701

May 2007 Section 6 Schematics
Schematics
About This Section
There are two groups of schematics in this section.
An illustration legend precedes each group of
drawings.
Electrical Schematics
Observe and Obey: Electrocution hazard. Contact with

Troubleshooting and repair procedures shall be result in death or serious injury.
completed by a person trained and qualified on Remove all rings, watches and
the repair of this machine. other jewelry.
Immediately tag and remove from service a Hydraulic Schematics
damaged or malfunctioning machine.
Repair any machine damage or malfunction hydraulic oil can penetrate and
before operating the machine. burn skin. Loosen hydraulic
Before Troubleshooting: the oil pressure to dissipate
Read, understand and obey the safety rules
or spray.
and operating instructions in the appropriate
operator's manual on your machine. General Repair Process
Be sure that all necessary tools and test
equipment are available and ready for use.
Malfunction Identify Troubleshoot
discovered symptoms
problem
still exists
Return to Inspect Perform

service problem and test repair
solved
Part No. 123701 GTH-1048 GTH-1056 6-1

Section 6 Schematics August 2007
Electrical Component Legend

REV B
Abbreviation Legend
B1 Battery L Light SW Switch
CB2 Circuit Breaker, 40A L7 = Low battery SW23 = Transmission control
CR Control relay L42 = Engine oil pressure SW24 = Parking brake
CR5 = Horn L61 = Back up light SW34 = Sway enable
CR11 = Boom up L63 = Low brake pressure SW35 = Auxiliary control
CR55 = Drive reverse L64 = Parking brake on SW39 = Right outrigger
CR56 = Drive forward L71 = Transmission oil pressure SW40 = Left outrigger
CR69 = Boom extend L72 = Transmission temperature SW42 = Tilt enable
CR88 = Power L73 = Low fuel level SW43 = Steer select
CR100 = Sway enable L74= 4-wheel steer select SW44 = Horn
D1 Alternator L75 = Crab steer select SW77 = Differential lock
F Fuse L76 = 2-wheel steer select U Electrical component
F6 = 20A, Power to controls M Motor U31 = Engine ECM
F19 = 10A, ECM power M3 = Engine starter U37 = Diode
F20 = Fuse block M9 = Heater fan motor Y Valve coil
FS2 Throttle pedal M10 = Windshield wiper motor Y5 = Transmission reverse
G Gauge M11 = Cab circulation fan motor Y6 = Transmission forward
G3 = Engine coolant temperature PS M12 = Windshield washer motor Y55 = Rear axle oscillate enable
G6 = Hourmeter Pressure switch Y67 = Parking brake release
G8 = Diagnostic display PS4 = Service brake Y68 = Differential lock
G11 = Fuel level PS6 = Parking brake Y70 = Sway left enable
G12 = Tachometer PS7 = Low brake pressure Y71 = Sway right enable
H Horn PS8 = Sway Y72 = Tilt
H2 = Auto-style horn PX Proximity switch Y73 = Right outrigger extend
H5 = Multifunction alarm PX1 = Boom extend Y74 = Right outrigger retract
KS1 Key switch PX2 = Boom angle Y75 = Left outrigger extend
S Sensor Y76 = Left outrigger retract
S1 = Engine coolant temperature Y77 = Auxiliary
S2 = Engine oil pressure Y78 = 4-wheel steer select
S11 = Transmission oil temperature Y79 = Crab steer select
S12 = Transmission oil pressure Y80 = Transmission "D"
S13 = Fuel level Y81 = Transmission "E"
Y82 = Sway enable
Y83 = Rear axle oscillate fast
6-2 GTH-1048 GTH-1056 Part No. 123701

August 2007 Section 6 Schematics
Proximity Switch Layout

REV B
Boom Extend Proximity Switch PX1

(under plate at top of boom tube)
(GTH-1056 only)
Boom Angle Proximity Switch PX2

(under boom pivot pin)
Part No. 123701 GTH-1048 GTH-1056 6-3

Fuse Box Layout

REV B
CB2
40A FUSE
U37A
HC-A
HC-D
HC-B U37B
GROUND
HC-C
4
CR56 CR100
1
5
CR55 CR11
2
FUSE 6
CR5 CR69
3 PANEL
7
CR22 or CR34
FUSE PANEL F9A

5A
F9B
5A
F20.1 F20.7
5A 5A
F20.2 F20.8
15A 5A MACHINE OPTIONS
F20.3 F20.9 (REFER TO ELECTRICAL SCHEMATIC)
10A 20A
F20.4 F20.10
10A 5A
F20.5 F20.11
5A 5A
F20.6 F20.12
5A 20A
6-4 GTH-1048 GTH-1056 Part No. 123701

Electrical and Hydraulic Symbols Legend

REV B
Electrical Schematic Symbols Hydraulic Schematic Symbols

ACC
BAT
KS1
KEY START M3
STARTER
Pressure switch Axle
SWITCH IGN
Hydraulic cylinder
Key switch Engine start
86 30
B Orifice Adjustable orifice Filter
D1
ALT
85 87 87A
G
Control relay Alternator

Check valve Flow regulator Relief valve
Fuse Circuit breaker
2 position 3 way 2 position 3 way

Horn or Alarm 3 position 4 way solenoid valve directional valve,
Light pilot-operated
solenoid valve
Valve coil with diode Valve coil 2 position 2 way

2 position 4 way
solenoid valve solenoid valve
Diode
P
Switch T
1 3 2 4
Joystick
Proximity switch Limit switch
Counterbalance
valve
Temperature switch Fuel level sender
Pressure switch
Battery
Part No. 123701 GTH-1048 GTH-1056 6-5

Electrical Schematic -
All Models REV B
Page 1 of 3
ACC
BAT
86 30
CR88
KS1 POWER
F20.3 F20.4
KEY START 85 87 87A RELAY SINGLE JOYSTICK
10A BN 10A
SWITCH IGN
PX1 OPTION
BOOM 2 3
EXTEND DUAL JOYSTICK
CB2 F19 F20.1 F20.2 (GTH-1056) BL OPTION
HC-A 10
11 1
40A 10A 5A 15A SW34 SW42
BN
PS8 SWAY TILT
PX2 SWAY ENABLE 12 2 ENABLE
2 6 SW24 BOOM 1 11
PRESSURE
PARKING ANGLE BL 12 HC-C SWITCH (N.O.)
BRAKE
JOHN DEERE ENGINE 1 9 8
(OPTION) CR11 86 30 5 86 30 6 CR69

(PERKINS ENGINE SHOWN BELOW) BOOM BOOM
L64 UP 85 87 87A 85 87 87A EXTEND
4
G8 F6 5 5
20A
DIAGNOSTIC U37A HC-C
4
DISPLAY HC-B 5 8 9
CAN SHIELD
7 6 2 1
CAN HIGH
CAN LOW
GROUND
DIMMER
POWER
PARKING BRAKE PS6 CR100

PRESSURE SWITCH (N.O.)
6 8
A5 A6 A2 A3 A4 A1 SW23 SERVICE BRAKE
SWAY
PS4 ENABLE
TRANSMISSION PRESSURE SWITCH (N.C.)
CONTROL
86 30 4
A1 B1 K2 L1 L4 M1 M4 B2 5 1
3
2 3 7
U31 ENGINE ECM 10 85 87 87A
D L2 L3 M2 A4 C3 A3 1 HC-D HC-C
W B
2 3 10 2 1
D1 U37B
BK
WH
RD
H5
G A B C CR55 CR56 2
FS2 DRIVE DRIVE

POWER (+5V)
RETURN
WIPER
4 HC-B HC-D 5 HC-A

THROTTLE REVERSE FORWARD 4 3 8 9 6 7 6 7
PEDAL
B1 Y81
86 30 2 86 30 1
Y55 Y71 Y72B
1 1 1 1
+ 85 87 87A 85 87 87A
2 2 2 2
1 1 1 1 1 1 1 1
L61
2 2 2 2 2 2 2 2
M3 Y67 Y80 Y5 Y6 Y83 Y82 Y70 Y72A
-
SWAY RELAY
12 VOLT BATTERY
ALTERNATOR
STARTER RELAY
POWER RELAY
PARKING BRAKE RELEASE COIL
PARKING BRAKE LIGHT
TRANSMISSION COIL 'D'
TRANSMISSION COIL 'E'
BACKUP LIGHT (OPTION)
REVERSE ENABLE RELAY
TRANSMISSION REVERSE COIL
FORWARD ENABLE RELAY
TRANSMISSION FORWARD COIL
REAR AXLE OSC FAST COIL
REAR AXLE OSC ENABLE COIL
SWAY ENABLE COIL
SWAY LEFT ENABLE COIL
SWAY RIGHT ENABLE COIL
TILT UP ENABLE COIL
TILT DOWN ENABLE COIL

STARTER MOTOR
PERKINS ENGINE
(OPTION) BACKUP LIGHT INCLUDED WITH
WORK LIGHT (OPTION) AND
G8 F6 ROAD LIGHT (OPTION)
DIAGNOSTIC 25A
DISPLAY
CAN SHIELD
CAN HIGH
CAN LOW
GROUND
DIMMER
POWER
A5 A6 A2 A3 A4 A1
20 21 22 7 8 15 16 40
U31 ENGINE ECM

1 2 3 9 10 54 33 41 45 35
D
W
BK
WH
RD
OR
PP
B
D1 A B C E F
RETURN
POWER (+5V)
IDLE SWITCH INPUT

IDLE SWITCH RETURN
WIPER
FS2
- NOTE -
THROTTLE MACHINE SHOWN IN THE STOWED ES0451B
PEDAL
POSITION WITH THE POWER OFF ES0452B
6-6 GTH-1048 GTH-1056 Part No. 123701

REV B All Models
Page 2 of 3
DOME FLASHING
LIGHT BEACONS
(OPTION) (OPTION)
F20.5 F20.7 F20.6 F20.8 F9A F9B

5A 5A 5A 5A 5A 5A
HC-A 4 HC-B 2
9 8 3 10
CR5 86 30 3 SW77 2 SW40 2 SW43

HORN DIFF LEFT STEER
85 87 87A LOCK OUTRGR SELECT
1 4 1
3
4
L78
H2 DOME
SW44 SW35 2 SW39 2
LIGHT
HORN AUXILIARY RIGHT
CONTROL OUTRGR
1 4 1 4
FB1
FLASHING
BEACONS
12 24 19 15 7 9
GAUGE CLUSTER
L76 G12 G6 G3 L72
L74 L75 L77 G11 L71 L63
1 Y77A 1 Y76 1 Y74 1 Y78

16 20 13 21 22 25
1
2
1
2
1
2
1
2
1 S13 S1 S12 S11 PS7
2
Y68 Y77B
2
Y75 2
Y73 2
Y79
2
HORN RELAY
HORN
DIFFERENTIAL LOCK COIL
AUX COIL A (PORT A1)
AUX COIL B (PORT A2)
LEFT OUTRIGGER UP COIL
LEFT OUTRIGGER DOWN COIL
RIGHT OUTRIGGER UP COIL
RIGHT OUTRIGGER DOWN COIL
4-WHEEL STEER COIL
CRAB STEER COIL
4-WHEEL STEER LIGHT
2-WHEEL STEER LIGHT
CRAB STEER LIGHT
GAUGE ILLUMINATION
HOURMETER
ENGINE COOLANT TEMP SENDER
TRANS OIL PRESSURE SENDER
TRANS OIL TEMP SENDER
DOME LIGHT (OPTION)

FLASHING BEACONS (OPTION)
FUEL SENDER
TACHOMETER
BRAKE PRESS WARN SWITCH (N.C.)
(OPTION)
- NOTE -
ES0451B MACHINE SHOWN IN THE STOWED
ES0452B POSITION WITH THE POWER OFF
Part No. 123701 GTH-1048 GTH-1056 6-7

All Models REV B
Page 3 of 3
HEATER W'SHIELD W'SHIELD WORK ROAD

DEFROST WIPER WASHER LIGHTS LIGHTS
(OPTION) (OPTION) (OPTION) (OPTION) (OPTION)
U34 U43
F20.9 F20.10 F20.11 F20.12 F20.12 FLASHER TURN SIGNAL
25A 5A 5A 20A 20A L 3 SHIFTER
X
SW38 SW36 PS5 PS5 6

HEATER W'SHIELD
SW45 BRAKE SW46 BRAKE 2
FAN WIPER WORK LIGHTS LIGHTS ROAD LIGHTS LIGHTS 5
N.O. N.O. 8
1 SW47 2 86 30 7 86 30 7
L H W'SHIELD CR22 CR34 4
WORK LIGHTS DRIVE LIGHTS 7
2 4 WASHER 4 85 87 87A 85 87 87A
M
YL
RD
OR
L59
M9 M10 M12 L30 L29 RIGHT
WORK DRIVE FRONT
LIGHTS LIGHTS TURN
F9C
10A
M11 L33
TAIL L60
LIGHT LEFT
FRONT
TURN
BK
RD
BK
RD
L34 L33
LEFT RIGHT
TAIL TAIL
LIGHT LIGHT
HEATER (OPTION)
WINDSHIELD WIPER (OPTION)
WINDSHIELD WASHER (OPTION)
LEFT HEADLIGHT
RIGHT HEADLIGHT
BRAKE LIGHT PRESS SWITCH (N.O.)

TAIL LIGHT
LEFT HEADLIGHT
RIGHT HEADLIGHT
LEFT TAIL LIGHT
BRAKE LIGHT PRESS SWITCH (N.O.)
FLASHER
RIGHT TAIL LIGHT
TURN SIGNAL SHIFTER
LEFT FRONT TURN LIGHT
RIGHT FRONT TURN LIGHT
- NOTE -
MACHINE SHOWN IN THE STOWED ES0451B
POSITION WITH THE POWER OFF ES0452B
6-8 GTH-1048 GTH-1056 Part No. 123701

Part No. 123701 GTH-1048 GTH-1056 6-9

Hydraulic Schematic -
Models with Single Joystick REV C
Page 1 of 3
PS4
SERVICE BRAKE PRESSURE SWITCH
STEER CYLINDERS 350 psi / 24 bar
FRONT REAR PS5

BRAKE LIGHT PRESSURE SWITCH
50 psi / 3.4 bar (OPTION)
L R L R
LS
DIFF LOCK
PARKING BRAKE
P
SERVICE
L
REAR AXLE
BRAKE FRONT AXLE REAR
LOCK UP
MANIFOLD CYLINDER
STEERING R A
WHEEL BRAKE PEDAL
T
P T PS6
PARKING BRAKE
PRESSURE SWITCH
250 psi / 17.2 bar R P E
LOW BRAKE PRESSURE
CR PS7 PRESSURE SWITCH
350 psi / 24 bar
CM CN CQ
SUP TS SUT BS SUR SRF SLR SRR BA TB BP BT TPB PBS PB DL JP TJ LUR LUP LUE
Y78
CL CG CH
CF CP Y83
Y67 Y68
CA 0.051 in 0.059 in
1.3 mm 1.5 mm
Y79
CK CJ
CE TR
400 psi
CS
CD 27.5 bar CB
2500 psi 50 psi
172 bar CC 3.4 bar
CO
Y55
400 psi
CI 27.5 bar
P2
T2
SECONDARY FUNCTION MANIFOLD

TEST PORT PRESSURES
TEST RELIEF PSI PSI
PORT VALVE (1) (2)
TS CD 450 2500
TB BI 450 (3) 3200
TPB CE 400 400
TJ CC 400 400
TR CB 50 50
LS 3200
TP BI 450 3200 to components shown in
(1) STANDBY PRESSURE (NO FUNCTIONS ACTIVATED) the manifold illustrations.
(2) RELIEF PRESSURE Refer to the Repair Section.
(3) MINIMUM HS0201B
6 - 10 GTH-1048 GTH-1056 Part No. 123701

REV C Models with Single Joystick
Page 2 of 3
4-WAY CONTROL (JOYSTICK)

P
1 3 2 4
TILT
CYLINDER
BOOM
EXTEND LIFT LIFT
CYLINDER CYLINDER CYLINDER
SWAY
CYLINDER
MASTER
CYLINDERS
SULS J1 ER EE J3 J2 LD LU J4 TU TD SR SL
ALS
AS
AG AH SLS
AP AQ AU AM AO
AV AAB AD AY
Y72B
Y72A
AR AT
Y71
AB AC 14 gpm AE 2 gpm AW
53 L/min 7.5 L/min
Y70
AX AN
AK
LS
AP
AA
Y82
P2 SP
LSP 3500 psi 3500 psi 3500 psi
241 bar 241 bar 241 bar AAC
AT
AL
0.1 gpm
0.4 L/min AJ AF AI
T2 ST
P TP T
AAA PRIMARY FUNCTION MANIFOLD
B
E
3 psi
0.2 bar

L2 S to components shown in
the manifold illustrations.
HYDRAULIC TANK Refer to the Repair Section.
HS0201B
Part No. 123701 GTH-1048 GTH-1056 6 - 11

Models with Single Joystick REV C
Page 3 of 3
A1 A2
ALS
AUXILIARY
EA ED
MANIFOLD
EB
Y77A Y77B
EC
AP AT
LEFT RIGHT
OUTRIGGER OUTRIGGER
CYLINDER CYLINDER
LSR LSE RSR RSE
DE DG DF DH
DA DB
Y76 Y75 Y74 Y73
DD DC
6 gpm 6 gpm
22.7 L/min 22.7 L/min
OUTRIGGER MANIFOLD

to components shown in
HS0201B Refer to the Repair Section.
6 - 12 GTH-1048 GTH-1056 Part No. 123701

Part No. 123701 GTH-1048 GTH-1056 6 - 13

Models with Dual Joysticks REV C
Page 1 of 3
PS4
SERVICE BRAKE PRESSURE SWITCH
STEER CYLINDERS 350 psi / 24 bar
FRONT REAR PS5

BRAKE LIGHT PRESSURE SWITCH
50 psi / 3.4 bar (OPTION)
L R L R
LS
DIFF LOCK
PARKING BRAKE
P
SERVICE
L
REAR AXLE
BRAKE FRONT AXLE REAR
LOCK UP
MANIFOLD CYLINDER
STEERING R A
WHEEL BRAKE PEDAL
T
P T PS6
PARKING BRAKE
PRESSURE SWITCH
250 psi / 17.2 bar R P E
LOW BRAKE PRESSURE
CR PS7 PRESSURE SWITCH
350 psi / 24 bar
CM CN CQ
SUP TS SUT BS SUR SRF SLR SRR BA TB BP BT TPB PBS PB DL JP TJ LUR LUP LUE
Y78
CL CG CH
CF CP Y83
Y67 Y68
CA 0.051 in 0.059 in
1.3 mm 1.5 mm
Y79
CK CJ
CE TR
400 psi
CS
CD 27.5 bar CB
2500 psi 50 psi
172 bar CC 3.4 bar
CO
Y55
400 psi
CI 27.5 bar
P2
T2
SECONDARY FUNCTION MANIFOLD

TEST PORT PRESSURES
TEST RELIEF PSI PSI
PORT VALVE (1) (2)
TS CD 450 2500
TB BI 450 (3) 3200
TPB CE 400 400
TJ CC 400 400
TR CB 50 50
LS 3200
TP BI 450 3200 to components shown in
(1) STANDBY PRESSURE (NO FUNCTIONS ACTIVATED) the manifold illustrations.
(2) RELIEF PRESSURE Refer to the Repair Section.
(3) MINIMUM HS0202B
6 - 14 GTH-1048 GTH-1056 Part No. 123701

REV C Models with Dual Joysticks
Page 2 of 3
4-WAY CONTROL (JOYSTICK) 4-WAY CONTROL (JOYSTICK)

P P
T T
1 3 2 4 4 2 3 1
TILT
CYLINDER SWAY
CYLINDER
BOOM
EXTEND LIFT LIFT
CYLINDER CYLINDER CYLINDER
MASTER PS8
CYLINDERS SWAY ENABLE
PRESSURE SWITCH
50 psi / 3.4 bar
SULS JE1 ER EE JE3 JL2 LD LU JL4 JT4 TU TD JT2 JS3 SR SL JS1 SS
BT ALS
BF BG SLS
BQ BR BV BP BN
BW
BS BU
BB BC BA
14 gpm BD
53 L/min
2 gpm BJ
BX BL 7.5 L/min
BK BO
LS
50 psi
3.4 bar AP
BAA
Y82
P2 SP
LSP 3500 psi 3500 psi 3500 psi
BM 241 bar 241 bar 241 bar
AT
0.1 gpm BI
BE BH
T2 0.4 L/min ST
P TP T
BZ PRIMARY FUNCTION MANIFOLD
B
E
3 psi
0.2 bar

L1 S to components shown in
HYDRAULIC TANK Refer to the Repair Section.
HS0202B
Part No. 123701 GTH-1048 GTH-1056 6 - 15

Models with Dual Joysticks REV C
Page 3 of 3
A1 A2
ALS
AUXILIARY
EA ED
MANIFOLD
EB
Y77A Y77B
EC
AP AT
LEFT RIGHT
OUTRIGGER OUTRIGGER
CYLINDER CYLINDER
LSR LSE RSR RSE
DE DG DF DH
DA DB
Y76 Y75 Y74 Y73
DD DC
6 gpm 6 gpm
22.7 L/min 22.7 L/min
OUTRIGGER MANIFOLD

to components shown in
HS0202B Refer to the Repair Section.
6 - 16 GTH-1048 GTH-1056 Part No. 123701

California Proposition 65
Warning
The exhaust from this product
contains chemicals known to
the State of California to
cause cancer, birth defects
or other reproductive harm.
Genie North America

Phone 425.881.1800
Toll Free USA and Canada
Distributed By:
800.536.1800
Fax 425.883.3475
Genie Australia Pty Ltd.

Phone +61 7 3375 1660
Fax +61 7 3375 1002
Genie Scandinavia Genie China

Phone +46 31 575100 Phone +86 21 53852570
Fax +46 31 579020 Fax +86 21 53852569
Genie France Genie Malaysia

Phone +33 (0)2 37 26 09 99 Phone +65 98 480 775
Fax +33 (0)2 37 26 09 98 Fax +65 67 533 544
Genie Iberica Genie Japan

Phone +34 93 579 5042 Phone +81 3 3453 6082
Fax +34 93 579 5059 Fax +81 3 3453 6083
Genie Germany Genie Korea

Phone +49 (0)4202 88520 Phone +82 25 587 267
Fax +49 (0)4202 8852-20 Fax +82 25 583 910
Genie U.K. Genie Brasil

Phone +44 (0)1476 584333 Phone +55 11 41 665 755
Fax +44 (0)1476 584334 Fax +55 11 41 665 754
Genie Mexico City Genie Holland

Phone +52 55 5666 5242 Phone +31 183 581 102
Fax +52 55 5666 3241 Fax +31 183 581 566
Part No.
Service Manual
123701
Rev A2
(from serial number GTH1007B-7101)
GTH-1048GTH-1056

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Par ts Manual

GTH-1048 from GTH1007B-7101

GTH-1056 from GTH1007B-7101

Part No. 123701

Copyright 2006 by Genie Industries

ii GTH-1048 GTH-1056 Part No. 123701

Serial Number Legend

SERIAL NUMBER: GTH1007B-7101

MANUFACTURE DATE: 04/12/07

TOTAL TRUCK WEIGHT(LBS): 29,000lbs / 13,182kg

MAX LIFT CAPACITY(LBS):

Part No. 123701 GTH-1048 GTH-1056 iii

This page intentionally left blank.

iv GTH-1048 GTH-1056 Part No. 123701

Do Not Perform Maintenance

Part No. 123701 GTH-1048 GTH-1056 v

Personal Safety Workplace Safety

Be sure to wear protective eye wear and

Be aware of potential crushing hazards

vi GTH-1048 GTH-1056 Part No. 123701

Section 1 Safety Rules

Section 2 Rev Specifications

Section 3 Rev Scheduled Maintenance Procedures

Part No. 123701 GTH-1048 GTH-1056 vii

Section 3 Rev Scheduled Maintenance Procedures, continued

viii GTH-1048 GTH-1056 Part No. 123701

Section 3 Rev Scheduled Maintenance Procedures, continued

Part No. 123701 GTH-1048 GTH-1056 ix

Section 4 Rev Repair Procedures

x GTH-1048 GTH-1056 Part No. 123701

Section 4 Rev Repair Procedures, continued

Part No. 123701 GTH-1048 GTH-1056 xi

Section 5 Rev Fault Codes

Section 6 Rev Schematics

xii GTH-1048 GTH-1056 Part No. 123701

Tire size 14.00 x 24

Tire pressure 50 psi

Lug pattern 10 x 13.189

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Part No. 123701 GTH-1048 GTH-1056 2-1

Performance Specifications Boom function speeds, maximum

Drive speed, maximum 18 mph GTH-1048

Fork rotate 19 to 21 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

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2-2 GTH-1048 GTH-1056 Part No. 123701

Hydraulic Specifications Optional Fluids

Hydraulic Oil Specifications Biodegradable Petro Canada Environ MV46

Cleanliness level, minimum 15/13 Mineral based Chevron Rykon MV

Genie specifications require hydraulic oils which

Note: Use Shell Tellus T46 hydraulic oil when oil

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Part No. 123701 GTH-1048 GTH-1056 2-3

Hydraulic Components Primary Function Manifold

Flow rate @ 2400 rpm 38 gpm Flow regulator, 14 gpm

Pump pressure, maximum 3190 psi Flow regulator, 2 gpm

Pressure compensator 3190 psi Flow regulator, 0.1 gpm

Parking brake relief valve pressure, maximum 400 psi

Diff lock relief valve pressure, maximum 400 psi

Rear lock-up relief valve pressure, maximum 50 psi

Flow regulator, 6 gpm