Genie GTH-1048 GTH-1056 Service Manual 123701 – PDF DOWNLOAD
Language : English
Pages : 153
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie GTH-1048 GTH-1056 Service Manual 123701 – PDF DOWNLOAD
Cover.................................................................................. 1 Important Information.................................................................. 2 Find a Manual for this Model........................................................... 2 Revision History....................................................................... 3 Serial Number Legend................................................................... 4 General Safety Rules................................................................... 5 Table of Contents...................................................................... 7 Specifications......................................................................... 13 Machine Specifications............................................................. 13 Performance Specifications......................................................... 14 Hydraulic Specification............................................................ 15 Hydraulic Component Specifications................................................. 18 Manifold Component Specifications.................................................. 19 Air Conditioner Refrigerant Specifications......................................... 19 John Deere 4045HF485 Engine Specifications......................................... 20 Perkins 1104D-E44TA Engine Specifications.......................................... 21 Dana T20000 Transmission Specifications............................................ 22 Dana Planetary 213 Drive Axle Specifications....................................... 22 Hydraulic Hose and Fitting Torque Specifications................................... 23 Torque Procedure................................................................... 24 Scheduled Maintenance Procedures....................................................... 25 Introduction....................................................................... 25 Pre-Delivery Preparation Report.................................................... 28 Maintenance Inspection Report...................................................... 29 Maintenance Inspection Report...................................................... 30 Checklist A Procedures............................................................. 31 A-1 Inspect the Manuals and Decals............................................. 31 A-2 Perform Pre-operation Inspection........................................... 32 A-3 Perform Function Tests..................................................... 32 A-4 Lubricate the Boom......................................................... 33 A-5 Perform Engine Maintenance - All Models.................................... 33 A-6 Perform Transmission Maintenance........................................... 34 A-7 Perform 30 Day Service..................................................... 34 A-8 Perform Axle Maintenance................................................... 35 A-9 Perform Engine Maintenance - John Deere Models............................. 35 A-10 Perform Axle Maintenance.................................................. 36 A-11 Perform Axle Maintenance.................................................. 36 Checklist B Procedures............................................................. 37 B-1 Inspect the Batteries...................................................... 37 B-2 Inspect the Electrical Wiring.............................................. 38 B-3 Check the Exhaust System................................................... 39 B-4 Inspect the Engine Air Filter.............................................. 40 B-5 Inspect the Tires, Wheels and Lug Nut Torque............................... 40 B-6 Perform Hydraulic Oil Analysis............................................. 41 B-7 Inspect the Fuel and Hydraulic Tank Cap Venting Systems.................... 41 B-8 Check the Boom Wear Pads................................................... 42 B-9 Lubricate the Driveshaft................................................... 43 B-10 Perform Engine Maintenance - John Deere Models............................ 44 Checklist C Procedures............................................................. 45 C-1 Inspect and Lubricate the Sequencing Chains................................ 45 C-2 Perform Engine Maintenance - John Deere Models............................. 46 C-3 Perform Axle Maintenance................................................... 47 C-4 Perform Transmission Maintenance - Dana Models............................. 47 C-5 Perform Engine Maintenance - Perkins Models................................ 48 C-6 Perform Engine Maintenance - Perkins Models................................ 48 C-7 Adjust the Boom Sequencing Chains.......................................... 49 C-8 Perform Axle Maintenance................................................... 50 C-9 Perform Axle Maintenance................................................... 50 Checklist D Procedures............................................................. 51 D-1 Inspect the Forks.......................................................... 51 D-2 Perform Transmission Maintenance - Dana Models............................. 51 D-3 Replace Hydraulic Tank Return Filter Element............................... 52 D-4 Perform Axle Maintenance................................................... 52 D-5 Perform Engine Maintenance - Perkins Models................................ 53 Checklist E Procedures............................................................. 54 E-1 Test or Replace the Hydraulic Oil.......................................... 54 E-2 Perform Engine Maintenance - John Deere Models............................. 55 E-3 Perform Engine Maintenance - Perkins Models................................ 55 E-4 Perform Engine Maintenance - Perkins Models................................ 56 E-5 Perform Engine Maintenance - John Deere Models............................. 56 E-6 Perform Engine Maintenance - Perkins Models................................ 57 Repair Procedures...................................................................... 58 Introduction....................................................................... 58 Boom Components.................................................................... 60 1-1 Boom Proximity Switch...................................................... 60 How to Test a Proximity Switch............................................. 60 How to Adjust the Boom Angle Proximity Switch.............................. 61 How to Adjust the Boom Extend Proximity Switch............................. 61 1-2 Boom....................................................................... 62 How to Replace the Boom Wear Pads.......................................... 62 How to Remove the Lifting Fork Frame....................................... 62 How to Remove the Cable Bridge Assembly , GTH-1056......................... 63 How to Replace the Retraction Chain........................................ 64 How to Replace the Extension Chains........................................ 67 How to Remove the Boom..................................................... 69 How to Disassemble the Boom - GTH-1048..................................... 71 How to Disassemble the Boom - GTH-1056..................................... 73 1-3 Boom Lift Cylinder......................................................... 76 1-4 Boom Extension Cylinder.................................................... 77 1-5 Fork Level Cylinder........................................................ 78 1-6 Hydraulic Hoses............................................................ 79 How to Replace the Fork Level and/or Auxiliary Cylinder Hoses, GTH-1048.... 79 How to Replace the Fork Level and/or Auxiliary Cylinder Hoses, GTH-1056.... 80 Operator's Compartment............................................................. 83 2-1 Operator's Compartment..................................................... 83 2-2 Machine Controls........................................................... 85 How to Remove the Steering Column.......................................... 85 How to Remove the Steering Wheel........................................... 85 How to Remove the Steer Orbitral........................................... 86 How to Remove the Joystick - Models with Single Joystick................... 86 How to Remove the Joystick - Models with Dual Joysticks.................... 87 How to Remove the Brake Pedal Assembly..................................... 87 How to Remove the Gauge Cluster Assembly................................... 88 How to Remove the Diagnostic Display....................................... 88 Fuel and Hydraulic Tanks........................................................... 89 3-1 Fuel and Hydraulic Tanks................................................... 89 Engines............................................................................ 90 4-1 Engines.................................................................... 90 How to Repair the John Deere 4045T Engine.................................. 90 How to Repair the Perkins 1104D-E44TA Engine............................... 90 How to Remove the Engine................................................... 90 4-2 Engine Fault Codes......................................................... 91 Transmission....................................................................... 92 5-1 Transmission............................................................... 92 How to Repair the Transmission............................................. 92 How to Remove the Transmission............................................. 92 Hydraulic Pump..................................................................... 94 6-1 Hydraulic Pump............................................................. 94 How to Test the Function Pump.............................................. 94 How to Remove the Function Pump............................................ 95 How to Install the Function................................................ 96 How to Prime the Function Pump............................................. 96 How to Adjust the Function Pump Standby Pressure........................... 97 How to Adjust the Function Pump Pressure Compensator....................... 98 Manifolds..........................................................................100 7-1 Primary Function Manifold Components - Models with Single Joystick.........100 7-2 Primary Function Manifold Components - Models with Dual Joysticks..........104 7-3 Secondary Function Manifold Components.....................................108 7-4 Outrigger Manifold Components..............................................110 7-5 Auxiliary Manifold Components (option).....................................112 7-6 Brake Manifold Components..................................................113 7-7 AC Hydraulic Manifold Components...........................................114 7-8 Valve Adjustments - Secondary Function Manifold............................115 How to Set the Steer System Pressure.......................................115 How to Set the Parking Brake System Pressure...............................116 How to Set the Differential Lock/Joystick System Pressure..................117 How to Set the Rear Lock-up System Pressure................................118 7-9 Valve Coils................................................................119 Axle...............................................................................121 8-1 Axles......................................................................121 How to Remove the Axle.....................................................121 How to Repair the Axle.....................................................121 Outriggers.........................................................................122 9-1 Outriggers.................................................................122 How to Remove an Outrigger.................................................122 How to Remove an Outrigger Cylinder........................................123 Fault Codes............................................................................125 Introduction.......................................................................125 Diagnostic Display.................................................................126 John Deere 4045HF485 Engine Fault Codes............................................128 Perkins 1104 Engine Fault Codes....................................................135 Section 6 Schematics...................................................................138 Introduction.......................................................................138 Proximity Switch Legend............................................................139 Fuse Panel Layout..................................................................140 Electrical Component Legend........................................................141 Wire Color Legend..................................................................142 Electrical Symbol Legend...........................................................143 Hydraulic Symbols Legend...........................................................144 Electrical Schematics..............................................................146 Electrical Schematic...........................................................146 Hydraulic Schematics...............................................................150 Hydraulic Schematic - Models with Single Joystick..............................150 Hydraulic Schematic - Models with Dual Joystick................................151 Back Cover.............................................................................153
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