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1. before serial number GTH1012 16292 Electrical Schematic View 1 Section 6 Schematics N ee Sey WHTRED NJ RED FUEL SENDER bot Dos WHTREH GAUGE CLUSTER BACKLIGHT m WHTBUR 9 TACHOMETER 2 P d GRNIWHT CRAB STEER LIGHT N N a TI 2WS LIGHT P P d
2. on HEATER DEFROSTER FAN WINDSHIELD WINDSHIELD WASH DOME LIGHT STROBE LIGHT WORK LIGHT ROAD LIGHT OPTION WIPER OPTION OPTION OPTION OPTION 1 e e e e e e e T 1 a HEAT VALVE A C SWITCH BLOWER SWITCH ii 9 POTENTIOMETER F9 F9 mo FH INLINE INLINE F12 25 Q 25 AMP 5 AMP 9 9 20 AMP FUSE FUSE FUSE FUSE FUSE FUSE FUSE Ld I gt A Jj 48 5 Bune sw 8 8 515 516 1 pt 1 1 2 a ROAD BRAKE TURN SIGNAL SHIFTER E X Er une i A sta 8 work uer FLASHER INLINE 85 10 E LIGHT PRESS FUSE 517 WINDSHIELI S Bg S 4 N RED WIPER WASH A i
3. 7 2 gt a C7 L C6 TRBEEBSS amp ES55555 zo EEH 00000000000000 85 lt E oz 26 F i r mft Ie XE CUBES E 08 C5 F151A F14 10A F11 10A F85A 32 cao 10 Go we ca zg SWITCHPWR PWRPORT DEFROSTFAN DOME BEACON Dn 7 60 BS F3 10A F6 5A F17 10A MAX F7 5A li CB3 Co CS wa C5 30 50 REAR AXLE OSCSTEER DIFF SW SPARE GAUGE CLS PWR 2 CB 1 F4 10A F1 15 F10 15A F16 1A i 30 15 mu Ci B nd 2 bs SWAY TILT BRAKE SHIFT WIPER WASHER GAUGE CLS ECU 28 bi F20 10A MAX F2 10A F12 20A F19 10A MAX Perkins Engine Circuit Breakers ze mco coco mo wo is 22 AUX HYD LIGHTS SPARE N E 3 CR4 Located in Tank Assembly a BE FLASHER F5 5A F18 10A MAX F9 25A F13 15A C 5 wo wo 15 ae HORN SPARE HVAC IGNITION zz CR11 CR12 CR13 m SWAY TILT U D Ex 55 lt A LATCH FAY L R 2 77 72 1 amp o 05 CR8 CR9 CR10 u BOOM FORWARI REVERSE
4. 8 I a SERVICE BRAKE BRAKE LIGHTS OPTION PRESSURE SWITCH ii PRESSURE S6IF S16 34 20 Pi FRONT STEER 6 GPM REAR STEER 6 GPM i 1 I 1 STEERING UNIT PARKING s Ss m REAR LOCK UP 5 GPM BRAKE REAR AXLE MANIFOLD FRONT AXLE BRAKE PEDAL WARNING LIGHT P PRESSURE PARKING BRAKE ao m SWITCH 350 PSI 050 2 Xr Ir SUP SF 9 65 BA TB PB PBS DL 4 Se ek i L Y78 L_ _ 1 sogas 55 96 Y67 eau Sw T sp 5 4 BO 10 9 En ps ja aa SECONDARY FUNCTION MANIFOLD FUNCTION MANIFOLD STABILIZER MANIFOLD Evaporator Note alpha callouts refer to components shown in BREATHER FILLER 3 PSI the manifold illustrations Refer to the Repair Section
5. Abbreviation Legend B1 Battery L Light SW Switch CB2 Circuit Breaker 40A L7 Low battery SW23 Transmission control C5 Capacitor 4700mf L42 Engine oil pressure SW24 Parking brake CR Control relay L61 Back up light SW34 Sway enable CR5 Horn L63 Low brake pressure SW35 Auxiliary control CR11 Boom up L64 Parking brake on SW39 Right outrigger CR55 Drive reverse L71 Transmission oil pressure SW40 Left outrigger CR56 Drive forward L72 Transmission temperature SW42 Tilt enable CR69 Boom extend L73 Low fuel level SW43 Steer select CR88 Power L74 4 wheel steer select SW44 Horn CR89 Parking brake L75 Crab steer select SWT77 Differential lock CR100 Sway enable L76 2 wheel steer select U Electrical component D1 Alternator M Motor U31 Engine ECM F Fuse M3 Engine starter U37 Diode F6 20A Power to controls Heater fan motor Y Valve coil F19 10A ECM power M10 Windshield wiper motor Y5 Transmission reverse F20 Fuse block M11 Cab circulation fan motor Y6 Transmission forward FS2 Throttle pedal PS M12 Windshield washer motor Y55 Rear axle oscillate enable G Gauge Pressure switch Y67 Parking brake release G3 Engine coolant temperature PS4 Service brake Y68 Differential lock G6 Hourmeter PS6 Parking brake Y70 Sway left enable G8 Dia
6. SP mye 300 Ps Si a i ire dre n in e e e 1 amp e i i 1 SECONDARY FUNCTION MANIFOLD MAIN FUNCTION MANIFOLD P P T STABILIZER MANIFOLD e pulse ee ee ee E 5 gt 2 BREATHER FILLER a B FR50 l ee 1 poly pid __4 LOAD SENSE PISTON PUMP XQ sl 3200 450 PSI RS SETTING 08 cL CT FE 3 66 CID 2400 RPM 3 gpm Ls z 8 Note alpha callouts refer 114 U min 8 to components shown in 8 the manifold illustrations Refer to the Repair Section RESERVOIR HS0202E gt gt Genie Part No 123701 GTH 1056 6 49 May 2015 Section 6 Schematics ul S Hydraulic Schematic Models with Dual Joystick 50 Genie Sweden Phone 0046 3157 5101 Fax 0046 3157 5104 Genie France Phone 0033 237 260 986 Fax 0033 237 260 998 Genie Iberica Phone 0034 900 808 110 Fax 0034 935 725 080 Genie Germany Phone 0800 180 9017 Phone 00
7. 7 SENDER RIGHT e FUEL GND 2 2 FUEL TANK L HORN GND 88 2 26 2 puse cd TRANSMISSION STABILIZER MANIFOLD SECONDARY MANIFOLD PRIMARY MANIFOLD 42 1 21640 7 COIL GROUND SV9 SWAY ENABLE C19 2 X LUG GND e C42 2 3 C41 7 COIL GROUND LEFT STB UP C69 2 3 C17 8 LEFT STB OWN C70 2 amp C17 12 SVS P BRAKE RELEASE C30 2 E C26 3 ee ee amp iT STI SV8 REAR AXLE FAST C35 2 C42 1122 C39 2 OIL PRESS S24 502 2 SV7 REAR AXLE FLOAT C31 2 ee E SV6 DIFF LOCK C32 2 C42 1222 6ROUND LUG SVD1B CRAB STEER C34 2 SVD1A 4WS C33 2 S23 BRAKE PRESSURE C36 1 e c42 C37 4 4 1 COIL GND C40 7 2 42 L637 5 4 2 COIL GND C41 7 C37 6 11 824 GND C39 2 C37 3 4 12 TRS GND K GND LUG C17 6 17 7 GROUND STUDS C267 I Scan C37 8 NOTE HARNESS PWR PORT C91 2 x c16 4 LUG GND o LEFT umi Germ ee FUEL GND m BASE UNIT TRANS GND Z DUAL JOYSTICK OPTION COILGND PARKING CONTROL SYSTEM GROUND TL _ S24 GND 52 6 0 C15 9 lt 16 1 LUG GND SS a ETER a 71 2 17 1 RT UP GND 19 C72 2 91C17 5 RT DWN GND 9 LUG GND33 C17 6 LUG GND z LUG GND32 1C17 7 LUG GND AIS C69 2 2 C17 8 LT UP GND 5 EIE a 19
8. RIGHT m C2 9 51 A TAILLT R e mm C45 352 C TAIL GND C51 2 pe LL 50 hd EP UGT c2 2 5 4 STOP LIGHT S16 PWR 049 1 2 5 2 Back PWR gay d STOP LIGHT 16 C49 B E amp CS1 B L 645 6 5 2 BACK GND 29 LIGHT 45 don s 47 1 41 1 2 7 C46 1 4 2 CAB LT L amp C2 6 5 LT R GND X C45 7 6 C46 1 4 LT L GND K C45 2 GROUND_STUDS 2 14 2 45 1 OTE HARNESS MAP 1551 LUG CND WORK LIGHTS OPTION LEFT 155 o 69 e D BUSS CONNECTOR 9 LUG GND33 C45 1 LUG GND oo 075 4 1 45 2 LT L GND C52 C S31C45 3 TAIL GND 50 2 1 45 6 BACK GND TO 75 3 45 7 LT R GND LUG GND32045 8 LUG OND GAUGE CLUSTER 4 GAUGE CLUSTER 55 522 13 17 48 4 69 HARNESS LEGEND WORK LIGHT OPTION Vd C50 1 gt C2 2 BACK PWR CA9 A 162 3 S16 PWR NUM PART DESCRIPTION 2159 C48 2 9 1C2 4 22 PWR 14 161444 GROUND BUSS 512 648 455 2 5 S22 RET 26 233989 HARNESS CAB LIGHT 97 75 2 55 2 6 CAB LT L 27 214334 HARNESS LIGHT POWER 9 75 1 2251 28 229677 HARNESS TAIL LIGHT LED COISA 9 29 229678 HARNESS BACKUP LIGHT LED 30 215331 HARNESS WORK LIGHTS Genie HEAD LT LEFT LIGHTS S22 2 6 S22 PWR 48 2
9. 100 QV RESISTOR ee 5 TA Hr gun d i 19 7 i p f 7 multimeter 9V DC battery 10Q resistor coil ao om Note Dotted lines in illustration indicate a reversed connection as specified in step 6 5 Momentarily connect the positive lead from the multimeter to the positive terminal on the 9V battery Note and record the current reading 6 Atthe battery or coil terminals reverse the connections Note and record the current reading Result Both current readings are greater than 0 mA and are different by a minimum of 20 The coil is good W 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 Section 4 Repair Procedures March 2015 Axle 8 1 Axles How to Remove the Axle AWARNING Podily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is required 1 Chock the wheels 2 Remove the fasteners securing the driveshaft to the transmission Lower the end of the driveshaft to the ground 3 Remove the fasteners securing the driveshaft to the axle remove the driveshaft from the mach
10. 12 14 ft lbs 16 19 Nm 18 Check valve 5 psi 0 3 bar AR Fork tilt up circuit sss 12 14 ft lbs 16 19 Nm 19 Check valve 5 psi 0 3 bar AS uius Steer left right circuit 12 14 ft Ibs 16 19 Nm 20 Check valve 5 psi 0 3 bar 5 Fork tilt down circuit 12 14 ft Ibs 16 19 Nm 21 Check valve 5 psi 0 3 bar Boom up 12 14 ft Ibs 16 19 Nm 22 Check valve 5 psi 0 3 bar AM uas Boom retract circuit 12 14 ft Ibs 16 19 Nm 23 Directional valve 3 position 4 way pilot operated AW Sway left right 33 37 ft Ibs 45 50 Nm 24 Flow regulator valve 14 53 L MIN AX Fork tilt up down circuit 20 ft Ibs 27 Nm 25 Solenoid valve 2 position 4 way AY au Function select boom up and fork tilt up 20 ft Ibs 27 Nm 26 Diagnostic nipple AAA Test port TP 27 Solenoid valve 2 position 4 way Function select boom extend and sway right 20 ft lbs 27 Nm 28 Solenoid valve 2 position 2 way Function select sway left right
11. 2 position 3 way solenoid valve t ilL un 2 position 4 way solenoid valve Axle o Filter Relief valve 2 position 3 way directional valve pilot operated Atie 2 position 2 way solenoid valve r i PI gt BEN c T 1 s i Q m 4 e oe 37 7 r 11 sd 1 Joystick Io TW i Ko l 1 n L Counterbalance valve Genie 1048 1056 Part No 123701 Section 6 Schematics May 2015 Harness Control System Power Single Joystick Section 6 Schematics Single Joystick May 2015 TEES Harness Map Control System Power FUEL SENDER ES0462F RIGHT FUEL RET C86 1 3 C10 9 AUX HYDRAULICS S14 POWER CONNECTED TO
12. 6 32 Electrical Schematic 6 35 before serialnumber GTH1012 16292 Electrical Schertratie rin ett der cree ena as du e ER 6 40 from serial number GTH1012 16292to GTH1014 19340 Electrical Schertiatic ient ui iet Evite deest 6 44 from serialnumber GTH1014 19341 GTH1014E 10001 Hydraulic Schematic Part No 123701 Models with Single 2 4 4 444000 6 48 Hydraulic Schematic Models with Dual 2 6 49 GTH 1048 GTH 1056 May 2015 n 1 TABLE OF CONTENTS This page intentionally left blank A TEREX COMPANY GTH 1048 GTH 1056 Part No 123701 September 2014 Section 2 Specifications Machine Specifications Fluid capacities Fuel tank 35 gallons 132 5 liters Hydraulic tank 44 gallons 166 5 liters Hydraulic system including tank 55 gallons 208 2 liters For operational specifications refer to the Operator s Manual Part No 123701 Genie Specifications Tires and wheels Tire size 14 00 x 24 Tire ply rating 12 Weight rough terrain tire 315 Ibs air filled 142 9 kg Weight rough terrain tire 967 35 Ibs foam filled 439 16 kg Weight rock lug tire 1013 35 Ibs foam filled 459 16 kg Tire pressure 50 psi models with air filled tires 3 45 bar Lug nut torque 465 ft
13. 4 0000 4 2 1 2 mers 4 4 13 Boom Lift Cylinder 40044 4 17 1 4 Boom Extension Cylinder 0222400 001000 4 18 1 5 1 4 19 Operator s Compartment 2 1__ 5 4 23 2 2 Machine Controls reed tieng es Pere ted rede 4 25 Fuel and Hydraulic Tanks 3 1 Fueland Hydraulic 4 29 Engines 4 1 Engines Intendente 4 30 42 Engine Fault Codes sse 4 32 Transmission 5 1 Transmission sosna eira ia doni 4 33 Hydraulic Pumps 6 1 Hydraulic Pump ee 4 35 Genie TEREX COMPANY xii 1048 GTH 1056 Part No 123701 May 2015 Section 4 Repair Procedures continued TABLE OF CONTENTS Part No 123701 Manifolds 7 1 Primary Function Manifold Components Models with Single Joystick 7 2 Primary Function Manifold Components Models with Dual Joysticks 7 3 Secondary Function Manifold Components 7 4 Outrigger Manifold 7 5 Auxiliary Manifold Components option
14. 404 nnn 3 27 D 2 Replace the Hydraulic Tank Return Filter Element 3 27 D 3 Perform Transmission Maintenance Dana Models 3 28 D 4 Perform Axle 3 28 0 5 Perform Engine Maintenance Deutz Models 3 29 0 6 Perform Engine Maintenance Perkins Models 3 29 D 7 Perform Transmission Maintenance ZF Models Checklist E Procedures E 1 Testor Replace the Hydraulic 3 30 E 2 Perform Engine Maintenance John Deere Models 3 31 E 3 Perform Engine Maintenance Perkins Models 3 31 E 4 Perform Engine Maintenance Deutz Models 3 32 E 5 Perform Engine Maintenance Perkins Models 3 32 E 6 Perform Engine Maintenance Perkins Models 3 33 E 7 Perform Engine Maintenance John Deere Models 3 33 E 8 Perform Engine Maintenance Deutz Models 3 34 E 9 Perform Engine Maintenance Perkins Models 3 34 Part No 123701 Genie GTH 1048 GTH 1056 Xi May 2015 2 2 1 TABLE OF CONTENTS Section 4 Repair Procedures eee 4 1 Boom Components 1 1 Proximity
15. NOTE HARNESS PERKINS T3 ENGINE LEFT BATTERY POWER AND GROUND DISTRIBUTION GND X4 PCB_BAT HARNESS LEGEND PERKINS 1104D NUM PART DESCRIPTION 4 227493 HARNESS TRANSMISSION 9 229033 CABLE BATTERY RED 3 0 10 130719 CABLE BATTERY BLACK 000 11 237933 HARNESS POWER LEAD 12 7 319 17 GROUND STRAP 12 IN 13 237933 HARNESS PCB GROUND 14 161444 ASSEMBLY GROUND BUSS 22 217940 HARNESS ENGINE WIRING PERKINS 41 236979 FORMING BUSS BAR 44 229819 PCBA POWER DISTRIBUTION ASSY 45 161524 ASSEMBLY POWER BUSS ES0462F Genie Part No 123701 GTH 1056 6 21 May 2015 Section 6 Schematics a Harness Map Perkins 1104D Engine Battery Power and Ground 22 23 Section 6 Schematics May 2015 ET Harness Map Perkins 854E Engine Battery Power and Ground Section 6 Schematics May 2015 Harness Map Perkins 854E Engine Battery Power and Ground 9 RIGHT 1 AMP 50 60 gt CB 1 CB2 CB Bl 29 Rush F amp a lt RED BAT CABLE BLACK BAT CABLE ENGINE gt PERKINS a gt 1204 T4i 2 o CB 9 fe PANEL x STARTER GROUND STUDS GND E UG GNDSE NOTE HARNESS PERKINS T4i ENGINE LEFT BATTERY
16. 20 ft lbs 27 Nm Genie 4 44 GTH 1048 GTH 1056 Part No 123701 March 2015 Section 4 Repair Procedures MANIFOLDS Y82 8 S e 8 26 ovs S AE Q E ws View A AG AH Note alpha callouts refer to corresponding notes on the hydraulic schematic alphanumeric callouts refer to the electrical schematic GO 9 Genie Part No 123701 GTH 1048 GTH 1056 4 45 Section 4 Repair Procedures March 2015 Br MANIFOLDS 7 2 Primary Function Manifold Components Models with Dual Joysticks The primary function manifold is located under the manifold inspection cover Index Schematic No Description Item Function Torque 1 Directional valve 3 position 4 way pilot operated BA Sway left right 33 37 ft Ibs 45 50 Nm 2 Directional valve 3 position 4 way pilot operated BB Boom extend retract 65 75 ft lbs 88 101 Nm 3 Directional valve 3 position 4 way pilot operated Boom up down 65 75 ft lbs 88 101 Nm 4 Directi
17. COII STI 25852 vL 8 Ble OE a e x T z re eo 58 2 Y 2 TCS 5K K8 BOOM EXTENSION RELAY 3 5 7 BIK K7 BOOM ANGLE RELAY z 4 A 2 3 a la al n 5 3l T o 57 b REAR AXLE FLOAT COIL 8 m GRN stt Rp gul BCUIBLR 1 e BIK lt amp le 52 8 FPE gt Eas was 59282 25252 95 9 ORG T REAR AXLE FAST COIL S24 rgis 41 14 4816 48288 SEES E T a l 8 K1 FORWARD ENABLE RELAY ing 5 je GRNIWHTISS ORG e E 4 18 see o e EI i yia lost T Bay gi FORWARD COIL lt E 5 BLUWHT XB 55 l x Sox a 8 is K2 REVERSE ENABLE RELAY e eoe 59 e iD BLK ul ul WHT REH MaS E e 3 2 5 5 REVERSE COIL prp l INE s a 85 2 gl GANWHTST TH E aa El no 5 e gK BACKUP ALARM lala E m 8 RED BACKUP LIGHT OPTION 881 E 8 an E TRANS COIL WHT YEL _ BK 5 gt gt ot bean x BLK D TRANS COIL B ES 7 PARKING BRAKE LIGHT amp BIS 8502 l e Mg fale PARKING BRAKE LATCH RELAY 81708 _ 4 ee ORG P BLU REI IS a BLUWAT T DT Pa PARKING BRAKE REL
18. 40 22 4 14 32 50 68 86 104 122 40 30 20 10 0 10 20 30 40 50 C Ambient Air Temperature Chevron hydraulic oil 5606A Petro Canada Environ MV 46 UCON Hydrolube HP 5046D Chevron Rando HD Premium MV optional oil cooler may be required Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie PartNo 123701 GTH 1048 GTH 1056 2 3 Section 2 Specifications September 2014 Chevron Rando HD Premium MV oil Chevron 5606A hydraulic oil fluid fluid properties properties ISO grade 32 ISO grade 15 Viscosity index 200 Viscosity index 300 Kinematic Viscosity Kinematic Viscosity cSt 200 F 100 C 7 5 cSt 200 F 100 C 5 5 cSt 104 F 40 C 33 5 cSt 104 F 40 C 15 0 cSt 40 F 40 C 510 Brookfield Viscosity 4 F 20 C 22 F 30 C 1040 3310 Flash Point 375 F 190 C Pour Point 58 F 50 C Maximum continuous operating 171 F 77 C temperature Note An hydraulic oil heating system is recommended when the ambient termperature is consistently below 0 F 18 C Note Do not operate the machine when the ambient temperature is below 20 F 29 C with Rando HD Premium MV Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie 1048 1056
19. DE find Left outrigger extend circuit 12 14 ft Ibs 16 19 Nm 6 Check valve 5 psi 0 3 bar Right outrigger extend circuit 12 14 ft lbs 16 19 Nm 7 Check valve 5 psi 0 3 bar Left outrigger retract circuit 12 14 ft lbs 16 19 Nm 8 Check valve 5 psi 0 3 bar Right outrigger retract 12 14 ft lbs 16 19 Nm Genie 4 52 GTH 1048 GTH 1056 Part No 123701 March 2015 Section 4 Repair Procedures MANIFOLDS DA 1 Note alpha callouts refer L __ to corresponding notes on the hydraulic schematic alphanumeric callouts refer to the electrical schematic 2 DD 4 Genie PartNo 123701 GTH 1048 GTH 1056 4 58 Section 4 Repair Procedures March 2015 MANIFOLDS 7 5 Auxiliary Manifold Components option The auxiliary manifold is located under the transmission inspection cover Index Schematic No Description Item Function Torque 1 Check valve 5 psi 0 3 bar EA S Auxiliary A1 circuit 12 14 ft Ibs 16 19 Nm 2 DOS valve 3 position 4 way EB
20. Cual LU Gia 081 m John Deere 4045HF485 engine a coolant temperature sender b oil pressure sender Starter relay Genie Perkins 1104D E44TA engine oil pressure sensor coolant temperature sender intake temperature sensor crank speed sensor ao oo 4 32 GTH 1048 GTH 1056 Part No 123701 March 2015 Section 4 Repair Procedures Transmission 5 1 How to Remove the Transmission Transmission How to Repair the Transmission Repair procedures and additional transmission information is available in the Dana T12000 Transmission Maintenance and Repair Manual Dana part number 0109 and the Dana 720000 Maintenance Manual Dana part number 0202 Dana T12000 Transmission Manual Genie part number 97489 Dana T20000 Maintenance Manual Genie part number 115025 Dana T20000 transmission a transmission temperature sender located opposite side of trans b transmission pressure send
21. Fuel Balance Control integrator injector 1 in firing order minimum value exceeded 23930 65178 Fuel Balance Control integrator injector 2 firing order maximum value exceeded 1 Fuel Balance Control integrator injector 2 in firing order minimum value exceeded Genie 5 18 GTH 1048 GTH 1056 PartNo 123701 September 2014 Section 5 Fault Codes ENGINE FAULT CODES MODELS WITH DEUTZ POWER SPN Suspect Parameter Number ASPN Alternate Suspect Parameter Number FMI Failure Mode Identifier SPN ASPN FMI Description 23931 65179 0 Fuel Balance Control integrator injector 3 in firing order maximum value exceeded 1 Fuel Balance Control integrator injector 3 in firing order minimum value exceeded 23932 65180 0 Fuel Balance Control integrator injector 4 in firing order maximum value exceeded 1 Fuel Balance Control integrator injector 4 in firing order minimum value exceeded 23933 65181 0 Fuel Balance Control integrator injector 5 in firing order maximum value exceeded 1 Fuel Balance Control integrator injector 5 in firing order minimum value exceeded 23934 65182 0 Fuel Balance Control integrator injector 6 in firing order maximum value exceeded 1 Fuel Balance Control integrator injector 6 in firing order minimum value exceeded 23935 65183 12 Timeout Error of CAN Transmit Frame EEC3VOL1 Engine send messages 23936 65184 12 Timeout Error of CAN Transmit Frame EEC3VOL2
22. AUX HYDRAULICS S14 POWER CONNECTED TO HARNESS 215332 WHEN AUX HYDRAULICS OPTION INSTALLED 9 STABILIZER MANIFOLD HORN HORN PWI R C88 1 RE C4 8 SECONDARY MA IFOLD PRIMARY MANIFOLD SV9 SWAY ENABLE 19 1 800 053 Iano Evr cal poou 754 TRANSMISSION 42 3 7 40 1 FORWARD COIL ENGINE 44 1 TR APS C44 23 TR GND 20829 1 542 4 27 049 2 REVERSE COL S ie S CH SV5 P BRAKE RELEASE 30 1 4 5 57 SWAY ENBL PWR 74 9 1 CONNECTORS DETAILS C42 71C40 3 B1 COIL apes RIGHT STE UP C71 1F amp C68 1 SVB REAR AXLE FAST 35 1 lt 4 3 57 SWAY ENBL RET C74 8 9 3 C42 8 2 C41 4 B2 COL RIGHT STB DWN C72 1 X C68 4 SV7 REAR AXLE FLOAT C31 1 x C4 C42 Ce ee COIL 44 7 SIP SV6 DIFF LOCK C32 1 FR c28 42 10 041 6 B4 COIL C44 855 CAN H C1 2 4 4 REV PWR K C40 2 C42 5 2 C87 1 TEMP S25 T 10 5 4 5 525 87 1 C42 62 39 1 OIL PRESS S24 S23 BRAKE PRESSURE C36 2 1 1 dog mre ro S5 PARKING BRAKE PWR C27 A E amp c4 6 C10 2 4 7 BI PWR C40 3 43 C18 BACKUP S5 PARKING BRAKE RET 27 4 C29 ae
23. FRONT WINDSHIELD WHASHER PUMP WASH PWR 92 1 lt 62 8 WASH GND C92 2 58 5 SKYLIGHT e WHASHER PUMP WASH PWR 93 115 lt 63 8 WINDSHIELD_ WIPER LEFT HEATER CONTROL PANEL WIPE RET C60 2 C62 2 WIPE PWR 60 11 62 4 WIPE ON C60 3 x amp C62 1 BLOWER SW POWER 78 5 78 SW MED 78 SW LOW C78 L C80 B c6 1 2 _ 80 VALVE CONTROL Genie POWER 76 VAL RET 76 C61 GROUND C76 C XK LUG GND lt lt 6 1 2 lt lt 80 FAN PWR 1 x c6 5 FAM GND 2 4 C6 6 517 WINDSHIELD W W 69 WIPE ON C62 1 x c60 3 WIPE RET 62 2 x C60 2 WIPE PWR C62 4 X C60 1 W W PWR C62 7 C6 3 Led LWASH PWR C62 8 XCWIN WP S21 518 SKYLIGHT W W 5 WIPE ON 63 11 6 lt 59 3 i5 WIPE RET C63 2 3 C59 2 9 WIPE PWR 63 41 59 1 w WPWR 63 7 C6 4 WASH PWR C63 8 X SK Y WP 63 2 1 59 2 WIPE RET 63 1 1 59 3 d WIPE PWR 6 8 C80 D 3 1 C62 7 2 C6 1 HVAC PWR 6 2 HVAC PWR C6 3 W W PWR C6 4 W W PWR C61 1 352 C6 5 FAN PWR C61 2 32 C6 6 FAN GND SKYLIGHT WIPER 58 DOME S19 GROUND STUDS C58 3 LIGHT I i C5
24. l e e MY D RED l 9 MOTOR SW 2 NO ae AA i 2 UE L m a a 19 SW 12 lt EM Se B 29 49 4 CONTROL PANEL YEL BLK YEL l 4 v 5 l BLOWER 2 2 LON 2 SWITCH DON 2 3 31 ER 9 o 4 BLK L M H 9 17 B e Sy E x 29 8 98 5 ma mg 2 7 2 D S 7 js K m 8 8 8 ABCDEF M al m a HEATER A C UNIT 2 l 22 08 6 9 l LON 1 25 27 21 5 L R H N INLINE BK ON AN 2 235 2 10 AMP 34571 FUSE a 375 Eats D 35 381822 29 9 3 4 4 8 4 5 THERMOSTAT 8 3 R2 8 a nS Qo 53 56 55 56 La io amp BLK 2 5 4 58 58 iad 85 87 87A 85 87 6 68 65 E ER COLD CUT OUT po 73 i 3 0 C 1 0 C 9 BLK a T gt 8 3 8 5 8 5 d 2 8 85 57186 5 g 82KW 8 ACTUATOR SEALED RED 4 27 HEATER VALVE 3 4 247 F BLOWER 1 86 30 R1 4 4 x4 D qu A ul 21 851 87 87A i 2 _ 23 13 t3 w o o w g g Eg g 9 g g8g E E 1 z z Ld e e Ld t pS 2 A c m d B 5 E qu B P E 8
25. GND 9 RED BAT CABLE BLACK BAT CABLE o kk M FUEL FUEL GLOW d ENGINE RELAY RELAY ALTERNATOR E 3 5 lt 5 STARTER 18 NA NT ENGINE EU GROUND STUDS IL GND E LUG GND NOTE HARNESS DEUTZ T3 T4i ENGINE LEFT ud BATTERY POWER AND lt GROUND DISTRIBUTION PCB BATE PCB GND X 4 2 HARNESS LEGEND DEUTZ TCD3 6 NUM PART DESCRIPTION 4 227493 HARNESS TRANSMISSION 9 229033 CABLE BATTERY RED 3 0 10 130719 CABLE BATTERY BLACK 000 11 237933 HARNESS POWER LEAD 12 7 319 17 GROUND STRAP 12 IN 13 237933 HARNESS PCB GROUND 18 219333 HARNESS ENGINE ECM TCD3 6 10K 19 219334 HARNESS ENGINE TCD3 6 41 236979 FORMING BUSS BAR 44 229819 POWER DISTRIBUTION ASSY 45 161524 ASSEMBLY POWER BUSS ES0462F Genie 6 20 GTH 1056 Part No 123701 May 2015 Section 6 Schematics ee Harness Map Perkins 1104D Engine Battery Power and Ground 9 1 RIGHT lt AX a RED BAT CABLE BLACK BAT CABLE de ENGINE p CIRCUIT BREAKER 5 PANEL 4 1 5 STARTER 2 GROUND_ STUDS GND 2106 6 0
26. Section 5 Fault Codes September 2014 pm s ENGINE FAULT CODES MODELS WITH DEUTZ POWER SPN Suspect Parameter Number ASPN Alternate Suspect Parameter Number FMI Failure Mode Identifier SPN ASPN FMI Description 23898 65146 13 check of missing injector adjustment value programming IMA injector 4 in firing order 23899 65147 13 check of missing injector adjustment value programming IMA injector 5 in firing order 23900 65148 13 check of missing injector adjustment value programming IMA injector 6 in firing order 23910 65158 0 Air Pump internal error 6 Air Pump over current 7 Airpump CAN communication interrupted no purge function available 9 Air Pump CAN communication lost 12 Air Pump internal error 14 Air pump doesn t achieve air mass flow setpoint 23911 65159 0 Burner dosing valve DV2 overcurrent at the end of the injection phase 3 Burner dosing valve DV2 short circuit to battery 4 Burner dosing valve DV2 short circuit to ground 7 Burner dosing valve DV2 blocked closed 11 Burner dosing valve DV2 short circuit high side powerstage 12 Burner dosing valve DV2 powerstage over temperature 23912 65160 0 Physical range check high for burner dosing valve DV2 downstream pressure shut off regeneration 1 Physical range check low for burner dosing valve DV2 downstream pressure shut off regeneration When burner injector is actuated the measu
27. oj A Ajn 52 NI wo N S 97 4 AIN n ge op 4 29 5 ojo FTF D oye DN rt Oo CO o PON S S Alo ool Ni 65 h5 C2 O1 A AT N A e A 94 Section 2 Specifications September 2014 lt M SPECIFICATIONS This page intentionally left blank Genie 2 18 GTH 1048 GTH 1056 PartNo 123701 September 2014 Section Scheduled Maintenance Procedures Scheduled Maintenance Procedures Observe and Obey Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine M Scheduled maintenance inspections shall be completed daily quarterly semi annually annually and every 2 years as specified on the Maintenance Inspection Report AWARNING Failure to perform each procedure as presented and scheduled could result in death serious injury or substantial damage Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Use only Genie approved replacement parts Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection Unless otherwise spe
28. 0 1 0 4 L min AL Load sense drain circuit 13 Check valve 5 psi 0 3 bar AM Sway right circuit 14 Priority flow regulator valve 2 gpm 7 6 AN Sway left right circuit 15 Check valve 5 psi 0 3 bar AQ issus Sway left circuit Genie 4 42 GTH 1048 GTH 1056 Part No 123701 March 2015 Section 4 Repair Procedures MANIFOLDS Y82 8 S e 8 26 ovs S AE Q E ws View A AG AH Note alpha callouts refer to corresponding notes on the hydraulic schematic alphanumeric callouts refer to the electrical schematic GO 9 Genie Part No 123701 GTH 1048 GTH 1056 4 43 Section 4 Repair Procedures March 2015 Br MANIFOLDS Primary Function Manifold Components Models with Single Joystick continued 16 Check valve 5 psi 0 3 bar AP sss Boom extend circuit 12 14 ft lbs 16 19 Nm 17 Check valve 5 psi 0 3 bar AQ Boom down circuit
29. 3 14 B 6 Perform Hydraulic Analysis 3 15 B 7 Inspect the Fuel and Hydraulic Tank Cap Venting Systems 3 16 B 8 Check the Boom Wear Pads sss 3 17 B 9 Lubricate the Driveshafts 3 18 B 10 Perform Engine Maintenance John Deere Models 3 18 Genie x 1048 GTH 1056 Part No 123701 May 2015 Section 3 TABLE OF CONTENTS Scheduled Maintenance Procedures continued Checklist C Procedures C 1 Perform Engine Maintenance John Deere Models 3 20 C 2 Perform Axle Maintenance 11 3 20 C 3 Perform Transmission Maintenance Dana Models 3 21 C 4 Perform Engine Maintenance 3 21 C 5 Perform Engine Maintenance Perkins Models 3 22 C 6 Perform Engine Maintenance Perkins Models 3 22 C 7 Inspectand Lubricate the Sequencing 3 23 C 8 Adjustthe Sequencing Chains sese 3 24 C 9 Perform Axle Maintenance 1 00 3 25 C 10 Perform Axle Maintenance 3 26 Checklist D Procedures 0 1 Inspect the
30. Auxiliary function enable 60 in Ibs 6 8 Nm 3 Flow regulator valve EC au Function speed control 25 ft Ibs 34 Nm 4 Check valve 5 psi 0 3 bar ED Auxiliary A2 circuit 12 14 ft Ibs 16 19 Nm Note alpha callouts refer to corresponding notes on the hydraulic schematic alphanumeric callouts refer to the electrical schematic Genie 4 54 GTH 1048 GTH 1056 PartNo 123701 March 2015 Section 4 Repair Procedures er MANIFOLDS 7 6 Brake Manifold Components The brake manifold is located under the manifold inspection cover Index Schematic No Description Item Function Torque 1 Pressure switch 450 psi 31 PS4 Clutch cut off pressure 11 ft Ibs 14 9 Nm 2 Pressure switch 50 psi 3 4 PS5 Brake light pressure option 11 ft lbs 14 9 Nm REAR AXLE Note callouts refer to corresponding notesonth electrical and hydraulic schematics TO FRONT AXLE TO BRAKE PEDAL Genie PartNo 123701 GTH 1048 GTH 1056 4 55 Section 4 Repair Procedures March 2015 MANIFOLDS 7 7 AC Hydraulic Mani
31. BACKUP ur gt d 4 CRI POWER RELAY PCB S e e CR2 OPTIONS POWER RELAY PCB 5 8 AK AN 34 8 lly 302 BR 026 3 sys PARKING BRAKE RELEASE COIL SM o amp z PARKING BRAKE LATCH RELAY PCB z 8 e i q a f og I S o Ei aaa L D E 2 5 15 30 _4 PARKING BRAKE LIGHT 655 9 4 1 e V 5 oa t 8 x 5 107 87 RD C103 1 RO WH 44 6 RD WH C44 8 ne ps VA ade xr a I lt SURT CM 3 B E EPS Ox 38 8 10 1 aprum 044 5 oy 5 yor 5 28 E Son o c 9 a EIS 3 amp 5 7 aaa E L c107 85 2107 86 in E 9 C5 7 RD STARTER SOLENOID amp RELAY STARTER MOTOR oa cz 08 RD 12 VOLT BATTERY 04 12 BKM 11 6 BK 1 Section 6 Schematics Electrical Schematic View 2 from serial number GTH1014 19341 GTH1014E 1001 May 2015 SKYLIGHT WASHER 2 ES 5063 8 NC BR 5063 1 GR WH 659 34 5 BL WH Ys 5058 4 BR 058 24 RD RD 59 1 WINDSHIELD WASHER RD 2 7 WASHER lt 082 8 OR yy BR 8 GR 60 3 RD 92 4 42 55082 2 BL 5080 4 BR RO 60 1 2 WINDSHIELD WIPER 10 AMP
32. F11 DEFROSTER FAN EV 66 5 RD C61 1 HVAC MOTOR T UN TERN i z s e s R E MEE lg r5 l 8 WH THERMOSTAT COLD CUT OUT 3 0 C 1 0 C T 38 A i 598 5 2 gl wf ge 5555 Ek z 76 8 25 E 8 288 55 8 wim a 85 g M TAA 5 F E 9 HEATER MOTOR 4 Bl D 2 5 2 4 E 1l IGHT SW 1 Pers m OR OR CB A i orem RD C80 8 BE E 35 im T gue LS zl e WH gl s BL_ C76 A BL amp l 8 Tp 5 9349 g k o Mi a is Sg E z 198 f Tent pet a 3 SBE St 968 5 3 88 amp g y C Sy 065 2 BK DOME LIGHT i 2 2 E c7 1 c7 1 2 RD om BK C7 apne 8 c J T E oo 7 WH CU5 L WH C47 1 74 2 BK 75 3 12045 7 Z uci c aaa UAT z Spaz 2 6 RD 75 2 80 46 1 46 2 BR 5575 4
33. 630 12 Access error EEPROM memory 639 14 CAN Bus 0 BusOff Status 651 3 General short circuit injector 1 5 Interruption of electric connection injector 1 652 3 General short circuit injector 2 5 Interruption of electric connection injector 2 653 3 General short circuit injector 3 5 Interruption of electric connection injector 3 654 3 General short circuit injector 4 5 Interruption of electric connection injector 4 655 3 General short circuit injector 5 5 Interruption of electric connection injector 5 656 3 General short circuit injector 6 5 Interruption of electric connection injector 6 677 3 Short circuit on high side starter relay 4 Short circuit on low side starter relay 5 No load error starter relay 12 Over load ECU power stage for Starter overtemp 729 5 Air Heater not connected 1079 13 Sensor supply voltage monitor error 1109 2 Engine off request ignored Genie 5 10 GTH 1048 GTH 1056 Part No 123701 September 2014 Section 5 Fault Codes ENGINE FAULT CODES MODELS WITH DEUTZ POWER SPN Suspect Parameter Number ASPN Alternate Suspect Parameter Number FMI Failure Mode Identifier SPN ASPN FMI Description 1180 3 Target range to high for exhaust gas temperature sensor 4 Target range to low for exhaust gas temperature sensor 11 Exhaust gas temperature value before turbine upstream not plausible 1231 14 CAN Bus 1 BusOff Status 1235 14 CAN Bus 2 BusOff Status 1
34. Brookfield Viscosity 4 F 20 C 22 F 30 C 1040 3310 Flash Point 180 F 82 C Pour Point 81 F 63 C Maximum continuous operating 124 F 51 C temperature Note Use of Chevron 5606A hydraulic fluid or equivalent is required when ambient termperatures are consistently below 0 F 18 C unless oil heating system is used Continued use of Chevron 5606A hydraulic fluid or equivalent when ambienttemperatures are consistently above 32 F 0 may result in component damage Part No 123701 September 2014 Section 2 Specifications 1 Petro Canada Environ MV 46 oil fluid properties ISO grade 46 Viscosity index 154 Kinematic Viscosity cSt 200 F 100 C 8 cSt 104 F 40 C 44 4 Flash Point 482 F 250 C Pour Point 49 F 45 C Maximum continuous operating 180 F 82 C temperature UCON Hydrolube HP 5046 hydraulic oil fluid properties ISO grade 46 Viscosity index 192 Kinematic Viscosity cSt 200 F 100 C 22 cSt 104 F 40 C 46 cSt 40 F 40 C 1300 Flash Point None Pour Point 81 F 63 C Maximum continuous operating 189 F 87 C temperature Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie Part No 123701 GTH 1048 GTH 1056 2 5 Section 2 Specifications September 2014 SPECIFICATIONS Hydrau
35. Checklist D YN R D D 1 Forks D 2 Hydraulic return filter D 3 Dana Transmission maintenance D 4 Axle maintenance D 5 Engine maintenance Deutz models D 6 Engine maintenance Perkins models D 7 ZF Transmission maintenance Checklist E YN R E E 1 Hydraulic oil E 2 Engine maintenance John Deere models B 8 Boom wear pads B 9 Lubricate driveshafts B 10 Engine maintenance John Deere models B 11 Engine maintenance Deutz models Checklist C Y NR C 1 Engine maintenance John Deere models C 2 Axle maintenance C 3 Dana Transmission maintenance C 4 Engine maintenance Deutz models C 5 Engine maintenance Perkins models Genie Part No 123701 E 3 Engine maintenance Perkins models Perform every 3000 hours 0 every 3000 hours E 4 Engine maintenance Deutz models E 5 Engine maintenance Perkins models Perform every 4000 hours E 6 Engine maintenance Perkins models Perform every 4500 hours E 7 Engine maintenance John Deere models Perform every 5000 hours E 8 Engine maintenance Deutz models Perform every 12 000 hours E 9 Engine maintenance Perkins models GTH 1048 GTH 1056 Section Scheduled Maintenance Procedures September 2014 Checklist A Procedures A 1 Inspect the Manuals and Decals Genie specifications require that this p
36. Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Part No 123701 September 2014 Section 2 Specifications Deutz TCD3 6 L4 Engine Displacement Number of cylinders Bore amp stroke Horsepower Peak Torque Firing order 221 cu in 3 62 liters 4 3 86 x 4 72 inches 98 x 120 mm 100 2300 rpm 74 6 kw 2300 rpm 302 Ib ft 1600 rpm 409 Nm Q 1600 rpm 1 3 4 2 Compression ratio 17 2 1 Combustion Direct injection Governor Electronic Low idle 1000 rpm Frequency 200 Hz Highidle 2400 rpm Frequency 500 Hz Lubrication system Minimum oil pressure 23 5 psi warm at low idle 1 6 bar Oil capacity 9 5 quarts including filter 9 liters Cil viscosity requirements Units ship with 15W 40 API CJ4 low emission LE oil Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator s Manual on your machine Part No 123701 Genie SPECIFICATIONS Fuel requirement For fuel requirements refer to the engine Operator s Manual on your machine Fuel injection pressure maximum 23200 psi 1600 bar Engine coolant Capacity 4 5 gallons 17 liters Type Extended Life Alternator Output 95 A 12V DC Starter Motor Normal load 300 400 A Relay max 60A Relay continuous 12A Cranking speed 2100
37. Genie A TEREX BRAND GTH 1048 GTH 1056 Serial Number Range from GTH1007A 11697 from GTH1007B 7101 from GTH1010 14001 from GTH1014E 10001 Part No 123701 Rev F2 May 2015 Introduction May 2015 Introduction Important Read understand and obey the safety rules and operating instructions in the Genie GTH 1056 Operator s Manualbefore attempting any maintenance or repair procedure This manual provides detailed scheduled maintenance information for the machine owner and user It also provides troubleshooting fault codes 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 dealer service center Compliance Machine Classification Group B Type 3 as defined by ISO 16368 Machine Design Life Unrestricted with proper operation inspection and scheduled maintenance Technical Publications Genie has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Genie policy Therefore product specifications are subject to change without notice Readers are encouraged to notify Genie of errors and send in suggestions for improvement All com
38. Part No 123701 Genie GTH 1048 GTH 1056 CHECKLIST B PROCEDURES 3 Visually inspect each lower wear pad at the fork end of the boom Result Some of the wear indicator of both wear pads is visible The wear pads are good W Result All of the wear indicator of one or both wear pads is not visible Replace both wear pads Refer to Repair Procedure 1 2 How to Replace the Boom Wear Pads Note Steps 4 through 6 do not apply for the large outside boom tube with external hard lines 4 Visually inspect both upper wear pads at the pivot end of the boom Result Some of the wear indicator of both wear pads is visible The wear pads are good W Result All of the wear indicator of one or both wear pads is not visible Replace both wear pads Refer to Repair Procedure 1 2 How to Replace the Boom Wear Pads 5 Visually inspect both side wear pad at the pivot end of the boom Result Some of the wear indicator of both wear pads is visible The wear pads are good W Result All of the wear indicator of one or both wear pads is not visible Replace both wear pads Refer to Repair Procedure 1 2 How to Replace the Boom Wear Pads 6 Visually inspect both lower wear pads at the pivot end of the boom Result Some of the wear indicator of both wear pads is visible The wear pads are good W Result All of the wear indicator of one or both wear pads is not visible Replace both wear pads Refer to Repair Procedure
39. Perkins 1204 Operation and Maintenance Manual Perkins part number SEBU8605 01 Perkins 1104 Operation and Maintenance Manual Genie part number 117765 Perkins 1204 Operation and Maintenance Manual Genie part number 218726 Genie PartNo 123701 GTH 1048 GTH 1056 3 33 Section Scheduled Maintenance Procedures September 2014 CHECKLIST E PROCEDURES E 6 Perform Engine Maintenance Perkins Models Note Engine specifications require that this procedure be performed every 4000 hours 1204 Engine Aftercooler Core Clean Test Required maintenance procedures and additional engine information is available in the Perkins 1204 Operation and Maintenance Manual Perkins part number SEBU8605 01 Perkins 1204 Operation and Maintenance Manual Genie part number 218726 Genie GTH 1048 GTH 1056 E 7 Perform Engine Maintenance John Deere Models Engine specifications require that this procedure be performed every 4500 hours or 60 months whichever comes first Required maintenance procedures and additional engine information is available in the John Deere 4045HF485 Operator s Manual John Deere part number OMRG36852 John Deere 4045HF485 Operator s Manual Genie part number 123703 Part No 123701 September 2014 Section Scheduled Maintenance Procedures E 8 Perform Engine Maintenance Deutz Models Note Engine specifications require that this procedure be performed every 500
40. Result Air passes through the fuel tank cap Proceed to step 8 W Result If air does not pass through the clean or replace the cap Proceed to step 7 Note When checking for positive tank cap venting air should pass freely through the cap 7 Using a mild solvent carefully wash the cap venting system Dry using low pressure compressed air Repeatthis procedure beginning with step 6 8 Install the breather cap onto the hydraulic tank Part No 123701 September 2014 Section Scheduled Maintenance Procedures B 8 Check the Boom Wear Pads Genie specifications require that this procedure be performed every 250 hours of operation 1 Select a boom tube Visually inspect both upper wear pads at the fork end of the boom Result Some of the wear indicator of both wear pads is visible The wear pads are good Result All of the wear indicator of one or both wear pads is not visible Replace both wear pads Refer to Repair Procedure 1 2 How to Replace the Boom Wear Pads Wear Pad with wear indicator visible Wear Pad with wear indicator not visible 2 Visually inspect both side wear pads at the fork end of the boom Result Some of the wear indicator of both wear pads is visible The wear pads are good Result All of the wear indicator of one or both wear pads is not visible Replace both wear pads Refer to Repair Procedure 1 2 How to Replace the Boom Wear Pads
41. Schematic standard wiring optional wiring 1 1 1 30 87 30 87A 12V 3 86 85 g 86 85 1 SPST SPST Ignition Start Input Relay Telematics with Active High input Telematics with Active Low input A Deutsch plug p n DTO6 08SA mates with the Genie Telematics connector Wireless Certifications Telematic device s should comply with specific wireless carrier certifications where applicable and comply with the following N America PTCRB FCC IC Europe CE R amp TTE Genie Part No 123701 GTH 1048 GTH 1056 6 9 Section 6 Schematics May 2015 Electrical Schematic Symbols Electrical and Hydraulic Symbols Legend Hydraulic Schematic Symbols iKS1 E Um uno IT Key switch Engine start 86 30 B Control relay Alternator 5 1 S Fuse Circuit breaker YN Horn or Alarm Light iE ER Valve coil with diode Valve coil Deo i 7 Diode Switch d Proximity switch Limit switch f 0 7 Temperature switch Fuel level sender vs D7 Pressure switch RE cedE Hydraulic cylinder Pressure switch X c Orifice Adjustable orifice 9 X Check valve Flow regulator 1121 3 position 4 way solenoid valve
42. machine Part No 123701 Genie Fuel requirement SPECIFICATIONS For fuel requirements refer to the engine Operation Manual on your machine Fuel Injection Pressure 23000 psi 1585 bar Engine coolant Capacity 4 9 gallons 18 5 liters Type Extended Life Alternator Output 120 A 12V DC Starter Motor Normal load 155A Relay max 50A Relay continuous 15A Cranking speed 200 300 rpm Glow Plugs Initial load 0 6 sec 12 amps ea Continuous load gt 6 sec 16 amps ea Battery Type 12V DC Group C31 Quantity 1 Cold cranking ampere 0 F 1000A Reserve capacity 25A rate 200 minutes Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice GTH 1048 GTH 1056 Section 2 Specifications September 2014 SPECIFICATIONS Dana T20000 Transmission Transmission Type 3 speed powershift converter ZF 4 WG 98 TC Transmission Transmission Type 4 speed powershift converter Speeds Forward 3 Speeds Forward 4 Speeds Reverse 3 Torque Converter Speeds Reverse 3 Torque Converter Maximum input 3100 rpm Maximum input 2600 rpm Size 12 inches Maximum torque 480 Nm Lubrication Lubrication Oil capacity 20 quarts Oil capacity 16 9 quarts 18 9 liters 16 liters Cil viscosity requirements Cil viscosity requirements Units ship with
43. 11 4 2 S4 RET S4 CC44 11 4 C S4RET 6 3 9 32 1 4 2 513 513 B S10 PWR C14 2 x4 C5 1 SWAY RET C9 3 58 12 j SVDTB PWR C14 4 X C11 3 35 1 5 4 3 SVB PWR mir RET 69 4 x S9 2 08 C11 C38 oN C13 13 C31 1 1C4 4 SV7 PWR 4 1 B ALRM PWR ALRM 23 IRAE amp C30 1 5 04 5 SV5 PWR C44 10 3 c13 8 lt H1 S23 RET K c36 2 C84 A d 1 TR APS e C44 1 7 5 15 89 11 10 8 ENG HARN q 2 B ALRM GND ALRM C14 1 4 2 SVD1A PWR C33 1 C84 B 4 2 TR GND amp C44 2 TE xm m Ug Eos oie 2 614 4 4 3 5 01 lt 34 1 C84 C 3 TR VCC C44 3 CPU PWR 1 5 6 00 m a C91 1 q 4 PWR PORT K C4 10 84 0 4 5 51 44 4 CAN C13 2 X C10 10 4444446 225 HARNESS LEGEND SJ CAN L Ci3 3 X C1O 1T 255595955 E NUM PART DESCRIPTION a 5 C11 4 2 04 10 PWR PORT C10 C44 2 014 1 SAN NAR 1 823054 HARNESS DASHBOARD C12 5 2 B1 PWR C42 7 C38 2 4 2 TR GND ENGINE 2 E LT LT TIT C12 7 5 C5 3 REV PWR 3 219457 HARNESS BACKUP ALARM 23 13 8 1 gt 12 5 lt 5 2 6 42 8 358 5 lt 4 3 6 d S SINAN C13 2122 C5 4 GC BK LT 4 162065 HARNESS TRANSMISSION 13 24 4 4 524 42 6 C38 5 4 4 TR IVST ENGINE SVD1B PWR C
44. 16 19 Nm 15 Priority flow regulator valve 2 7 6 BO Sway left right circuit 20 ft lbs 27 Nm Genie 4 46 GTH 1048 GTH 1056 PartNo 123701 March 2015 Section 4 Repair Procedures MANIFOLDS Note alpha callouts refer to corresponding notes on the hydraulic schematic alphanumeric callouts refer to the electrical schematic OTIO fom BW U 1 o 3 84 E Genie Part No 123701 GTH 1048 GTH 1056 4 47 Section 4 Repair Procedures March 2015 MANIFOLDS Primary Function Manifold Components Models with Dual Joysticks continued 16 Check valve 5 psi 0 3 bar Sway right circuit 12 14 ft Ibs 16 19 Nm 17 Check valve 5 psi 0 3 bar Boom extend circuit 12 14 ft lbs 16 19 Nm 18 Check valve 5 psi 0 3 bar Boom down circuit 12 14 ft Ibs 16 19 Nm 19 Check valve 5 psi 0 3 bar Fork tilt down circuit 12 14 ft Ibs 16 19 Nm 20 Check valve 5 psi 0 3 bar BT Steer le
45. 2 LOAD SENSE PISTON PUMP Y 3200 450 PSI PC LS SETTING A A 58 A 3 66 C 2400 RPM NAX Oo RESERVOIR Expansion Valve Compressor Condenser Receiver Drier HS0201E Genie 6 48 GTH 1056 Part No 123701 pressure PESSE SH 56 S16 FRONT STEER 6 GPM REAR STEER 6 FT DIFF LOCK 30 7 La PARKING REAR LOCK UP 5 GP I je BRAKE EJ 1 REAR AXLE MANIFOLD FRONT AXLE E RAKE BRAKE PEDAL PRR PARKING BRAKE T lt i H RESSURE SWITCH 5 xm 0152 SR 98 sm jp 87 18 PB Yn M ECT CT yer Y68 T gt 9 May 2015 Section 6 Schematics TLT 14 10 GPM p T 4 WAY CONTROL Hydraulic Schematic Models with Dual Joystick AUX HYD 15 GPN
46. GTH 1048 GTH 1056 4 Remove the drain plug from the hydraulic tank and completely drain the tank Bodily injury hazard Beware of ACAUTION hot oil Contact with hot oil may cause severe burns 5 Rinse out the inside of the tank using a mild solvent 6 Install the drain plug and securely tighten Do not over tighten 7 Fillthe tank with hydraulic oil until the fluid level is in the center of the sight glass at the rear of the tank 8 Clean up any oil that may have spilled Section Scheduled Maintenance Procedures September 2014 CHECKLIST E PROCEDURES E 2 Perform Engine Maintenance John Deere Models Engine specifications require that this procedure be performed every 2000 hours or two years whichever comes first Required maintenance procedures and additional engine information is available in the John Deere 4045HF485 Operator s Manual John Deere part number OMRG36852 John Deere 4045HF485 Operator s Manual Genie part number 123703 Genie GTH 1048 GTH 1056 E 3 Perform Engine Maintenance Perkins Models Note Engine specifications require that this procedure be performed every 2000 hours 1104 Engine Aftercooler core inspect Alternator inspect Engine mounts inspect Starting Motor inspect Turbocharger inspect Water pump inspect 1204 Engine Aftercooler core inspect Engine mounts inspect Starting motor inspect Turbocharger inspect Required mainten
47. Inside of the chassis 2 Inspectfor a liberal coating of dielectric grease in the following locations All harness connectors 3 Start the engine and raise the boom so there is enough room to access and remove all the covers attached to the chassis 4 Attach a lifting strap from an overhead crane to the boom Support the boom Do not apply any lifting pressure Part No 123701 September 2014 Section Scheduled Maintenance Procedures 5 Remove all engine covers tank covers and chassis covers ADANGER 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 that is not properly supported 6 Inspect the following areas for burnt chafed corroded pinched and loose wires Engine Transmission Manifolds Chassis 7 Inspect for a liberal coating of dielectric grease in all connections between the engine transmission and the operator s compartment 8 Install all covers removed in step 5 Remove the lifting strap from the overhead crane 10 Start the engine and lower the boom to the stowed position Turn the machine off Part No 123701 Genie GTH 1048 GTH 1056 CHECKLIST B PROCEDURES B 3 Check the Exhaust System Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the exhaust system is essential to good engin
48. fitting Non adj SAE O ring Boss Port tube fitting installed into Steel SAE Dash size Thread Size Flats SAE Dash size Torque 4 7 16 20 2 4 ORFS 37 Adj 15 ft Ibs 20 3 Nm 6 9 16 18 11 4 ORFS Non adj 26 ft lbs 35 3 Nm 37 Non adj 22 ft lbs 30 Nm 8 3 4 16 1 6 ORFS Adj Non adj 35 ft lbs 47 5 N 10 7 8 14 1 m 37 Adj Non adj 29 ft lbs 39 3 Nm E 1 16 12 1 171 12 1 8 ORFS Adj Non adj 60 ft lbs 81 3 Nm 16 1 5 16 12 1 37 Adj Non adj 52 ft lbs 70 5 Nm 20 15 12 1 10 ORFS Adj Non adj 100 ft lbs 135 6 Nm 37 Adj Non adj 85 ft lbs 115 3 Nm 24 1 7 e 12 1 12 All types 135 ft lbs 183 Nm 16 All types 200 ft Ibs 271 2 Nm 20 All types 250 ft Ibs 339 Nm 24 All types 305 ft lbs 413 5 Nm Genie 2 14 GTH 1048 GTH 1056 Part No 123701 September 2014 Section 2 Specifications Torque Procedure Seal Lok fittings 1 Replace the O ring The O ring must be replaced anytime the seal has been broken The O ring cannot be re used if the fitting or hose end has been tightened beyond finger tight 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 available in the O ring field service kit Genie part number 49612 2 Lubricate the O ring before installation 3 Be sure that the fa
49. ixl GRN BLK e 4WS LIGHT g 85 i m 5 sige cantar 9N gt CRAB STEER COIL b p GAN a 9 GRN BIK kd VU NTES BLK 4WS COIL a Dal JE war RIGHT STABILIZER DOWN COIL N Dj WHT RED gt gi RIGHT STABILIZER UP COIL w 6 gt K IS No 5 BLU LEFT STABILIZER DOWN COIL Us Bale E BLU RED nim LEFT STABILIZER UP COIL L MEME DAE wx e Le AUX COILB zel 5388 lt REDIBIK Bk 561 E Ue E YEL A RED WHT S AUX COIL A BSc eu 5 4 F Bale 2 a 5 t iras ORGIRED ORG BLK ES M pK DIFFERENTIAL LOCK COIL x n EE 8 fo gc 9 BLUWHT N BLU e gi HORN RELAY PE HORN 3e BLU BLK Bus S izi Z g m E gt 5 uj vED TILT DOWN ENABLE COIL 5 len 5 Beas M e 5 REDWHT gt amp ORG BLK 19 ORG RED Ra pud COIL uj E E e S 8 5 tu lU BLKIWHT T BLK SWAY RIGHT ENABLE COIL 5 O Mer eg e i Pep 8 E TPT BLUBLK wur gt 5 GRNBIK L mm al sume SWAY LEFT ENABLE COIL e a vu Y K6 SWAY ENABLE RELAY gt B t Ba 2 5 3 58 ees s 1 a
50. 0 Place boom tube number 1 on a structure capable of supporting it AWARNING C shing hazard Boom tube number 1 could become unbalanced and fall when removed from the boom tube number 0 if not properly supported and attached to the overhead crane Note During removal the overhead crane strap will need to be adjusted for proper balancing Part No 123701 March 2015 Section 4 Repair Procedures ee BOOM COMPONENTS 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 RING 8 Using the overhead crane raise the boom to 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 uu 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 cylinde
51. 045 2 Cp gt Pct BR Ur cB Ue dpe R RIGHT FRONT BLINKER s sl RD yp 052 2 BR PONE LURES N aes GR BK 26 70 RD WH C51 C BR t 4 RIGHT TALIGHT 2 9 OR 51 BK OR EK C52 B Rp 52 6045 3 el 5 OR CS2 A c BK Pp al Ro cane LE ACC MEUM CH E _C49 A p C49 B RD 55 BK C51 B Wily CSI C BR 8 3 ge 2 9 OR CS1 A BK pN E 2 xl 28 a yh CH QM 047 10 X 5074 2 BK 05 388 06 7 Richt 3l 32 6 RD 079 2 RD_CAB 1 53046 2 BR 05 4 SR 05 2 Lert cas ur 1 ani Fs oF C2 4 OR BK C48 2 pe CR5 LIGHTS 6 45 Genie GTH 1056 Part No 123701 ES0462G May 2015 Section 6 Schematics me Electrical Schematic View 2 from serial number GTH1014 19341 GTH1014E 1001 46 47 Section 6 Schematics May 2015 Hydraulic Schematic Models with Single Joystick 6 48 Section 6 Schematics May 2015 Hydraulic Schematic Models with Single Joystick AUX HYD 15 CPN p 4 WAY CONTROL 14 10 CPM
52. 1 7 bar Drive brake circuit 20 ft Ibs 27 Nm 10 Pressure switch 350 psi 24 PS7 Low brake pressure 11 ft lbs 14 9 Nm 11 Pressure switch 250 psi 17 2 56 Parking brake pressure 11 ft lbs 14 9 Nm 12 Orifice 0 059 in 1 5 mm 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 iius Rear lock up retract 20 ft Ibs 27 Nm 15 Diagnostic nipple CM Test port TB 16 Diagnostic nipple ON 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 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 uet Test port Genie 4 50 GTH 1048 GTH 1056 PartNo 123701 March 2015 Section 4 Repair Proce
53. 11 6 27 SERVICE BRAKE S6 RET 29 2 4 7 ENGINE HARNESS 2 16 c69 1 22 c67 1 LT STB UP 511 C70 1 2 C67 4 LT STB DWN LEFT H TRAPS caa A 38 1 S 7 2 ris 1272 1878 C38 2 C10 4 Uo C71 1 x1c68 1 RT STB UP 1512 84 0 38 5 ci 2 se C72 1 2 c68 4 RT STB DWN RIGHT oS a 1 gon 67 2 9268 2 SW PWR STB lt lt 055 21 C28 16 a BAT 90 1 amp 5 7 6 NOTE HARNESS ACC C90 2 X C5 8 C42 3 C1 1 FWR PWR E START C90 4 C15 6 42 4 1 2 REV PWR BASE UNIT LEFT SYL_ IGN c90 3 Re C5 9 10 8 1 1 3 SIS RET SINGLE JOYSTICK OPTION os C10 6 2 BARM CONTROL SYSTEM POWER PWR PORT C91 1 x C11 4 C44 1022 C1 6 B ALRM 3 GEI NE En C12 8 C21 1 2 C3 3 SV1 PWR PCB sw ewr Ci5 2 x cs 11 a ya CONNECTORS DETAILS C22 1 2 C3 6 SV4 PWR CONNECTORS DETAILS lt lt m B C73 agel START 15 61 90 4 C19 1 221C5 7 SV9 PWR C24 C25 4 5 START 15 8 12 6 C73 A2 C3 8 SW PWR MEN T E Em sri E RT C28 oe 6134 73 9 3 9 owe C44 12 1 SW PW rA ues 53 cep ih S13 PWR k 524 SVDIA PWR C14 1 x C11 2 D S 1 TILTPWR C9 2 ENS C44 9 4 2 S3 RET S3 C44
54. 2 C10 7 4 9 B3 PWR k C41 5 42 C25 BRAKE MANIFOLD 10 12 10 B4 PWR K C41 6 22 05 SERVICE BRAKE S5 RET 29 11 27 C44 8 SERVICE BRAKE S6 RET C29 2 4 7 o 4 gt ENGINE HARNESS 3 D 69 1 gt 1 67 1 11 5 511 _ CR 9 C70 1 21067 4 LT STB DWN LEFT tj RAPS 038 19 2 5 C3 123 c67 2 SwPwR _ STB E _TR GND C84 B X C38 2 gt 68 2 SltRvcc 6 38 35 Cio o C71 1 2 068 1 RT STB UP S12 T CB4 D amp C38 5 en C72 1 268 4 RT STB DWN RIGHT 67 2 68 2 SW PWR STB Yong 2 d BAT 2 mp cg NOTE HARNESS MAP t ed m zn START C90 4 X C15 6 42 5 5 1 uS ME BASE UNIT 5 IGN C90 3 R amp c5 9 ae NR PORT 691 C10 7 2 1C1 5 INDIC PWR PwR PORT ceris L 644 1032 01 6 B ALRM PCB on z SDI SW PWR c15 2 xe c5 11 2 C19 1 Cc3 7 SV9 PWR CONNECTORS DETAILS amp w BRAKE SV C15 1 7 05 10 C73 A 2 C3 8 SW PWR CONNECTORS DETAILS lt lt BRAKE CR C15 4 5 12 CI3 C SYlC3 9 S4 RET C73 C28 Bo MEE C73 B2 C3 10 S3 RET C24 C25 poh C4 9 4 1 813 PWR k S13 Eu C13 4 NEP COE founi WR ey 124 1 5 5 EIES 32 1 4 2 513 513 SVDIA PWR 14 1 lt 11 2 95102 3 SVB PWR C44 9 4 2 S3 RET 6 53 44 11 4 2 54 6 54 is STORES Siem pereue cis C11 C38 iu D C30
55. 2 Startthe engine Allow the engine to idle after warming the engine to operating temperature 3 Without operating any machine controls observe the reading on the pressure gauge Result The pressure gauge reads 450 25 psi 31 1 7 bar The pump is functioning correctly W Result The pressure gauge fails to read 450 25 psi 31 1 7 bar The pressure setting needs to be adjusted See Repair Procedure 6 1 How to Adjust the Function Pump Pressure 4 Turn the machine off Remove the pressure gauge from the test port AWARNING 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 Part No 123701 Genie GTH 1048 GTH 1056 MANIFOLDS 5 Install a O to 500 psi O to 50 bar pressure gauge into test port TR at the top of the secondary function manifold schematic item CS See 7 8 Secondary Function Manifold Components 6 Startthe engine Allow the engine to idle O Result The pressure gauge reads 50 psi 3 4 bar The pressure setting is correct Proceed to step 11 W Result The pressure gauge fails to read 50 psi 3 4 bar The pressure setting needs to be adjusted Proceed to step 7 7 Turn the machine off Hold the steer pressure reducing relief valve with a wrench and remove the cap schematic item CB 8 Adjust the internal hex socket Turn it clock
56. 2014 p s ENGINE FAULT CODES MODELS WITH DEUTZ POWER SPN Suspect Parameter Number ASPN Alternate Suspect Parameter Number FMI Failure Mode Identifier SPN ASPN FMI Description 23550 64798 12 T50 start switch active for too long 23601 64849 13 Sensor supply voltage monitor 3 error ECU 23602 64850 0 Fan control out of range system reaction initiated 23603 64851 9 Timeout Error of CAN Receive Frame AMB Ambient Temperature Sensor 23605 64853 9 Timeout Error of CAN Receive Frame TSC1 AE Traction Control 23606 64854 9 Timeout Error of CAN Receive Frame TSC1 AR Retarder 23612 64860 12 ECU reported internal software error Internal software error ECU Softwarereset CPU Rail pressure disrupted Minimum rail pressure exceeded RailMeUn3 Setpoint of metering unit in overrun mode not plausible Metering unit Fuel System short circuit to battery Metering unit Fuel System short circuit to ground Metering unit Fuel System open load Metering unit Fuel System powerstage over temperature Physical range check high for exhaust gas temperature upstrem SCR CAT A 23613 64861 23615 64863 NIN oF OJIN 23619 64867 23632 64880 0 Pressure overload of SCR System 1 Pressure build up error SCR System 2 Metering control is not performed in time error 16 Pump pressure SCR metering unit too high 18 Pump pressure SCR metering unit too low 2363
57. 213 Axle Maintenance and Repair Manual Dana part number 0243 Dana 213 Axle Maintenance and Repair Manual Genie part number 115026 Part No 123701 September 2014 Section Scheduled Maintenance Procedures C 3 Perform Transmission Maintenance Dana Models Transmission specifications require that this procedure be performed every 500 hours or semi annually whichever comes first Required maintenance procedures and additional transmission information is available in the Dana T20000 Maintenance Manual Dana part number 0202 Dana T20000 Maintenance Manual Genie part number 115025 Part No 123701 Genio GTH 1048 GTH 1056 CHECKLIST C PROCEDURES C 4 Perform Engine Maintenance Deutz Models Note Engine specifications require that this procedure be performed every 500 hours Coolant additive concentration check Intake pipes check for damage V belts check Fuel pre filter clean change insert if necessary Required maintenance procedures and additional engine information is available in the Deutz TCD3 6 Operation Manual Deutz part number 0312 3907 Deutz TCD3 6 Operation Manual Genie part number 218707 Section Scheduled Maintenance Procedures September 2014 CHECKLIST C PROCEDURES C 5 Perform Engine Maintenance Perkins Models Note Engine specifications require that this procedure be performed every 500 hours 1104 Engine V belts in
58. 6 7 Telematics Connector Legend 6 9 Electrical and Hydraulic Symbols 5 6 10 xiv GTH 1048 GTH 1056 Part No 123701 May 2015 Section6 TABLE OF CONTENTS Schematics continued Harness Map Control System Power Single JOYStiCK 22 5 eA AA 6 12 Harness Map Control System Ground Single Joystick deett cd 6 13 Harness Map Control System Power Dual Joysticks nnne nennen 6 16 Harness Map Control System Ground Dual Joysticks e Hi n ctn ieee eee teen 6 17 Harness Map Deutz 3 6TCD Engine Battery Power and Ground sssssssssseseeeeeeeeeeneennee nnne 6 20 Harness Perkins 11040 Engine Battery Power and Ground 6 21 Harness Map Perkins 854E Engine Battery Power and Ground 6 24 Harness Map Options Auxiliary Hydraulics Beacon and 3rd Gear Lockout 6 25 Harness Map Options Work Lights ia einai N a 6 28 Harness Options RFoadLights iine te ied eiie ns 6 29 Harness Map Options Enclosed Cab with Heater ccccsccccecssseseeeeeeeseeeseeeeesesesneeeeeeeseseneeeenss 6 31 Harness Map Options Enclosed Cab with HVAC
59. 7 Inspect the Fuel and Hydraulic Tank Cap Venting Systems Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Perform this procedure more often if dusty conditions exist Free breathing fuel and hydraulic tank caps are essential for good machine performance and service life A dirty or clogged tank cap may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the caps be inspected more often 77777117 Explosion and fire hazard Engine fuels are combustible Perform this procedure in an open well 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 clean or replace the cap Proceed to step 3 Note When checking for positive tank cap venting air should pass freely through the cap Genie GTH 1048 GTH 1056 3 Using a mild solvent carefully wash the cap venting system Dry using low pressure compressed air Repeat this procedure beginning with step 2 4 Install the fuel tank cap onto the fuel tank 5 Remove the breather cap from the hydraulic tank 6 Check for proper venting
60. A 3 Perform Function Tests Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Completing the function tests is essential to safe machine operation Function tests are designed to discover any malfunctions before the machine is put into service A malfunctioning machine must never be used If malfunctions are discovered the machine must be tagged and removed from service Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine Section Scheduled Maintenance Procedures September 2014 CHECKLIST A PROCEDURES A 4 Lubricate the Boom Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Greasing the specified locations is essential for good machine performance and service life Operating the machine with little or no grease may cause the machine to perform poorly and continued use could cause component damage 1 Fully extend the boom Raise the boom as needed 2 Lubricate the top and bottom boom tube wear pads Note Do not lubricate the side wear pads 3 Return the boom to the stowed position Grease Specification Chevron Ultra duty grease EP NLGI 2 lithium based or equivalent Genie 3 8 1048 1056 5 Perform Engine Maintenance All Models Note Engine specificati
61. COL PW as 88568 553 20 1 5020 2 BR 17 4 c sys SWAY RIGHT ENABLE yii 17 3 SWAY LEFT ENABLE COL PU 3 4 CR12 SWAY FUNCTION RELAY PCB ie CRE SWAY ENABLE RELAY PCB 03 7 RAM 15 19 2 _BR_C17 1K SWAY ENABLE a 4 BL BK C3i 626 44 REAR AXLE FLOAT COL SM e ym se 3 OR C35 5 yf35 2 BR 026 100 ss REAR AXLE FAST COL SM BOOM EXTEND RELAY PCB CR7 BOOM ANGLE RELAY PCB at ifs R14 BOOM ANGLE MONITOR PCB EE s m oder e RA 5 5 Y s 12 C10 3 YL C42 8 ort AL PEINT B2 TRANSMISSION COIL pa E 1 as 1 52 2 0 0 5 OR 42 00 OR 6 B4 TRANSMISSION COIL N n 1 04 9 lt 105 1 5 E d i 92 SKA ons B3 TRANSMISSION COIL 5 sys 30 3 14 25 i A E E C 7 BR P TRANSMISSION coL J BB BE p i 1 ae 4 CR9 FORWARD ENABLE RELAY QA E FORWARD COL a s m 5 i 4 T 3 CR10 REVERSE ENABLE RELAY 50 He 1 5 2 2 42 4 R S ett 5 602 4 BUB 00 2 REVERSE cok of 58 E C12 12 12 11 an 5 WH 644 10 WH BK C18 2 BACKUP ALARM ES gt 8 ere domm 22 2 RO WH C50 1 WH lt BR
62. Chevron RPM SAE 10W Extreme operating temperatures may require the use of alternative transmission oils For oil requirements refer to the Dana T20000 Maintenance Manual Dana part number 0202 Dana 0202 Maintenance Manual Genie part number 115025 Units ship with Chevron Delo 400 LE SAE 15W40 Extreme operating temperatures may require the use of alternative transmission oils For oil requirements refer to the ZF 4 WG 98 TC Maintenance Manual ZF part number 5872 134 002 ZF 4WG 98 TC Operating Manual Genie part number 1258405 Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie GTH 1048 GTH 1056 Part No 123701 September 2014 Section 2 Specifications Dana Planetary 213 Drive Axle Steering Intergrated steer cylinder Joints Heavy duty double U joints Steering angle maximum 45 Front Axle Lubrication Front differential 15 quarts 14 2 liters Axle planetary end each 2 quarts 1 9 liters Rear Axle Lubrication Rear differential 15 quarts 14 2 liters Axle planetary end each 2 quarts 1 9 liters Cil viscosity requirements Differential Chervron Supreme 80W90 LS Planetary ends Chervron Supreme 80W90 LS For additional axle information refer to the Dana 213 Axle Maintenance and Repair Manual Dana part number 0243 Dana 213 Axle Maintenance and Repair Manual Genie part number 11502
63. 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 Grounded Circuit Contact Servicing Dealer 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 Genie Part No 123701 GTH 1048 GTH 1056 Section 5 Fault Codes September 2014 ENGINE FAU
64. During removal the overhead crane strap will need to be adjusted for proper balancing 25 Working at the fork end of the boom remove the wear pads from boom tube number 1 26 Support and slide boom tube number 2 out of boom tube number 1 Place boom tube number 2 on a structure capable of supporting it AWARNING C Shing hazard Boom tube number 2 could become unbalanced and fall when removed from the boom tube number 1 if not properly supported and attached to the overhead crane Note During removal the overhead crane strap will need to be adjusted for proper balancing Section 4 Repair Procedures March 2015 BOOM COMPONENTS How to Disassemble the Boom GTH 1056 AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the extension cylinder See 1 4 How to Remove the Extension Cylinder 2 Remove the boom See 1 2 How to Remove the Boom 3 Selecta lift cylinder Remove the fasteners securing the lift cylinder rod end pivot pin t
65. Electronic Injector Circuit Shorted 07 Cylinder 6 Electronic Injector Fuel Flow Low 13 Cylinder 6 Injector QR Code String Error 000676 03 Glow Plug Relay Voltage High 04 Glow Plug Relay Voltage Low 000898 09 Vehicle Speed or Torque Message Invalid 000970 31 Auxiliary Engine Shutdown Signal 000971 31 Auxiliary Engine Derate Signal 001079 03 Sensor Supply Voltage 3 Out of Range High 04 Sensor Supply Voltage 3 Out of Range Low 001080 03 Fuel Rail Pressure Sensor Supply Voltage 2 Out of Range High 04 Fuel Rail Pressure Sensor Supply Voltage 2 Out of Range Low 001109 31 Engine Protection System Approaching Shutdown 001110 31 Engine Protection System Shutdown Engine 001136 00 ECU Temperature High Most Severe 16 ECU Temperature High Moderately Severe 001172 03 Turbo Compressor Inlet Temperature Input Voltage Out of Range High 04 Turbo Compressor Inlet Temperature Input Voltage Out of Range Low 16 Turbo Compressor Inlet Temperature High Moderately Severe Genie Corrective Action Contact Servicing Dealer Check Injector Wiring or Injector Solenoid Check Injector Wiring or Injector Solenoid Injector Failed or Flow Limiter Closed Contact Servicing Dealer Contact Servicing Dealer Check Injector Wiring or Injector Solenoid Check Injector Wiring or Injector Solenoid Injector Failed or Flow Limiter Closed Contact Servicing Dealer Contact Servicing Dealer Check Injector Wiring or Injector Solenoid Check Injector Wiring or Inj
66. March 2015 Section 4 Repair Procedures How to Remove the Boom AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer Service is strongly recommended Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the lifting fork and frame See 1 2 How to Remove the Lifting Fork Frame 2 Attach a lifting strap from an overhead 10 ton 10 000 kg crane to the fork end of the boom Support the boom Do not apply any lifting pressure 3 Selecta fork level cylinder Remove the fasteners securing the fork level cylinder rod end pivot pin to the boom 4 Usinga lifting strap from another overhead crane support the rod end of the fork level cylinder Do not apply any lifting pressure 5 Use a soft metal drift to remove the fork level cylinder pivot pin 6 Lower the fork level cylinder onto the chassis Crushing hazard Keep hands AWARNING clear of the cylinder manifold when lowering the cylinder 7 Repeatthis procedure beginning with step 3 for the other fork level cylinder 8 Selecta lift cylinder Tag disconnect and plug the hydraulic hos
67. No 4 13 ft lbs 18 Nm SAE No 6 18 ft lbs 24 Nm SAE No 8 50 ft lbs 68 Nm SAE No 10 55 ft lbs 75 Nm SAE No 12 75 ft lbs 102 Nm AC Refrigerant Specifications System Full Charge R134a 1 Ib 14 oz Part No 123701 Genio GTH 1048 GTH 1056 SPECIFICATIONS Valve Coil Resistance Specifications Note The following coil resistance specifications are at an ambient temperature of 68 F 20 C As valve coil resistance is sensitive to changes in air temperature the coil resistance will typically increase or decrease by 4 for each 18 F 20 C that your air temperature increases or decreases from 68 F 20 C Description Specification Solenoid valve 2 position 4 way 8 90 12V DC with diode schematic items AA AD AY AAB and BAA Solenoid valve 2 position 2 way 12V DC with diode schematic items AAC DOS valve 3 position 4 way 12V DC with diode schematic items CA and EB Solenoid valve 2 position 2 way 12V DC with diode schematic items FA Solenoid valve 2 position 3 way 12V DC with diode schematic items CF CO and CP Solenoid valve 2 position 4 way 7 3Q 12V DC with diode schematic items CG Solenoid valve 3 position 4 way 7 30 12V DC with diode schematic items DA and DB Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Section 2 Specificat
68. POWER A GROUND DISTRIBUTION PCB gt PCB PCB GND E HARNESS LEGEND PERKINS 1204E NUM PART DESCRIPTION 4 227493 HARNESS TRANSMISSION 9 229033 CABLE BATTERY RED 3 0 10 130719 CABLE BATTERY BLACK 000 11 237933 HARNESS POWER LEAD 13 237933 HARNESS PCB GROUND 14 161444 ASSEMBLY GROUND BUSS 20 220016 ENGINE HARNESS 1204E E44TA 21 220015 WIRING HARNESS 1204E E44TA 41 236979 FORMING BUSS BAR 44 229819 PCBA POWER DISTRIBUTION ASSY 45 161524 ASSEMBLY POWER BUSS ES0462F Genie 6 24 GTH 1056 Part No 123701 May 2015 Section 6 Schematics Harness Options Auxiliary Hydraulics Beacon and 3rd Gear Lockout RIGHT Z Le AUX HYD MANIFOLD 55 1 gt 56 1 AUX A PWR LUG GNDSS 56 2 AUX A GND ios 57 1 AUX B PWR 9 LUG GND22 57 2 AUX B GND V g 90 11 098 1 AUX HYD S14 HERTZ TLEMATICS FLASHING L SET K p 85 5571 A PWR BAT C98 1 lt lt 90 1 pe 2 Gl ICN C9023 re c9a_9 C57 122 C55 4 B PWR IGN 98 9 209036 22 2 lt 24 lt 68 2 51 55 2 SW PWR GND 98 15 100 630 lt B GROUND_STUDS E g HARNESS _ _ 098 15 3 amp 6 OTE HARNESS MAP o foot H C56 2 95
69. RIGHT LEFT UGHT WINDSHIELD WINDSHIELD WIPER WASHER WINDSHIELD WIPER STROBE UGHT Genie Part No 123701 GTH 1056 6 40 Section 6 Schematics May 2015 Electrical Schematic View 2 from serial number GTH1012 16292 to 19340 BL BER sab Eg 5 d PETI E ES0462D Genie 6 41 GTH 1056 Part No 123701 May 2015 Section 6 Schematics Electrical Schematic View 2 from serial number GTH1012 16292 to 19340 42 43 Section 6 Schematics May 2015 Electrical Schematic View 1 from serial number GTH1014 19341 GTH1014E 1001 6 44 May 2015 from serial number GTH1014 19341 GTH1014E 1001 Electrical Schematic View 1 Section 6 Schematics 8 a ps ow cm S24 TRANS OIL PRESS SW N C TR N s25 8 Ej Sp 425 RDAM c87 B 525 TRANS OIL TEMP SW N O TR 1 2 suot 9 i al 23 1 BLAM C36 1 X Sp 036 2 26 11 BR 4 S23 BRAKE PRESS SW N C SM g S 2 3 2 n
70. S22 RET 48 4 lt lt 2 4 X amp C13 17 2 5 GTH 1056 Part No 123701 ES0462F May 2015 Section 6 Schematics 2 Harness Options Road Lights RIGHT FRONT a x C2 95 A TAIL LT R BLINKER G gt BLR CND LUG GNO RIGHT C54 C51 g 62 32 z 53 52 C53 C52 FRONT J BULPWRL BRAKE_MANIFOLD a BLINKER 4 31 5 END STOP LIGHT S16 PWR 049 1 2 3 B HB TAL BLL LEFT 2 BL L GND x 1 UG GND C66 5X LEFT STOP LIGHT S16 RET C49 B X C2 11 645 3 9 C TAILL GND TAILLIGHT C75 c2 2 51 1 BACK PWR BACKUP E LT C47 1 44 CAB LTR j C2 7 C45 6 gt 2 BACK GND 3 LIGHT 1 C46 1 4 2 CAB LT L amp C2 6 C50 1 C47 1 4 3 LT R GND amp C45 7 8 C46 1 4 L L GND K C45 2 e GROUND STUDS 223 NOTE HARNESS H TURN_SGNL SHIFTER LEFT dely 63 299 9021 C45 8 ROAD LIGHTS OPTION 516 2 muxo 22 32 ins 55 5 BUSS
71. WINDSHIELD W W WIPE ON C62 1 C60 3 WIPE RET C62 2 X C60 2 62 7 6 3 W W PWR NUM PART DESCRIPTION C63 7 32 106 4 W W PWR 14 161444 ASSEMBLY GROUND BUSS gt NOV WIPE PWR C62 4 FX amp C601 PANE 34 233812 HARNESS ENCLOSED CAB W W PWR C62 7 6 6 3 35 234859 HARNESS FAN LWASH PWR 62 8 4 WIN WP 36 233940 HARNESS POWER DOME LIGHT 21 WAN 37 123817 DOME LIGHT WITH CONNECTORS Le non cas 39 238126 HARNESS A C WIPE RET C63 2 KE C59 2 40 217874 HARNESS CHASSIS A C WIPE PWR 083 4 59 1 KZ W W PWR 63 7 6 4 50462 WASH PWR 63 8 X SKY WP Genie PartNo 123701 GTH 1056 6 33 May 2015 Section 6 Schematics pu E Harness Map Options Enclosed Cab with HVAC 34 35 Section 6 Schematics May 2015 Electrical Schematic View 1 before serial number GTH1012 16292 BLK HOURMETER K EE ENGINE COOLANT TEMP SENDER BLU BLK va oes 5 s e m TRANS OIL TEMP SWITCH N O 3 REDMWHT BLK o rd N x gt S T 2 e e 3 gi TRANS OIL PRESSURE SWITCH 30 e T e BRAKE PRESS WARN SWITCH N C BLU WHT BLK May 2015
72. all decals on the machine for legibility and damage Result The machine is equipped with all required decals and all decals are legible and in good condition W Result The machine is not equipped with all required decals or one or more decals are illegible or in poor condition Remove the machine from service until the decals are replaced 4 Always return the manuals to the storage container after use compartment Note Contact your authorized Genie distributor or Genie Industries if replacement manuals or decals are needed Genie 3 6 GTH 1048 GTH 1056 PartNo 123701 September 2014 Section Scheduled Maintenance Procedures A 2 Perform Pre operation Inspection Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Completing a Pre operation Inspection is essential to safe machine operation The Pre operation Inspection is a visual inspection performed by the operator prior to each work shift The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests The Pre operation Inspection also serves to determine if routine maintenance procedures are required Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine Part No 123701 Genie GTH 1048 GTH 1056 3 7 CHECKLIST A PROCEDURES
73. amp C83 2 C83 122 c85 1 A C PWR Go C80 C 2 1c83 1 85 1 LUG GND22 C83 2 A C GND X C82 2 WINDSHIELD WIPER SKYLIGHT WIPER NDSHIELD e 34 wiPe PwR 60 11 62 4 5 63 4 71 56 1 WIPE PWR WIPE RET C60 2 X lt C62 2 C63 235 C59 2 WIPE RET WIPE ON C60 3 3 C62 1 C63 1331C59 3 WIPE ON WPE GND C60 4 x amp C58 1 C58 2 2 C59 4 WIPE GND HEATER 89 DOME 519 CONTROL PANEL __ LIGHT r 4 BLOWER SW NOTE HARNESS MAP POWER 78 21 ENCLOSED CAB LEFT SW HI 78 amp 80 SW MED 78 lt 80 WITH HVAC OPTION SW LOW C78 L X CB0 D A C SW PWR 78 lt lt 77 1 e 54 558555 8 8 lva BUSS connector 52 A C SWITCH 60 4 5 58 1 WIPE GND 2 7 A C SW PWR C77 1 78 C59 4 3 058 2 WIPE GND 282402444191 gt 2 A C ON 77 5 lt lt 80 LUG GND22 C58 3 LUG GND 888888 555 98 GROUND C77 4 XK LUG GND 69 LUG GND3x1C58 4 LUG GND T Ld 92 2 1 58 5 WASH GND 53528 385 LT VALVE CONTROL D C93 2 31C58 6 WASH GND 829 58 POWER 76 21 ce ul t VAL RET C76 B X C80 A C76 A 7 SL j dd GROUND C76 C XX LUG GND QE M C61 DOME PWR 8 15 65 1 36 H PWR Ee 68 5 DOME GND C8 2 X C65 2 FAM GND 2 X C6 6 e C6 1 HVAC PWR HVAC PWR HARNESS LEGEND CAB W HVAC OPTION 517
74. boom 9 Measure the gap between the washer and the spacer The gap should be between 0 125 to 0 25 inch 3 2 mm to 6 35 mm Part No 123701 Genie GTH 1048 GTH 1056 CHECKLIST C PROCEDURES C 9 Perform Axle Maintenance Axle specifications require that this procedure be performed every 700 hours of operation Required maintenance procedures and additional axle information is available in the Dana 213 Axle Maintenance and Repair Manual Dana part number 0243 Dana 213 Axle Maintenance and Repair Manual Genie part number 115026 Section 3 Scheduled Maintenance Procedures September 2014 CHECKLIST C PROCEDURES C 10 Perform Axle Maintenance Axle specifications require that this procedure be performed every 800 hours of operation Required maintenance procedures and additional axle information is available in the Dana 213 Axle Maintenance and Repair Manual Dana part number 0243 Dana 213 Axle Maintenance and Repair Manual Genie part number 115026 Genie 3 26 GTH 1048 GTH 1056 PartNo 123701 September 2014 Section Scheduled Maintenance Procedures Checklist D Procedures D 1 D 2 Inspect the Forks Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first OR whenever permanent deformation of the forks is suspected Maintaining the lifting forks in good condition is essential to safe operation and good machine performa
75. every 250 hours Engine oil and filter change Engines with exhaust after treatment system Deutz DQC II LA approved oil API CJ 4 low ash approved oil Deutz DQC III LA approved oil in extreme conditions Engines without exhaust after treatment system Deutz DQC II LA approved oil API CJ 4 low ash approved oil Deutz DQC III approved oil in extreme conditions Deutz III LA approved oil in extreme conditions Required maintenance procedures and additional engine information is available in the Deutz TCD3 6 Operation Manual Deutz part number 0312 3907 Deutz TCD3 6 Operation Manual Genie part number 218707 Genie CHECKLIST B PROCEDURES PartNo 123701 GTH 1048 GTH 1056 Section Scheduled Maintenance Procedures September 2014 Checklist C Procedures C 1 Perform Engine Maintenance John Deere Models Engine specifications require that this procedure be performed every 500 hours or semi annually whichever comes first Required maintenance procedures and additional engine information is available in the John Deere 4045HF485 Operator s Manual John Deere part number OMRG36852 John Deere 4045HF485 Operator s Manual Genie part number 123703 Genio GTH 1048 GTH 1056 C 2 Perform Axle Maintenance Axle specifications require that this procedure be performed after 500 hours of operation Required maintenance procedures and additional axle information is available in the Dana
76. ft lbs 88 101 Nm 65 75 ft lbs 88 101 Nm 20 ft lbs 27 Nm 46 54 ft lbs 61 72 Nm 20 ft lbs 27 Nm 25 ft lbs 34 Nm 25 ft lbs 34 Nm 20 ft lbs 27 Nm 25 ft lbs 34 Nm 20 ft lbs 27 Nm 12 14 ft lbs 16 19 Nm 20 ft lbs 27 Nm 12 14 ft lbs 16 19 Nm Index Schematic No Description Item Function 1 Solenoid valve 2 position 4 way BA usua Function select boom extend and sway left 2 Directional valve 3 position 4 way pilot operated Boom extend retract 3 Directional valve 3 position 4 way pilot operated AC Boom up down 4 Solenoid valve 2 position 4 way AD Function select boom down and fork tilt down 5 Directional valve 3 position 4 way pilot operated Fork tilt up down 6 Relief valve 3500 psi 241 bar AF Fork tilt up relief Check valve pilot operated 100 psi 6 9 AQ Fork tilt down circuit 8 Check valve pilot operated 100 psi 6 9 Fork tilt up circuit 9 Relief valve 3500 psi 241 bar Al za Fork tilt down relief 10 Relief valve 3500 psi 241 bar AJ auus System relief 11 Diagnostic nipple cakes Test port LS 12 Flow regulator valve
77. inspections 1 Parkthe machine on a firm level surface level the boom and engage the parking brake 2 Fully extend the boom 3 Inspect the chains for the following conditions Elongation BL866 chain Measure 12 pitches of the extend chain for machines using BL866 chain Note For identification this chain typically measures one inch between pin centers when new BL666 chain Measure 16 pitches of the extend chain for machines using BL666 chain Note For identification this chain typically measures 3 4 inch between pin centers when new Note Both the extend and retract chains should be measured Note Measurement should be taken in the area where the chain articulates most frequently over the sheaves Result The distance measures 12 36 inches 313mm or less The chain is within specifications Continue with inspection Result If the distance is greater than 12 36 inches 313mm the machine shall be removed from service until the chain is replaced Note The boom chain s normal life expectancy can be expressed as a maximum percent of elongation of 396 Section Scheduled Maintenance Procedures September 2014 CHECKLIST C PROCEDURES Edge wear Check the chain for wear on the link plate edges caused by running back and forth over the sheave The maximum reduction of material should not exceed 5 Cracked plates Check link side plates for any cracks These are generally a sign
78. irre 7 057 2 855 AUXILIARY HYDRAULICS 555585855 amp BEACON TOP GEAR LOCKOUT AWA An amp HERTZ TELEMATICS OPTIONS JC I T TY TI Il DS 555505050500 i L 4 4 4 6 4 6 4 6 lt a AUX HYDRAULICS S14 POWER CONNECTED TO HARNESS 214538 OR 215446 C68 2 WHEN AUX HYDRAULICS OPTION INSTALLED 9 TOP GEAR LOCKOUT HARNESS CONNECTED TO DASHBOARD HARNESS PCB BEAC PWR 7 11 64 1 823054 WHEN GEAR LOCKOUT OPTION INSTALLED BEAC GND C7 2 C64 2 TT vtovxvte CN OD SE L0 P 00 O HARNESS LEGEND AUX BEA LKOT OPTIONS Te daba NUM PART DESCRIPTION 14 161444 ASSEMBLY GROUND BUSS 23 215332 HARNESS AUXILIARY HYDRAULICS 24 229683 HARNESS BEACON POWER 258555555 25 229862 HARNESS POWER BEACON LIGHT 43333359 42 826879 HARNESS TOP GEAR LOCKOUT 2222222 E 43 1255981 HARNESS HERTZ TELEMATICS 5885052 ES0462F F N R SHIFTE Genie PartNo 123701 GTH 1056 6 25 May 2015 Section 6 Schematics E Harness Map Options Auxiliary Hydraulics Beacon and 3rd Gear Lockout 26 Section 6 Schematics May 2015 Harness Map Options Work Lights Section 6 Schematics May 2015 Harness Map Options Work Lights
79. 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 subject to change without notice GTH 1048 GTH 1056 Section 2 Specifications September 2014 lt M SPECIFICATIONS Performance Specifications Boom function speeds maximum Drive speed maximum 18 mph GTH 1048 29 km h up 12 to 14 seconds Draw bar pull 29 000 Ib S Boom down 13 to 15 seconds 13 154 kg OK TON Boom extend 16 to 18 seconds Lift capacity maximum 10 000 Ibs 4545 kg 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 Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie 2 2 GTH 1048 GTH 1056 Part No 123701 September 2014 Section 2 Specifications Hydraulic Specifications Hydraulic Fluid Specifications Genie specifications require hydraulic oils which are designed to give maximum protection to hydraulic systems have the ability to perform over a wide temperature range and the viscosity index should exceed 140 They should provide excellent antiwear oxidation corrosion inhibition seal conditioning and foam and aeration s
80. located on the gauge cluster in the operator s compartment The gauge cluster also includes two warning lights They are an amber colored light which signals an abnormal engine condition which should be corrected as soon as possible and a red colored light which signals an engine condition which requres 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 Active Fault Codes Active Fault Codes will be displayed on the gauge cluster whenever a fault is detected If multiple fault codes are detected the fault codes will scroll on the display 15 10 20 S 100 2 25 Gauge Cluster from Serial Number GTH1012 16292 FMI Code SPN Code or ASPN Code amber warning light red stop engine light RON PartNo 123701 Genie 1048 1056 DIAGNOSTIC DISPLAY All Models Active Codes vs Stored Codes Active fault codes indicating an engine condition or conditions which have not been corrected are displayed at the moment the fault is detected Stored fault codes are the cumulative history of fault codes which the ECM has detected These fault codes may be recalled by service personnel at a later time even if the condition which caused the engine fault has ceased to exist Note Additional hardware will be necessary to access stored codes on machines from serial numbe
81. m Genie 4 2 GTH 1048 GTH 1056 How to Test a Proximity Switch 1 Remove the switch from the machine Do not disconnect the switch wire harness from the machine 2 Start the engine 3 Move the switch away from any ferrous or metallic object Result The light of the limit switch assembly is not illuminated 4 Move the switch close to any ferrous or metallic object Result The light of the proximity switch assembly turns on The switch is functioning correctly Part No 123701 March 2015 Section 4 Repair Procedures How to Adjust the Boom Angle Proximity Switch The boom angle proximity switch is attached to a mounting bracket located between the boom and the chassis directly beneath the boom pivot pin The switch location is adjustable 1 Startthe engine 2 Raise the boom to 60 Confirm with a digital 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 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 digit
82. of chain fatigue Turning pins Check the pins The position of the riveting must be parallel with the top and bottom of the side plate If any of these conditions are discovered during the inspection the chain must be replaced After inspection and before being returned to service the chains must be lubricated with a quality chain lubricant Note Do not use grease to lubricate chains The chain plates should be brushed with a wire brush prior to lubrication to clear the space between the plates The lubricant must penetrate the chain joint to prevent wear Applying lubricant to the external surfaces will prevent rust but the chains should be articulated to make sure the lubricant penetrates to the working surfaces between the pins and links Lubricant may be applied with a brush sprayed or poured on but the chain should be well flooded with lubricant and the boom should be extended and retracted to insure that the lubricant penetrates to the working surfaces All excess lubricant should be wiped away from the external surfaces Note Do not use solvents to remove excess lubricant Genie GTH 1048 GTH 1056 C 8 Adjust the Boom Sequencing Chains Note Genie specifications require that this procedure be performed every 500 hours or semi annually whichever comes first 1 Raise the boom to the horizontal position 2 Extend the boom fully then retract the boom approximately 1 inch 25 mm 3 Tie strin
83. pin is removed from the machine 13 Remove the inspection cover at the pivot end of the boom 14 Working at the pivot end of the boom remove the hose keepers from the hose roller assembly Note The hose keepers ensure that the hoses do not jump off the hose rollers Part No 123701 March 2015 Section 4 Repair Procedures tube 3 extension chains tube 2 extension chains boom tube number 0 boom tube number 1 boom tube number 2 boom tube number 3 15 Working at the pivot end of the boom remove the fasteners securing the cable bridge rear mount bracket to the boom assembly Remove the bracket from the boom 16 Working at the pivot end of the boom tag disconnect and plug the hydraulic hoses at the hard lines of the cable bridge Cap the fittings 17 Working at the pivot end of the boom remove the fasteners securing the hose roller assembly to boom tube number 1 Remove the hose roller assembly from the boom 18 Working at the fork end of the boom remove the fasteners securing the cable track mount bracket to boom tube number 3 Part No 123701 Genie GTH 1048 GTH 1056 BOOM COMPONENTS a cable bridge mount bracket b track mount bracket c bridge slider 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 boom Note Pay attention to how the hoses are
84. the Function Pump Note When removing a hose assembly or fitting the fitting and or hose end must be torqued to specification during installation Refer to Section 2 Hyaraulic Hose and Fitting Torque Specifications 1 Tag disconnect and plug the high pressure hydraulic hose from the primary function manifold Cap the fitting on the main valve AWARNING ded injury hazard Spraying ydraulic 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 Note The high pressure hose is the smaller of the two hoses 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 engine in the closed position Part No 123701 Genie GTH 1048 GTH 1056 Hydraulic Pump 4 Observe the pressure gauge while cranking the engine in one second intervals O Result If the pressure gauge reads 3190 psi 220 bar immediately stop The pump is good Result If the pressure fails to reach 3190 psi 220 bar the pump needs to be adjusted OR or the pump or pump coupling is faulty and will need to be serviced or replaced Component damage hazard There is no relief valve in the hydraulic pump and the pump can be damaged if the pressure is allowed to exceed specification When testing the pump crank the engine in one second intervals until
85. the correct pressure is confirmed Do not over pressurize the pump 5 Remove the pressure gauge and install the high pressure hose onto the pump Torque to specification Refer to Section 2 Specifications AWARNING injury hazard Spraying ydraulic 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 Section 4 Repair Procedures March 2015 HYDRAULIC PUMP How to Remove the Function Pump AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer Service is strongly recommended Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications Note Perform this procedure with the engine off and cool 1 Open the access door above the hydraulic tank 2 Disconnect the battery from the machine AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 3 Tag and disconnect the wire harness from the pump 4 Tagand disconnect the case drain h
86. the fasteners securing the dual chain tensioner to the top of boom tube number 1 After noting the orientation and assembly order of the components remove the fasteners and pull the tensioner free of the boom Refer to Illustration 1 Illustration 1 tube 3 extension chains dual chain tensioner tube 2 extension chains single chain tensioner boom tube number 0 boom tube number 1 boom tube number 2 boom tube number 3 ro Q0 09 March 2015 7 GTH 1056 Working at the fork end of the boom loosen evenly the fasteners securing the single chain tensioners to the top of boom tube number 0 After noting the orientation and assembly order of the components remove the fasteners and pull the tensioners free of the boom Refer to Illustration 1 GTH 1048 Working at the fork end of the boom loosen the fasteners securing the single chain tensioners to the top of boom tube number 1 After noting the orientation and assembly order of the components remove the fasteners and pull the tensioners free of the boom Refer to Illustration 2 Illustration 2 extension chains single chain tensioner boom tube number 1 boom tube number 2 boom tube number 3 Genie GTH 1048 GTH 1056 Part No 123701 March 2015 Section 4 Repair Procedures 9 Remove the inspection cover from the pivot end of the boom 10 GTH 1056 Locate the two chain anchors of the boom retraction chains wh
87. to Section 2 Hydraulic Hose and Fitting Torque Specifications Install all hoses onto the hydraulic pump Torque to specification Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications Locate the case drain filler plug at the side of the function pump Remove the plug and slowly fill the case drain port of the pump with hydraulic fluid until the oil level is even with the bottom of the hole Install the plug and torque to 40 ft Ibs 54 Nm 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 Check for hydraulic leaks and clean up any oil that may have spilled Genie case drain filler plug case drain hose c hydraulic supply line from tank o mv GTH 1048 GTH 1056 Part No 123701 March 2015 Section 4 Repair Procedures HYDRAULIC PUMP How to Adjust the Function Pump Standby Pressure 1 Connect 0 to 1000 psi 0 to 100 bar pressure gauge to test port 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 S p 3 Observe the pressure reading on the pressure gauge A Result The pressure gauge reads A 450 25 psi 31 1 7 bar Th
88. 0 Maintenance Manual CHECKLIST A PROCEDURES A 7 Perform 30 Day Service The 30 day maintenance procedure is a one time sequence of procedures to be performed after the first 30 days or 40 hours of usage After this interval refer to the maintenance checklists for continued scheduled maintenance 1 Perform the following maintenance procedures John Deere models 9 Perform Engine Maintenance John Deere Models 5 Inspect the Tires Wheels and Lug Nut Torque D 2 Replace the Hydraulic Tank Return Filter Element i t 115025 Perkins Deutz models ZF 4 WG 98 TC Operating Manual B 5 Inspect the Tires Wheels and Genie part number 1258405 Lug Nut Torque D 2 Replace the Hydraulic Tank Return Filter Element Genie Part No 123701 GTH 1048 GTH 1056 3 9 Section Scheduled Maintenance Procedures September 2014 CHECKLIST A PROCEDURES A 8 Perform Axle Maintenance Axle specifications require that this procedure be performed every 50 hours or monthly whichever comes first Required maintenance procedures and additional axle information is available in the Dana 213 Axle Maintenance and Repair Manual Dana part number 0243 Dana 213 Axle Maintenance and Repair Manual A 9 Perform Engine Maintenance John Deere Models Engine specifications requires that this one time procedure be performed after 100 hours of operation Required maintenance
89. 0 hours General engine overhaul Required maintenance procedures and additional engine information is available in the Deuiz TCD3 6 Operation Manual Deutz part number 0312 3907 Deutz TCD3 6 Operation Manual CHECKLIST E PROCEDURES E 9 Perform Engine Maintenance Perkins Models Note Engine specifications require that this procedure be performed every 12 000 hours or every three years whichever comes first 1104 and 1204 Engines Cooling System Coolant Extended life coolant change Required maintenance procedures and additional engine information is available in the Perkins 1104 Operation and Maintenance Manual Perkins part number SEBU7833 01 Genie part number 218707 OR the Perkins 1204 Operation and Maintenance Manual Perkins part number SEBU8605 01 Perkins 1104 Operation and Maintenance Manual Genie part number 117765 Perkins 1204 Operation and Maintenance Manual Genie part number 218726 Genio PartNo 123701 GTH 1048 GTH 1056 3 35 March 2015 Section 4 Repair Procedures Observe and Obey Repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Repairs Start Read understand and obey the safety rules and operating instructions in the appropriate opera
90. 0 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 Part No 123701 Pre Delivery Preparation Fundamentals It is the responsibility of the dealer to perform the Pre delivery Preparation The Pre delivery Preparation is performed prior to each delivery The inspection is designed to discover if anything is apparently wrong with a machine before it is put into service A damaged or modified machine must never be used If damage or any variation from factory delivered condition is discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications Scheduled maintenance inspections shall be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual Genie A TEREX BRAND Genie UK The Maltings Wharf Road Grantham Lincolnshire Watertown SD 57201 6150 NG31 6BH England 605 882 4000 44 1476 584333 Copyright 2011 Terex Corporation Genie is a registered trademark of Terex South Dakota Inc 133192 RevD Terex South Dakota Inc USA 500 Oak Wood Road PO Box 1
91. 1 1C4 5 5 5 PS7 RET 9 3 74 ROBA RM San ELE C27 A C4 6 S5 PWR 44 10 4 a ae i lt 13 8 41 523 36 22 C84 A d 1 TR APS k C44 1 7 5 515 9 1 10 C29 2 5 64 7 S6 RET ENG HARN q 2 B ALRM GND K ALRM C14 1 4 2 SVD1A PWR amp C33 1 C84 B 4 2 TR GND C44 2 me C88 1 21C4 8 HORN PWR C14 4 4 3 SVD1B PWR E C34 1 684 3 TR VCC C44 3 ci3 1E c5 6 Sub em crei C28 1 2 C4 9 SV13 PWR HARNESS LEGEND DJ C91 1 4 4 PWR PORT f C4 10 C84 D 4 5 TRAVS1 C44 4 D H 13 2 10 10 ETE C11 4 C4 10 PWR PORT gt L C13 3R c10 11 255595950 NUM PART DESCRIPTION C10 C44 O SVD1A PWR Ct3 4 3 C14 1 D C14 2 5 C5 1 S10 PWR 1 823054 HARNESS DASHBOARD START 4 amp SCPWR 13 5 5 5 MMMMMMM C12 9 05 2 FWR PWR 2 214539 HARNESS SECONDARY MANIFOLD d C382 ENGINE 12 7 5565 3 REV PWR 3 219457 HARNESS BACKUP ALARM S23 RET 8 1 1 C13 2122 C5 4 GC BK LT f C12 3 4 3 B2 PWR C42 8 C38 3 3 TR VCC amp ENGINE o d 4 162065 HARNESS TRANSMISSION C13 24 4 S24 RET j C42 6 638 5 4 4 TR VSI R ENGINE MM ee ISES OMS IBODBODEES C13 5 2x D8 5 GC PWR C13 7 4 5 825 RET C42 5 C10 6 4 5 IGNITION ENGINE INDIC PWR 13 161 10 7 0 lee C13 1 22 05
92. 1 2 How to Replace the Boom Wear Pads 7 Repeatthis procedure beginning with step 1 for each remaining boom tube Section Scheduled Maintenance Procedures September 2014 CHECKLIST B PROCEDURES B 9 Lubricate the Driveshafts Genie requires thatthis procedure be performed every 250 hours or quarterly whichever comes first Greasing the specified locations is essential for good machine performance and service life Operating the machine with little or no grease may cause the machine to perform poorly and continued use may cause component damage 1 Usinga grease gun thoroughly grease the driveshafts at each of the locations indicated in the illustration Grease Specification Chevron Ultra duty grease EP NLGI 2 lithium based or equivalent a rear driveshaft b frontdriveshaft Genie GTH 1048 GTH 1056 B 10 Perform Engine Maintenance John Deere Models Engine specifications require that this procedure be performed every 250 hours of operation Required maintenance procedures and additional engine information is available in the John Deere 4045HF485 Operator s Manual John Deere part number OMRG36852 John Deere 4045HF485 Operator s Manual Genie part number 123703 Part No 123701 September 2014 Section 3 Scheduled Maintenance Procedures B 11 Perform Engine Maintenance Deutz Models Note Engine specifications require that this procedure be performed
93. 100 Troubleshooting Manual John Deere 4045HF485 Operator s Manual Genie part number 123583 Genie part number 123703 John Deere 4045T Workshop Manual Genie part number 108443 to Repair the John Deere 4045T Alternator Manual Deutz TD3 6 L4 and TCD3 6 L4 Genie part number 108502 Engines John Deere 4045T Fuel Systems Manual Repair procedures and additional engine information Genie part number 108503 is available in the Deutz TCD3 6 Operation Manual Deutz part number 0312 3907 and the Deutz TD3 6 L4 and TCD3 6 L4 Workshop Manual Deutz part number 0312 3965en Deutz TCD3 6 Operation Manual Genie part number 218707 Deutz TD3 6 and TCD3 6 Workshop Manual Genie part number 1251788 Genie GTH 1048 GTH 1056 Part No 123701 March 2015 Section 4 Repair Procedures How to Remove the Engine Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Open the access door above the hydraulic tank 2 Disconnect the battery from the machine AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 3 Remove the fasteners securing the engine access cover from the rear of the machine Remove the cover from the machine 4 Perkins models Open the engi
94. 13 13 X C14 4 555555557 C13 7 4 5 825 RET C42 5 1062 5 IGNITION ENGINE INDIC PWR 13 16 10 7 mine 13 5 21 5 5 GC PWR 5 123588 HARNESS BOOM EXT SW 1056 C90 3 4 6 IGNITION K C44 5 1 4 6 GC BK LT C13 21 C5 4 zzzzzzzO C13 1 22 05 6 CPU PWR 6 217207 HARNESS THROTTLE PEDAL 10 1 4 6 5 FUEL RET C13 22Ex c10 9 1 90 1 gt 1 5 7 BAT C12 4 7 B3 PWR K C42 9 C10 11 7 S24 13 24 C104 Yar gt seek C90 2 5165 8 ACC 7 214443 ASSEMBLY FOOT SWITCH 89 1 5 8 515 1 3 10 10 4 8 _S24 RET_C13 24 oomeyoEE C90 3 5 165 9 IGN 8 117664 HARNESS BOOM ANGLE SWITCH C13 22 4 9 FUEL RET e C86 1 C73 B 4 9 S3 RET k C24 2 513 L 15 1 gt 1 5 10 BRAKE SV 15 227494 CONTROLLER HYD ERGO 2 SWITCH dose p oe ee c ncn DIFFERENTIAL FON R SHIFTER 15 2 65 11 SW PWR 16 214538 HARNESS PRIMARY MANIFOLD SJ C12 2 4 12 B4 PWR K C42 10 C73 A 4 12 SW PWR k C24 1 LOCK SWITCH 15 4 105 12 BRAKE CR 43 1255981 HARNESS HERTZ TELEMATICS Genie GTH 1056 Part No 123701 May 2015 Section 6 Schematics 5 5 Harness Control System Ground Single Joystick P il rd RIGHT FUEL SENDER gt FUEL GND C86 2 C37 2 FUEL TANK KD TRANSMISSION PRIMARY M
95. 14 Section Scheduled Maintenance Procedures Models with air filled tires 4 Puton protective clothing and eye wear 5 Checkthe air pressure in the tire Refer to Section 2 Specifications O Result The air pressure meets specification The tire is at the correctly filled level Result The air pressure does not meet specification Add air until the air pressure meets specification 6 Repeatthis procedure beginning with step 5 for each remaining tire Part No 123701 Genie GTH 1048 GTH 1056 3 15 CHECKLIST B PROCEDURES B 6 Perform Hydraulic Oil Analysis Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil may cause the machine to 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 Section Scheduled Maintenance Procedures September 2014 CHECKLIST B PROCEDURES B
96. 150 Instructions Use the operator s manual on your machine The Pre delivery Preparation consists of completing the Pre operation Inspection the Maintenance items and the Function Tests Use this form to record the results Place a check in the appropriate box after each part is completed Follow the instructions in the operator s manual If any inspection receives an N remove the machine from service repair and reinspect it After repair place a check in the R box Legend Y yes completed unable to complete R repaired Comments 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 Section 3 Scheduled Maintenance Procedures September 2014 asa This page intentionally left blank Genie 3 4 GTH 1048 GTH 1056 PartNo 123701 September 2014 Section 3 Scheduled Maintenance Procedures Maintenance Inspection Report Model Serial number Date Hour meter Machine owner Inspected by print Inspector signature Inspector title Inspector company Instructions Make copies of this report to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily or 8 hour Inspection A Quarterly or 250 hour Inspection A
97. 2 5 617 11 5 9 0 0 210 CPU PWR 13 61 16 2 C70 2 951 17 12 LT DWN GND 2 SS es dd a 9 2 71 26 2 HORN GND 1 HARNESS LEGEND GND DJ C30 2 591C26 3 SV5 GND 5 C31 2 9 C26 4 SV7 GND NUM PART DESCRIPTION 32 2 5 26 5 5 6 0 0 m 1 823054 HARNESS DASHBOARD eee PUE 2 214539 HARNESS SECONDARY MANIFOLD UE D 34 2 1 26 9 SVDIB GND 9 C35 2 5 026 10 sv8 cnD l2 17 214446 HARNESS PRIMARY MANIFOLD DJ C36 1 321C26 11 S23 GND 43 1255981 HARNESS HERTZ TELEMATICS ee 15 9 16 1 520 0 165 C13 6 321016 2 GC GND LUG GND22 C16 3 LUG GND 5 ES0462F c91 2 3 c16 4 GND PoRT 9 acu dam ng EP c a Genie PartNo 123701 GTH 1056 6 17 May 2015 Section 6 Schematics p Harness Map Control System Ground Dual Joystick 19 Section 6 Schematics May 2015 Harness Map Deutz TCD3 6 Engine Battery Power and Ground Section 6 Schematics May 2015 Harness Map Deutz 3 6TCD Engine Battery Power and Ground 9 9 D e o RIGHT 50 au 20 430 60 gt LL DA CB 2 2 B amp A lt eee sul
98. 2 m 9 9 m I a m 5 d 2 ux 4 E 1 m 8 gs d 3 NOTE CIRCLED NUMBERS E 5 B B E 5 B B 5 E 2 e PRINTED ON WIRES 3 E e 5 5 2 B 8 E S 2 2 5 9 a 2 o i m 2 3 T Gk g 5 amp 5 8 2 a da dme Aad 4 4 4 1 MACHINE SHOWN THE STOWED POSITION WITH THE POWER OFF ES0451F ES0452E Genie PartNo 123701 GTH 1056 6 37 May 2015 Section 6 Schematics Electrical Schematic View 2 before serial number GTH1012 16292 38 39 Section 6 Schematics May 2015 eal Electrical Schematic View 1 from serial number GTH1012 16292 to 19340 6 40 May 2015 Section 6 Schematics Electrical Schematic View 1 from serial number GTH1012 16292 to 19340 DPF DISABLED PERKINS T4i 9 pos NOTET OR BK 2 1 lis C32 2 BR 4 ghee D 23 8 4 n i 72 2 BR C68 1 71 1 71 2 BR 3 ge cg C11 4 fo BR 51 19 1 C3 1 DEUTZ T3 T4 30AMP 3RD GEAR LOCKOUT OPTION PERKINS T4 SOAMP PERKINS T3 CR12 SWAY FUNCTION RELAY CR6 SWAY ENABLE RELAY SWAY ENABLE COL SV9 REAR AXLE FLOAT COIL SV7 C10 7 BL C2 10 a N e e C TAL UGHT C2 9 C52 B 52 LEFT 2 7 2 8 8 1 652 N N CAB LIGHT LIGHT ROAD LIGHTS TAL UGHT C51 B C51 C
99. 3 64881 11 Nox conversion rate insufficient 23698 64946 11 Shut off request from supervisory monitoring function 23717 64965 12 Timeout Error of CAN Transmit Frame AmbCon Weather environments 23718 64966 3 SCR mainrelay primary side short circuit to battery SCR mainrelay short circuit to battery only CV56B 4 SCR mainrelay primary side short circuit to ground SCR mainrelay short circuit to ground only CV56B 5 SCR mainrelay primary side open load SCR mainrelay open load only CV56B 12 SCR mainrelay powerstage over temperature only CV56B Genie 5 14 GTH 1048 GTH 1056 Part No 123701 September 2014 Section 5 Fault Codes ENGINE FAULT CODES MODELS WITH DEUTZ POWER SPN Suspect Parameter Number ASPN Alternate Suspect Parameter Number FMI Failure Mode Identifier SPN ASPN FMI Description 23719 64967 SCR heater urea supplymodule short circuit to battery SCR heater urea supplymodule short circuit to ground SCR heater relay urea supply module open load Urea supply module heater temperature plausibility error Urea supply module heater temperature signal disrupted Urea supply module heater temperature plausibility error Urea supply module temperature signal disrupted Urea supply module temperature measurement not available Urea supply module PWM signal signal disrupted Detection of AdBlue filled SCR system in Init State Timeout Error of CAN Receive Frame Active TSC1
100. 49 4221 491 821 Fax 0049 4221 491 820 Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 61 7 3375 1002 Genie China Phone 86 21 53853768 Fax 86 21 53852569 Genie Singapore Phone 65 67533544 Fax 65 67533544 Genie Japan Phone 81 3 6436 2020 Fax 81 3 5445 1231 Genie Korea Phone 82 2 558 7267 Fax 82 2 558 3910 Genie U K Phone 0044 1476 584 333 Fax 0044 1476 584 330 Genie Brasil Phone 55 11 4082 5600 Fax 55 22 4082 5630 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566 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
101. 6 Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice PartNo 123701 GTH 1048 GTH 1056 Genie SPECIFICATIONS Section 2 Specifications September 2014 SPECIFICATIONS Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with Parker Seal Lok fittings and hose ends Genie specifications require SAE O ring Boss Port tube fitting installed into Aluminum all types that fittings and hose ends be torqued to 4 specification when they are removed and installed or when new hoses or fittings are installed is Seal Lok Fittings 8 hose end ORFS 40 SAE Dash size Torque 42 4 10 ft lbs 13 6 Nm ae 6 30 ft lbs 40 7 Nm 20 8 40 ft lbs 54 2 Nm 24 10 60 ft lbs 81 3 Nm 12 85 ft lbs 115 Nm 16 110 ft lbs 150 Nm 20 140 ft lbs 190 Nm NU Adjustable 24 180 ft lbs 245 Nm fitting Adj JIC 37 Fittings swivel nut or hose connection SAE Dash size Torque 14 ft lbs 19 Nm 23 ft lbs 31 2 Nm 36 ft lbs 54 2 Nm 62 ft lbs 84 Nm 84 ft lbs 114 Nm 125 ft lbs 169 5 Nm 151 ft lbs 204 7 Nm 184 ft lbs 249 5 Nm Non adjustable
102. 6 4 49 Section 4 Repair Procedures March 2015 sm t MANIFOLDS 7 3 Secondary Function Manifold Components The secondary function manifold is located under the manifold inspection cover Index Schematic No Description Item Function Torque 1 DOS valve 3 position 4 way Steer 2 222422221 60 in Ibs 6 8 Nm 2 Pressure reducing relief valve 50 psi 3 4 CB Rear lock up circuit 25 27 ft lbs 34 37 Nm 3 Pressure reducing relief valve 400 psi 27 5 co Differential lock up circuit 25 27 ft lbs 34 37 Nm 4 Pressure reducing relief valve 2500 psi 172 CD isses Steer circuit 25 27 ft lbs 34 37 Nm 5 Pressure reducing relief valve 400 psi 27 5 CE uus Drive brake circuit 25 27 ft lbs 34 37 Nm 6 Solenoid valve 2 position 3 way CP aun Parking brake select 20 ft Ibs 27 Nm 7 Solenoid valve 2 position 4 way 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
103. 6 CPU PWR 3 149988 HARNESS BOOMIEXT SV 1058 C90 3 4 6 IGNITION C44 5 C10 1 4 6 START ENGINE GC BK LT C13 21 C5 4 C90 1 2 C5 7 BAT 6 217207 HARNESS THROTTLE PEDAL L3 FUEL RET 13 22 10 9 0 0 0 0 0 0 C90 2 2 C5 8 ACC 7 214443 ASSEMBLY FOOT SWITCH C12 4 7 B3 PWR K C42 9 C10 11 7 CAN L K ENGINE S24RET Ci3 24 amp ci 4 SARS Wege 89 1 lt 8 515 lt 1 3 C10 10 lt 8 CAN H ENGINE anna Mog gt E 5 heey 8 117664 HARNESS BOOM ANGLE SWITCH C13 22 4 9 FUEL RET K C86 1 C73 B q 9 S3 RET K C24 2 3 7 ups a Ld DERE 17 215446 HARNESS PRIMARY MANIFOLD DJ 13 2 4 10 6 44 8 C1 6 10 B ALRM C18 1 F N R SHIFTER ar 43 1255981 HARNESS HERTZ TELEMATICS z i DIFFERENTIAL C15 4 2 C5 12 BRAKE CR C13 3 411 CAN L C44 7 73 lt 11 54 25 2 LOCK SWITCH 12 2 4 12 4 42 10 73 4 12 5 24 1 ES n Genie GTH 1056 Part No 123701 ES0462F May 2015 Section 6 Schematics Harness Control System Ground Dual Joystick
104. 65368 Timeout error of CAN Receive Frame ComRxSCRHtDiag 24121 65369 Timeout error of CAN Receive Frame ComRxTrbChActr 24122 65370 Timeout error of CAN Receive Frame ComRxUQSens 24123 65371 Timeout error of CAN Receive Frame ComSCRHICtl 24124 65372 Timeout error of CAN Receive Frame ComTxAT1IMG 24125 65373 Timeout error of CAN Receive Frame ComTxTrbChActr 5 o o o 0 o o o OF Genio PartNo 123701 GTH 1048 GTH 1056 5 25 Section 5 Fault Codes September 2014 k m tl Engine Fault Codes Models with Perkins Power SPN Suspect Parameter Number FMI Failure Mode Identifier SPN FMI Description 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 105 3 Intake manifold air tem
105. 7 6 Brake Manifold Components 7 7 Hydraulic Manifold Components 7 8 Valve Adjustments Secondary Function Manifold 1 9 CollS eerte ete e Axle Components 847 eerie Outriggers 9 1 ten GTH 1048 GTH 1056 xiii May 2015 TABLE OF CONTENTS Section 5 Fault Codes Introduction eet hee ce evi et ii 5 1 Diagnostic gt ctae teet nt ee e ters a bed ng 5 2 Engine Fault Codes Models with John Deere 5 4 Engine Fault Codes Models with Deutz Power 5 8 Engine Fault Codes Models with Perkins 5 26 Section 6 Schematics ITROCUCTION MERERI EE 6 1 Proximity Switch eren nnne nnne nnne 6 2 Fuse Box Layout before serial number GTH1012 16292 6 3 Fuse Box Layout from serialnumber GTH1012 16292 6 4 Fuse Box Layout from serial number GTH1014E 10353 sse 6 5 Electrical Component Legend before serial number GTH1012 16292 6 6 Electrical Component amp Wire Color Legend from serial number 87 1012 16299
106. 761 1 Urea tank temperature sensor value is out of the target range to low warning condition is generated 3031 0 Urea tank temperature sensor value out of the target range to high Urea tank temperature sensor value is out of the target range to low warning condition is generated 3224 1 Plausibility error Min for NOx sensor upstream of SCR Cat 9 Timeout Error of CAN Receive Frame AT11G1Vol AT101 AT10G1Vol 3234 9 Timeout Error of CAN Receive Frame AT11IG1Vol AT101 AT10G1Vol 11 Nox sensor value downstream not plausible stuck in range 3241 1 Target range to low for SCR catalyst upstream temperature sensor 3251 0 Differential pressure sensor value DPF out of target range to high 1 Differential pressure sensor value DPF out of target range to low 3253 2 Differential pressure sensor signal DPF not plausible 3 Target range to high for differential pressure sensor DPF 4 Target range to low for differential pressure sensor DPF 3361 3 Short circuit to battery at powerstage of Urea dosing valve 4 Short circuit to ground at powerstage of Urea dosing valve 7 Dosing valve blocked 3532 3 Target range to high for urea tank level sensor 4 Target range to low for urea tank level sensor 4243 11 Urea heating procedure not successful 4334 0 Target range to high for urea pump module pressure sensor before pressure build up 1 Physical range check low for urea pump module pressure sensor 4343 11 General pressu
107. 8 4 9 I C80 F gt LUG GND C 6 C 227529 G GA T 1 59 peeled 77199 o BUSS CONNECTOR os 25 60 4 58 1 WIPE GND 8 m C59 4 32 C58 2 WIPE GND Ld LUG GND3 gt C58 3 LUG GND 21599888 88 G8 LUG GND721C58 4 LUG GND E C92 2 2 C58 5 WASH OND GIT QGEeHS as C93 2 33 C58 6 WASH GND 59 5 W mee eot oozzodo TF 5 99555 07 DOME PWR C8 1 X C65 1 36 4 DOME GND C8 2 Feces 2 4 GTH 1056 Part No 123701 NOTE HARNESS MAP ENCLOSED CAB WITH HEAT OPTION HARNESS LEGEND CAB W HEATER OPTION NUM PART DESCRIPTION 14 161444 ASSEMBLY GROUND BUSS 34 233812 HARNESS ENCLOSED CAB 35 234859 HARNESS 36 233940 HARNESS POWER DOME LIGHT 37 123817 LIGHT WITH CONNECTORS 38 234861 HARNESS CAB HEATER ES0462F May 2015 Section 6 Schematics Si Harness Map Options Enclosed Cab with HVAC RIGHT WINDSHIELD WHASHER PUMP WASH PWR C92 1 x c62 8 WASH GND C92 2 3 C58 5 SKYLIGHT WHASHER PUMP WASH PWR C93 1 3 C63 8 E WASH GND 95 2 X C58 6 pe 6 A C CONTROL VALVE A C DRIER SW _ 82 1 A C PWRIx 49 37185 22 A C PWR 82 2 A C GND X
108. 8 Sway Enable Switch S9 Tilt Enable Switch 10 Steer Select Switch 11 Left Stabilizer Switch 12 Right Stabilizer Switch 13 Differential Lock Switch 14 Auxiliary Cont Switch 15 Horn Switch 16 Brake Light Pressure Switch S17A Windshield Wiper Motor Switch S17B Windshield Washer Switch S18A Windshield Wiper Motor Switch S18B Windshield Washer Switch 19 Dome Light Switch S21 Enclosed Cab Fan Switch 22 Road Work Light Switch 23 Brake Pressure Warning Switch 524 Transmission Oil Pressure Switch 525 Transmission Temp Switch 6 7 GTH 1048 GTH 1056 Section 6 Schematics May 2015 Electrical Component Legend Electrical Component amp Wire Color Abbreviation Legend TP Throttle Pedal Wire Color Legend TSS Turn Signal Shifter Y Valve Coil BL Blue Y70 Sway Left Enable SV1 BL BK Blue Black Y72A Tilt Up Enable SV2 BL RD Blue Red Y71 Sway Right Enable SV3 BL WH Blue White Y72B Tilt Down Enable SV4 BK Black Y67 Parking Brake Release SV5 BK RD Black Red Y68 Differential Lock SV6 BK WH Black White Y55 Rear Axle Float SV7 BK YL Black Yellow Y83 Rear Axle Fast SV8 BR Brown Y82 Sway Enable SV9 GR Green Y77A Auxiliary A Y77B GR BK Green Black Y80 D Transmission GR WH Green White Yel E Transmission RD Red Y6 Transmission Forward RD BK Red Black Y5 Transmission Reverse RD WH Red White Y on orange r eer Y75 Left Stabilizer Down OR BK Oraige Black Y76 Left Stabilizer Up OR RD Orange Red
109. 8 Zo E 15 5 8 i Ba E x s e 3 e 9 w 8 g Y 8 8 5 s 8 B 86885 8232233835 2 8 amp amp 222282 8 A AR AA amp 8 8 B 2 BR 5 2 E 5 N 7 N N Sy N 7 7 5 8 5 5 AEN wen TON AN 8 7 e kS az 7 oN 7 ON 65 ION ae 1 2 C13 3 S Ifl eun SVD1B CRAB STEER COIL SM K 2 BR 026 8 cosi OR BK 2 2 BR 026 50 oye DIFFERENTAL LOCK COLS 072 2 BR 17 5 _ RIGHT STABILIZER DOWN COIL STN WH RO en BR 017 11 RIGHT STABILIZER UP BL cm ig 8R 17 2 0 very STABILIZER DOWN RO e Ilona sm 17 8 LEFT STABILIZER UP COIL STW RD BK c57 UN luce 5 56 2 BR 3 oe ee RD EM 911 4 ROH 91 1 2 5 91 2 BR d POWER PORT 5 E 395 51 5 et BL 010 6 BL 09 12 CR3 HORN RELAY PCB 88 7 5 2 64 8 588 14 88 2 BR_026 2 HORN re r pen oe g CRI3 TILT FUNCTION RELAY PCB Sade 2 3 6 1 BR_CI7 1Q 4 SV4 TILT DOWN ENABLE COIL PN 8 5 5 o 28 id 1 BR 017 9 2 sy TLT UP ENABLE
110. ACAUTION situation which if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage Note Used to indicate additional operation or procedure information Indicates that a specific result is expected after performing a series of steps Indicates that an incorrect result has occurred after performing a series of steps Section 4 Repair Procedures March 2015 Boom Components 1 1 Boom Proximity Switches Both the boom angle proximity switch and the boom extend proximity switch are proximity switches These switches function by sensing a change in the electromagnetic field of the switch due to the introduction of metal into the field A proximity switch is simply a metal detector The switch generates an electromagnetic field at the face of the switch This field senses when steel has been moved close to the switch as well as when the steel has been moved away which is how the switch contacts open and close These switches are of a fail safe design Should 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
111. AE Timeout Error of CAN Receive Frame Passive TSC 1AE Timeout Error of CAN Receive Frame Active TSC1AR Timeout Error of CAN Receive Frame Passive TSC1AR Timeout Error of CAN Receive Frame Passive TSC 1DE Timeout Error of CAN Receive Frame TSC1TE active Passive Timeout Error of CAN Receive Frame TSC1TE Setpoint Active Timeout Errorof CAN Receive Frame TSC1TR Passive Timeout Error of CAN Receive Frame TSC1TR Turbo charger wastegate CAN Fehler Timeout Error of CAN Transmit Frame TrbCH Status Wastegate 23793 65041 9 Timeout Error of CAN Receive Frame UAA10 AGS sensor service message 23720 64968 23721 64969 23722 64970 23723 64971 23766 65014 23767 65015 23768 65016 23769 65017 23770 65018 23776 65024 23777 65025 23778 65026 23779 65027 23788 65036 Of NO NIO 23794 65042 9 Timeout Error of CAN Receive Frame UAA11 AGS sensor data 23803 65051 9 Timeout Error of CAN Receive Frame RxEngPres Status burner airpump 23867 65115 12 Timeout Error of CAN Transmit Frame UAA1 on CAN 2 Burner Air Pump Control 23895 65143 13 Check of missing injector adjustment value programming IMA injector 1 in firing order 23896 65144 13 check of missing injector adjustment value programming IMA injector 2 in firing order 23897 65145 13 check of missing injector adjustment value programming IMA injector 3 in firing order Genio PartNo 123701 GTH 1048 GTH 1056 5 15
112. ANIFOLD C42 1 3 C40 7 COIL GROUND sve SWAY ENABLE 19 2 lt lt 17 11 422 041 7 COIL GROUND 5 1 SWAY LEFT 21 2 17 3 SV3 SWAY RIGHT 20 2 17 4 42 11 1 639 2 OIL PRESS S24 SV2 TITL UP C23 2 C17 9 SV4 TILT DOWN 22 2 lt lt 17 10 C42 1272 GROUND LUG STABILIZER MANIFOLD SECONDARY MANIFOLD LEFT STB UP 069 2 c7 12 Svs P BRAKE RELEASE C30 2 26 3 Lone ons s SV8 REAR AXLE FAST C35 2 4 26 10 SV7 REAR AXLE FLOAT 631 2 34 0264 SV6 DIFF LOCK 32 2 lt 26 5 SVDIB CRAB STEER C34 2 X C26 9 SVD1A 445 C33 2 26 8 S23 BRAKE PRESSURE C36 1 lt amp 26 11 FRONT 357 6 11 S24 GND K C39 2 C37 3 12 TRS GND K GND LU C42 7 C37 4 lt H1 COIL GND K C40 7 C42 C37 5 lt 2 COIL GND C41 7 GROUND_STUDS Cee NOTE HARNESS LUG GND2 JC37 1 LUG GND BASE UNIT PARKING BRAKE S2 32 GND C15 9 C16 1 C86 2 52 037 2 FUEL GND SINGLE JOYSTICK OPTION 42 12 1 37 5 TRANS GND E S CONTROL SYSTEM GROUND C42 2 32 C37 5 COIL GND M C42 11 2 C37 6 S24 GND LUG GND221C37 8 LUG GND LEFT BUSS CONNECTO 71 2 1 7 1 RT UP GND C21 2 32 C17 3 SV1 GND 20 2 1 17 4 SV3 GND C72 2 33 C17 5 RT D
113. AWARNING Crushing hazard The cylinder will Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and 6 Fitting Torque Specifications 7 1 Extend the outrigger until the pad just touches the ground Do not rest the weight of the 8 machine on the outrigger fall if not properly supported when the pivot pin is removed from the machine Raise the cylinder to a vertical position Remove the fasteners securing the outrigger cylinder rod end pivot pin to the machine Use a soft metal drift to remove the pivot pin Remove the cylinder from the machine 2 Tag disconnect and plug the two hydraulic AWARNING Crushing hazard The cylinder will supply hoses at the outrigger cylinder Cap the fittings AWARNING 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 Component damage hazard Hoses can be damaged if they are kinked or pinched 3 Attach a lifting strap from an overhead crane to the barrel end of the outrigger cylinder Support the cylinder Do not apply any lifting pressure 4 Remove the fasteners securing the outrigger cylinder barrel end pivot pin to the chassis Genie fall if not properly supported when the pivot pin is r
114. B Semi annually or 500 hour Inspection A B C Annually or 1000 hour Inspection A B C D 2 Year or 2000 hour Inspection A B C D E Place a check in the appropriate box after each inspection procedure is completed Use the step by step procedures in this section to learn how to perform these inspections If any inspection receives an tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable N no remove from service R repaired Comments Checklist A Y NR Checklist C Y N R A 1 Manuals and decals A 2 Pre operation inspect A 3 Function tests A 4 Lubricate boom A 5 Engine maintenance A 6 Transmission maintenance Perform after 40 hours A 7 30 day service Perform every 50 hours A 8 Axle maintenance Perform after 100 hours A 9 Engine maintenance John Deere models A 10 Axle maintenance Perform every 200 hours A 11 Axle maintenance Checklist B B 1 Battery B 2 Electrical wiring B 3 Exhaust system B 4 Engine air filter B 5 Tires and wheels B 6 Hydraulic oil B 7 Tank venting systems C 6 Engine maintenance Perkins models C 7 Inspect and lubricate chains C 8 Sequencing chains Perform every 700 hours C 9 Axle maintenance Perform every 800 hours C 10 Axle maintenance
115. CONNECTOR AW leocococl 196 0 0 71 45 1 LUG GND 9962222 C75 4 3 C45 2 LT L GND ool A 52 1 45 3 TAIL L GND 1 51 5 45 4 TAIL R GND IY AAA C50 2 9 C45 6 BACK GND 2252210 75 3 45 7 LT R GND LUG GND32 C45 8 LUG GND N GAUGE CLUSTER SS S22 RET C13 17 C48 4 9 PCB HARNESS LEGEND ROAD LIGHT OPTION UV NUM PART DESCRIPTION TT C66 3 951C2 1 SHFTR 3 14 161444 ASSEMBLY GROUND BUSS 29 650 1 5162 2 BACKPWR 26 233989 HARNESS CAB LIGHT agg C49 A 2 C2 3 S16 PWR 27 214334 HARNESS CAB LIGHT POWER FEJO 48 2 2 4 S22 PWR 28 229677 HARNESS TAIL LIGHT LED Q1 C48 492 C2 5 S22 RET 31 123929 ROAD LIGHT BLINKER nin 32 215329 HARNESS ROAD LIGHTS C52 A 92 02 8 TAILLTL 33 123925 HARNESS BACKUP LIGHT C51 A 2 C2 9 TAIL LT R og LIGHTS 522 C66 2 21c2 10 sHFTR 2 S22 PWR C48 2 49 1 2 11 SIG RET S22 RET 048 4 amp amp C13 17 C66 6 21C2 12 SHFTR 6 HEAD LT roe C2 5 ES0462F Genie PartNo 123701 GTH 1056 6 29 May 2015 Section 6 Schematics 2 4 4 2 4 Harness Map Options Road Lights 30 Section 6 Schematics May 2015 Harness Map Options Enclosed Cab with Heater Section 6 Schematics Harness Map Options Enclosed Cab with Heater May 2015 S RIGHT
116. CONTINUED Revision Date Section Procedure Schematic Page Description Electronic Version Click on any procedure or page number highlighted in blue to view the update Genie iv GTH 1048 GTH 1056 Part No 123701 May 2015 INTRODUCTION Serial Number Legend A TEREX BRAND Terex South Dakota Inc 18340 NE 76th Street 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 10107 7101 LIFT CAPACITY LBS AT MAX LIFT HEIGHT 6000 LBS 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 TM Serial number located inside chassis at tank side of machine stamped on chassis Genie Part No 123701 GTH 1048 GTH 1056 May 2015 This page intentionally left blank Genie vi GTH 1048 GTH 1056 Part No 123701 May 2015 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 machi
117. EASE COIL BLU WHT amp 4 9 p M gi POWER RELAY 42 REDIWHT N BIK STARTER RELAY 5 9 40 05 Lr 5 9 2 f RED E 2 Q wox l e e STARTER MOTOR 8 E g nuo B i 7 Baer Sj Ei 844 IMMER EEE at g GROUND s y T9 dv SL an 3 g gee i 2 z luz CAN SHIELD gr 8i FON gt 5 D Z2 E 1555 cux E ig 8 g 258 EH EN i B lo OLE VAUDATONSWTCHINPUT M al T ay WED weal D eu 1 THROTTLE POWER 50 IE 15 El m rep lt THROTTLE 19 noxae dn THROTTLE RETURN VS GROUND E YEL WHT a oe M MT GHEDIBEACK Y 99 o l CY 8x 2 18 v 28 vW IW vl IT a a o zu 2 E 28 oe mi EO SV IW 5 m E gt e FRE a BLK ago gee asna 5 gs ae amp 3NIONS a n sa 80 div 05 a a V e e e e RED aux 12 VOLT BATTERY WHT BLK Part No 123701 GTH 1056 6 36 May 2015 Section 6 Schematics Electrical Schematic View 2 before serial number GTH1012 16292
118. Engine send messages 23938 65186 9 Timeout Error BAM to packet for CAN Receive Frame AT1IGCVol1 information factors amp Sensorcalibration for NOX Sensor SCR system upstream cat DPF system downstream cat 23939 65187 9 Timeout Error BAM to BAM for CAN Receive Frame AT1IGCVol1 information factors amp Sensorcalibration for NOX Sensor SCR system upstream cat DPF system downstream cat 23940 65188 9 Timeout Error POK2PCK for CAN Receive Frame AT1IGCVol1 information factors amp Sensorcalibration for NOX Sensor SCR system upstream cat DPF system downstream cat Genie Part No 123701 GTH 1048 GTH 1056 5 19 Section 5 Fault Codes September 2014 pm s ENGINE FAULT CODES MODELS WITH DEUTZ POWER SPN Suspect Parameter Number ASPN Alternate Suspect Parameter Number FMI Failure Mode Identifier SPN ASPN FMI Description 23941 65189 9 Timeout Error BAM to packet for CAN Receive Frame AT1OGCVol2 information factors amp Sensorcalibration for NOX Sensor SCR system downstream cat DPF system downstream cat 23942 65190 9 Timeout Error BAM to BAM for CAN Receive Frame AT1OGCVol2 information factors amp Sensorcalibration for NOX Sensor SCR system downstream cat DPF system downstream cat 53943 65191 9 Timeout Error for CAN Receive Frame AT10GCVol2 information factors amp Sensorcalibration for NOX Sensor SCR system do
119. GTH 1056 only Boom Angle Proximity Switch PX2 under boom pivot pin Genie GTH 1048 GTH 1056 Part No 123701 May 2015 Section 6 Schematics CR56 CR55 CR5 Fuse Box Layout before serial number GTH1012 16292 CcB2 O 40A FUSE U37A e n uH H HC D ad EE M U37B 1 3 GROUND ISI HU He e L DE T o On ae m Do ean IE g 2 FUSE 8 1 3 PANEL 8 5 FUSE PANEL CR100 CR11 CR69 CR22 or CR34 MACHINE OPTIONS REFER TO ELECTRICAL SCHEMATIC PCB Board Fuse Panel located in the Cab PartNo 123701 GTH 1048 GTH 1056 Genie Section 6 Schematics May 2015 Fuse Box Layout from serial number GTH1012 16292
120. HARNESS 215332 WHEN AUX HYDRAULICS OPTION INSTALLED FUEL TANK 4 MW Boom ane s3j 4 HORN BOOM EXT S HORN PWR CB88 1 X C4 8 ENGINE _ TRANSMISSION _ cu 1x maes STABILIZER MANIFOLD PRIMARY _MANIFOLD c42 3 9 C40 1 FORWARD COIL 2 51 TRGND SECONDARY MANIFOLD SV9 SWAY ENABLE c19 1 xe c3 7 LTD 40 2 REVERSE COIL 44 3 5 TR VCC Z LEFT STB UP C69 1 x C67 1 C42 7 51C40 3 B1 COIL 44 4 5 TR IVS1 LEFT STB DWN 70 1 67 4 SV5 P BRAKE RELEASE C30 1 X C4 5 SV SWAY LEFT C21 1 lt C3 3 CONNECTORS DETAILS EE 553 NLPWR L RIGHT STB UP 671 411 Ke C68 1 SV8 REAR AXLE FAST C35 1 X C4 SV3 SWAY RIGHT C20 1 x C3 4 C42 8 2 C41 4 B2 COIL EWR RIGHT STB DWN 72 1 6 4 4 SV7 REAR AXLE FLOAT C31 1 X C4 SV2 UP C23 1 X C3 5 C42 42 9 41 5 COIL SV6 DIFF LOCK C32 1 FR C28 SV4 TILT DOWN C22 1 lt C3 6 Biss Dus a Co C42 102 C41 6 B4 COL aie SVDIB E ae E C1 2 4 REV PWR K C40 2 42 5 C87 1 OIL TEMP S25 E ol C10 5 4 5 S25 RET C87 1 C42 62 C39 1 OIL PRESS S24 S23 BRAKE PRESSURE C36 2 11 1 PUR EE c S5 PARKING BRAKE PWR 27 X C4 6 16 BACKUP S5 PARKING BRAKE RET 27 C29 3 ALARM 2 C10 7 4 9 B3 PWR k C41 AC42 pm ALARM BRAKE MANIFOLD 10 12 10 B4 PWR7K C41 6 5 SERVICE BRAKE 55 29
121. LT CODES MODELS WITH JOHN DEERE POWER SPN FMI Description of Fault 000651 02 Cylinder 1 Injector Part Number Not Recognized 05 Cylinder 1 Electronic Injector Circuit Open 06 Cylinder 1 Electronic Injector Circuit Shorted 07 Cylinder 1 Electronic Injector Fuel Flow Low 13 Cylinder 1 Injector QR Code String Error 000652 02 Cylinder 2 Injector Part Number Not Recognized 05 Cylinder 2 Electronic Injector Circuit Open 06 Cylinder 2 Electronic Injector Circuit Shorted 07 Cylinder 2 Electronic Injector Fuel Flow Low 13 Cylinder 2 Injector QR Code String Error 000653 02 Cylinder 3 Injector Part Number Not Recognized 05 Cylinder 3 Electronic Injector Circuit Open 06 Cylinder 3 Electronic Injector Circuit Shorted 07 Cylinder 3 Electronic Injector Fuel Flow Low 13 Cylinder 3 Injector QR Code String Error 000654 02 Cylinder 4 Injector Part Number Not Recognized 05 Cylinder 4 Electronic Injector Circuit Open 06 Cylinder 4 Electronic Injector Circuit Shorted 07 Cylinder 4 Electronic Injector Fuel Flow Low 13 Cylinder 4 Injector QR Code String Error 000655 02 Cylinder 5 Injector Part Number Not Recognized 05 Cylinder 5 Electronic Injector Circuit Open 06 Cylinder 5 Electronic Injector Circuit Shorted 07 Cylinder 5 Electronic Injector Fuel Flow Low 13 Cylinder 5 Injector QR Code String Error 000656 02 Cylinder 6 Injector Part Number Not Recognized 05 Cylinder 6 Electronic Injector Circuit Open 06 Cylinder 6
122. Manual on your machine Engine coolant Capacity 4 6 gallons 17 liters Type Extended Life Alternator Output 85 A 14V DC Fan belt tension 90 ft lb 400 N Alternator bolt torque 16 ft lb 22 Nm Starter Motor Normal load 68 Relay max 50A Relay continuous 20A Cranking speed 130 200 rpm Glow Plugs Initial load 0 4 sec 20 amps ea Continuous load gt 4 sec 15 amps ea Battery Type 12V DC Group C31 Quantity 1 Cold cranking ampere 09 1000A Reserve capacity 25A rate 200 minutes 2 10 GTH 1048 GTH 1056 Part No 123701 September 2014 Section 2 Specifications Perkins 1204E E44TA Engine Displacement Number of cylinders Bore and stroke Horsepower Peak Torque 268 5 cu in 4 4 liters 4 4 13 x 4 99 inches 105 x 124 mm 124 2000 rpm 92 7 kW 2000 rpm 391 Ib ft 1400 rpm 530 Nm Q 1400 rpm Firing order 1 3 4 2 Compression ratio 16 5 1 Governor Electronic Low idle 800 rpm Frequency Hz High idle 2200 rpm Frequency Hz Lubrication system Pressure Hot 2300 rpm 28 64 psi Minimum oil pressure 7 1 psi 0 49 bar Maximum oil capacity 8 8 quarts including filter 8 3 liters Cil viscosity requirements Units ship with 15W 40 API CJ4 low ash oil Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operation and Maintenance Manual on your
123. N message 24044 65292 9 CAN message 5 5 57 not received from slave 24038 65286 Genio PartNo 123701 GTH 1048 GTH 1056 5 23 Section 5 Fault Codes September 2014 pm s ENGINE FAULT CODES MODELS WITH DEUTZ POWER SPN Suspect Parameter Number ASPN Alternate Suspect Parameter Number FMI Failure Mode Identifier SPN ASPN FMI Description 24045 65293 9 Master Slave CAN Message Counter Error of CAN Receive Frame ComMSMoFOvR 24046 65294 9 Master Slave CAN Checksum Error of CAN Receive Frame ComMSMoFOvR 24047 65295 9 Master Slave CAN Messsage Length Error of CAN Receive Frame ComMSMoFOvR 24048 65296 9 Timeout error CAN message ComMSMoF OvR1TO error memory Slave 24049 65297 9 Message copy error in the Master Slave data transfer 24052 65300 11 MS ECU reported internal error 24055 65303 4 Spark Plug Control Unit SPCU short circuit to ground 24057 65305 2 Electric fuel pump fuel pressure build up error 24062 65310 12 EAT system HMI disrupted 24068 65316 2 Master ECU and Slave ECU have been identified as the same types 24069 65317 9 Timeout Error of CAN Receive Frame MSMon_FidFCCTO Master Slave CAN communication faulty Timeout error of CAN Transmit Frame DPFBrnAirPmpCtl Timeout error of CAN Transmit Frame ComDPFBrnPT Timeout error of CAN Transmit Frame ComDPFCO Timeout error of CAN Transmit Frame ComDPFHisDat Timeout error of CAN Transmi
124. WITCH PWRPORT DEFROSTFAN DOME BEACON 20 CR14 60 Amp N BS 10A F65A 17 10 75 BOOM ae 29 ANGLE CB3 10 C5 5 30 Amp 50 Amp REAR AXLE OSC STEER DIFFSW SPARE GAUGE CLS PWR esq a CB2 CB1 F4 10A F115A F10 15A F161A C4 130 I5 foo gt SWAY TILT BRAKE SHIFT WIPERWASHER GAUGE CLS ECU N J zo gt E E 28 ni F20 1A F2 10A 12 20 CES Perkins Engine Circuit Breakers ro 1 10 GO GO 1 55 AUXHYD LIGHTS TELEM Located in Tank Assembly 22 52 ANGLE MONITOR FLASHER m 2 2 F5 5A F18 10A MAX F9 25A F13 15A 5 foc to 15 HORN SPARE HVAC IGNITION C3 3 zz CR11 CR12 CR13 gt PBRAKE SWAY TILT U D z3 A LATCH UR ENBL P ENABLE 2 06 5 z c 2 2 n o D5 A cro CR10 D4 BOOM FORWARD REVERSE 2 EXTEND ENABLE d ENABLE C2 8 jo 58 8 IAS E gt 0 CRS CR6 h 82 D Ea d LIGHTS SWAY BOOM m oy Ur OPTION ENABLE d ANGLE e a es Bp o n 8 C1 R1 DN CR2 A MAIN peso OPTIONS 5 SERVICE zd d POWER POWER di HORN 22 EE o NES 08 B 5 OG e 9 C9 JOYSTICK PCB 237361 HARNESS ev T PCB Board Fuse Panel located in the Cab Genie Part No 123701 GTH 1048 GTH 1056 6 5 Section 6 Schematics n M May 2015 Electrical Component Legend before serial number GTH1012 16292
125. WN GND LUG GND22 C17 6 LUG GND m LUG GND221C17 7 LUG GND 5 C69 2 35 C17 8 LT UP GND C23 2 321C17 9 SV2 GND C22 2 33 C17 10 SV4 GND C19 2 32 C17 11 SV9 GND C70 2 321017 12 LT DWN GND c88 2 3 c26 2 HORN GND 30 2 c28 3 SVS GND HARNESS LEGEND GND SJ 631 2 22 026 4 SV7 GND NUM PART DESCRIPTION C322 22102675 SV6 GND o 1 823054 HARNESS DASHBOARD GAUGE CLUSTER BUSS CONNECTOR UU END 2 214539 HARNESS SECONDARY MANIFOLD 32 2 51 26 8 SVD1A GND 4 162065 HARNESS TRANSMISSION C34 2 9 C26 9 SVD1B GND 14 161444 ASSEMBLY GROUND BUSS 26 10 SV8 GND 16 214538 HARNESS PRIMARY MANIFOLD SJ C35 2 gt C36 1 2 1626 11 S25 ND 43 1255981 HARNESS HERTZ TELEMATICS BUSS CONNECTOR C15 9 32 C16 1 S2 GND C13 6 2 C16 2 GC GND LUG GND22 C16 3 LUG GND C91 2 321C16 4 GND PORT ES0462F BUSS CONN Genie PartNo 123701 GTH 1056 6 13 May 2015 Section 6 Schematics p Harness Map Control System Ground Single Joystick Section 6 Schematics May 2015 Harness Control System Power Dual Joystick Section 6 Schematics Harness Map Control System Power Dual Joystick RIGHT May 2015 FUEL SENDER a FUEL RET 86 1 lt lt 10 9 FUEL TANK
126. Y73 Right Stabilizer Down WH White Y74 Right Stabilizer Up WH BK White Black AC Control WH RD White Red 6 8 GTH 1048 GTH 1056 Part No 123701 May 2015 Section 6 Schematics EEE Telematics Connector Legend Genie installed Telematics connector is wired with an Active High digital input e A Deutsch plug p n DTO6 08SA mates with the Genie Telematics connector Pin Circuit Type Circuit Properties Genie Machine Function s Telematics Use Case 12 VDC Battery Positive constant 1 System Power 5 Amp Max allowed draw power Supply power to device 2 System Ground 0 VDC Battery Negative Device GND Engine Run Hour meter 3 Digital Output1 12 VDC Monitor Engine Hours 12V engine run OV engine off 4 Digital Output2 12 VDC Boom Angle Status i Monitor machine utilization 0V boom 55 12V boom gt 55 5 Digital Output3 12 VDC Parking Brake m Monitor machine utilization 12V active OV inactive Remote Machine Disable 6 Digital Input 1 12 VDC Configurable Active High or Active Remote Engine Shutdown Low via wiring at the Disable Relay 7 CAN HIGH J1939 Databus HIGH J1939 Receive J1939 Engine data CAN LOW J1939 Databus LOW J1939 Receive J1939 Engine data Remote Disable Relay Configuration Telematic device software should monitor that Pin 3 is at OV before activating Disable Relay Telematics Active High Schematic Telematics Active Low
127. acket onto the 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 Part No 123701 March 2015 Section 4 Repair Procedures Operator s Compartment 2 1 3 Locate the secondary function manifold under Operator s Compartment How to Remove the Operator s Compartment The operator s compartment is used to activate machine functions while sitting in the operator s drivers seat Within the operator s compartment there is a transmission column shifter steering selector 4 way controller accelerator pedal brake pedal and a differential lock switch All of these components are replaceable For further information or assistance consult the Genie Industries Service Department AWARNING 00 injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is required 1 Open the access door above the hydraulic tank 2 Disconnect the battery from the machine AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Part No 123701 Genie GTH 1048 GTH 1056 4 23 the mani
128. al level Result The light of the proximity switch assembly is not illuminated The proximity switch is properly calibrated Result The light of the proximity switch assembly is illuminated The proximity switch is not calibrated correctly Repeat this procedure beginning with step 4 PartNo 123701 Genie GTH 1048 GTH 1056 4 3 BOOM COMPONENTS How to Adjust the Boom Extend Proximity Switch The boom extend proximity switch assembly used only on the GTH 1056 is secured to the top surface of the number 0 boom tube at the center of the boom The proximity switch assembly is fixed in position and is not adjustable a angle proximity switch b extend proximity switch GTH 1056 Section 4 Repair Procedures March 2015 BOOM COMPONENTS 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 fast
129. allow oil to squirt or spray Section 4 Repair Procedures March 2015 OPERATOR S COMPARTMENT 10 Tag disconnect and plug the hydraulic hoses at ports J1 J2 J3 and J4 of the primary function manifold Cap the fittings 11 Models with dual joystick Tag disconnect and plug the hydraulic hoses at ports JT2 JT4 JS3 and JS1 of the primary function manifold Cap the fittings 12 Remove the fasteners securing the joystick mount to the operator s compartment Remove the joystick assembly 13 Models with single joystick With the base of the joystick above the top of the hydraulic tank tag disconnect and plug the hydraulic hose at port T of the joystick Cap the fitting Note Removing the hydraulic hose from port T of the joystick with the joystick below the hydraulic oil level in the hydraulic tank will result in excessive hydraulic fluid leaking from the hose Do not disconnect the hose from the joystick if the joystick is below the hydraulic oil level in the hydraulic tank 14 Models with dual joystick Locate the tee fitting which joins together the hydraulic hoses from port T of both joysticks to the tank return hydraulic hose 15 Models with dual joystick With the tee fitting above the top of the hydraulic tank tag disconnect and plug the tank return hydraulic hose from the tee fitting Cap the fitting Note Removing the hydraulic hose from the tee fitting with the tee fitting below the hydraulic oil leve
130. allow oil to squirt or spray Component damage hazard Hoses can be damaged if they are Section 4 Repair Procedures March 2015 2 4 ____ TRANSMISSION kinked or pinched 6 Tag disconnect and plug the hydraulic pump high pressure line at the function manifold Cap the fitting AWARNING 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 Component damage hazard Hoses can be damaged if they are 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 11 Attach a lifting strap from an overhead crane to 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 Genie 4 34 GTH 1048 GTH 1056 Part No 123701 March 2015 Section 4 Repair Procedures 6 1 Hydraulic Pump How to Test
131. ance procedures and additional engine information is available in the Perkins 1104 Operation and Maintenance Manual Perkins part number SEBU7833 01 OR the Perkins 1204 Operation and Maintenance Manual Perkins part number SEBU8605 01 Perkins 1104 Operation and Maintenance Manual Genie part number 117765 Perkins 1204 Operation and Maintenance Manual Genie part number 218726 Part No 123701 September 2014 Section Scheduled Maintenance Procedures E 4 Perform Engine Maintenance Deutz Models Note Engine specifications require that this procedure be performed every 3000 hours V rib belt and tensioning pulley replace Required maintenance procedures and additional engine information is available in the Deutz TCD3 6 Operation Manual Deutz part number 0312 3907 Deutz TCD3 6 Operation Manual CHECKLIST E PROCEDURES E 5 Perform Engine Maintenance Perkins Models Note Engine specifications require that this procedure be performed every 3000 hours 1104 Engine Alternator Belt Inspect Adjust Replace Fuel Injector test change 1204 Engine Alternator inspect Alternator and Fan Belts replace Diesel Particulate Filter clean Radiator Pressure Cap clean replace Genie part number 218707 Required maintenance procedures and additional engine information is available in the Perkins 1104 Operation and Maintenance Manual Perkins part number SEBU7833 01 OR the
132. ard Ignoring active fault codes may result in engine damage 1 Duringnormaloperation engine parameters are visible in the diagnostic display When an engine fault is detected the engine parameters on display are immediately replaced with a WARNING message Also on display are the SPN and FMI codes which are combined to show an engine fault code If the word Next appears at the bottom of the display this indicates that additional active fault codes exist Use the arrow keys to scroll to the next code Press the Enter key to acknowledge the active code and return to the engine parameter display Accessthe Stored Fault Codes 1 Genie GTH 1048 GTH 1056 Turn the key switch to the on position Do not start the engine Press the Menu key Use the Arrow keys to scroll to Stored Codes Press the Enter key to view the stored code If the word Next appears at the bottom of the screen there are additional codes being stored Use the Arrow key to scroll to the next stored code Press the Menu key to return to the main menu Diagnostic display before Serial Number GTH1012 16292 a amber warning light b stop engine light menu key d arrow scroll keys e enter key Part No 123701 September 2014 Section 5 Fault Codes Models from Serial Number GTH1012 16292 The fault code is displayed on the LCD display which is
133. aulic tank 2 Disconnect the battery from the machine AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 3 Fully press and release the brake pedal a minimum of 10 times to release the hydraulic pressure in the brake system 4 Tag disconnect and plug the hydraulic hoses at ports BP and BT of the secondary hydraulic manifold Cap the fittings AWARNING 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 5 Follow the hydraulic hose from port A of the brake pedal manifold to the brake manifold Tag disconnect and plug this hydraulic hose at the brake manifold Cap the fitting 6 Remove the fasteners securing the brake pedal assembly to the dash frame 7 Gentley rotate the brake pedal in an upwards direction and slowly move the brake pedal assembly away from the dash frame while feeding all loose hoses through the opening of the chassis Section 4 Repair Procedures March 2015 OPERATOR S COMPARTMENT How to Remove the Dash Cluster Assembly 1 Open the access door above the hydraulic tank 2 Disconnect the battery from the machine AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all
134. ble bridge Cap the fittings 4 Working at the pivot end of the boom remove the fasteners securing the hose roller assembly to boom tube number 1 Remove the hose roller assembly from the boom 5 Working at the fork end of the boom remove the fasteners securing the cable track mount bracket to boom tube number 3 6 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 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 Section 4 Repair Procedures How to Replace the Retraction Chains Note Perform this procedure on a firm level surface with the boom in the stowed position and the wheels chocked 1 2 3 4 5 Start the engine and allow the engine to idle Raise the boom to a horizontal position Fully retract the boom Extend the boom approximately 1 inch 2 5 cm Turn the machine off and remove the key from the key switch GTH 1056 Working at the fork end of the boom loosen
135. ce seal O ring is seated and retained properly 4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight 5 Tighten the nut or fitting to the appropriate torque per given size as shown in the table 6 Operate all machine functions and inspect the hoses and fittings and related components to confirm that there are no leaks JIC 37 fittings 1 Align the tube flare hex nut against the nose of the fitting body body hex fitting and tighten the hex nut to the body hex fitting to hand tight approximately 30 in Ibs 3 4 Nm 2 Make areference mark on one of the flats of the hex nut and continue it on to the body hex fitting with a permanent ink marker Refer to Figure 1 Part No 123701 Genie GTH 1048 GTH 1056 SPECIFICATIONS v Figure 1 8 TY A N a hex nut b reference mark body hex fitting 3 Working clockwise on the body hex fitting make a second mark with a permanent ink marker to indicate the proper tightening position Refer to Figure 2 Note Use the 37 Fittings table on the previous page to determine the correct number of flats for the proper tightening position Note The marks indicate that the correct tightening positions have been determined Use the second mark on the body hex fitting to properly tighten the joint after it has been loosened 1 7 lt Figure 2 E a hex fittin
136. ches and other jewelry Note If the machine has been in operation allow the coil to cool at least 3 hours before performing this test 1 Tag and disconnect the wiring from the coil to be tested 2 Test the coil resistance using a multimeter set to resistance Q Refer to the Valve Coil Resistance Specification table W Result If the resistance is not within the adjusted specification plus or minus 1096 replace the coil Genie GTH 1048 GTH 1056 Valve Coil Resistance Specification Note The following coil resistance specifications are at an ambient temperature of 68 F 20 C As valve coil resistance is sensitive to changes in air temperature the coil resistance will typically increase or decrease by 4 for each 18 F 20 C that your air temperature increases or decreases from 68 F 20 C Description Specification Solenoid valve 2 position 4 way 8 90 12V DC with diode schematic items AA AD AY AAB and BAA Solenoid valve 2 position 2 way 12V DC with diode schematic items AAC and EA DOS valve 3 position 4 way 12V DC with diode schematic items CA and EB Solenoid valve 2 position 2 way 12V DC with diode schematic items FA Solenoid valve 2 position 3 way 12V DC with diode schematic items CF CO and CP Solenoid valve 2 position 4 way 7 30 12V DC with diode schematic items CG Solenoid valve 3 position 4 way 7 30 12V DC with diode schematic i
137. cified perform each maintenance procedure with the machine in the following configuration Machine parked on a firm level surface Boomin the stowed position Key switch in the off position with the key removed Wheels chocked Part No 123701 Genie GTH 1048 GTH 1056 3 1 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 Symbols Legend Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death ADANGER Indicates an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous ACAUTION situation which if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performing a series of steps Section Scheduled Maintenance Procedures September 2014 SCHEDULED MAINTENANCE PROCEDURES Maintenance Symbols Legend Note The foll
138. cylinder supply hoses at the cylinder manifold Cap the fittings AWARNING 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 Component damage hazard Hoses can be damaged if they are kinked or pinched 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 Genie GTH 1048 GTH 1056 7 Securely connect a 30 feet 10 m length of rope to each end of the hoses disconnected in steps 5 and 6 Securely tie off the other end of each section of rope to the boom structure 8 Working at the pivot end of the boom select 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 in a difficult reassembly Be sure each section of rope is securely attached to both the hose and the boom structure before pulling the hose out of the boom 9 Remove the rope from each end of the hose Discard the hose 10 Securely install a section of rope onto each end of the new hose assembly 11 Install the new hose assembly into the boom in the same manner the hose was removed Using the rope carefully pull the hose through the boom until each end is accessible 12 Install both ends of the hos
139. d of the chain Securely tie off the other end of the rope to the boom structure 11 GTH 1056 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 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 14 On a workbench remove the bow tie clip securing the chain anchor pin to the chain assembly Remove the pin and chain anchor pin from the assembly Section 4 Repair Procedures March 2015 BOOM COMPONENTS 15 Install the chain anchor pin and clip onto the new chain 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 rope to carefully pull the chain through the boom just until the end of the chain is accessible 18 Working at the pivot end of the boom and using the fasteners removed in step 12 install the chain anchor onto the boom tube Securely tighten the fasteners Do not over tight
140. draulic pump onto the transmission Install the fasteners and tighten to finger tight Torque the fasteners evenly to 85 ft Ibs 115 Nm Install the smaller high pressure hose onto the pump outlet Torque the fasteners to 27 37 ft lbs 37 50 Nm Install the larger low pressure hose onto the pump outlet Install the hose retaining rings and fasteners Torque the fasteners to 55 66 ft Ibs 74 90 Nm 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 Install the case drain hose onto the pump and torque to specification Refer to Section 2 Specifications Securely install the wire harness onto the pump Check the level of the hydraulic fluid in the hydraulic tank Add fluid if needed Part No 123701 Genie GTH 1048 GTH 1056 4 37 Section 4 Repair Procedures HYDRAULIC PUMP 9 Prime the pump See 6 1 How to Prime the Function Pump 10 Start the engine and inspect for leaks 11 Turn the machine off 12 Adjust the pump pressure See 6 1 How to Adjust the Function Pump Standby Pressure and How to Adjust the Function Pump Pressure Pressure Compensator Section 4 Repair Procedures March 2015 HYDRAULIC PUMP How to Prime the Function Pump Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer
141. dures MANIFOLDS GC 60 9 9 e 2 e e lt o Q d Y67 e 5 OW CK P 9 GO G Note alpha callouts refer 13 55 to corresponding notes NJ the hydraulic schematic 9 alphanumeric callouts refer to the electrical schematic qa e A NS PS6 Genie Part No 123701 GTH 1048 GTH 1056 4 51 Section 4 Repair Procedures March 2015 MANIFOLDS 7 4 Outrigger Manifold Components The outrigger manifold is located under the outrigger inspection cover Index Schematic No Description Item Function Torque 1 Solenoid valve 3 position 4 way us 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 Flow regulator valve 6 22 7 DC Right outrigger 25 ft lbs 34 Nm 4 Flow regulator valve 6 22 7 DD Left outrigger circuit esses 25 ft lbs 34 Nm 5 Check valve 5 psi 0 3 bar
142. e F1 15 Amp Break Shift F2 10 Amp Aux Hydraulics F3 10 Amp Rear Axle Oscillate F4 10 Amp Sway Tilt F5 5 Amp Horn F6 5 Amp Steer Differential Switch F7 5 Amp Gauge Cluster Power F8 5 Amp Dome Beacon Light F9 25 Amp HVAC F10 15 Amp Windshield Wiper Washer F11 10 Amp Defrost Fan F12 20 Amp Lights F13 15 Amp Ignition F14 10 Amp Power Port F15 1 Amp Switch Power F16 1 Amp Gauge Cluster ECU F17 Spare F18 Spare F21 HVAC Control Panel Part No 123701 L ooz Genie LED Light L1 Ignition Power ON L2 Options Power Relay ON L3 Horn Relay ON L4 Turn Signal ON L5 Road Lights Work Lights ON L6 Sway Enable Coil Power ON L7 Boom Angle ON L8 Boom Extend ON L9 Brake Pressure ON L10 Backup Light Alarm ON L11 Parking Brake Latch ON L12 Sway Enable ON L13 Tilt Circuit Power ON L14 Horn Power ON L15 Cab Tail Light Power ON L16 Rear Axle Float Coil Power ON L17 Rr Ax Fast Power GTH1056 ON L18 Parking Brake Power ON L19 Forward Coil Power ON L20 Reverse Coil Power ON L21 PB Release Coil Power ON L22 Sway L R Enable Coil Power ON L23 Tilt U D Enable Coil Power ON L24 Forward Shift ON L25 Parking Brake Release OFF L26 Brake Light Power ON L27 Hazard Power ON L28 Not Used Motor Resistor Switch 1 Key Start Switch S2 Parking Brake Switch S3 Boom Angle Switch S4 Boom Extend Switch S5 Parking Brake Pressure Switch S6 Service Brake Pressure Switch S7 Sway Enable Pressure Switch S
143. e ZF 4 WG 98 TC Maintenance Manual ZF part number 5872 134 002 ZF 4 WG 98 TC Operating Manual Genie part number 1258405 Genie 3 30 1048 GTH 1056 PartNo 123701 September 2014 Section Scheduled Maintenance Procedures Checklist E Procedures E 1 Test or Replace the Hydraulic Oil Genie specifications require that this procedure be performed every 2000 hours or two years whichever comes first Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more 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 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 Part No 123701 Genie
144. e tensioner mount at the fork end of boom tube number O Install the mounting components removed in step 7 Evenly tighten the chain tensioners to the top of the boom tube until they 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 are securely tightened 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 have been correctly adjusted Genie 4 8 GTH 1048 GTH 1056 How to Replace the Extension Chains Note Perform this procedure on a firm level surface with the boom in the stowed position and the wheels chocked 1 Start the engine and allow the engine to idle 2 Raise the boom to a horizontal position 3 Fully retract the boom 4 Turn the machine off and remove the key from the key switch 5 GTH 1056 Working at the fork end of the boom loosen the fasteners securing the dual chain tensioner to the top of boom tube number 1 After noting the orientation and assembly order of the components remove the fasteners and pull the tensioner free of the boom Refer to Illustration 1 Illustration 1 tube 3
145. e assembly onto the correct connection points Torque to specification Refer to Section 2 Specifications 13 Repeat this procedure for the remaining hose to be replaced beginning with step 8 14 Remove the lifting strap from the fork frame 15 Install the cover onto the rear of the boom Install and securely tighten the retaining fasteners Part No 123701 March 2015 Section 4 Repair Procedures How to Replace the Fork Level and or Auxiliary Cylinder Hoses GTH 1056 Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications Replace the lower hoses 1 Fully retract the boom 2 Fully lower the tips of the lifting forks 3 Remove the covers from the pivot end of the boom 4 Attach a lifting strap from an overhead crane to the top of the lifting fork frame Support the frame Do not apply any lifting pressure 5 Working at the pivot end of the boom remove the fasteners securing the cable bridge rear mount bracket to the boom assembly Remove the bracket from the boom 6 Tag disconnect and plug the hydraulic hoses at the hard lines of the cable bridge Cap the fittings AWARNING edd injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate graduall
146. e inner or secondary filter element 4 Clean the inside of the canister and the gasket with a damp cloth 5 Inspect the primary and secondary air filter elements If needed blow from the inside out using low pressure dry compressed air or carefully tap out dust 6 Install the secondary filter element first then install the primary filter element 7 Install the front cover onto the air cleaner assembly and secure the latches Genie GTH 1048 GTH 1056 B 5 Inspect the Tires Wheels and Lug Nut Torque Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the tires and wheels in good condition including proper wheel fastener torque is essential to safe operation and good performance Tire and or wheel failure could result in a machine tip over Component damage may also result if problems are not discovered and repaired in a timely fashion AWARNING P fdily injury hazard An overinflated tire can explode and could result in death or serious injury AWARNING Tip over hazard Do not use temporary flat tire repair products Note The tires on some machines are foam filled and do not need air added to them 1 Check all tire treads and sidewalls for cuts cracks punctures and unusual wear 2 Check each wheel for damage bends and cracks 3 Check each lug nut for proper torque Refer to Section 2 Specifications Part No 123701 September 20
147. e performance and service life Running the engine with a damaged or leaking exhaust System can cause component damage and unsafe operating conditions AWARNING injury hazard Do not inspect while the engine is running Remove the key to secure from operation Bodily injury hazard Beware of ACAUTION hot engine components Contact with hot engine components may cause severe burns 1 Remove the center engine cover and set aside Open the right side engine access cover Be sure that all fasteners are tight Inspect all welds for cracks A N 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 Section Scheduled Maintenance Procedures September 2014 CHECKLIST B PROCEDURES B 4 Inspect the Engine Air Filter Genie requires thatthis procedure be performed every 250 hours or quarterly whichever comes first Perform this procedure more often if dusty conditions exist Maintaining the engine air filter in good condition is essential to good engine performance and service life Failure to perform this procedure can lead to poor engine performance and component damage Note Perform this procedure with the engine off 1 Release the latches on the front cover of the air cleaner assembly Remove the cover 2 Gently twist and pull out the external or primary filter element 3 Remove th
148. e pump is EA C MARAN E functioning correctly Proceed to step 6 ul iii 2 Result The pressure gauge fails to read 450 25 psi 31 1 7 bar The pressure setting needs to be adjusted Proceed to step 4 noc 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 standby pressure adjustment screw decrease the pressure Tighten the set screw set screw c hydraulic supply line from tank 6 Turn the engine off and remove the pressure gauge AWARNING al injury hazard Spraying ydraulic 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 Genie Part No 123701 GTH 1048 GTH 1056 4 39 Section 4 Repair Procedures March 2015 HYDRAULIC PUMP How to Adjust the Function Pump Pressure Compensator Note Two people will be required to perform this procedure 1 Connect a 0 to 5000 psi 0 to 350 bar 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 Start the engine and allow the engine to run at low idle 3 Fully retract the boom Continue to activate the boom retract function and observe the pressure reading
149. eaction generated Target range to high for oil pressure sensor Target range to low for oil pressure sensor 108 Target range to high for ambient air pressure sensor Target range to low for ambient air pressure sensor 110 Coolant temperature is out of target range system reaction generated Target range to high for coolant temperature sensor Target range to low for coolant temperature sensor Genie 5 8 1048 1056 PartNo 123701 September 2014 Section 5 Fault Codes ENGINE FAULT CODES MODELS WITH DEUTZ POWER SPN Suspect Parameter Number ASPN Alternate Suspect Parameter Number FMI Failure Mode Identifier SPN ASPN FMI Description 111 1 Coolant level underneath the allowed minimum 157 Target range to high for rail pressure sensor Target range to low for rail pressure sensor 168 Battery voltage is out of the target range to high Battery voltage is out of the target range to low Battery voltage is out of the target range warning condition is generated Target range to high for battery voltage sensor Target range to low for battery voltage sensor 172 Ambient air temperature sensor value is not plausible Target range to high for intake air sensor Target range to low for intake air sensor 174 175 Low fuel temperature is out of target range system reaction generated Oil temperature is out of target range system reacti
150. econdary Function Manifold Components 6 Startthe engine Allow the engine to idle O Result The pressure gauge reads 400 psi 27 5 bar The pressure setting is correct Proceed to step 11 W Result The pressure gauge fails to read 400 psi 27 5 bar The pressure setting needs to be adjusted Proceed to step 7 7 Turn the machine off Hold the steer pressure reducing relief valve with a wrench and remove the cap schematic item CC 8 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Component damage hazard Do not adjust the relief valve pressures higher than specifications 9 Install the relief valve cap 10 Repeat this procedure beginning with step 6 11 Turn the machine off Remove the pressure gauge from the test port AWARNING 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 Part No 123701 March 2015 Section 4 Repair Procedures How to Set the Rear Lock up System Pressure Note Be sure that the hydraulic oil level is visible in the inspection glass of the hydraulic tank 1 Install a O to 1000 psi to 100 bar pressure gauge into test port TP at the top of the primary function manifold schematic item AAA or BZ See 7 1 or 7 2 Primary Function Manifold Components
151. ector Solenoid Injector Failed or Flow Limiter Closed Contact Servicing Dealer Contact Servicing Dealer Check Injector Wiring or Injector Solenoid Check Injector Wiring or Injector Solenoid Injector Failed or Flow Limiter Closed Contact Servicing Dealer Contact Servicing Dealer Check Injector Wiring or Injector Solenoid Check Injector Wiring or Injector Solenoid Injector Failed or Flow Limiter Closed Contact Servicing Dealer Contact Servicing Dealer Check Injector Wiring or Injector Solenoid Check Injector Wiring or Injector Solenoid Injector Failed or Flow Limiter Closed Contact Servicing Dealer Check Relay and Wiring Check Relay and Wiring Contact Servicing Dealer Non Engine Fault Check Other Shutdown Devices Non Engine Fault Check Other Shutdown Devices Check Wiring Check Wiring Check Wiring Check Wiring Check Fault Codes Check Fault Codes Contact Servicing Dealer Contact Servicing Dealer Contact Servicing Dealer Contact Servicing Dealer Contact Servicing Dealer 5 6 1048 1056 Part No 123701 September 2014 SPN 001180 001209 001347 001569 002630 002659 002790 002791 002795 523222 523229 FMI 00 16 02 03 04 03 05 07 31 03 04 15 16 02 15 17 16 02 03 04 05 06 07 13 31 07 12 03 04 03 04 Description of Fault Turbo Turbine Inlet Temperature High Most Severe Turbo Turbine Inlet Temperature High Moderatel
152. ector open circuit Cylinder 2 injector short Cylinder 2 injector not responding 653 Cylinder 3 injector data incorrect Cylinder 3 injector open circuit Cylinder 3 injector short Cylinder 3 injector not responding 654 Cylinder 4 injector data incorrect Cylinder 4 injector open circuit Cylinder 4 injector short Cylinder 4 injector not responding 678 8V DC supply short to battery positive 8V DC supply shorted to ground 723 1188 1196 1347 Secondary engine speed signal abnormal Turbo wastegate drive current low Machine security system module non communication Fuel rail pump output current low Fuel rail pump output current high Fuel rail pressure valve solenoid not responding 2882 3509 3509 Mode selector switch data erratic intermittent or incorrect 5V DC power supply sensor short to battery positive 5V DC power supply sensor short to ground For further engine fault code troubleshooting and diagnostic information refer to the Perkins 1100 Troubleshooting Manual Perkins part number SENR9982 01 Perkins 1100 Troubleshooting Manual Genie part number 123583 Genie PartNo 123701 GTH 1048 GTH 1056 5 27 Section 5 Fault Codes September 2014 This page intentionally left blank Genie 5 28 GTH 1048 GTH 1056 PartNo 123701 May 2015 Section 6 Schematics Observe and Obey Troubleshooting and repair procedu
153. edures Part No 123701 INMOCUCHON E 3 1 Pre delivery Preparation 3 3 Maintenance Inspection 3 5 Genie GTH 1048 GTH 1056 ix May 2015 TABLE OF CONTENTS Section 3 Scheduled Maintenance Procedures continued Checklist A Procedures 1 Inspect the Manuals and 3 6 2 Perform Pre operation Inspection 3 7 Perform Function Tests 2 00 0 11121 3 7 A 4 Lubricate the 4 4444 3 8 5 Perform Engine 3 8 6 Perform Transmission Maintenance All Models 3 9 7 Perform 30 Day 2 000 000 3 9 8 Perform Axle Maintenance 3 10 9 Perform Engine Maintenance John Deere Models 3 10 A 10 Perform Axle 2 3 11 A 11 Perform Axle 3 11 Checklist B Procedures B 1 Inspect the 20 0 1 11 3 12 B 2 Inspect the Electrical Wiring seeeeee 3 12 B 3 Check the Exhaust System s sss 3 13 B 4 Inspect the Engine Air Filter 3 14 B 5 Inspect the Tires Wheels and Lug Nut
154. eive Frame DM19Vol1 NOX sensor upstream 23993 65241 9 Timeout Error of CAN Receive Frame DM19Vol2 NOX sensor downstream 23995 65243 13 check of missing injector adjustment value programming IMA injector 7 in firing order 23996 65244 13 check of missing injector adjustment value programming IMA injector 8 in firing order Genie PartNo 123701 GTH 1048 GTH 1056 5 21 Section 5 Fault Codes September 2014 pm s ENGINE FAULT CODES MODELS WITH DEUTZ POWER SPN Suspect Parameter Number ASPN Alternate Suspect Parameter Number FMI Failure Mode Identifier SPN ASPN FMI Description 23998 65246 4 Injector cylinder bank 2 slave short circuit 23999 65247 12 Injector powerstage output Slave defect 24000 65248 3 Injector 7 in firing order short circuit High side to low side short circuit in the injector 7 in firing order Injector 7 in firing order interruption of electric connection Injector 8 in firing order short circuit High side to low side short circuit in the injector 8 in firing order Injector 8 in firing order interruption of electric connection 24004 65252 Too many recognized misfires in cylinder 7 in firing order 24005 65253 12 Too many recognized misfires in cylinder 8 in firing order 24001 65249 Nia A OJO 24011 65259 0 Zerofuel calibration injector 7 in firing order maximum value exceeded 1 Zerofuel calibration
155. ely Severe 31 Oil Pressure Detected with Zero Engine Speed 000102 02 Manifold Air Pressure Sensor In Range Failure 03 Manifold Air Pressure Voltage Out of Range High 04 Manifold Air Pressure Voltage Out of Range Low 000103 00 Turbocharger Speed High Most Severe 02 Turbocharger Speed Data Incorrect 05 Turbocharger Harness Open Circuit 06 Turbocharger Harness Shorted To Ground 08 Turbocharger Speed Signal In Range Failure 31 Turbocharger Speed Signal Missing 000105 00 Exhaust Gas Recirculation Air Temperature High Most Severe 03 Exhaust Gas Recirculation Air Temperature Input Voltage Out of Range High 04 Exhaust Gas Recirculation Air Temperature Input Voltage Out of Range Low 15 Exhaust Gas Recirculation Air Temperature High LeastSevere 16 Exhaust Gas Recirculation Air Temperature High Moderately Severe 000108 02 Barometric Air Pressure Sensor Signal Invalid 31 Barometric Air Pressure Sensor Signal Invalid 000110 00 Engine Coolant Temperature High Most Severe 03 Engine Coolant Temperature Input Voltage Out of Range High 04 Engine Coolant Temperature Input Voltage Out of Range Low 15 Engine Coolant Temperature High Least Severe 16 Engine Coolant Temperature High Moderately Severe 17 Engine Coolant Temperature Low Least Severe Genie September 2014 Ss SSS Corrective Action Check Sensor and Wiring Check Sensor and Wiring Contact Servicing Dealer Check Sensor and Wiring Check Sensor and Wiring Contact Servicing Dealer C
156. emoved from the machine 4 66 GTH 1048 GTH 1056 Part No 123701 September 2014 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 the repair of this machine ADANGER Crushing testing 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 AWARNING with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a firm level surface Bodily injury h d S AWARNING injury hazard Spraying 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 ve
157. en 19 Remove the rope from the chain and install the chain into the chain anchor of the tensioner assembly Secure the chain to the chain anchor using the pin and clip removed in step 8 20 Repeat this procedure beginning with step 10 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 number O Install the mounting components removed in step 6 Evenly tighten the chain tensioners to the top of the boom tube until they are securely tightened Genie GTH 1048 GTH 1056 24 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 7 Evenly tighten the chain tensioners to the top of the boom tube until they are securely tightened 25 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 have been correctly adjusted Part No 123701
158. eners 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 accion Rm the Boom rushing hazard The fork frame ACAUTION could fall if not properly supported when the lock pin is removed from 4 Install the wear pads Install and securely tighten the fasteners Do not over tighten Note Do not lubricate the side wear pads Genie 4 4 GTH 1048 GTH 1056 Part No 123701 March 2015 Section 4 Repair Procedures How to Remove the Cable Bridge Assembly GTH 1056 Inside the four section boom of the GTH 1056 a cable bridge is used to route hydraulic lines through the boom assembly to the fork level cylinder and auxiliary connections if equipped The three section boom on the GTH 1048 does not require the use of a cable bridge 1 Remove the inspection cover at the pivot end of the boom 2 Working at the pivot end of the boom remove the fasteners securing the cable bridge rear mount bracket to the boom assembly Remove the bracket from the boom a cable bridge mount bracket b cable track mount bracket cable bridge slider Part No 123701 Genie GTH 1048 GTH 1056 BOOM COMPONENTS 3 Working at the pivot end of the boom tag disconnect and plug the hydraulic hoses at the hard lines of the ca
159. er transmission shift coil F drive forward function blue wire d transmission shift coil R drive reverse function brown wire e transmission shift coil 2 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 Genie GTH 1048 GTH 1056 Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Open the access door above the hydraulic tank 2 Disconnect the battery from the machine AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 3 Place a drain pan or other suitable container under the hydraulic tank Refer to Section 2 Specifications 4 Remove the drain plug from the hydraulic tank and completely drain the tank Bodily injury hazard Beware of ACAUTION 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 AWARNING 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
160. ere they attach to the chain anchor mount at the lower side of boom tube 2 and 3 Refer to Illustration 3 GTH 1048 Locate the chain anchor of the boom retraction chain where it attaches to the chain anchor mount at the lower side of boom tube 3 Refer to Illustration 4 Illustration 3 a chain anchor boom tube number 3 b chain anchor boom tube number 2 Illustration 4 a chain anchor Part No 123701 Genie GTH 1048 GTH 1056 BOOM COMPONENTS 11 Select a chain anchor Remove the fasteners securing the chain anchor pivot pin to the anchor mount of the boom tube Remove the pivot pin and pull the chain anchor free of the mount 12 Using a strap from an overhead crane support the extend cylinder Do not apply any lifting pressure 13 Working at the fork end of the boom remove the fasteners securing the boom extend cylinder pivot pin to the boom 14 Use a soft metal drift to remove the pivot pin 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 chain out of the boom Note Rope coming l
161. ere with the removal of the engine from the chassis 16 Remove the fasteners securing the driveshaft to the transmission Secure the bearing caps onto the universal joint of the driveshaft Note Using adhesive tape to secure the caps to the universal joint may be helpful 17 Remove the fasteners securing the engine tray to the chassis 18 Support and secure the engine tray to a forklift of adequate capacity 19 Remove the engine tray from the machine Section 4 Repair Procedures March 2015 ENGINES 4 2 Engine Fault Codes How to Retrieve Engine Fault EI T 0 6 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
162. es at the lift cylinder manifold Cap the fittings on the cylinder manifold Part No 123701 Genie GTH 1048 GTH 1056 BOOM COMPONENTS 9 Remove the fasteners securing the lift cylinder barrel end pivot pin to the chassis 10 Support and secure the barrel end of the lift cylinder to the boom 11 Use a soft metal drift to remove the lift cylinder pivot pin 12 Repeat this procedure beginning with step 8 for the other lift cylinder 13 Tag disconnect and plug the hydraulic hoses at the hydraulic hard line connections at the pivot end of the boom Cap the fittings 14 Using the overhead crane raise the boom to a horizontal position Crushing hazard The lift cylinders AWARNING will fall if not properly supported when the boom is raised 15 Remove the fasteners securing the boom pivot pin to the chassis 16 Use a soft metal drift to remove the boom pivot pin Crushing hazard The boom will fall if not properly supported when the pivot pin is removed from the machine 17 Carefully remove the boom assembly from the machine and place it on a structure capable of supporting it Crushing hazard The boom could become unbalanced and fall if not properly supported when removed from the machine Component damage hazard The weight of the boom assembly may crush the hydraulic hard lines under the boom Use caution when placing the boom assembly onto a structure capable of supporting it Section 4 Repair P
163. extension chains dual chain tensioner tube 2 extension chains single chain tensioner boom tube number 0 boom tube number 1 boom tube number 2 boom tube number 3 ro Q0 0M Part No 123701 March 2015 GTH 1056 Working at the fork of the boom loosen evenly the fasteners securing the single chain tensioners to the top of boom tube number 0 After noting the orientation and assembly order of the components remove the fasteners and pull the tensioners free of the boom Refer to Illustration 1 GTH 1048 Working at the fork end of the boom loosen the fasteners securing the single chain tensioners to the top of boom tube number 1 After noting the orientation and assembly order of the components remove the fasteners and pull the tensioners free of the boom Refer to Illustration 2 Illustration 2 extension chains single chain tensioner boom tube number 1 boom tube number 2 boom tube number 3 Part No 123701 Genie GTH 1048 GTH 1056 4 9 Section 4 Repair Procedures BOOM COMPONENTS 8 Select a chain tensioner Remove the bow tie clip securing the chain anchor pin to the chain assembly Remove the chain anchor pin from the assembly and remove the chain anchor from the tensioner assembly 9 Repeat this procedure beginning with step 8 for the other chains 10 Working at the fork end of the boom select a chain Securely connect a 30 foot 10 m length of rope to the en
164. fold Components The AC Hydraulic manifolds are located under the manifold inspection cover Index Schematic No Description Item Function Torque 1 Solenoid valve 2 position 2 WAY FA Controls 20 ft lbs 27 1 Nm 2 Flow control valve 3 gpn 11 3 FB Regulates 33 37 ft lbs 45 50 Nm 2 Note alphanumeric callouts refer to corresponding notes on the electrical and hydraulic schematics Genie 4 56 GTH 1048 GTH 1056 PartNo 123701 March 2015 Section 4 Repair Procedures MANIFOLDS This page intentionally left blank Genie PartNo 123701 GTH 1048 GTH 1056 4 57 Section 4 Repair Procedures March 2015 MANIFOLDS 7 8 Valve Adjustments Secondary Function Manifold How to Set the Steer System Pressure Note Be sure that the hydraulic oil level is visible in the inspection glass of the hydraulic tank 1 Install a O to 1000 psi O to 100 bar pressure gauge into test port TP at the top of the primary function manifold schematic item AAA or BZ See 7 1 or 7 2 Primary Function Manifold Components 2 Startthe engine Allow the engine to idle after warming the engine to operating temperature 3 Without operating any machine controls observe the reading on the
165. fold inspection cover Tag disconnect and plug the hydraulic hoses at ports BP and BT of the secondary function manifold Cap the fittings See 7 8 Secondary Function Manifold Components 4 Locate the brake manifold under the manifold inspection cover Tag disconnect and plug the hydraulic hose at the underside of the brake manifold Cap the fitting See 7 6 Brake Manifold Components 5 Working under the dashboard locate the hydraulic hose at port L of the steering orbitral 6 Working at the front axle locate the hydraulic hose connected to the front axle steer cylinder at the operator s compartment side of the machine Tag disconnect and plug the hydraulic hose Cap the fitting 7 Tag disconnect and plug the hydraulic hoses at ports SUP SUR and SUT of the secondary function manifold Cap the fitting AWARNING 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 8 Tag disconnect and plug the hydraulic hose at port SULS of the primary function manifold Cap the fitting 9 Tag disconnect and plug the hydraulic hose at port JP of the secondary function manifold Cap the fitting AWARNING 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
166. ft right circuit 12 14 ft Ibs 16 19 Nm 21 Check valve 5 psi 0 3 bar BU Fork tilt up circuit 12 14 ft Ibs 16 19 Nm 22 Check valve 5 psi 0 3 bar BV Boom up 12 14 ft Ibs 16 19 Nm 23 Check valve 5 psi 0 3 bar BW Boom retract circuit 12 14 ft Ibs 16 19 Nm 24 Directional valve 2 position 2 way pilot operated BX Fork tilt circuit eese 25 ft lbs 34 Nm 25 Diagnostic nipple Test port TP 26 Solenoid valve 2 position 2 way Function select sway left right 20 ft Ibs 27 Nm Genie 4 48 GTH 1048 GTH 1056 Part No 123701 March 2015 Section 4 Repair Procedures MANIFOLDS Note alpha callouts refer to corresponding notes on the hydraulic schematic alphanumeric callouts refer to the electrical schematic BM BN 9 YE View B ES 5 G2 3 _ o 4 w BR 18 Genie Part No 123701 GTH 1048 GTH 105
167. function Working at the fork end of the boom tag disconnect and plug the auxiliary hoses at the fittings Cap the fittings Genie GTH 1048 GTH 1056 10 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 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 11 Remove the fasteners securing the cable track to the cable track mount bracket 12 Remove the fasteners securing the cable track mount bracket to the cable bridge Remove the bracket from the boom 13 Carefully pull the cable track through the opening at the front of boom until the hose connections are accessible 14 Tag disconnect and plug the affected hoses Cap the fitting Remove the hose from the cable track 15 Install the new hose assembly and torque to specification Refer to Section 2 Specifications 16 Install the cable bridge and cable track into the boom 17 Install the cable track mount bracket and cable bridge slider Securely tighten all fasteners Do not over tighten 18 Working at the pivot end of the boom install the hydraulic hoses onto the hard lines of the cable bridge and torque to specification Refer to Section 2 Specifications 19 Install the cable bridge mount br
168. g b reference mark second mark Section 2 Specifications September 2014 SPECIFICATIONS 4 Tighten the hex nut until the mark on the hex nut is aligned with the second mark on the body hex fitting 5 Operate all machine functions and inspect the hoses and fittings and related components to confirm that there are no leaks Genie 2 16 GTH 1048 GTH 1056 Part No 123701 September 2014 Section 2 Specifications SPECIFICATIONS SAE FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual A574 High h Grade 8 62 5 igh Strengt Black Oxide Bolts LUBED DRY LUBED DRY LUBED Nm Nm _ Nm _ TiO 140 130 120 760 740 LUBED DRY LUBED DRY LUBED ft Ibs 13 18 74 20 23 53 26 37 14 7 15 8 I 2 o Q 24 27 1 44 7 50 1 67 8 25 27 44 49 70 33 9 28 4 36 6 32 5 59 6 51 5 at 98 66 4 43 583 631 68 9 Nm A 37 50 di 20 64 867 one 12 80 108 4 110 1 120 18 o 122 10 162 130 160 780 m 280 379 810 420 ze 19 320 483 430 583 450 60 60 878 60 908 759 480 650 640 867 680 92 910 1233 1044 12 718 710 962 750 3016 950 1342 1139 1749 1477 8 1952 1654 TY 2074 1 2304 3620 160 2067 METRIC FASTENER TORQUE CHART This c
169. g line on each end of the chain being sure to pull the string taut 4 Atthe midpoint of the string measure the distance between the string and the chain surface corresponding to the surface the string line is attached to Result The distance is 0 25 to 0 5 inch 6 35 to 12 7 mm No adjustment to the chain is necessary Proceed to step 8 Result The distance is less than a 0 25 inch 6 35 mm OR is greater than 0 5 inch 12 7 mm The chain requires adjustment Proceed to step 5 5 Working at the fork end of the large boom tube locate the adjustable chain anchor on the top of the boom section String Line SOCDCDE 9X6 9X6 9X6 9X6 DE Part No 123701 September 2014 Section Scheduled Maintenance Procedures 6 Place an adjustable wrench across the flat part of the chain just ahead of the chain anchor Tighten the wrench onto the chain 7 Using a1 7 16 inch wrench adjust the nut as required to tighten or loosen the chain Repeat this procedure beginning with step 4 until the gap is between 0 25 to 0 5 inch 6 35 to 12 7 mm Note If the adjusting bolt runs out of threads before the chain tension is correct the chain has stretched too far and the chain must be replaced D 99969696 DE O OO O 559 zu nut washer spacer chain anchor 8 Fully retract the
170. gnostic display PS7 Low brake pressure Y71 Sway right enable G11 Fuel level PS8 Sway Y72 Tilt G12 Tachometer PX Proximity switch Y73 Right outrigger extend H Horn PX1 Boom extend Y74 Right outrigger retract H2 Auto style horn PX2 Boom angle Y75 Left outrigger extend H5 Multifunction alarm S Sensor Y76 Left outrigger retract KS1 Key switch 1 Engine coolant temperature Y77 Auxiliary S2 Engine oil pressure Y78 4 wheel steer select 11 Transmission oil temperature Y79 Crab steer select 12 Transmission oil pressure Y80 Transmission D 13 Fuel level Y81 Transmission E Y82 Sway enable Y83 Rear axle oscillate fast Genie 6 6 GTH 1048 GTH 1056 PartNo 123701 May 2015 SS Ti Electrical Component Legend from serial number GTH1012 16292 ALT CB CR Section 6 Schematics Electrical Component amp Wire Color Abbreviation Legend Alternator Battery B1 Main Battery Circuit Breaker CB1 50 Amp Circuit Breaker CB2 30 Amp Circuit Breaker CB3 60 Amp Circuit Breaker Capacitor C1 4700 uf Control Relay CR1 Main Power CR2 Options Power CR3 Service Horn CR4 Flasher CR5 Lights Option CR6 Sway Enable CR7 Boom Angle CR8 Boom Extend CR9 Forward Enable CR10 Reverse Enable CR11 Parking Brake Latch CR12 Sway Left Right Enable CR13 Tilt Up Down Enable CR15 HVAC Blower L CR16 HVAC Blower M CR17 HVAC Blower H Diode Engine Control Unit Fus
171. hart is to be used as a guide only unless noted elsewhere in this manual Size 6 46 Class 8 8 Class 10 9 03 Class 12 9 mm 6 L7 94 7 82 7 108 4 2 149 162 142 203 176 230 189 281 244 325 271 515 133 569 474 827 691 N e e N 108 4 122 162 176 217 244 110 120 150 170 210 240 380 420 A Poy oa 5 8 gt o DRY 884 68 775 91 195 32 DRY DRY 7 600 458 622 612 830 536 727 715 970 B5 570 562 762 583 791 778 055 682 925 909 1293 Genio PartNo 123701 1048 1056 2 17 E c iv 1 ile c wo ile c c ile ER c 00 D D o o N EN alo OW CO ol Al a O1 CO CO zx A A o 5 T NI A a a c 07 9 lt c 0 le ER Ee c 0 1 c 0 1 A mI PSN SJA e N s PORSA baa ESDS AR N N T P E eo E AR m ER d ol lt e zv NIS Nin oo RINI Cyn Copco NI ojoj o AININ RO OF CO o Tu 24 i Oy OY 0
172. he ground wire of the steer column 12 Support and secure the steer orbitral to the dash frame 13 Remove the fasteners securing the steer column and steer orbitral to the dash frame 14 Lower the steer orbitral and remove the steer column from the machine How to Remove the Steering Wheel 1 Open the access door above the hydraulic tank 2 Disconnect the battery from the machine AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 3 Remove the horn button from the steering wheel Remove the nut securing the steering wheel to the column and remove the steering wheel Section 4 Repair Procedures March 2015 OPERATOR S COMPARTMENT How to Remove the Steer Orbitral 1 Remove the steering column See 2 2 How to Remove the Steering Column 2 Working under the dashboard locate the hydraulic hose at port L of the steering orbitral 3 Follow the hydraulic hose from port L of the steer orbitral to its connection at the front axle of the machine Tag disconnect and plug the hydraulic hose at the front axle Cap the fitting t LS LO TO 4 Tag disconnect and plug the hydraulic hoses at ports SUP SUR and SUT of the secondary function manifold Cap the fitting AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraul
173. heck Switch and Wiring Check Switch and Wiring Check Sensor and Wiring Check Sensor and Wiring Check Sensor and Wiring Check Sensor and Wiring Check Sensor and Wiring Stop and Drain Water Separator Check Oil Level Check Sensor and Wiring Check Sensor and Wiring Check Oil Level Contact Servicing Dealer Contact Servicing Dealer Contact Servicing Dealer Contact Servicing Dealer Contact Servicing Dealer Contact Servicing Dealer Contact Servicing Dealer Contact Servicing Dealer Contact Servicing Dealer Contact Servicing Dealer Check Air Cleaner Aftercooler or Room Temperature Check Sensor and Wiring Check Sensor and Wiring Check Air Cleaner Aftercooler or Room Temperature Check Air Cleaner Aftercooler or Room Temperature Contact Servicing Dealer Contact Servicing Dealer Check Cooling System Reduce Power Check Sensor and Wiring Check Sensor and Wiring Check Cooling System Reduce Power Check Cooling System Reduce Power Check Cooling System 5 4 1048 1056 Part No 123701 September 2014 Section 5 Fault Codes ENGINE FAULT CODES MODELS WITH JOHN DEERE POWER SPN Description of Fault Corrective Action 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 Ser
174. ic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 5 Tag disconnect and plug the hydraulic hose at port SULS of the primary function manifold Cap the fitting 6 Slowly move the steer orbitral away from the dash frame while feeding all loose hoses through the opening of the chassis Genie GTH 1048 GTH 1056 How to Remove the Joystick Models with Single Joystick 1 Open the access door above the hydraulic tank 2 Disconnect the battery from the machine AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 3 Remove the fasteners securing the joystick mount panel to the side console 4 Tag and disconnect the joystick wire harness from the machine 5 Tag disconnect and plug the hoses from ports 1 2 3 4 P and T of the joystick Cap the fittings Note Removing the hydraulic hose from port T of the joystick with the joystick below the hydraulic oil level in the hydraulic tank will result in excessive hydraulic fluid leaking from the hose Do not disconnect the hose from the port if the joystick is below the hydraulic oil level in the hydraulic tank 6 Remove the fasteners securing the joystick to the mount panel Remove the joystick i 2 D 2 Joystick port orientation ee Part No 123701 March 2015 Section 4 Repa
175. ice check Engine mounts check Hose clamps and hoses check V rib belt and tensioning pulley check Fuel filter cartridge replace Filter insert for fuel pre filter replace Required maintenance procedures and additional engine information is available in the Deuiz TCD3 6 Operation Manual Deutz part number 0312 3907 Deutz TCD3 6 Operation Manual CHECKLIST D PROCEDURES D 6 Perform Engine Maintenance Perkins Models Note Engine specifications require that this procedure be performed every 1000 hours 1104 Engine Engine valve lash inspect adjust 1204 Engine Water pump inspect Required maintenance procedures and additional engine information is available in the Perkins 1104 Operation and Maintenance Manual Perkins part number SEBU7833 01 OR the Perkins 1204 Operation and Maintenance Manual Perkins part number SEBU8605 01 Perkins 1104 Operation and Maintenance Manual Genie part number 117765 SIUE Perkins 1204 Operation and Maintenance Manual Genie part number 218726 Genio PartNo 123701 GTH 1048 GTH 1056 3 29 Section 3 Scheduled Maintenance Procedures September 2014 CHECKLIST D PROCEDURES D 7 Perform Transmission Maintenance ZF Models Transmission specifications require that this procedure be performed every 1500 hours Transmission oil and filter change Required maintenance procedures and additional transmission information is available in th
176. ine 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 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 Genie GTH 1048 GTH 1056 7 Support and secure the axle to an appropriate lifting device 8 Remove the fasteners securing the sway cylinder rod end pivot pin to the chassis 9 Use a soft metal drift to remove the pivot pin 10 Remove the fasteners securing the axle to the chassis Remove the axle from the machine Crushing hazard The axle will fall if not properly supported when the fasteners are removed from the machine Bolt torque specification 380 ft lbs 515 Nm Axle mounting bolts How to Repair the Axle Repair procedures and additional axle information is available in the Dana 213 Axle Maintenance and Repair Manual Dana part number 0243 Dana 212 Axle Maintenance and Repair Manual Genie part number 115026 Part No 123701 March 2015 Section 4 Repair Procedures 9 1 Outriggers How to Remove an Outrigger 1 Extend the outrigger until the pad just touches the ground Do not rest the weight of the machine on the outrigger 2 Tag disconnect and plug the hydraulic supply hoses at the outrigger cylinder Cap the fitting
177. ing timer below limit 1 23974 65222 14 SCR Tamper detection derating timer below limit 2 Genie 5 20 GTH 1048 GTH 1056 PartNo 123701 September 2014 Section 5 Fault Codes ENGINE FAULT CODES MODELS WITH DEUTZ POWER SPN Suspect Parameter Number ASPN Alternate Suspect Parameter Number FMI Failure Mode Identifier SPN ASPN FMI Description 23975 65223 14 Urea quality derating timer below limit 1 23976 65224 14 Urea qulaity derating timer below limit 2 23977 65225 14 Urea tank level derating timer below limit 1 23978 65226 14 Urea tank level derating timer below limit 2 23980 65228 14 Bad quality of reduction agent detected 23981 65229 Urea tank without heating function heating phase 23982 65230 Powerstage diagnosis disabled high battery voltage Powerstage diagnosis disabled low battery voltage Charging lamp short circuit to battery Charging lamp short circuit to ground Charging lamp open load Charging lamp over temperature Fuel Balance Control integrator injector 7 in firing order maximum value exceeded 23988 65236 OINO A oj 23989 65237 Fuel Balance Control integrator injector 7 in firing order minimum value exceeded 23990 652388 0 Fuel Balance Control integrator injector 8 in firing order maximum value exceeded 1 Fuel Balance Control integrator injector 8 in firing order minimum value exceeded 23992 65240 9 Timeout Error of CAN Rec
178. injector 7 in firing order minimum value exceeded 24012 65260 0 Zerofuel calibration injector 8 in firing order maximum value exceeded 1 Zerofuel calibration injector 8 in firing order minimum value exceeded 24013 65261 7 Burner operation disturbed 24014 65262 1 Air pressure glow plug flush line below limit 24016 65264 2 Air Pump air flow is not plausible 11 HFM sensor electrical fault 24017 65265 12 Spark plug control unit SPCU internal error 24018 65266 14 DPF wasn t regenerated power reduction phase 1 manuell regeneration request 24019 65267 11 Air Pump air lines blocked 24020 65268 14 Engine power Not enough oxygen for regeneration 24021 65269 11 Burner fuel line pipe leak behind Shut Off Valve 24022 65270 14 DPF wasn t regenerated power reduction phase 2 manuell regeneration request 24023 65271 14 DPF wasn t regenerated warning condition manuell regeneration mode 24024 65272 11 Deviation of the exhaust gas temperature setpoint to actual value downstream DOC too high 24025 65273 5 DPF system operating voltage error 14 Particulate filter regeneration not succesful 24028 65276 CAN message PROEGRActr plausibility error 24029 65277 2 Timeout Error of CAN Receive Frame ComEGRActr exhaust gas recirculation positioner N Genie 5 22 GTH 1048 GTH 1056 Part No 123701 September 2014 Section 5 Fault Codes ENGINE FAULT CODES MODELS WITH DEUTZ POWER SPN Suspect Para
179. ions September 2014 SPECIFICATIONS John Deere 4045HF485 Engine Displacement Number of cylinders Bore amp stroke 275 cu in 4 5 liters 4 4 19 x 5 inches 106 x 127 mm Horsepower 125 2400 rpm 93 2 kw Q 2400 rpm Firing order 1 3 4 2 Low idle 800 rpm Frequency 160 Hz High idle 2400 rpm Frequency 480 Hz Compression ratio 17 1 Valve clearances cold Intake 0 14 in 0 36 mm Exhaust 0 18 in 0 46 mm Lubrication system Oil pressure 60 25 psi warm at rated speed with full load 4 13 1 7 bar Oil pressure 15 psi warm at low idle 1 bar Oil capacity 14 quarts including filter 13 2 liters Cil 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 Genie GTH 1048 GTH 1056 Injection system Injection pump make Stanadyne Peak injection pressure 10 000 psi 690 bar Fuel requirement For fuel requirements refer to the engine Operator s Manual on your machine Engine coolant Capacity 7 gallons 26 5 liters Alternator Output 95 A 14V DC Battery Type 12V DC Group C31 Quantity 1 Cold cranking ampere 09 1000A Reserve capacity 25A rate 200 minutes
180. ir Procedures How to Remove the Joystick Models with Dual Joysticks 1 Open the access door above the hydraulic tank 2 Disconnect the battery from the machine AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 3 Remove the fasteners securing the joystick mount panel to the side console 4 Tag and disconnect the joystick wire harness from the machine 5 Tag disconnect and plug the hoses from ports 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 hydraulic tank tag disconnect and plug the tank return hydraulic hose from the tee fitting Cap the fitting Note Removing the hydraulic hose from port T of the joystick with the joystick below the hydraulic oil level in the hydraulic tank will result in excessive hydraulic fluid leaking from the hose Do not disconnect the hose from the port if the joystick is below the hydraulic oil level in the hydraulic tank 8 Remove the fasteners securing the joystick to the mount panel Remove the joystick 2 E Joystick port orientation Part No 123701 Genie GTH 1048 GTH 1056 OPERATOR S COMPARTMENT How to Remove the Brake Pedal Assembly 1 Open the access door above the hydr
181. l in the hydraulic tank will result in excessive hydraulic fluid leaking from the hose Do not disconnect the hose from the tee fitting if the tee fitting is below the hydraulic oil level in the hydraulic tank 16 Working inside the chassis tag and disconnect the wire harnesses at the connectors next to the operator s compartment Genie GTH 1048 GTH 1056 17 Support and secure the operator s compartment to an adjustable table capable of supporting the weight and that will allow the operator s compartment to remain in an upright and stable position Component damage hazard Wrapping a strap around the cab and lifting using an overhead crane can put excessive pressure on the glass windows of the cab causing the windows to break Do not lift the cab using a strap from an overhead crane if the strap contacts the windows Note Placing a wedge between the operator s compartment and the adjustable table may be required to keep the operator s compartment stable 18 Remove the lower fasteners securing the operator s compartment to the chassis 19 Remove the upper fasteners securing the operator s compartment to the chassis AWARNING hazard The operator s compartment will fall if not properly supported when the fasteners are removed from the machine 20 Slowly move the operator s compartment away from the chassis while feeding all loose hoses cables and wires through the opening of the chassis Compo
182. lic 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 0103 66 cuin Fork tilt relief valve pressure maximum 3500 psi 0 to 60 cc 241 bar Flow rate 2400 rpm 38 gom 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 Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie GTH 1048 GTH 1056 Part No 123701 September 2014 Section 2 Specifications Manifold Component Specifications Plug torque SAE No 2 50 in lbs 6 Nm SAE
183. mand 23240 64488 9 Timeout CAN message FunModCtl Function Mode Control 23330 64578 14 Immobilizer status fuel blocked 23350 64598 4 Injector cylinder bank 1 short circuit 23352 64600 Injector cylinder bank 2 short circuit 23354 64602 12 Injector powerstage output defect 23450 64698 Multiple Stage Switch constant speed plausibility error Multiple Stage Switch constant speed short circuit to battery Multiple Stage Switch constant speed short circuit to ground Multiple Stage Switch engine speed control parameter plausibility error Multiple Stage Switch engine speed control parameter short circuit to battery 23008 64256 23009 64257 A 23451 64699 gt Multiple Stage Switch engine speed control parameter short circuit to ground 23452 64700 Multiple Stage Switch engine torque limitation curve plausibility error Multiple Stage Switch engine torque limitation curve short circuit to battery Multiple Stage Switch engine torque limitation curve short circuit to ground Pressure Relief Valve PRV forced to open Maximum rail pressure in limp home mode exceeded PRV Pressure Relief Valve PRV error Rail pressure out of tolerance range Rail pressure out of tolerance range 12 Pressure Relief Valve PRV forced to open system reaction initiated 14 Pressure Relief Valve PRV is open 23470 64718 NARON Genie PartNo 123701 GTH 1048 GTH 1056 5 13 Section 5 Fault Codes September
184. meter Number ASPN Alternate Suspect Parameter Number FMI Failure Mode Identifier SPN ASPN FMI Description 24030 65278 7 EGR actuator internal error 24031 65279 13 EGR actuator calibration error 24032 65280 2 EGR actuator status message EGRCust is missing 24033 65281 7 EGR actuator due to overload in Save Mode 24034 65282 3 Disc separator short circuit to battery 4 Disc separator short circuit to ground 5 Disc Separator open load 12 Disc Separator powerstage over temperature 24035 65283 12 Injector diagnostics time out error in the SPI communication 24036 65284 12 Injector diagnostics Slave time out error in the SPI communication 24037 65285 3 Ashlamp short circuit to battery 4 Ashlamp short circuit to ground 5 Ashlamp open load 9 Timeout error of CAN Receive Frame ComMS Sys1TO error memory Slave Master Slave internal CAN message 24039 65287 9 Timeout error of CAN Receive Frame ComMS Sys2TO error memory Slave Master Slave internal CAN message 24040 65288 9 Timeout error of CAN Receive Frame ComMS Sys3TO error memory Slave Master Slave internal CAN message 24041 65289 9 Timeout error of CAN Receive Frame ComMS Sys4TO error memory Slave Master Slave internal CAN message 24042 65290 9 Timeout error of CAN Receive Frame ComMS Sys5TO error memory Slave Master Slave internal CAN message 24043 65291 9 Timeout error of CAN Receive Frame ComMS 5 56 error memory Slave Master Slave internal CA
185. munications will be carefully considered for future printings of this and all other manuals Contact Us http www genielift com e mail techsup genieind com Genie ii 1048 GTH 1056 Serial Number Information Genie offers the following Service Manuals for these models Title Part No GTH 1056 Service Manual from GTH1006A 8414 to 1007 11442 97487 Copyright O 2011 by Terex Industries 123701 Rev F September 2014 Second Edition Sixth Printing Genie is a registered trademark of Terex South Dakota Inc in the USA and many other countries GTH is a trademark of Terex South Dakota Inc 6 Printed on recycled paper Printed in U S A Part No 123701 May 2015 Revision History Revision Date Section Procedure Schematic Page Description 72012 C1 3 2013 did ey 29 211 212 213 int 3 8 3 19 3 21 3 22 3 29 3 31 3 32 3 33 3 34 6 22 6 23 6 2013 5 8 17 5 18 19 ud ais 3 19 3 21 22 9 2014 Hydraulic Oil A 6 D 7 ZF Transmission maint Deutz Fault Codes Telematics Connector Legend Electrical Schematic Harness Maps 6 3 3 2015 4 55 Electrical Schematics Hydraulic Schematics 5 2015 6 5 6 40 Electronic Version Click on any procedure or page number highlighted in blue to view the update Genie Part No 123701 GTH 1048 GTH 1056 May 2015 REVISION HISTORY
186. nce Failure to detect damage to the forks could result in a hazardous operating condition 1 Thoroughly clean the lifting forks 2 Inspect the forks for the following Surface cracks Straightness of the blade and shank Fork angle at 90 degrees Relative height of fork tips shall not differ more than 3 of blade length Excessive wear to the forks fork mount or legible markings Result If any of the above criteria are not met the fork shall be removed from service until it is repaired or replaced Part No 123701 Genie GTH 1048 GTH 1056 Replace Hydraulic Tank Return Filter Element Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Replacing the hydraulic return filter element is essential to good machine performance and service life A dirty or clogged filter element may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filter element be replaced more often Bodily injury hazard Beware of ACAUTION hot oil Contact with hot oil may cause severe burns 1 Startthe engine Retract the boom and lower the forks to the ground Shut off the engine 2 Open the hydraulic tank cover Remove the hydraulic tank filler cap 4 Using a wrench loosen the hydraulic tank return filter element cap 5 Remove and properly discard the filter elemen
187. ne access cover at the tank side of the machine Locate the fuel supply line where it is attached to the fuel filter water separator 5 Perkins models Tag disconnect and plug the fuel supply hose at the fuel filter water separator Cap the fitting 6 Perkins models Locate the fuel return hose connection just above the fuel filter water separator 7 Perkins models Tag disconnect and plug the fuel return hose at the fuel filter water separator Cap the fitting 8 John Deere models Open the engine access cover at the tank side of the machine Locate the fuel supply line where it is attached to the fuelfilter water separator Part No 123701 Genie GTH 1048 GTH 1056 ENGINES 9 John Deere models Tag disconnect and plug the fuel supply hose at the fuel filter water separator Cap the fitting 10 John Deere models Open the engine access cover at the operator s compartment side of the machine Locate the fuel return hose at the fuel pump 11 John Deere models Tag disconnect and plug the fuel return hose at the fuel pump Cap the fitting 12 Open the transmission access cover at the top of the machine Locate the transmission cooler 13 Tag disconnect and plug the coolant hoses at the transmission cooler Cap the fittings 14 Tag and disconnect the engine wire harnesses near the operator s compartment 15 Remove the air cleaner from the machine Remove all intake and exhaust components which would interf
188. ne will result in death or serious injury Many of the hazards identified in the operator s manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless M You are trained and qualified to perform maintenance on this machine M You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulations M You have the appropriate tools lifting equipment and a suitable workshop Genie Part No 123701 1048 GTH 1056 vii Section 1 Safety Rules May 2015 SAFETY RULES Personal Safety Any person working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe operation of the machine should be your top priority messages that follow this symbol to avoid possible injury or death Indicates an imminently hazardous ADANGER y situation which if not avoided will result in death or serious injury Read each procedure thoroughly This manual and the decals on the machine use signal words to identify the following Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous ACAUTION situation which if no
189. nent damage hazard Hoses cables and wires can be damaged if they are kinked or pinched Bolt torque specification 750 ft lbs 1017 Nm Operator s cab mounting bolts Part No 123701 March 2015 Section 4 Repair Procedures 2 2 Machine Controls How to Remove the Steering Column 1 Open the access door above the hydraulic tank 2 Disconnect the battery from the machine AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 3 Remove the fasteners securing the transmission control lever to the column 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 the opening 5 Remove the fasteners securing the dash panel to the dashboard 6 Carefully pull the dash panel towards the seat of the operator s compartment 7 Tag and disconnect the wire harness from the componments of the dash panel Remove the 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 PartNo 123701 Genie GTH 1048 GTH 1056 OPERATOR S COMPARTMENT 10 Rotate the dash frame towards the seat of the operator s compartment Remove the dashboard from the machine 11 Tag and disconnect t
190. o the boom 4 Using a lifting strap from an overhead crane support the lift cylinder Do not apply any lifting pressure 5 Use a soft metal drift to remove the lift cylinder rod end pivot pin Remove the cylinder from the boom Crushing hazard The cylinder AWARNING could become unbalanced and fall if not properly supported when removed from the machine 6 Repeat this procedure beginning with step 3 for the other lift cylinder Genie GTH 1048 GTH 1056 7 Remove the fastener securing the fork level cylinder rod end pivot pin to the fork frame mount 8 Use a soft metal drift to remove the rod end pivot pin 9 Attach a lifting strap from an overhead crane to the barrel end of the fork level cylinder Support the cylinder Do not apply any lifting pressure 10 Tag disconnect and plug the fork level cylinder hoses from the cylinder manifolds Cap the fittings AWARNING injury hazard Spraying ydraulic 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 Component damage hazard Hoses can be damaged if they are kinked or pinched 11 Remove the fasteners securing the fork level cylinder barrel end pivot pin to the boom 12 Use a soft metal drift to remove the pivot pin Remove the cylinder from the machine AWARNING Crushing hazard The cylinder could fall if not properly supported when the pivot
191. od end pivot pin 9 Attach a lifting strap from an overhead crane to the barrel end of the fork level cylinder Support the cylinder Do not apply any lifting pressure 10 Tag disconnect and plug the fork level cylinder hoses from the cylinder manifolds Cap the fittings AWARNING injury hazard Spraying ydraulic 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 Component damage hazard Hoses can be damaged if they are kinked or pinched 11 Remove the fasteners securing the fork level cylinder barrel end pivot pin to the boom 12 Use a soft metal drift to remove the pivot pin Remove the cylinder from the boom AWARNING Crushing hazard The cylinder could fall if not properly supported when the pivot pin is removed from the machine 13 Remove the inspection cover at the pivot end of the boom 14 Remove the hose keepers from the hose roller assembly Note The hose keepers ensure that the hoses do not jump off the hose rollers Part No 123701 March 2015 Section 4 Repair Procedures extension chains boom tube number 1 boom tube number 2 boom tube number 3 15 Working the pivot end of the boom remove the clamps securing the hoses to the inside of boom tube number 3 16 Working at the fork end of the boom remove the clamps securing the hoses to the inside of bo
192. om tube number 3 17 Working at the pivot end of the boom pull the fork level hydraulic hoses from the boom and lay them to the side 18 Working at the pivot end of the boom remove the fasteners securing the hose roller assembly to boom tube number 2 Remove the hose roller assembly from the boom 19 Working at the fork end of the boom loosen evenly then remove the fasteners securing the chain tensioners to the top of boom tube number 1 Part No 123701 Genie GTH 1048 GTH 1056 BOOM COMPONENTS 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 22 Working at the pivot end of the boom remove the fasteners securing the retraction chain roller to boom tube number 2 Remove the chain roller from the boom 23 Working at the fork end of the boom remove the wear pads from boom tube number 2 24 Support and slide boom tube number 3 out of boom tube number 2 Place boom tube number 3 on a structure capable of supporting it Crushing hazard Boom tube AWARNING number 3 could become unbalanced and fall when removed from the boom tube number 2 if not properly supported and attached to the overhead crane Note
193. on and Maintenance Manual Genie part number 218726 Genie GTH 1048 GTH 1056 Part No 123701 September 2014 Section Scheduled Maintenance Procedures C 7 Inspect and Lubricate the Sequencing Chains Genie specifications require that this procedure be performed every 500 hours or semi annually whichever comes first In extremely dusty or hostile environments it may be necessary to lubricate the chains more often Maintaining the sequencing chains in good condition is essential to safe operation and good machine performance Failure to detect damage to the chains could result in a hazardous operating condition Environments in which Genie Telehandlers operate can vary widely from outdoor moisture and temperature extremes to mildly corrosive or highly corrosive industrial atmospheres in addition to abrasive exposures such as sand and grit In addition dynamic shock loading can impose abnormal loads above the endurance limit of the chains Examples of dynamic shock loading are High velocity movement of load followed by sudden abrupt stops Carrying loads in suspension over irregular surfaces and rough terrain Attempting to inch loads which are beyond the rated capacity of the vehicle Part No 123701 Genie GTH 1048 GTH 1056 CHECKLIST C PROCEDURES The load cycles and environmental conditions make it impossible to predict chain life It is therefore necessary to conduct regular
194. on generated Physical Range Check low for Oil Temperature Oil temperature value is not plausible Target range to high for oil temperature sensor Target range to low for oil temperature sensor 190 Engine speed target range exceeded FOC range 1 Speed sensor of crankshaft and camshaft signals are out of phase Speed sensor signal not plausible 11 Engine speed target range exceeded FOC range 2 12 Speed sensor no signal 14 Engine speed target range exceeded overrun mode ANO IFWNHOILOI RWNIBRWNH OC 412 0 Differential pressure sensor value AGR out of target range to high 1 Differential pressure sensor value AGR out of target range to low 3 SRC high for EGR cooler downstream temperature sensor 4 SRC low for EGR cooler downstream temperature sensor 9 2 520 597 Timeout Error of CAN Receive Frame TSC1TR Break Lever Main switch and Break Lever Redundancy switch status not plausible Genie PartNo 123701 GTH 1048 GTH 1056 5 9 Section 5 Fault Codes September 2014 pm SSS ENGINE FAULT CODES MODELS WITH DEUTZ POWER SPN Suspect Parameter Number ASPN Alternate Suspect Parameter Number FMI Failure Mode Identifier SPN FMI Description 624 3 Short circuit to battery on SVS lamp 4 Short circuit to ground on SVS lamp 5 No load error SVS lamp 12 Temperature to high for power stage of SVS lamp
195. on the pressure gauge Result The pressure gauge reads 3190 50 psi 2203 4 bar The pump is functioning correctly Proceed to step 7 Result The pressure gauge fails to read 3190 50 psi 2203 4 bar The pressure setting needs to be adjusted Proceed to step 5 Loosen the set screw for the pressure compensator adjustment screw Adjust the pressure compensator pressure Turn the adjustment screw clockwise to increase the pressure or counterclockwise to decrease the pressure Tighten the set screw Component damage hazard Do not adjust the pressure compensator higher than specified Genie a pressure compensator adjustment screw b set screw c hydraulic supply line from tank 7 Turn the engine off and remove the pressure gauge AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray GTH 1048 GTH 1056 Part No 123701 March 2015 Section 4 Repair Procedures Y This page intentionally left blank Genie Part No 123701 GTH 1048 GTH 1056 4 41 Section 4 Repair Procedures March 2015 Manifolds 7 1 Primary Function Manifold Components Models with Single Joystick The primary function manifold is located under the manifold inspection cover Torque 20 ft lbs 27 Nm 65 75
196. onal valve 3 position 4 way pilot operated BD Fork tilt 46 54 ft lbs 61 72 Nm Relief valve 3500 psi 241 bar uu Fork tilt up 2 4 222222 20 ft lbs 27 Nm Check valve pilot operated 100 psi 6 9 BF seine Fork tilt down circuit esses 25 ft lbs 34 Nm 7 Check valve pilot operated 100 psi 6 9 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 Bla System relief sees 25 ft lbs 34 Nm 10 Shuttle valve BJ os Function select sway left right 20 ft Ibs 27 Nm 11 Diagnostic nipple BK Test port LS 12 Flow regulator valve 14 53 BL Fork tilt up down circuit 20 ft Ibs 27 Nm 13 Flow regulator valve 0 1 0 4 L min BM Pilot pressure drain circuit 20 ft Ibs 27 Nm 14 Check valve 5 psi 0 3 bar BN Sway left 12 14 ft Ibs
197. ons require that this procedure be performed every 8 hours or daily whichever comes first Engine oil level check Coolant level check add Fuel system filter water separator drain Engine tightness check or leaks Exhaust system check for leaks Required maintenance procedures and additional engine information is available in the Perkins 1100D Operation and Maintenance Manual Perkins part number SEBU8172 00 Perkins 1204 Operation and Maintenance Manual Perkins part number SEBU8605 01 Deutz TCD3 6 Operation Manual Deutz part number 0312 3907 OR the John Deere 4045HF485 Operator s Manual John Deere part number OMRG36852 Perkins 1100D Operation and Maintenance Manual Genie part number 123702 Perkins 1204 Operation and Maintenance Manual Genie part number 218726 Deutz TCD3 6 Operation Manual Genie part number 218707 John Deere 4045HF485 Operator s Manual Genie part number 123703 Part No 123701 September 2014 Section Scheduled Maintenance Procedures A 6 Perform Transmission Maintenance All Models Transmission specifications require that this procedure be performed every 8 hours or daily whichever comes first Transmission oil level check Required maintenance procedures and additional Transmission information is available in the Dana T20000 Maintenance Manual Dana part number 0202 orthe ZF 4 WG 98 TC Maintenance Manual ZF part number 5872 134 002 Dana T2000
198. oose 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 17 Remove the rope from the end of the chain and 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 Secure the chain anchor to the mount using the pivot pin and fasteners removed in step 11 Securely tighten the fasteners Do not over tighten Section 4 Repair Procedures March 2015 BOOM COMPONENTS 20 Working at the pivot end of the boom route the chain over the roller and install the chain onto the boom assembly using the pivot pin removed in step 11 Securely tighten the fasteners Do not over tighten 21 GTH 1056 Repeat this procedure beginning with step 11 for the remaining chain anchor 22 Install the inspection cover removed in step 9 onto the boom Install and securely tighten the fasteners Do not over tighten 23 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 6 and securely tighten the fasteners 24 GTH 1056 Install the chain tensioners into th
199. ork frame mount 7 3 Use a soft metal drift to remove the pivot pin 4 Attach a lifting strap from an overhead crane to the barrel end of the fork level cylinder Support the cylinder Do not apply any lifting pressure Genie connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Component damage hazard Hoses can be damaged if they are kinked or pinched Remove the fasteners securing the fork level cylinder barrel end pivot pin to the boom Use a soft metal drift to remove the pivot pin Remove the cylinder from the machine AWARNING Crushing hazard The cylinder could fall if not properly supported when the pivot pin is removed from the machine PartNo 123701 GTH 1048 GTH 1056 4 19 Section 4 Repair Procedures March 2015 BOOM COMPONENTS How to Replace the Fork Level and or Auxiliary Cylinder Hoses GTH 1048 Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Fully retract the boom 2 Fully lower the tips of the lifting forks 3 Remove the covers from the pivot end of the boom 4 Attach a lifting strap from an overhead crane to the top of the lifting fork frame Support the frame Do not apply any lifting pressure 5 Tag disconnect and plug the fork level
200. orking at the fork end of the boom loosen evenly then remove the fasteners securing the chain tensioners to the top of boom tube number 0 28 Working at the fork end of the boom remove the fasteners securing the extension chain rollers to the top of boom tube number 1 Remove the chain rollers from the boom 29 Working at the pivot end of the boom remove the fasteners securing the retraction chain block pivot pin to boom tube number 2 Remove the pivot pin 30 Working at the pivot end of the boom remove the fasteners securing the chain roller to boom tube number 2 Remove the chain roller from the boom Genie GTH 1048 GTH 1056 31 Working at the fork end of the boom remove the wear pads from boom tube number 1 32 Support and slide boom tube number 2 out of boom tube number 1 Place boom tube number 2 on a structure capable of supporting it AWARNING Cushing hazard Boom tube number 2 could become unbalanced and fall when removed from the boom tube number 1 if not properly supported and attached to the overhead crane Note During removal the overhead crane strap will need to be adjusted for proper balancing 33 Working at the pivot end of the boom remove the fasteners securing the chain roller to boom tube number 1 Remove the chain roller from the boom 34 Working at the fork end of the boom remove the wear pads from boom tube number 0 35 Support and slide boom tube number 1 out of boom tube number
201. ose 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 Genie GTH 1048 GTH 1056 5 Tag disconnect and plug the large hydraulic pump supply hose at the pump Cap the fitting on the pump Note Placing the open end of the pump supply hose below the fluid level in the hydraulic tank will result in excessive hydraulic fluid leaking from the hose Do not lower the open end of the pump supply hose to below the fluid level of the hydraulic tank until the hose is plugged 6 Tag disconnect and plug the high pressure hose at the pump Cap the fitting on the pump AWARNING uid injury hazard Spraying ydraulic 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 7 Tagand disconnect the transmission cooler hoses at the transmission cooler Cap the fittings A CAUTION Burn hazard Contact with hot engine components may cause severe burns 8 Remove the fasteners securing the pump to the transmission Remove the pump from the machine Part No 123701 March 2015 How to Install the Function Pump 1 Carefully install the hy
202. owing symbols have been used in this manual to help communicate the intent of the instructions When one or more of the symbols appear at the beginning of a maintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Indicates that a cold engine will be required to perform this procedure Indicates that a warm engine will be required to perform this procedure Indicates that dealer service will be required to perform this procedure ES is cs Genie 3 2 1048 1056 Pre delivery Preparation Report The pre delivery preparation report contains checklists for each type of scheduled inspection Make copies of the Pre delivery Preparation report to use for each inspection Store completed forms as required Maintenance Schedule 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 Section and the Maintenance Inspection Report have been divided into five subsections A B C D and E Use the following chart to determine which group s of procedures are required to perform a scheduled inspection Inspection Checklist Daily or every 8 hours A Quarterly or every 250 hours A B Semi annually or every 500 hours A B C Annually or every 100
203. perature 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 168 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 190 0 Engine overspeed 626 5 Ether start aid current low 6 Ether start aid current high 630 2 System parameters incorrect 631 2 Personality module mismatch 637 11 Engine timing calibration invalid Genie GTH 1048 GTH 1056 Part No 123701 September 2014 Section 5 Fault Codes ENGINE FAULT CODES MODELS WITH PERKINS POWER SPN Suspect Parameter Number FMI Failure Mode Identifier SPN FMI Description 637 139 Engine timing calibration required 639 41939 data link communications J1939 data link malfunction Cylinder 1 injector data incorrect Cylinder 1 injector open circuit Cylinder 1 injector short Cylinder 1 injector not responding k RWI NDOANINDOANINDANIN 651 652 Cylinder 2 injector data incorrect Cylinder 2 inj
204. pressure gauge Result The pressure gauge reads 450 25 psi 31 1 7 bar The pump is functioning correctly Result The pressure gauge fails to read 450 25 psi 31 1 7 bar The pressure setting needs to be adjusted See Repair Procedure 6 1 How to Adjust the Function Pump Pressure 4 Turn the machine off Remove the pressure gauge from the test port AWARNING 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 Genie GTH 1048 GTH 1056 5 Install a O to 3500 psi O to 250 bar pressure gauge into test port TS at the top of the secondary function manifold schematic item CR See 7 3 Secondary Function Manifold Components 6 Startthe engine Allow the engine to idle 7 Fully turn and hold the steering wheel in the left direction and allow the wheels to fully turn to the left Continue holding the steering while observing the pressure reading on the pressure gauge O Result The pressure gauge reads 2500 psi 172 bar The pressure setting is correct Proceed to step 12 W Result The pressure gauge fails to read 2500 psi 172 bar The pressure setting needs to be adjusted Proceed to step 8 8 Turn the machine off Hold the steer pressure reducing relief valve with a wrench and remove the cap schematic item CD 9 Adjust the internal hex socket T
205. procedures and additional engine information is available in the John Deere 4045HF485 Operator s Manual John Deere part number OMRG36852 Genie part number 115026 John Deere 4045HF485 Operator s Manual Genie part number 123703 Genio GTH 1048 GTH 1056 Part No 123701 September 2014 Section Scheduled Maintenance Procedures A 10 Perform Axle Maintenance Axle specifications require that this one time procedure be performed after 100 hours of operation Required maintenance procedures and additional axle information is available in the Dana 213 Axle Maintenance and Repair Manual Dana part number 0243 Dana 213 Axle Maintenance and Repair Manual Genie part number 115026 Part No 123701 Genio GTH 1048 GTH 1056 CHECKLIST A PROCEDURES A 11 Perform Axle Maintenance Axle specifications requires that this procedure be performed every 200 hours of operation Required maintenance procedures and additional axle information is available in the Dana 213 Axle Maintenance and Repair Manual Dana part number 0243 Dana 213 Axle Maintenance and Repair Manual Genie part number 115026 Section 3 Scheduled Maintenance Procedures September 2014 Checklist B Procedures B 1 Inspect the Battery Genie requires thatthis procedure be performed every 250 hours or quarterly whichever comes first Proper battery condition is essential to good engine performance and operational
206. r GTH1012 16292 Decoding Fault Codes The Suspect Parameter Number SPN or the Alternate Suspect Parameter Number ASPN and the Failure Mode Identifier FMI when combined are the basis for an engine fault code The SPN or ASPN number indicates the affected component the FMI number reveals the type of failure that has occurred Comparing the combination of numbers to the fault code chart on the following pages will help to determine the exact engine fault and a corrective course of action For additional information refer to the engine operator s manual which came with your machine Section 5 Fault Codes Engine Fault Codes Models with John Deere Power SPN FMI Description of Fault 000028 03 Throttle 3 Voltage Out of Range High 04 Throttle 3 Voltage Out of Range Low 14 Throttle 3 Voltage Out of Range 000029 03 Throttle 2 Voltage Out of Range High 04 Throttle 2 Voltage Out of Range Low 14 Throttle 2 Voltage Out of Range 000091 03 Throttle Voltage Out of Range High 04 Throttle Voltage Out of Range Low 14 Throttle Voltage Out of Range 00094 03 Fuel Pressure Voltage Out of Range High 04 Fuel Pressure Voltage Out of Range Low 000097 03 Water in Fuel Voltage Out of Range High 04 Water in Fuel Voltage Out of Range Low 16 Water in Fuel Detected 000100 01 Engine Oil Pressure Low Most Severe 03 Engine Oil Pressure Voltage Out of Range High 04 Engine Oil Pressure Voltage Out of Range Low 18 Engine Oil Pressure Low Moderat
207. r manifold Cap the fittings AWARNING 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 Component damage hazard 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 Genie Part No 123701 GTH 1048 GTH 1056 4 17 Section 4 Repair Procedures March 2015 BOOM COMPONENTS 1 4 Boom Extension Cylinder How to Remove the Extension Cylinder Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Raise the boom to a horizontal position 2 Tag disconnect and plug the hydraulic hoses at the boom extension cylinder manifold Cap the fittings AWARNING 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 Component damage hazard Hoses can be damaged if they are kinked or pinched Genie GTH 1048 GTH 1056 3 A
208. re check error SCR 4345 11 General backflow line plausibility error SCR Genie Part No 123701 GTH 1048 GTH 1056 5 11 Section 5 Fault Codes September 2014 pm s ENGINE FAULT CODES MODELS WITH DEUTZ POWER SPN Suspect Parameter Number ASPN Alternate Suspect Parameter Number FMI Failure Mode Identifier SPN ASPN FMI Description 4360 Urea catalyst upstream temperature out of the target range to high Urea catalyst upstream temperature out of the target range to low 4361 Target range to high for urea catalyst exhaust gas temperature sensor upstream Target range to low for urea catalyst exhaust gas temperature sensor upstream 4365 Urea tank temperature too high Short circuit to battery error on urea tank sensor Short circuit to ground error on urea tank sensor a 4366 4374 4375 SCR main relay short circuit open load Co Pressure stabilization error dosing valve SCR Short circuit to battery on powerstage for urea pump motor Short circuit to ground on powerstage for urea pump motor Noload error on powerstage for urea pump motor 4376 Short circuit to battery on SCR reversal valve Short circuit to ground on SCR reversal valve No load error SCR reversal valve 4765 Exhaust gas temperature sensor value upstream DOC out of target range to high Exhaust gas temperature sensor
209. red pressure does not rise above ca 1250mbar abs expected ca 2400mbar p 2 Burner dosing valve DV2 downstream pressure sensor plausibility error 3 Sensor error burner dosing valve DV2 downstream pressure sensor signal range check high 4 Sensor error burner dosing valve DV2 downstream pressure sensor signal range check low 23913 65161 3 Sensor error glow plug control diagnostic line voltage signal range check high 4 Sensor error glow plug control diagnostic line voltage signal range check low Genie 5 16 GTH 1048 GTH 1056 PartNo 123701 September 2014 eee eee Section 5 Fault Codes ENGINE FAULT CODES MODELS WITH DEUTZ POWER SPN Suspect Parameter Number ASPN Alternate Suspect Parameter Number FMI Failure Mode Identifier SPN 23914 23915 23916 23917 23918 ASPN 65162 65163 65164 65165 65166 FMI Description 3 4 5 11 12 OJR ON Glow plug control short circuit to battery Glow plug control short circuit to ground Glow plug control open load Glow plug control internal error Glow plug control powerstage over temperature dosing valve DV1 overcurrent at the end of the injection phase HCl dosing valve DV1 short circuit to battery dosing valve DV1 short circuit to ground dosing valve DV1 blocked dosing valve DV1 short circuit high side powerstage dosing valve DV1 powerstage over tempera
210. res shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine 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 Part No 123701 Genie GTH 1048 GTH 1056 6 1 Schematics About This Section There are two groups of schematics in this section An illustration legend precedes each group of drawings Electrical Schematics AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Hydraulic Schematics AWARNING 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 General Repair Process Malfunction Identify discovered symptoms gt Troubleshoot problem still exists Return to service problem solved Section 6 Schematics May 2015 Proximity Switch Layout Boom Extend Proximity Switch PX1 under plate at top of boom tube
211. return hoses Cap the fittings 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 appropriate lifting device 13 Remove the fasteners securing the tank assembly to the chassis Remove the tank from the machine AWARNING Crushing hazard The tank assembly could become unbalanced and fall if not properly supported when removed from the machine Section 4 Repair Procedures March 2015 Engines 4 1 Engines How to Repair the John Deere 4045T Engine Repair procedures and additional engine information is available in the John Deere 4045HF485 Operator s Manual John Deere part number OMRG36852 and the John Deere 4045T Workshop Manual John Deere part number CTM104 and the How to Repair the Perkins 1104D E44TA Engine Repair procedures and additional engine information is available in the Perkins 1100 Operation and Maintenance Manual Perkins part number SEBU8172 00 and the Perkins 1104 Service Manual Perkins part number RENR9401 and the Perkins 1100 Troubleshooting Manual Perkins part number SENR9982 01 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 114764 Perkins 1
212. rger Actuator Not Responding or Out Of Adjustment Turbocharger Actuator Bad Intelligent Device Or Component Sensor Supply Voltage 5 Out of Range High Sensor Supply Voltage 5 Out of Range Low Sensor Supply Voltage 4 Out of Range High Sensor Supply Voltage 4 Out of Range Low Genie Part No 123701 Section 5 Fault Codes _ _ _ _ ENGINE FAULT CODES Corrective Action Contact Servicing Dealer Contact Servicing Dealer Contact Servicing Dealer Contact Servicing Dealer Contact Servicing Dealer Contact Servicing Dealer Check Pump Wiring Check Fuel Filter and Lines Check Fault Codes Contact Servicing Dealer Contact Servicing Dealer Contact Servicing Dealer Contact Servicing Dealer Contact Servicing Dealer Contact Servicing Dealer Contact Servicing Dealer Contact Servicing Dealer Contact Servicing Dealer Contact Servicing Dealer Contact Servicing Dealer Contact Servicing Dealer Contact Servicing Dealer Contact Servicing Dealer Contact Servicing Dealer Contact Servicing Dealer Contact Servicing Dealer Contact Servicing Dealer Contact Servicing Dealer Contact Servicing Dealer Contact Servicing Dealer Contact Servicing Dealer Contact Servicing Dealer Contact Servicing Dealer MODELS WITH JOHN DEERE POWER GTH 1048 GTH 1056 Section 5 Fault Codes September 2014 Engine Fault Codes Models with Deutz Power SPN Suspect Parameter Number ASPN Al
213. rings watches and other jewelry 3 Remove the fasteners securing the transmission control lever to the column Carefully separate the lever from the column 4 Reach under the dashboard gently push the dash cluster through the opening in the dashboard 5 Tag and disconnect the wire harness from the dash cluster Remove the dash cluster from the machine Genie GTH 1048 GTH 1056 How to Remove the Diagnostic Display 1 Open the access door above the hydraulic tank 2 Disconnect the battery from the machine AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 3 Reach under the dashboard and gently loosen and remove the locknut securing the diagnostic display to the dashboard Gently push the diagnostic display through the opening in the dashboard 4 Tagand disconnect the wire harness from the diagnostic display Remove the diagnostic display from the machine MI Part No 123701 March 2015 Section 4 Repair Procedures Fuel and Hydraulic Tank 3 1 Fuel and Hydraulic Tank How to Remove the Fuel and Hydraulic Tank Assembly Explosion and fire hazard Engine fuels are combustible Remove the fuel tank in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher wi
214. rk area a J properly ventilated and well lit NII mp Part No 123701 May 2015 Introduction Section 1 Section 2 Section 3 Table of Contents Important Information eene nnne nnn ii Serial Number Legend siiis ipea erpen eene iii Safety Rules General Safety Rules nennen nennen enne Specifications Machine Specifications 0 0 2 1 Performance Specifications 0 222 0 0 2 2 Hydraulic Specifications sese 2 3 Hydraulic Component Specifications 2 6 Manifold Component Specifications 2 7 AC Refrigerant Specification 2 20004 00 0 2 7 Valve Coil Resistance Specifications 2 7 John Deere 4045TH485 2 8 Deutz TCD3 6 L4 Engine 00 nnne enne 2 9 Perkins 11040 44 en 2 10 Perkins 1204 44 2 11 20000 2 12 Dana Planetary 213 Drive 2 12 Hydraulic Hose and Fitting Torque 5 2 13 SAE and Metric Fasteners Torque Charts 2 16 Scheduled Maintenance Proc
215. rocedure be performed every 8 hours or daily whichever comes first Maintaining the operators and safety manuals in good condition is essential to safe machine operation Manuals are included with each machine and should be stored in the container provided in the operator s compartment An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition In addition maintaining all of the safety and instructional decals in good condition is mandatory for safe machine operation Decals alert operators and personnel to the many possible hazards associated with using this machine They also provide users with operation and maintenance information An illegible decal will fail to alert personnel of a procedure or hazard and could result in unsafe operating conditions 1 Checkto make sure that the operator s and safety manuals are present and complete in the storage container in the operator s 2 Examine the pages of each manual to be sure that they are legible and in good condition Result The operator s manual is appropriate for the machine and all manuals are legible and in good condition W Result The operator s manual is not appropriate for the machine or all manuals are not in good condition or is illegible Remove the machine from service until the manual is replaced 3 Open the operator s manual to the decals inspection section Carefully and thoroughly inspect
216. rocedures March 2015 BOOM COMPONENTS How to Disassemble the Boom GTH 1048 AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer Service is strongly recommended Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the extension cylinder See 1 4 How to Remove the Extension Cylinder 2 Remove the boom See 1 2 How to Remove the Boom 3 Selecta lift cylinder Remove the fasteners securing the lift cylinder rod end pivot pin to the boom 4 Using a lifting strap from an overhead crane support the lift cylinder Do not apply any lifting pressure 5 Use a soft metal drift to remove the lift cylinder rod end pivot pin Remove the cylinder from the boom Crushing hazard The cylinder AWARNING could become unbalanced and fall if not properly supported when removed from the machine 6 Repeat this procedure beginning with step 3 for the other lift cylinder Genie GTH 1048 GTH 1056 7 Remove the fastener securing the fork level cylinder rod end pivot pin to the fork frame mount 8 Use a soft metal drift to remove the r
217. 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 20 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 21 Working at the pivot end of the boom carefully remove the cable bridge from the boom 22 Working at the fork end of the boom remove the fasteners securing the dual chain tensioner to the top of boom tube number 1 23 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 Section 4 Repair Procedures March 2015 BOOM COMPONENTS 24 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 25 Working at the fork end of the boom remove the wear pads from boom tube number 2 26 Support and slide boom tube number 3 out of boom tube number 2 Place boom tube number 3 on a structure capable of supporting it Crushing hazard Boom tube AWARNING number 3 could become unbalanced and fall when removed from the boom tube number 2 if not properly supported and attached to the overhead crane Note During removal the overhead crane strap will need to be adjusted for proper balancing 27 W
218. rpm Glow Plugs Initial load 0 6 sec 80 amps Continuous load gt 6 sec 40 amps Battery Type 12V DC Group C31 Quantity 1 Cold cranking ampere 0 F 1000A Reserve capacity 25A rate 200 minutes Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice GTH 1048 GTH 1056 2 9 Section 2 Specifications September 2014 SPECIFICATIONS Perkins 1104D E44TA Engine Displacement 269 cu in 4 4 liters Number of cylinders 4 Bore and stroke 4 13 x 5 inches 105 x 127 mm Horsepower 125 2400 rpm 93 2 kW 2400 rpm Firing order 1 3 4 2 Compression ratio 16 2 1 Low idle 1000 rpm Frequency 200 Hz High idle 2500 rpm Frequency 500 Hz Valve clearance cold Intake 0 013 in 0 35 mm Exhaust 0 013 in 0 35 mm Lubrication system Oil pressure at operating temperature 43 58 psi 2 96 4 bar Oil capacity 10 quarts including filter 9 5 liters Cil viscosity requirements 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 machine Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie Injection system Injector pressure minimum Fuel requirement 23700 psi 1634 bar For fuel requirements refer to the engine Operation
219. ry slowly to allow Wheels chocked the oil pressure to dissipate gradually Do not allow oil to squirt or spray Genie Part No 123701 GTH 1048 GTH 1056 5 1 Section 5 Fault Codes September 2014 Diagnostic Display When the engine Electronic Control Module ECM detects an abnormal operating condition a fault code is immediately stored in the ECM memory Models before Serial Number GTH1012 16292 The fault code is displayed on the engine diagnostic display which is located on the dashboard in the operator s compartment This backlit LCD display allows the operator to view these fault codes a description of the code and corrective action needed When not being used to display fault codes the display shows the many readouts of engine functions in both English and metric units Located at the upper corners of the diagnostic display are amber and red indicator lights Depending on the severity of a detected engine fault one of these lights will illuminate indicating an active engine fault Amber WARNING An amber colored light signals an abnormal engine condition which should be corrected as soon as possible Red STOP ENGINE 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 Accessthe Active Fault Codes Component damage haz
220. s AWARNING 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 Component damage hazard Hoses can be damaged if they are kinked or pinched 3 Attach a lifting strap from an overhead crane to the barrel end of the fork level cylinder Support the cylinder Do not apply any lifting pressure 4 Remove the fasteners securing the outrigger 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 AWARNING Crushing hazard The cylinder may become unbalanced and fall if not properly supported when the pivot pin is removed from the machine Genie Outriggers 6 Attach a lifting strap from an overhead crane to the outrigger assembly Support the outrigger Do not apply any lifting pressure Remove the fasteners securing the outrigger pivot pin to the machine Use a soft metal drift to remove the pivot pin Remove the outrigger assembly from the machine AWARNING Crushing hazard The outrigger will fall if not properly supported when the pivot pin is removed from the machine PartNo 123701 GTH 1048 GTH 1056 4 65 Section 4 Repair Procedures March 2015 OUTRIGGERS How to Remove an Outrigger 5 Use a soft metal drift to remove the pivot pin Cylinder
221. safety Damaged cables and connections can result in engine component damage and hazardous conditions i ith AWARNING Electrocution hazard Contact wi hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry Bodily injury hazard Batteries AWARNING contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water 1 Put on protective clothing and eye wear 2 that the battery cable connections are free of corrosion Note Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables 3 Be sure thatthe battery hold downs and cable connections are tight Genie 1048 1056 2 Inspect the Electrical Wiring Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining electrical wiring in good condition is essential to safe operation and good machine performance Failure to find and replace burnt chafed corroded or pinched wires could result in unsafe operating conditions and may cause component damage Electrocution hazard Contact with AWARNING hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Inspect the following areas for burnt chafed corroded and loose wires Inside of the operator s compartment
222. sige 1 2 m EXTEND ENABLE ENABLE cy t g 72 QO gt o Iz EA 22 Eu d SWAY BOOM 8 of p OPTION ENABLE amp ANGLE B ay NS Te d 5 C1 Q CRI JON cre pm a oca Bones ae fom 22 CAP1 FN E 22 be P 7 50 Amp S C9 i JOYSTICK CB 1 437361 HARNESS s BATe 5 John Deere Engine Circuit Breakers PCB Board Fuse Panel located in the Cab Located in Tank Assembly Genie 6 4 GTH 1048 GTH 1056 PartNo 123701 May 2015 Section 6 Schematics Fuse Box Layout from serial number GTH1014E 10353 RN3 RN2 PCBA 237363 al gt C 2 gt 6 O N OS Eu BBs 00000000000000 28 3E oz w B o 25 oe o g 00000000000000 PS EJ r oT I f p oT r r SSSBSBRBRBRBRBERERB ea 5 F151A F14 10A F1110A F8 5A 39 zm 1 10 foo foo Ff ig S
223. slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Section 4 Repair Procedures March 2015 MANIFOLDS How to Set the Differential Lock Joystick System Pressure Note Be sure that the hydraulic oil level is visible in the inspection glass of the hydraulic tank 1 Install a O to 1000 psi O to 100 bar pressure gauge into test port TP at the top of the primary function manifold schematic item AAA or BZ See 7 1 or 7 2 Primary Function Manifold Components 2 Start the engine Allow the engine to idle after warming the engine to operating temperature 3 Without operating any machine controls observe the reading on the pressure gauge O Result The pressure gauge reads 450 x25 psi 31 1 7 bar The pump is functioning correctly W Result The pressure gauge fails to read 450 25 psi 31 1 7 bar The pressure setting needs to be adjusted See Repair Procedure 6 1 How to Adjust the Function Pump Pressure 4 Turn the machine off Remove the pressure gauge from the test port AWARNING 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 Genie GTH 1048 GTH 1056 5 Install a O to 1000 psi O to 100 bar pressure gauge into test port TJ at the top of the secondary function manifold schematic item CQ See 7 3 S
224. spect Parameter Number FMI Failure Mode Identifier SPN ASPN FMI Description 23919 65167 0 Physical range check high for airpump pressure shut off regeneration Physical range check low for airpump pressure shut off regeneration Sensor airpump pressure plausibility error Sensor error airpump pressure signal range check high Sensor error airpump pressure signal range check low Physical range check high for exhaustgas back pressure burner shut off regeneration OJR ON 23920 65168 Physical range check low for exhaustgas back pressure burner shut off regeneration Sensor exhaustgas back pressure plausibility error Sensor error exhaustgas back pressure burner signal range check high Sensor error exhaustgas back pressure burner signal range check low Physical range check high for burner temperature Physical range check low for burner temperature Sensor burner temperature plausibility error Sensor error burner temperature signal range check high Sensor error burner temperature signal range check low Sensor burner temperature plausibility error Burner shut of valve short circuit to battery Burner shut of valve short circuit to ground Burner shut off valve open load Shut off valve blocked Over temperature error on burner shut of valve Fuel Balance Control integrator injector 1 in firing order maximum value exceeded 23921 65169 23922 65170 A Oj BOD OF B WO ND 23929 65177
225. spect adjust replace 1204 Engine Engine oil and filter change API CJ 4 low ash approved oil Fuel system primary filter water separator element replace Fuel system secondary filter replace Fan clearance check Required maintenance procedures and additional engine information is available in the Perkins 1104 Operation and Maintenance Manual Perkins part number SEBU7833 01 OR the Perkins 1204 Operation and Maintenance Manual Perkins part number SEBU8605 01 Perkins 1104 Operation and Maintenance Manual Genie part number 117765 Perkins 1204 Operation and Maintenance Manual C 6 Perform Engine Maintenance Perkins Models Note Engine specifications require that this procedure be performed every 500 hours or annually 1104 Engine Engine oil and filter change API CH 4 or API CI 4 approved oil Fuel system primary filter water separator element replace Fuel system secondary filter replace Crankcase breather canister replace Hoses and clamps inspect replace Radiator clean 1204 Engine Radiator clean Required maintenance procedures and additional engine information is available in the Perkins 1104 Operation and Maintenance Manual Perkins part number SEBU7833 01 OR the Perkins 1204 Operation and Maintenance Manual Perkins part number SEBU8605 01 Perkins 1104 Operation and Maintenance Manual Genie part number 218726 Genie part number 117765 Perkins 1204 Operati
226. sure gauge from the test port AWARNING 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 Part No 123701 5 9 Section 4 Repair Procedures MANIFOLDS Install a O to 1000 psi O to 100 bar pressure gauge into test port TPB at the top of the secondary function manifold schematic item CN See 7 3 Secondary Function Manifold Components Start the engine Allow the engine to idle Result The pressure gauge reads 400 psi 27 5 bar The pressure setting is correct Proceed to step 11 Result The pressure gauge fails to read 400 psi 27 5 bar The pressure setting needs to be adjusted Proceed to step 7 Turn the machine off Hold the parking brake pressure reducing relief valve with a wrench and remove the cap schematic item CE Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Component damage hazard Do CAUTION not adjust the relief valve pressures higher than specifications Install the relief valve cap 10 Repeat this procedure beginning with step 6 11 Turn the machine off Remove the pressure gauge from the test port AWARNING Bodily injury hazard Spraying Genie GTH 1048 GTH 1056 hydraulic oil can penetrate and burn skin Loosen hydraulic connections very
227. t Note To reduce the amount of oil spilled it may be 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 Section Scheduled Maintenance Procedures September 2014 CHECKLIST D PROCEDURES D 3 Perform Transmission Maintenance Dana Models Transmission specifications require that this procedure be performed every 1000 hours or annually whichever comes first Required maintenance procedures and additional transmission information is available in the Dana T20000 Maintenance Manual Dana part number 0202 Dana T20000 Maintenance Manual Genie part number 115025 Genie GTH 1048 GTH 1056 D 4 Perform Axle Maintenance Axle specifications require that this procedure be performed every 1000 hours of operation Required maintenance procedures and additional axle information is available in the Dana 213 Axle Maintenance and Repair Manual Dana part number 0243 Dana 213 Axle Maintenance and Repair Manual Genie part number 115026 Part No 123701 September 2014 Section Scheduled Maintenance Procedures D 5 Perform Engine Maintenance Deutz Models Note Engine specifications require that this procedure be performed every 1000 hours or annually whichever comes first Charge air cooler entry area drain lube oil condensate Cold starting dev
228. t Frame ComDPFTstMon Timeout error of CAN Receive Frame ComRxDPFBrnAirPmpCtl Timeout error of CAN Receive Frame ComRxDPFBrnAirPmp Timeout error of CAN Receive Frame ComRxDPFCtl 24097 65345 24098 65346 24099 65347 24100 65348 24101 65349 24102 65350 24103 65351 24104 65352 o co OF o OF Genie 5 24 GTH 1048 GTH 1056 PartNo 123701 September 2014 Section 5 Fault Codes ENGINE FAULT CODES MODELS WITH DEUTZ POWER SPN Suspect Parameter Number ASPN Alternate Suspect Parameter Number FMI Failure Mode Identifier SPN ASPN FMI Description 24105 65353 Timeout error of CAN Transmit Frame ComEGRMsFlw 24106 65354 Timeout error of CAN Receive Frame ComRxEGRMsFlw1 24107 65355 Timeout error of CAN Receive Frame ComRxEGRMsFlw2 24108 65356 Timeout error of CAN Transmit Frame ComEGRTVActr 24109 65357 Timeout error of CAN Receive Frame ComRxEGRTVActr 24110 65358 Timeout error of CAN Transmit Frame ComETVActr 24111 65359 Timeout error of CAN Receive Frame ComRxETVActr 24112 65360 Timeout ComITVActr 24113 65361 Timeout error of CAN Receive Frame ComRxITVActr 24114 65362 Timeout error of CAN Transmit Frame A1DOC 24115 65363 Timeout error of CAN Transmit Frame AT1S 24116 65364 Timeout error of CAN Transmit Frame SCR2 24117 65365 Timeout error of CAN Transmit Frame SCR3 24118 65366 Timeout error of CAN Receive Frame ComRxCMO 24119 65367 Timeout error of CAN Receive Frame ComRxCustSCR2 24120
229. t avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage Be sure to wear protective eye wear and other protective clothing if the situation warrants it jl 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 Genie viii GTH 1048 GTH 1056 Workplace Safety Be sure keep sparks flames lighted tobacco away from flammable and combustible materials like battery gases and engine fuels Always have an approved fire extinguisher within easy reach Be sure that all tools and working areas are properly maintained and ready for use Keep work surfaces clean and free of debris that could get into machine components and cause damage MN other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted Use only chains or straps that are in good condition and of ample capacity Be sure any forklift overhead crane or Be sure that fasteners intended for one time use i e cotter pins and self locking nuts are not reused These components may fail if they are used a second time Be sure to properly dispose of old oil or other fluids Use approved container Please be environmentally safe Be sure that your workshop or wo
230. tems DA and DB Part No 123701 March 2015 Section 4 Repair Procedures How to Test a Coil Diode Genie incorporates spike suppressing diodes in all of its coils Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil Faulty diodes can fail to protect the electrical system resulting in a tripped circuit breaker or component damage AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Testthe coil for resistance See 7 8 How to Test a Coil 2 Connecta 100 resistor to the negative terminal of a known good 9V DC battery Connect the other end of the resistor to a terminal on the Coil Note The battery should read 9V DC or more when measured across the terminals Resistor 100 Genie part number 27287 Seta multimeter to read DC amperage Note The multimeter when set to read DC amperage should be capable of reading up to 800 mA PartNo 123701 Genie GTH 1048 GTH 1056 MANIFOLDS 4 Connectthe negative lead to the other terminal on the coil Note If testing a single terminal coil connect the negative lead to the internal metallic ring at either end of the coil COIL A MULTI METER
231. ternate Suspect Parameter Number FMI Failure Mode Identifier SPN ASPN FMI Description 29 3 Hand throttle error short circuit to battery on idle validation switch or sensor error 4 Hand throttle error short circuit to ground on idle validation switch or sensor error 51 3 Temperature to high for power stage of EGR Valve 2 9 3 6 Throttle Valve 6 1 7 8 or position sensor error 4 Open load actuator EGR Valve 2 9 3 6 Throttle Valve 6 1 7 8 or position sensor error 5 Target range to low for actuator EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 Target range to high for actuator EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 The actuator position for EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 is not plausible Open load actuator EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 Target range to high for accelerator pedal sensor Target range to low for accelerator pedal sensor PWM signal accelerator pedal out of target range to high Plausibility check between APP1 and APP2 or APP1 and idle switch Low fuel pressure is out of target range system reaction generated Target range to high for low fuel pressure sensor Target range to low for low fuel pressure sensor Water in Fuel Sensor Short Circuit to U Batt Water level in fuel prefilter above maximum value N 91 97 Aw 100 High oil pressure system reaction generated Low oil pressure system r
232. thin easy reach Explosion and fire hazard Never drain or store fuel in an open container due to the possibility of fire Explosion and fire hazard When transferring fuel connect a grounding wire between the machine and pump or container 1 Open the access door above the hydraulic tank 2 Disconnect the battery from the machine AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 3 Remove the battery from the machine 4 Tag and disconnect the wire harness from the fuel level terminals 5 Remove the filler cap from the hydraulic tank Part No 123701 Genie GTH 1048 GTH 1056 6 Place a drain pan or other suitable container under the hydraulic tank Refer to Section 2 Specifications 7 Remove the drain plug from the hydraulic tank and completely drain the tank Bodily injury hazard Beware of ACAUTION hot oil Contact with hot oil may cause severe burns 8 Remove the filler cap from the fuel tank 9 Using an approved hand operated pump drain the fuel tank into a container of suitable capacity Refer to Section 2 Specifications Explosion and fire hazard When transferring fuel connect a grounding wire between the machine and pump or container Note Be sure to only use a hand operated pump suitable for use with gasoline and or diesel fuel 10 Tag disconnect and plug the fuel supply and
233. tor s manual on your machine Be sure that all necessary tools and parts available and ready for use Use only Genie approved replacement parts Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a firm level surface Boomin the stowed position Key switch in the off position with the key removed Wheels chocked Part No 123701 Genie 1048 1056 4 1 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 Perform disassembly procedures to the point where repairs can be completed Then to re assemble perform the disassembly steps in reverse order Symbols Legend A Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates an imminently hazardous situation which if not avoided will result in death or serious injury Indicates a potentially hazardous AWARNING situation which if not avoided could result in death or serious injury Indicates a potentially hazardous
234. ttach a lifting strap from an overhead crane to the center point of the boom extension cylinder Support the cylinder Do not apply any lifting pressure 4 Remove the extension cylinder support loop from the underside of the boom Note The extension cylinder support loop is located at the fork end of the boom 5 Remove the fasteners securing the extension cylinder pivot pins to the boom 6 Use a soft metal drift to remove both pivot pins Remove the cylinder from the machine Crushing hazard The boom will fall if not properly supported when the pivot pins are removed from the machine Note During removal the overhead crane strap will need to be adjusted for proper balancing Part No 123701 March 2015 Section 4 Repair Procedures BOOM COMPONENTS 1 5 5 Tag disconnect and plug the fork level cylinder Fork Level Cylinder hoses from the cylinder manifolds Cap the fittings How to Remove the Fork Level AWARNING 2 lly injury hazard Spraying 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 replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the lifting fork frame See 1 2 How to Remove the Lifting Fork Frame 6 2 Remove the fastener securing the fork level cylinder rod end pivot pin to the f
235. ture Physical range check high for dosing valve DV1 downstream pressure shut off regeneration Physical range check low for dosing valve DV1 downstream pressure shut off regeneration Sensor HCI dosing valve DV1 downstream pressure plausibility error Sensor error HCI dosing valve DV1 downstream pressure signal range check high 2 ye WH Sensor error dosing valve DV1 downstream pressure signal range check low Physical range check high for DV1 amp DV2 upstream pressure shut off regeneration Physical range check low for DV1 amp DV2 upstream pressure shut off regeneration Sensor DV1 amp DV2 upstream pressure plausibility error Sensor error DV1 amp DV2 upstream pressure signal range check high Sensor error DV1 amp DV2 upstream pressure signal range check low Physical range check high for DV1 amp DV2 upstream temperature shut off regeneration Physical range check low for DV1 amp DV2 upstream temperature shut off regeneration Sensor DV1 amp DV2 upstream temperature plausibility error Sensor error DV1 amp DV2 upstream temperature signal range check high Sensor error DV1 amp DV2 upstream temperature signal range check low Genie Part No 123701 GTH 1048 GTH 1056 5 17 Section 5 Fault Codes September 2014 m rn ENGINE FAULT CODES MODELS WITH DEUTZ POWER SPN Suspect Parameter Number ASPN Alternate Su
236. uppression properties Cleanliness level minimum 15 13 Water content maximum 250 ppm Recommended Hydraulic Fluid Hydraulic oil type Chevron Rando HD Premium MV Viscosity grade 32 Viscosity index 200 Optional fluids Biodegradable Petro Canada Environ MV 46 Fire resistant UCON Hydrolube HP 5046 Mineral based Shell Tellus S2 V 32 Shell Tellus S2 V 46 Chevron Hydraulic Oil 5606A Note Genie specifications require additional equipment and special installation instructions for the approved optional fluids Consult the Genie Service Department before use Optional fluids may not have the same hydraulic lifespan and may result in component damage Note Extended machine operation can cause the hydraulic fluid temperature to increase beyond it s maximum allowable range If the hydraulic fluid temperature consistently exceeds 200 F 90 C an SPECIFICATIONS Do not top off with incompatible hydraulic fluids Hydraulic fluids may be imcompatible due to the differences in base additive chemistry When incompatible fluids are mixed insoluble materials may form and deposit in the hydraulic system plugging hydraulic lines filters control valves and may result in componentdamage Note Do not operate the machine when the ambient air temperature is consistently above 120 F 49 C Hydraulic Fluid Temperature Range
237. urn it clockwise to increase the pressure or counterclockwise to decrease the pressure Component damage hazard Do CAUTION not adjust the relief valve pressures higher than specifications 10 Install the relief valve cap 11 Repeat this procedure beginning with step 6 12 Turn the machine off Remove the pressure gauge from the test port AWARNING 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 Part No 123701 March 2015 How to Set the Parking Brake System Pressure Note Be sure that the hydraulic oil level is visible in the inspection glass of the hydraulic tank 1 Install a to 1000 psi to 100 bar pressure gauge into test port TP at the top of the primary function manifold schematic item AAA or BZ See 7 1 or 7 2 Primary Function Manifold Components Start the engine Allow the engine to idle after warming the engine to operating temperature Without operating any machine controls observe the reading on the pressure gauge Result The pressure gauge reads 450 25 psi 31 1 7 bar The pump is functioning correctly Result The pressure gauge fails to read 450 25 psi 31 1 7 bar The pressure setting needs to be adjusted See Repair Procedure 6 1 How to Adjust the Function Pump Pressure Turn the machine off Remove the pres
238. value upstream DOC out of target range to low 4766 Exhaust gas temperature sensor value downstream DOC out of target range to high Exhaust gas temperature sensor value downstream DOC out of target range to low k 4768 Exhaust gas temperature sensor signal upstream DOC not plausible Exhaust gas temperature sensor voltage to high Exhaust gas temperature sensor voltage to low 4769 Exhaust gas temperature sensor signal downstream DOC not plausible Target range to high for exhaust gas temperature sensor downstream DOC Target range to low for exhaust gas temperature sensor downstream DOC BWP Genie 5 12 1048 1056 Part No 123701 September 2014 Section 5 Fault Codes ENGINE FAULT CODES MODELS WITH DEUTZ POWER SPN Suspect Parameter Number ASPN Alternate Suspect Parameter Number FMI Failure Mode Identifier SPN ASPN FMI Description 23006 64254 3 Controller mode switch short circuit to battery 4 Controller mode switch short circuit to ground 1 Manipulation control was triggered 2 Timeout error in Manipulation control 9 Pressure Relief Valve PRV reached maximun allowed opening count 10 Pressure relief valve PRV reached maximun allowed open time 23212 64460 9 Timeout Error of CAN Receive Frame ComEngPrt Engine Protection 23216 64464 9 Timeout Error of CAN Receive Frame PrHtEnCmd pre heat command engine com
239. vicing 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
240. wise to increase the pressure or counterclockwise to decrease the pressure Component damage hazard Do not adjust the relief valve pressures higher than specifications 9 Install the relief valve cap 10 Repeat this procedure beginning with step 6 11 Turn the machine off Remove the pressure gauge from the test port AWARNING 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 Section 4 Repair Procedures March 2015 MANIFOLDS 7 9 Valve Coils How to Test a Coil A properly functioning coil provides an electromagnetic force which operates the solenoid valve Critical to normal operation is continuity within the coil Zero resistance or infinite resistance indicates the coil has failed Since coil resistance is sensitive to temperature resistance values outside specification can produce erratic operation When coil resistance decreases below specification amperage increases As resistance rises above specification voltage increases While valves may operate when coil resistance is outside specification maintaining coils within specification will help ensure proper valve function over a wide range of operating temperatures AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings wat
241. with step 8 15 Install the cable bridge rear mount bracket onto the cable bridge and the boom assembly Securely tighten the fasteners Do not over tighten 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 Section 4 Repair Procedures March 2015 BOOM COMPONENTS Replace the upper hoses 1 Fully retract the boom 2 Fully lower the tips of the lifting forks 3 Remove the covers from the pivot end of the boom 4 Attach a lifting strap from an overhead crane to the top of the lifting fork frame Support the frame Do not apply any lifting pressure 5 Working at the pivot end of the boom remove the fasteners securing the cable bridge rear mount bracket to the boom assembly Remove the bracket from the boom 6 Tag disconnect and plug the hydraulic hoses at the hard lines of the cable bridge Cap the fittings AWARNING 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 Component damage hazard Hoses can be damaged if they are kinked or pinched 7 Return the cable bridge to its original position 8 Working at the fork end of the boom tag disconnect and plug the fork level cylinder hoses at the cylinder manifolds Cap the fittings 9 Models with auxiliary
242. wnstream cat DPF system downstream cat 23946 65194 Zerofuel calibration injector 1 in firing order maximum value exceeded Zerofuel calibration injector 1 in firing order minimum value exceeded Zerofuel calibration injector 2 in firing order maximum value exceeded Zerofuel calibration injector 2 in firing order minimum value exceeded Zerofuel calibration injector 3 in firing order maximum value exceeded 23947 65195 Zerofuel calibration injector 3 in firing order minimum value exceeded 23948 65196 23949 65197 Zerofuel calibration injector 4 in firing order maximum value exceeded Zerofuel calibration injector 4 in firing order minimum value exceeded Zerofuel calibration injector 5 in firing order maximum value exceeded Zerofuel calibration injector 5 in firing order minimum value exceeded Zerofuel calibration injector 6 in firing order maximum value exceeded Zerofuel calibration injector 6 in firing order minimum value exceeded EGR cooler downstream temperature out of range system reaction initiated Exhaust gas temperature EGR downstream out of range system reaction initiated 23950 65198 23951 65199 Oo Oj OF Oj 23960 65208 1 cooler downstream temperature out of range system reaction initiated Exhaust gas temperature EGR downstream out of range system reaction initiated 23973 65221 14 SCR Tamper detection derat
243. y Do not allow oil to squirt or spray Component damage hazard Hoses can be damaged if they are kinked or pinched Part No 123701 Genie GTH 1048 GTH 1056 BOOM COMPONENTS 7 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 8 Securely connect a 30 feet 10 m length of rope to the end of each hose disconnected in steps 6 and 7 Securely tie off the other end of each section of rope to the boom structure 9 Working at the pivot end of the boom select 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 in a difficult reassembly Be sure each section of rope is securely attached to both the hose and the boom structure before pulling the hose out of the boom 10 Remove the rope from the hose Discard the hose 11 Securely install a section of rope onto the correct end of the new hose assembly 12 Install the new hose assembly into the boom by routing the hose under the roller at the pivot end of the boom Using the rope carefully pull the hose through the boom until the end is accessible 13 Install both ends of the hose assembly onto the correct connection points Torque to specification Refer to Section 2 Specifications 14 Repeat this procedure for the remaining hose to be replaced beginning
244. y Severe Exhaust Pressure Incorrect Exhaust Pressure Sensor Voltage Out of Range High Exhaust Pressure Sensor Voltage Out of Range Low Fuel Pump Pressurizing Assembly 1 Sensor Voltage High Fuel Pump Pressurizing Assembly 1 Sensor Circuit Open Shorted to Ground or Overloaded Fuel Pump Assembly 1 Rail Pressure Contro Mismatch Engine Protection Derate Exhaust Gas Recirculation Fresh Air Temperature High Most Severe Exhaust Gas Recirculation Fresh Air Temperature Voltage Out of Range High Exhaust Gas Recirculation Fresh Air Temperature Voltage Out of Range Low Exhaust Gas Recirculation Fresh Air Temperature High Least Severe Exhaust Gas Recirculation Fresh Air Temperature High Moderately Severe Exhaust Gas Recirculation Flow Temperature Mismatch Exhaust Gas Recirculation Flow Rate Above Normal Exhaust Gas Recirculation Flow Rate Below Normal Turbocharger Compressor Outlet Temperature High Most Severe Exhaust Gas Recirculation Valve Sensor Voltage Mismatch Exhaust Gas Recirculation Valve Sensor Voltage Out of Range High Exhaust Gas Recirculation Valve Sensor Voltage Out of Range Low Exhaust Gas Recirculation Valve Current Low or Open Circuit Exhaust Gas Recirculation Valve Current High or Grounded Circuit Exhaust Gas Recirculation Valve Not Responding or Out of Adjustment Exhaust Gas Recirculation Valve Out of Calibration Exhaust Gas Recirculation Valve Off Exhaust Gas Recirculation Valve Position Error Turbocha

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