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Genie GTH-1056 Service & Repair Manual 1278145 – PDF DOWNLOAD
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Genie GTH-1056 Service & Repair Manual 1278145 – PDF DOWNLOAD
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Description
Genie GTH-1056 Service & Repair Manual 1278145 – PDF DOWNLOAD
Language : English
Pages : 153
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie GTH-1056 Service & Repair Manual 1278145 – PDF DOWNLOAD
Introduction Introduction.............................................................. 2 Important Information.............................................................. 2 Find a Manual for this Model....................................................... 2 Serial Number Legend............................................................... 4 Section 1 Safety Rules................................................................. 5 General Safety Rules............................................................... 5 Section 3 Repair Procedures ........................................................... 7 How to Test a Proximity Switch 18.................................................. 7 How to Adjust the Boom Angle Proximity Switch 19................................... 7 How to Adjust the Boom Extend Proximity Switch 19.................................. 7 How to Replace the Boom Wear Pads 20............................................... 7 How to Remove the Lifting Fork Frame 20............................................ 7 How to Remove the Cable Bridge Assembly 21......................................... 8 How to Replace the Retraction Chain 22............................................. 8 How to Replace the Extension Chains 24............................................. 8 How to Remove the Boom 26.......................................................... 8 How to Disassemble the Boom - GTH-1056 28.......................................... 8 How to Replace the Fork Level and/or Auxiliary Cylinder Hoses, GTH-1056 34......... 8 How to Remove the Steering Column 38............................................... 8 How to Remove the Steering Wheel 38................................................ 8 How to Remove the Steer Orbitral 39................................................ 8 How to Remove the Joystick - Models with Single Joystick 39........................ 8 How to Remove the Joystick - Models with Dual Joysticks 40......................... 8 How to Remove the Brake Pedal Assembly 40.......................................... 8 How to Remove the Gauge Cluster Assembly 41........................................ 8 How to Remove the Diagnostic Display 41............................................ 8 How to Repair the Perkins 1104D-E44TA Engine 43.................................... 8 How to Repair the Deutz TCD3.6 Engine 43........................................... 8 How to Remove the Engine 43........................................................ 8 How to Repair the Transmission 45.................................................. 8 How to Remove the Transmission 45.................................................. 8 How to Test the Function Pump 47................................................... 9 How to Remove the Function Pump 48................................................. 9 How to Install the Function 49..................................................... 9 How to Prime the Function Pump 49.................................................. 9 How to Adjust the Function Pump Standby Pressure 50................................ 9 How to Adjust the Function Pump Pressure Compensator 51............................ 9 How to Set the Steer System Pressure 69............................................ 9 How to Set the Parking Brake System Pressure 70.................................... 9 How to Set the Differential Lock/Joystick System Pressure 71....................... 9 How to Set the Rear Lock-up System Pressure 72..................................... 9 How to Remove the Axle 75.......................................................... 9 How to Repair the Axle 75.......................................................... 9 How to Remove an Outrigger 76...................................................... 9 How to Remove an Outrigger Cylinder 77............................................. 9 Section 2 Specifications............................................................... 11 Machine Specifications............................................................. 11 Performance Specifications......................................................... 12 Hydraulic Oil Specifications....................................................... 12 Hydraulic Component Specifications................................................. 15 Manifold Component Specifications.................................................. 16 Air Conditioner Refrigerant Specifications......................................... 16 DEF Storage Specifications......................................................... 17 Deutz TCD3.6 L4 Engine Specifications.............................................. 18 Deutz TCD3.6 L4 T4F Engine Specifications.......................................... 19 Perkins 1104D-E44TA Engine Specifications.......................................... 20 Perkins 1204E-E44TA Engine Specifications.......................................... 21 ZF 4 WG-98 TC Transmission Specifications.......................................... 22 Dana Planetary Drive Axle Specifications (223_212HY)............................... 22 Hydraulic Hose and Fitting Torque Specifications................................... 23 Torque Procedure................................................................... 24 Section 3 Repair Procedures............................................................ 26 Introduction....................................................................... 26 Boom Components.................................................................... 28 1-1 Boom Proximity Switch...................................................... 28 How to Test a Proximity Switch............................................. 28 How to Adjust the Boom Angle Proximity Switch.............................. 29 How to Adjust the Boom Extend Proximity Switch............................. 29 1-2 Boom....................................................................... 30 How to Replace the Boom Wear Pads.......................................... 30 How to Remove the Lifting Fork Frame....................................... 30 How to Remove the Cable Bridge Assembly.................................... 31 How to Replace the Retraction Chain........................................ 32 How to Replace the Extension Chains........................................ 34 How to Remove the Boom..................................................... 36 How to Disassemble the Boom - GTH-1056..................................... 38 1-3 Boom Lift Cylinder......................................................... 41 1-4 Boom Extension Cylinder.................................................... 42 1-5 Fork Level Cylinder........................................................ 43 1-6 Hydraulic Hoses............................................................ 44 How to Replace the Fork Level and/or Auxiliary Cylinder Hoses, GTH-1056.... 44 Operator's Compartment............................................................. 46 2-1 Operator's Compartment..................................................... 46 2-2 Machine Controls........................................................... 48 How to Remove the Steering Column.......................................... 48 How to Remove the Steering Wheel........................................... 48 How to Remove the Steer Orbitral........................................... 49 How to Remove the Joystick - Models with Single Joystick................... 49 How to Remove the Joystick - Models with Dual Joysticks.................... 50 How to Remove the Brake Pedal Assembly..................................... 50 How to Remove the Gauge Cluster Assembly................................... 51 How to Remove the Diagnostic Display....................................... 51 Fuel and Hydraulic Tanks........................................................... 52 3-1 Fuel and Hydraulic Tanks................................................... 52 Engines............................................................................ 53 4-1 Engines.................................................................... 53 How to Repair the Perkins 1104D-E44TA Engine............................... 53 How to Repair the Deutz TCD3.6 Engine...................................... 53 How to Remove the Engine................................................... 53 4-2 Engine Fault Codes......................................................... 54 Transmission....................................................................... 55 5-1 Transmission............................................................... 55 How to Repair the Transmission............................................. 55 How to Remove the Transmission............................................. 55 Hydraulic Pump..................................................................... 57 6-1 Hydraulic Pump............................................................. 57 How to Test the Function Pump.............................................. 57 How to Remove the Function Pump............................................ 58 How to Install the Function................................................ 59 How to Prime the Function Pump............................................. 59 How to Adjust the Function Pump Standby Pressure........................... 60 How to Adjust the Function Pump Pressure Compensator....................... 61 Manifolds.......................................................................... 64 7-1 Primary Function Manifold Components - Models with Single Joystick......... 64 7-2 Primary Function Manifold Components - Models with Dual Joysticks.......... 68 7-3 Secondary Function Manifold Components..................................... 72 7-4 Outrigger Manifold Components.............................................. 74 7-5 Auxiliary Manifold Components (option)..................................... 76 7-6 Brake Manifold Components.................................................. 77 7-7 AC Hydraulic Manifold Components........................................... 78 7-8 Valve Adjustments - Secondary Function Manifold............................ 79 How to Set the Steer System Pressure....................................... 79 How to Set the Parking Brake System Pressure............................... 80 How to Set the Differential Lock/Joystick System Pressure.................. 81 How to Set the Rear Lock-up System Pressure................................ 82 7-9 Valve Coils................................................................ 83 Axle............................................................................... 85 8-1 Axles...................................................................... 85 How to Remove the Axle..................................................... 85 How to Repair the Axle..................................................... 85 Outriggers......................................................................... 86 9-1 Outriggers................................................................. 86 How to Remove an Outrigger................................................. 86 How to Remove an Outrigger Cylinder........................................ 87 Section 4 Fault Codes.................................................................. 89 Introduction....................................................................... 89 Diagnostic Display................................................................. 90 Deutz TCD3.6 Engine Fault Codes.................................................... 91 Perkins 1104 Engine Fault Codes....................................................115 Section 5 Schematics...................................................................117 Introduction.......................................................................117 Proximity Switch Legend............................................................118 Fuse Panel Layout..................................................................119 Deutz TCD3.6 T4F Module............................................................120 Electrical Component & Wire Color Abbreviation Legend..............................121 Telematics Connector Pin Legend....................................................124 Electrical Symbol Legend...........................................................126 Hydraulic Symbols Legend...........................................................127 Electrical Schematics..............................................................129 Electrical Schematic...........................................................130 Electrical Schematic (from GTH10E-11890 to 12499)..............................134 Electrical Schematic- Deutz T4F Engine Harness.................................141 Hydraulic Schematics...............................................................148 Hydraulic Schematic - Models with Single Joystick (to SN GTH10E-12499).........149 Hydraulic Schematic - Models with Dual Joystick (to SN GTH10E-12499)...........150 Hydraulic Schematic - Electronic Joystick (from SN GTH10E-12500)...............152
S.S 04/24
