Genie GTH-1048 User manual

Parts Manual
Serial Number Range
Service Manual
Part No. 123701
Rev F2
May 2015
Serial Number Range
GTH-1048
GTH-1056
from GTH1007B-7101
from GTH1007A-11697
from GTH1014E-10001
from GTH1010-14001

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GTH-1048 • GTH-1056 Part No. 123701
ii
Introduction
Introduction
Copyright © 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.
Printed on recycled paper
Printed in U.S.A.
Important
Read, understand and obey the safety rules and
operating instructions in the Genie GTH-1056
Operator's Manual before 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
communications will be carefully considered for
future printings of this and all other manuals.
Contact Us:
http://www.genielift.com
e-mail: [email protected]
Serial Number Information
Genie offers the following Service Manuals for
these models:
Title Part No.
GTH-1056 Service Manual
(from GTH1006A-8414
to GTH-1007A-11442) .......................................... 97487

May 2015
Part No. 123701 GTH-1048 • GTH-1056
Revision History
Revision Date Section Procedure / Schematic Page / Description
C 7/2012 2 - Spec. 2-5
3 - Maint. 3-20, 3-22
4 - Repair 4-56
5 - Fault 5-2, 5-3
6 - Schem. 6-4, 6-6, 6-10, 6-14, 6-18, 6-22
C1 3/2013 2 - Spec. 2-3, 2-7, 2-9, 2-11, 2-12, 2-13
3 - Maint. 3-8, 3-19, 3-21, 3-22, 3-29, 3-31, 3-32, 3-33, 3-34
6 - Schem. 6-22, 6-23
D 6/2013 5- Fault. 5-8 - 17, 5-18 - 19
E 8/23/2013 3-Maint 3-19, 3-21-22
F 9/2014 2 - Spec Hydraulic Oil
3 - Maint. A-6, D-7- ZF Transmission maint.
2 - Fault Deutz Fault Codes
6 - Schem. Telematics Connector Legend, Electrical Schematic
Harness Maps, 6-3
F1 3/2015 2 - Repair 4-55, Electrical Schematics, Hydraulic Schematics
F2 5/2015 6- Schem. 6-5, 6-40
Electronic Version
Click on any procedure or page number
highlighted in blue to view the update.
iii

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GTH-1048 • GTH-1056 Part No. 123701
REVISION HISTORY, CONTINUED
Revision Date Section Procedure / Schematic Page / Description
Electronic Version
Click on any procedure or page number
highlighted in blue to view the update.
iv

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Part No. 123701 GTH-1048 • GTH-1056
v
Serial Number Legend
INTRODUCTION
GTH10 07 B - 7101
Year of
manufacture
Model
Facility code
Sequence
number
MODEL:
Terex South Dakota, Inc.
18340 NE 76th Street
Redmond, WA 98052
USA
GTH1048
A TEREX BRAND
SERIAL NUMBER:GTH1007B-7101
ATTACHMENT:
MANUFACTURE DATE:04/12/07
TOTAL TRUCK WEIGHT(LBS): 29,000lbs / 13,182kg
MAX LIFT CAPACITY(LBS):
10000 LBS
LIFT CAPACITY(LBS)
AT MAX LIFT HEIGHT:
OUTRIGGERS UP:
OUTRIGGERS DOWN:N/A
N/A
6000 LBS
THIS FORKLIFT TRUCK COMPLIES
WITH:
ASME B56.6-2002 SAFETY STD FOR
ROUGH TERRAIN FORKLIFT TRUCK
Serial label
(located inside fork frame)
(models with quick attach frame)
Serial label
(located inside chassis at tank side of machine) Serial number
(stamped on chassis)

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vi
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May 2015
Part No. 123701 GTH-1048 • GTH-1056
Safety Rules
Section 1 • Safety Rules
vii
Danger
Failure to obey the instructions and safety rules
in this manual and the appropriate Operator's
Manual on your machine will result in death or
serious injury.
Many of the hazards identified in the
operator’s manual are also safety hazards
when maintenance and repair procedures
are performed.
Do Not Perform Maintenance
Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
- manufacturer’s instructions and safety rules
- employer’s safety rules and worksite
regulations
- applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.

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viii
Section 1 • 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.
Read each procedure thoroughly. This
manual and the decals on the machine,
use signal words to identify the following:
Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicates an imminently hazardous
situation which, if not avoided, will
result in death or serious injury.
Indicates a potentially hazardous
situation which, if not avoided,
could result in death or serious
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may cause minor or moderate
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may result in property damage.
Be sure to wear protective eye wear and
other protective clothing if the situation
warrants it.
Be aware of potential crushing hazards
such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved
steel-toed shoes.
Workplace Safety
Be sure to keep sparks, flames and
lighted tobacco away from flammable and
combustible materials like battery gases
and engine fuels. Always have an
approved fire 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.
Be sure any forklift, overhead crane or
other lifting or supporting device is fully
capable of supporting and stabilizing the
weight to be lifted. Use only chains or
straps that are in good condition and of
ample capacity.
Be sure that fasteners intended for one
time use (i.e., cotter pins 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 an approved container.
Please be environmentally safe.
Be sure that your workshop or work area
is properly ventilated and well lit.
SAFETY RULES

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Part No. 123701 GTH-1048 • GTH-1056
Table of Contents
ix
Introduction
Important Information ......................................................................................... ii
Serial Number Legend ....................................................................................... iii
Section 1 Safety Rules
General Safety Rules ........................................................................................ v
Section 2 Specifications
Machine Specifications ................................................................................ 2 - 1
Performance Specifications ......................................................................... 2 - 2
Hydraulic Oil Specifications ......................................................................... 2 - 3
Hydraulic Component Specifications ............................................................ 2 - 6
Manifold Component Specifications ............................................................. 2 - 7
AC Refrigerant Specification ........................................................................ 2 - 7
Valve Coil Resistance Specifications ........................................................... 2 - 7
John Deere 4045TH485 Engine .................................................................... 2 - 8
Deutz TCD3.6 L4 Engine .............................................................................. 2 - 9
Perkins 1104D-E44TA Engine .................................................................... 2 - 10
Perkins 1204E-E44TA Engine .................................................................... 2 - 11
Dana T20000 Transmission ........................................................................ 2 - 12
Dana Planetary 213 Drive Axle ................................................................... 2 - 12
Hydraulic Hose and Fitting Torque Specifications....................................... 2 - 13
SAE and Metric Fasteners Torque Charts .................................................. 2 - 16
Section 3 Scheduled Maintenance Procedures
Introduction .................................................................................................. 3 - 1
Pre-delivery Preparation Report .................................................................... 3 - 3
Maintenance Inspection Report .................................................................... 3 - 5

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TABLE OF CONTENTS
x
Section 3 Scheduled Maintenance Procedures, continued
Checklist A Procedures
A-1 Inspect the Manuals and Decals ......................................................... 3 - 6
A-2 Perform Pre-operation Inspection ........................................................ 3 - 7
A-3 Perform Function Tests ...................................................................... 3 - 7
A-4 Lubricate the Boom ............................................................................. 3 - 8
A-5 Perform Engine Maintenance .............................................................. 3 - 8
A-6 Perform Transmission Maintenance - All Models ................................ 3 - 9
A-7 Perform 30 Day Service ...................................................................... 3 - 9
A-8 Perform Axle Maintenance ................................................................ 3 - 10
A-9 Perform Engine Maintenance - John Deere Models ........................... 3 - 10
A-10 Perform Axle Maintenance ................................................................ 3 - 11
A-11 Perform Axle Maintenance ................................................................ 3 - 11
Checklist B Procedures
B-1 Inspect the Battery ........................................................................... 3 - 12
B-2 Inspect the Electrical Wiring ............................................................. 3 - 12
B-3 Check the Exhaust System .............................................................. 3 - 13
B-4 Inspect the Engine Air Filter .............................................................. 3 - 14
B-5 Inspect the Tires, Wheels and Lug Nut Torque .................................. 3 - 14
B-6 Perform Hydraulic Oil Analysis ......................................................... 3 - 15
B-7 Inspect the Fuel and Hydraulic Tank Cap Venting Systems .............. 3 - 16
B-8 Check the Boom Wear Pads ............................................................. 3 - 17
B-9 Lubricate the Driveshafts .................................................................. 3 - 18
B-10 Perform Engine Maintenance - John Deere Models ........................... 3 - 18

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TABLE OF CONTENTS
xi
Section 3 Scheduled Maintenance Procedures, continued
Checklist C Procedures
C-1 Perform Engine Maintenance - John Deere Models ........................... 3 - 20
C-2 Perform Axle Maintenance ................................................................ 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 Inspect and Lubricate the Sequencing Chains ................................... 3 - 23
C-8 Adjust the Sequencing Chains .......................................................... 3 - 24
C-9 Perform Axle Maintenance ................................................................ 3 - 25
C-10 Perform Axle Maintenance ................................................................ 3 - 26
Checklist D Procedures
D-1 Inspect the Forks .............................................................................. 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 Maintenance ................................................................ 3 - 28
D-5 Perform Engine Maintenance - Deutz Models ................................... 3 - 29
D-6 Perform Engine Maintenance - Perkins Models ................................. 3 - 29
D-7 Perform Transmission Maintenance - ZF Models
Checklist E Procedures
E-1 Test or Replace the Hydraulic Oil ...................................................... 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

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GTH-1048 • GTH-1056 Part No. 123701
TABLE OF CONTENTS
xii
Section 4 Repair Procedures
Introduction .................................................................................................. 4 - 1
Boom Components
1-1 Boom Proximity Switches ................................................................... 4 - 2
1-2 Boom .................................................................................................. 4 - 4
1-3 Boom Lift Cylinder ............................................................................ 4 - 17
1-4 Boom Extension Cylinder ................................................................. 4 - 18
1-5 Fork Level Cylinder ........................................................................... 4 - 19
Operator's Compartment
2-1 Operator's Compartment ................................................................... 4 - 23
2-2 Machine Controls .............................................................................. 4 - 25
Fuel and Hydraulic Tanks
3-1 Fuel and Hydraulic Tanks ................................................................. 4 - 29
Engines
4-1 Engines ............................................................................................ 4 - 30
4-2 Engine Fault Codes .......................................................................... 4 - 32
Transmission
5-1 Transmission .................................................................................... 4 - 33
Hydraulic Pumps
6-1 Hydraulic Pump ................................................................................ 4 - 35

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TABLE OF CONTENTS
xiii
Section 4 Repair Procedures, continued
Manifolds
7-1 Primary Function Manifold Components -
Models with Single Joystick ............................................................. 4 - 42
7-2 Primary Function Manifold Components -
Models with Dual Joysticks .............................................................. 4 - 46
7-3 Secondary Function Manifold Components ...................................... 4 - 50
7-4 Outrigger Manifold Components....................................................... 4 - 52
7-5 Auxiliary Manifold Components (option) ........................................... 4 - 54
7-6 Brake Manifold Components ............................................................ 4 - 55
7-7 AC Hydraulic Manifold Components .................................................. 4 - 56
7-8 Valve Adjustments - Secondary Function Manifold ........................... 4 - 58
7-9 Valve Coils ....................................................................................... 4 - 62
Axle Components
8-1 Axles ................................................................................................ 4 - 64
Outriggers
9-1 Outriggers ......................................................................................... 4 - 65

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GTH-1048 • GTH-1056 Part No. 123701
xiv
Section 5 Fault Codes
Introduction .................................................................................................. 5 - 1
Diagnostic Display ....................................................................................... 5 - 2
Engine Fault Codes - Models with John Deere Power ................................... 5 - 4
Engine Fault Codes - Models with Deutz Power ........................................... 5 - 8
Engine Fault Codes - Models with Perkins Power....................................... 5 - 26
Section 6 Schematics
Introduction .................................................................................................. 6 - 1
Proximity Switch Layout ............................................................................... 6 - 2
Fuse Box Layout
(before serial number GTH1012-16292) ........................................................ 6 - 3
Fuse Box Layout
(from serial number GTH1012-16292) ........................................................... 6 - 4
Fuse Box Layout
(from serial number GTH1014E-10353) ......................................................... 6 - 5
Electrical Component Legend
(before serial number GTH1012-16292) ........................................................ 6 - 6
Electrical Component & Wire Color Legend
(from serial number GTH1012-16292) ........................................................... 6 - 7
Telematics Connector Legend ...................................................................... 6 - 9
Electrical and Hydraulic Symbols Legends ................................................. 6 - 10
TABLE OF CONTENTS

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Part No. 123701 GTH-1048 • GTH-1056
TABLE OF CONTENTS
Section 6 Schematics, continued
Harness Map - Control System Power
Single Joystick........................................................................................... 6 - 12
Harness Map - Control System Ground
Single Joystick........................................................................................... 6 - 13
Harness Map - Control System Power
Dual Joysticks ........................................................................................... 6 - 16
Harness Map - Control System Ground
Dual Joysticks ........................................................................................... 6 - 17
Harness Map - Deutz 3.6TCD Engine
Battery Power and Ground ......................................................................... 6 - 20
Harness Map - Perkins 1104D 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 ................................................................................................ 6 - 28
Harness Map - Options
Road Lights ................................................................................................ 6 - 29
Harness Map - Options
Enclosed Cab with Heater .......................................................................... 6 - 31
Harness Map - Options
Enclosed Cab with HVAC ........................................................................... 6 - 32
Electrical Schematic .................................................................................. 6 - 35
(before serial number GTH1012-16292)
Electrical Schematic .................................................................................. 6 - 40
(from serial number GTH1012-16292 to GTH1014-19340)
Electrical Schematic .................................................................................. 6 - 44
(from serial number GTH1014-19341, GTH1014E-10001)
Hydraulic Schematic -
Models with Single Joystick ....................................................................... 6 - 48
Hydraulic Schematic -
Models with Dual Joysticks ........................................................................ 6 - 49

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TABLE OF CONTENTS
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Section 2 • SpecificationsSeptember 2014
Part No.123701 GTH-1048 • GTH-1056 2 - 1
Specifications
Machine Specifications
Fluid capacities
Fuel tank 35 gallons
132.5 liters
Hydraulic tank 44 gallons
166.5 liters
Hydraulic system 55 gallons
(including tank) 208.2 liters
For operational specifications, refer to the
Operator's Manual.
Tires and wheels
Tire size 14.00 x 24
Tire ply rating 12
Weight, rough terrain tire 315 lbs
(air filled) 142.9 kg
Weight, rough terrain tire 967 ±35 lbs
(foam filled) 439 ±16 kg
Weight, rock lug tire 1013 ±35 lbs
(foam filled) 459 ±16 kg
Tire pressure 50 psi
(models with air-filled tires) 3.45 bar
Lug nut torque 465 ft-lbs
630 Nm
Lug pattern 10 x 13.189
Wheel diameter 24 in
60.1 cm
Wheel width 9 in
22.9 cm
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.

Section 2 • Specifications September 2014
2 - 2 GTH-1048 • GTH-1056 Part No.123701
SPECIFICATIONS
Performance Specifications
Drive speed, maximum 18 mph
29 km/h
Draw bar pull 29,000 lbs
13,154 kg
Lift capacity, maximum 10,000 lbs
4545 kg
Boom function speeds, maximum
GTH-1048
Boom up 12 to 14 seconds
Boom down 13 to 15 seconds
Boom extend 16 to 18 seconds
Boom retract 15 to 17 seconds
Fork rotate 19 to 21 seconds
GTH-1056
Boom up 17 to 19 seconds
Boom down 23 to 25 seconds
Boom extend 14 to 16 seconds
Boom retract 13 to 15 seconds
Fork rotate 3 to 6 seconds
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.

Section 2 • SpecificationsSeptember 2014
Part No.123701 GTH-1048 • GTH-1056 2 - 3
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 suppression 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
optional oil cooler may be required.
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
component damage.
Note: Do not operate the machine when the
ambient air temperature is consistently above
120°F / 49°C.
Hydraulic Fluid Temperature Range
1 Chevron hydraulic oil 5606A
2 Petro-Canada Environ MV 46
3 UCON Hydrolube HP-5046D
4 Chevron Rando HD Premium MV
-40
-40
-22
-30
-4
-20
14
-10
32
-0
50
10
68
20
86
30
104
40
122
50
F
C
1
2
3
4
Ambient Air Temperature
Continuous improvement of our products is a
Genie policy. Product specifications are subject
to change without notice.

Section 2 • Specifications September 2014
2 - 4 GTH-1048 • GTH-1056 Part No.123701
Chevron Rando HD Premium MV oil
fluid properties
ISO grade 32
Viscosity index 200
Kinematic Viscosity
cSt @ 200°F / 100°C 7.5
cSt @ 104°F / 40°C 33.5
Brookfield Viscosity
cP @ -4°F / -20°C 1040
cP @ -22°F / -30°C 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.
Chevron 5606A hydraulic oil fluid
properties
ISO grade 15
Viscosity index 300
Kinematic Viscosity
cSt @ 200°F / 100°C 5.5
cSt @ 104°F / 40°C 15.0
cSt @ -40°F / -40°C 510
Brookfield Viscosity
cP @ -4°F / -20°C 1040
cP @ -22°F / -30°C 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 an oil
heating system is used.
Continued use of Chevron 5606A
hydraulic fluid, or equivalent, when
ambient temperatures are
consistently above 32°F / 0°C may
result in component damage.
Continuous improvement of our products is a
Genie policy. Product specifications are subject
to change without notice.