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Genie GTH-1056, Service And Repair Manual

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Genie GTH-1056 Service And Repair Manual Download Page 40

Service and Repair Manual

 

April 2017

 

Boom Components 

 

 

30 

GTH-1056

 

Part No. 1278145 

 

 

 

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. 

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 
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  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 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. 

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. 

 

Crushing 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 0. Place boom tube 
number 1 on a structure capable of supporting 
it. 

 

Crushing 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. 

Summary of Contents for GTH-1056

Page 1: ...99 includes GTH1016E 11281 GTH1016E 11282 GTH1016E 11286 from GTH10E 11800 This manual includes Repair procedures Fault Codes Electrical and Hydraulic Schematics For detailed maintenance procedures refer to the appropriate Maintenance Manual for your machine Part No 1278145 Rev A1 April 2017 ...

Page 2: ...ed 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 printin...

Page 3: ... Page Description A 3 2016 Initial Release A1 4 2016 Repair Revise manifold torque values Hydraulic Schematics Reference Examples Electronic Version Click on any content or procedure in the Table of Contents to view the update Section Repair Procedure 4 2 Section Fault Codes All charts Section Schematics Legends and schematics ...

Page 4: ... 31 2016 1 Model 2 Model year 3 Facility code 4 Sequence number 1 Serial label 2 Serial number stamped on chassis 3 Serial label located inside fork frame From September 1 2016 1 Model 2 Facility code 3 Sequence number 1 Serial label 2 Serial number stamped on chassis 3 Serial label located inside fork frame ...

Page 5: ...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 h...

Page 6: ...re 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...

Page 7: ...ecifications 8 Deutz TCD3 6 L4 T4F Engine Specifications 9 Perkins 1104D E44TA Engine Specifications 10 Perkins 1204E E44TA Engine Specifications 11 ZF 4 WG 98 TC Transmission Specifications 12 Dana Planetary 213 Drive Axle Specifications 12 Hydraulic Hose and Fitting Torque Specifications 13 Torque Procedure 14 Section 3 Repair Procedures 16 Introduction 16 Boom Components 18 1 1 Boom Proximity S...

Page 8: ...w to Remove the Steering Wheel 38 How to Remove the Steer Orbitral 39 How to Remove the Joystick Models with Single Joystick 39 How to Remove the Joystick Models with Dual Joysticks 40 How to Remove the Brake Pedal Assembly 40 How to Remove the Gauge Cluster Assembly 41 How to Remove the Diagnostic Display 41 Fuel and Hydraulic Tanks 42 3 1 Fuel and Hydraulic Tanks 42 Engines 43 4 1 Engines 43 How...

Page 9: ...els with Dual Joysticks 58 7 3 Secondary Function Manifold Components 62 7 4 Outrigger Manifold Components 64 7 5 Auxiliary Manifold Components option 66 7 6 Brake Manifold Components 67 7 7 AC Hydraulic Manifold Components 68 7 8 Valve Adjustments Secondary Function Manifold 69 How to Set the Steer System Pressure 69 How to Set the Parking Brake System Pressure 70 How to Set the Differential Lock...

Page 10: ...l Legend 115 Hydraulic Symbols Legend 116 Harness Map Control System Single Joystick 117 Harness Map Control System Dual Joystick 120 Harness Map Deutz 3 6TCD T4F Engine 121 Harness Map Perkins 1204 T4F Engine 124 Harness Map Work Lights 125 Harness Map Road Lights 128 Harness Map Enclosed Cab with Heat 129 Harness Map Enclosed Cab with HVAC 132 Harness Map Auxiliary Hydraulics Beacon and Top Gear...

Page 11: ... 9 kg Weight rough terrain tire foam filled 967 35 lbs 439 16 kg Weight rock lug tire foam filled 1013 35 lbs 459 16 kg Tire pressure models with air filled tires 50 psi 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 Fluid capacities Fuel tank 35 gallons 132 5 liters Hydraulic tank 44 gallons 166 5 liters Hydraulic system inc...

Page 12: ...itioning and foam and aeration suppression properties Cleanliness level minimum ISO 15 13 Water content maximum 250 ppm Recommended Hydraulic Fluid Hydraulic oil type Chevron Rando HD Premium Viscosity grade 32 Viscosity index 200 Optional Hydraulic Fluids Mineral based Shell Tellus S2 V 32 Shell Tellus S2 V 46 Shell Tellus S4 VX 32 Shell Shell Donax TG Dexron III Chevron 5606A Biodegradable Petro...

Page 13: ... 49 C Hydraulic Fluid Temperature Range Ambient air temperature 1 Chevron hydraulic oil 5606A 2 Petro Canada Environ MV 46 3 UCON Hydrolube HP 5046D 4 Chevron Rando HD premium oil MV Chevron Rando HD Premium Oil MV Fluid Properties ISO Grade 32 Viscosity index 200 Kinematic Viscosity cSt 200 F 100 C cSt 104 F 40 C 7 5 33 5 Brookfield Viscosity cP 4 F 20 C cP 22 F 30 C 1040 3310 Flash point 375 F 1...

Page 14: ...m 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 Petro Canada Environ MV 46 Fluid Properties ISO Grade 46 Viscosity index 154 Kinematic Viscosity cSt 200 F 100 C cSt 104 F 40 C 8 0 44 4 Flash point 482 F 250 C Pour point 49 F 45 C Maximum continuous operating temperature 180 F 82 C Shell ...

Page 15: ...4 F 40 C cSt 0 F 18 C 22 46 1300 Flash point None Pour point 81 F 63 C Maximum continuous operating temperature 189 F 87 C Hydraulic Component Specifications Function pump Type variable displacement piston pump Displacement 0 to 3 66 cu in 0 to 60 cc Flow rate 2400 rpm 38 gpm 144 L min Pump pressure maximum 3190 psi 220 bar Pressure compensator 3190 psi 220 bar Standby pressure 464 psi 32 bar ...

Page 16: ...1 gpm 1 4 L min Secondary Function Manifold Steer relief valve pressure maximum measured at test port TS 2500 psi 172 bar Parking brake relief valve pressure maximum measured at test port TPB 400 psi 27 5 bar Diff lock relief valve pressure maximum measured at test port TJ 400 psi 27 5 bar Rear lock up relief valve pressure maximum measured at test port TR 50 psi 3 4 bar Outrigger Manifold Flow re...

Page 17: ...April 2017 Service and Repair Manual Specifications Part No 1278145 GTH 1056 7 Air Conditioner Refrigerant Specifications System Full Charge R134a 1 lb 14 oz ...

Page 18: ...osity requirements Unit ships 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 Operator Manual for your engine Fuel injection system Injection pump pressure maximum 23200 psi 1600 bar Fuel requirement For fuel requirements refer to the engine Operator Manual for your engine Engine coolant Capacity...

Page 19: ...scosity requirements Unit ships 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 Operator Manual for your engine Fuel injection system Injection pump pressure maximum 23200 psi 1600 bar Fuel requirement For fuel requirements refer to the engine Operator Manual for your engine Engine coolant Capaci...

Page 20: ...liters Oil viscosity requirements Unit ships with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Manual for your engine Fuel requirement For fuel requirements refer to the engine Operator Manual for your engine Fuel injection pressure minimum 23700 psi 1635 bar Starter motor Normal load 68A Relay max 50A Relay ...

Page 21: ...ty 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 machine Fuel requirement For fuel requirements refer to the engine Operator Manual for your engine Fuel injection pressure minimum 23000 psi 1585 bar Starter motor Normal load 155A ...

Page 22: ...F 4 WG 98 TC Maintenance Manual ZF 4 WG 98 TC Operating Manual Genie part number 1258405 Dana Planetary 213 Drive Axle Steering Integrated 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 e...

Page 23: ...1 8 3 4 16 1 10 7 8 14 1 12 1 1 16 12 1 16 1 5 16 12 1 20 1 5 8 12 1 24 1 7 8 12 1 SAE O ring Boss Port tube fitting installed into Aluminum all types SAE Dash Size Torque 4 14 ft lbs 19 Nm 6 23 ft lbs 31 2 Nm 8 36 ft lbs 54 2 Nm 10 62 ft lbs 84 Nm 12 84 ft lbs 114 Nm 16 125 ft lbs 169 5 Nm 20 151 ft lbs 204 7 Nm 24 184 ft lbs 249 5 Nm Adjustable Fitting Non adjustable fitting 1 jam nut SAE O ring...

Page 24: ...nd 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 Refer to the appropriate torque chart in this section 6 Operate all machine functions and inspect the hose fittings and related components to confirm there are no leaks JIC 37 fittings 1 Align the tube flare hex nut ag...

Page 25: ...umber of flats for the proper tightening position Note The marks indicate 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 Illustration 2 1 body hex fitting 2 reference mark 3 second mark 4 Tighten the hex nut until the mark on the hex nut is aligned with the second mark on the body hex fittin...

Page 26: ...erstand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all necessary tools and parts are 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 Machine Configuration Unless otherwise specified perf...

Page 27: ... personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates a 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 avoi...

Page 28: ...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 switch is a component 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 How to Test a Pr oxi mity Switch How to Test a Proximity Switch 1 Remove...

Page 29: ...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 digital level Result The light of the proximity switch assembly is not illuminated The proximity switch is properly calibrated R...

Page 30: ...te Do not lubricate the side wear pads 4 Install the wear pads Install and securely tighten the fasteners Do not over tighten How to R emove the Lifting For kFr ame How to Remove the Lifting Fork Frame 1 With the boom in the stowed position attach a lifting strap from an overhead crane to the top of the lifting fork frame at the front of the boom Support the frame Do not apply any lifting pressure...

Page 31: ...rd lines of the cable 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 ...

Page 32: ...oom 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 1 tube 3 extension chains 2 dual chain tensioner 3 tube 2 extension chains 4 single chain tensioner 5 boom tube number 0 6 boom tube number 1 7 boom tube number 2 8 boom tube number...

Page 33: ...r access to the chain anchor bolts 14 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 15 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 ...

Page 34: ...ghten the chain tensioners to the top of the boom tube until they are securely tightened 24 Adjust the chains Refer to Maintenance Procedure in the appropriate Service or Maintenance Manual for your machine 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...

Page 35: ...hains 9 Working at the fork end of the boom select a chain 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 10 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 11 Remove the fasteners securing the extension chain anch...

Page 36: ...intenance Procedure in the appropriate Service or Maintenance Manual for your machine 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 How to R emove the Boom How to Remove the Boom Bodily injury hazard This procedure requires spec...

Page 37: ... 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 cylinder 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 b...

Page 38: ...remove the lift cylinder rod end pivot pin Remove the cylinder from the boom Crushing hazard The cylinder 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 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...

Page 39: ...e 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 1 cable bridge mount bracket 2 cable track mount bracket 3 cable bridge slider 19 Wo...

Page 40: ...ing 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...

Page 41: ...osen 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 p...

Page 42: ...s 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 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 b...

Page 43: ...ove 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 5 Tag disconnect and plug the fork level cylinder hoses from the cylinder manifolds Cap the fittings Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pre...

Page 44: ... 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...

Page 45: ...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 ...

Page 46: ...nction manifold Cap the fittings Refer to 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 Refer to 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 loc...

Page 47: ...l 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 17 Support and secure the operator s compartment to an adjustable table capable of supporting the...

Page 48: ...h panel Remove the dash panel from the machine 7 Loosen the two lower fasteners securing the dash frame to the operator s compartment 8 Remove the two upper fasteners securing the dash frame to the operator s compartment 9 Rotate the dash frame towards the seat of the operator s compartment Remove the dashboard from the machine 10 Tag and disconnect the ground wire of the steer column 11 Support a...

Page 49: ... 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 How to R emove the Joystick Models with Si ngle Joystick How to Remove the Joystick Models with Single Joystick 1 Disconnect the battery from the machine Electrocution burn hazard Contact with electrically charged circuits coul...

Page 50: ... the hose from the port if the joystick is below the hydraulic oil level in the hydraulic tank 7 Remove the fasteners securing the joystick to the mount panel Remove the joystick How to R emove the Brake Pedal Assembl y How to Remove the Brake Pedal Assembly 1 Disconnect the battery from the machine Electrocution burn hazard Contact with electrically charged circuits could result in death or serio...

Page 51: ...pull the cluster through the opening in the dashboard 4 Tag and disconnect the wire harness from the dash cluster Remove the dash cluster from the machine How to R emove the Diagnostic Displ ay How to Remove the Gauge Cluster Assembly 1 Disconnect the battery from the machine Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rin...

Page 52: ...c tank 5 Place a drain pan or other suitable container under the hydraulic tank Refer to Specifications Machine Specifications 6 Remove the drain plug from the hydraulic tank and completely drain the tank Bodily injury hazard Beware of hot oil Contact with hot oil may cause severe burns 7 Remove the filler cap from the fuel tank 8 Using an approved hand operated pump drain the fuel tank into a con...

Page 53: ...D3 6 L4 and TCD3 6 L4 Engine Repair procedures and additional engine information is available in the Deutz TCD3 6 Operation Manual and the Deutz TD3 6 L4 and TCD3 6 L4 Workshop Manual Deutz TCD3 6 Operation Manual Genie part number 218707 Deutz TD3 6 and TCD3 6 Workshop Manual Genie part number 1251788 How to Remove the Engine Note When removing a hose assembly or fitting the O ring if equipped on...

Page 54: ...the fuel supply line where it is attached to the fuel filter water separator Tag disconnect and plug the fuel supply hose at the fuel filter water separator Cap the fitting Open the engine access cover at the operator s compartment side of the machine Locate the fuel return hose at the fuel pump Tag disconnect and plug the fuel return hose at the fuel pump Cap the fitting All Models 13 Open the tr...

Page 55: ...ntrol 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 23 To learn the specifics of and how to use the fault codes refer to Fault Codes Section ...

Page 56: ...e When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Open the access door above the hydraulic tank 2 Disconnect the battery from the machine Electrocution burn hazard Contact with electrically ch...

Page 57: ...lug 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 fro...

Page 58: ...isconnected in step 1 3 Hold the manual fuel shut off lever on the engine in the closed position 4 Observe the pressure gauge while cranking the engine in one second intervals 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 ne...

Page 59: ... hose at the top of the pump Cap the fitting on the pump Note Placing the open end of the case drain hose below the hydraulic oil level in the hydraulic tank will result in excessive hydraulic fluid leaking from the hose Do not lower the open end of the case drain hose to below the fluid level of the hydraulic tank until the hose is plugged 5 Tag disconnect and plug the large hydraulic pump supply...

Page 60: ...install the wire harness onto the pump 8 Check the level of the hydraulic fluid in the hydraulic tank Add fluid if needed 9 Prime the pump Refer to Repair Procedure How to Prime the Function Pump 10 Start the engine and inspect for leaks 11 Turn the machine off 12 Adjust the pump pressure Refer to Repair Procedures How to Adjust the Function Pump Standby Pressure and How to Adjust the Function Pum...

Page 61: ...off the engine 5 Check for hydraulic leaks and clean up any oil that may have spilled How to Adj ust the Functi on Pump Standby Pr essure How to Adjust the Function Pump Standby Pressure 1 Connect a 0 to 1000 psi 0 to 100 bar pressure gauge to test port TP on the primary function manifold Refer to Primary Function Manifold Components 2 Start the engine and allow the engine to run at low idle 3 Obs...

Page 62: ... to dissipate gradually Do not allow oil to squirt or spray How to Adj ust the Functi on Pump Pressure Compensator How to Adjust the Function Pump Standby Pressure 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 Refer to Primary Function Manifold Components 2 Start the engine and allow...

Page 63: ...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 7 Turn the engine off and remove the pressure gauge Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the ...

Page 64: ...tional valve 3 position 4 way pilot operated AE Fork tilt up down 50 ft lbs 68 Nm 6 Relief valve 3500 psi 241 bar AF Fork tilt up relief 25 30 ft lbs 34 41 Nm 7 Check valve pilot operated 100 psi 6 9 bar AG Fork tilt down circuit 40 45 ft lbs 54 61 Nm 8 Check valve pilot operated 100 psi 6 9 bar AH Fork tilt up circuit 40 45 ft lbs 54 61 Nm 9 Relief valve 3500 psi 241 bar AI Fork tilt down relief ...

Page 65: ...April 2017 Service and Repair Manual Manifolds Part No 1278145 GTH 1056 55 ...

Page 66: ...ircuit 20 ft lbs 27 Nm 20 Check valve 5 psi 0 3 bar AT Fork tilt down circuit 20 ft lbs 27 Nm 21 Check valve 5 psi 0 3 bar AU Boom up circuit 20 ft lbs 27 Nm 22 Check valve 5 psi 0 3 bar AV Boom retract circuit 20 ft lbs 27 Nm 23 Directional valve 3 position 4 way pilot operated AW Sway left right 50 ft lbs 68 Nm 24 Flow regulator valve 14 gpm 53 L min AX Fork tilt up down circuit 70 75 ft lbs 95 ...

Page 67: ...April 2017 Service and Repair Manual Manifolds Part No 1278145 GTH 1056 57 ...

Page 68: ...ar BE Fork tilt up relief 25 30 ft lbs 33 9 40 7 Nm 6 Check valve pilot operated 100 psi 6 9 bar BF Fork tilt down circuit 40 45 ft lbs 54 61 Nm 7 Check valve pilot operated 100 psi 6 9 bar BG Fork tilt up circuit 40 45 ft lbs 54 61 Nm 8 Relief valve 3500 psi 241 bar BH Fork tilt down relief 25 30 ft lbs 33 9 40 7 Nm 9 Relief valve 3500 psi 241 bar BI System relief 40 45 ft lbs 54 61 Nm 10 Shuttle...

Page 69: ...April 2017 Service and Repair Manual Manifolds Part No 1278145 GTH 1056 59 ...

Page 70: ...ve 5 psi 0 3 bar BR Boom down circuit 20 ft lbs 27 1 Nm 19 Check valve 5 psi 0 3 bar BS Fork tilt down circuit 20 ft lbs 27 1 Nm 20 Check valve 5 psi 0 3 bar BT Steer left right circuit 20 ft lbs 27 1 Nm 21 Check valve 5 psi 0 3 bar BU Fork tilt up circuit 20 ft lbs 27 1 Nm 22 Check valve 5 psi 0 3 bar BV Boom up circuit 20 ft lbs 27 1 Nm 23 Check valve 5 psi 0 3 bar BW Boom retract circuit 20 ft ...

Page 71: ...April 2017 Service and Repair Manual Manifolds Part No 1278145 GTH 1056 61 ...

Page 72: ... Solenoid valve 2 position 4 way CG Rear axle fast oscillate select 50 ft lbs 67 8 Nm 8 Check valve 4 psi 0 3 bar CH Rear lock up extend circuit 25 30 ft lbs 34 40 7 Nm 9 Check valve 25 psi 1 7 bar CI Drive brake circuit 25 30 ft lbs 34 40 7 Nm 10 Pressure switch 350 psi 24 bar PS7 Low brake pressure 11 ft lbs 14 9 Nm 11 Pressure switch 250 psi 17 2 bar PS6 Parking brake pressure 11 ft lbs 14 9 Nm...

Page 73: ...April 2017 Service and Repair Manual Manifolds Part No 1278145 GTH 1056 63 ...

Page 74: ...DB Right outrigger extend retract 40 ft lbs 54 Nm 3 Flow regulator valve 6 gpm 22 7 L min DC Right outrigger circuit 45 50 ft lbs 61 67 8 Nm 4 Flow regulator valve 6 gpm 22 7 L min DD Left outrigger circuit 45 50 ft lbs 61 67 8 Nm 5 Check valve 5 psi 0 3 bar DE Left outrigger extend circuit 13 ft lbs 17 6 Nm 6 Check valve 5 psi 0 3 bar DF Right outrigger extend circuit 13 ft lbs 17 6 Nm 7 Check va...

Page 75: ...April 2017 Service and Repair Manual Manifolds Part No 1278145 GTH 1056 65 ...

Page 76: ...smission inspection cover Index No Description Schematic Item Function Torque 1 Check valve 5 psi 0 3 bar EA Auxiliary A1 circuit 12 14 ft lbs 16 19 Nm 2 DO3 valve 3 position 4 way EB Auxiliary function enable 60 in lbs 6 8 Nm 3 Flow regulator valve EC Function speed control 25 ft lbs 34 Nm 4 Check valve 5 psi 0 3 bar ED Auxiliary A2 circuit 12 14 ft lbs 16 19 Nm ...

Page 77: ...ld Components The brake manifold is located under the manifold inspection cover Index No Description Schematic Item Function Torque 1 Pressure switch 450 psi 31 bar PS4 Clutch cut off pressure 11 ft lbs 14 9 Nm 2 Pressure switch 50 psi 3 4 bar PS5 Brake light pressure option 11 ft lbs 14 9 Nm ...

Page 78: ... Manifold Components The AC Hydraulic manifolds are located under the manifold inspection cover Index No Description Schematic Item Function Torque 1 Solenoid valve 2 position 2 way FA Controls motor 20 ft lbs 27 1 Nm 2 Flow control valve 3 gpm 11 3 lpm FB Regulates flow 33 37 ft lbs 45 50 Nm ...

Page 79: ...ally Do not allow oil to squirt or spray 5 Install a 0 to 3500 psi 0 to 250 bar pressure gauge into test port TS at the top of the secondary function manifold Refer to Secondary Function Manifold Components 6 Start the 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 obs...

Page 80: ...sen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 5 Install a 0 to 1000 psi 0 to 100 bar pressure gauge into test port TPB at the top of the secondary function manifold Refer to Secondary Function Manifold Components 6 Start the engine Allow the engine to idle Result The pressure gauge reads 400 psi 27 5 bar The pressure sett...

Page 81: ...Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 5 Install a 0 to 1000 psi 0 to 100 bar pressure gauge into test port TJ at the top of the secondary function manifold Refer to Secondary Function Manifold Components 6 Start the engine Allow the engine to idle Result The pressure gauge reads 400 psi 27 5 bar The pressure se...

Page 82: ...en hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 5 Install a 0 to 500 psi 0 to 50 bar pressure gauge into test port TR at the top of the secondary function manifold Refer to Secondary Function Manifold Components 6 Start the engine Allow the engine to idle Result The pressure gauge reads 50 psi 3 4 bar The pressure setting is...

Page 83: ... Test the coil resistance Result The resistance should be within specification plus or minus 30 Result If the resistance is not within specification plus or minus 30 replace the coil 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 ...

Page 84: ...he coil Resistor 10Ω Genie part number 27287 Note The battery should read 9V DC or more when measured across the terminals 1 multimeter 2 9v DC battery 3 10Ω resistor 4 coil Note Dotted lines in illustration indicate a reversed connection as specified in step 6 3 Set a multimeter to read DC current Note The multimeter when set to read DC current should be capable of reading up to 800 mA 4 Connect ...

Page 85: ...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 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...

Page 86: ...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 Crushing hazard The cylinder may become unbalanced and fall if not properly s...

Page 87: ...c 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 p...

Page 88: ...Service and Repair Manual April 2017 78 GTH 1056 Part No 1278145 This page intentionally left blank ...

Page 89: ...stowed position Key switch in the off position with the key removed Wheels chocked 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 Read each appropriate fault code thoroughly Attempting short cuts may produce hazardous ...

Page 90: ...ult codes will scroll on the display 1 FMI Code 2 SPN Code 3 amber warning light 4 red stop engine light 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 ...

Page 91: ...speed plausibility error 91 3 Sensor error accelerator pedal signal range check high 4 Sensor error accelerator pedal signal range check low 11 Plausibility error between APP1 and APP2 or APP1 and idle switch 94 1 Low fuel pressure system reaction initiated 3 Sensor error low fuel pressure signal range check high 4 Sensor error low fuel pressure signal range check low 97 3 Sensor error water in fu...

Page 92: ...ail pressure signal range check low 164 2 Rail pressure safety function is not executed correctly 168 0 Physikal range check high for battery voltage 1 Physikal range check low for battery voltage 2 High battery voltate warning threshold exceeded 2 Battery voltage system reaction initiated 3 Sensor error battery voltage signal range check high 3 Sensor error battery voltage signal range check high...

Page 93: ...ut of range signal disrupted 14 Speed detection out of range signal disrupted 411 0 Physical range check high for differential pressure Venturiunit EGR 1 Physical range check low for differential pressure Venturiunit EGR 3 Sensor error differential pressure Venturiunit EGR signal range check high 4 Physical range check low for EGR differential pressure Sensor error differential pressure Venturiuni...

Page 94: ...on of electric connection 654 3 Injector 4 in firing order short circuit 4 High side to low side short circuit in the injector 4 in firing order 5 Injector 4 in firing order interruption of electric connection 655 3 Injector 5 in firing order short circuit 4 High side to low side short circuit in the injector 5 in firing order 5 Injector 5 in firing order interruption of electric connection 656 3 ...

Page 95: ...temperature 1 Physikal range check low for ECU temperature 3 Sensor error ECU temperature signal range check high 4 Sensor error ECU temperature signal range check low 1176 3 Sensor error pressure sensor upstream turbine signal range check high 4 Sensor error pressure sensor downstream turbine signal range check high 1180 0 Exhaust gas temperature turbine upstream out of range system reaction init...

Page 96: ...firing order 1325 12 Too many recognized misfires in cylinder 3 in firing order 1326 12 Too many recognized misfires in cylinder 4 in firing order 1327 12 Too many recognized misfires in cylinder 5 in firing order 1328 12 Too many recognized misfires in cylinder 6 in firing order 1639 0 Sensor error fan speed signal range check high 1 Sensor error fan speed signal range check low 1761 14 Urea tank...

Page 97: ...tuator temperature high 2797 4 Injector diagnostics timeout error of short circuit to ground measurement cyl Bank 0 2798 4 Injector diagnostics short circuit Bank 0 Bank 1 Injector diagnostics timeout error of short circuit to ground measurement cyl Bank 1 3031 0 AdBlue Tank temperature maximum exceeded 1 DEF Tank temperature below minimum 3 Sensor error urea tank temperature short circuit to batt...

Page 98: ...essure DPF signal range check low 3361 3 Urea dosing valve short circuit to battery 4 Urea dosing valve short circuit to ground 7 AdBlue dosing valve blocked SCR 3519 3 DEF quality sensor internal temperature sensor short circuit to battery or open lead 4 DEF quality sensor internal temperature sensor short circuit to ground 12 DEF tank temperature temperature too high 13 Temperature at UQS invali...

Page 99: ... heater relay urea pressureline open load 11 General pressure check error SCR 4345 3 SCR heater urea returnline short circuit to battery 4 SCR heater urea returnline short circuit to ground 5 SCR heater relay urea returnline open load 11 Sensor backflow line pressure SCR plausibility error 4360 0 Physical range check high for urea catalyst upstream temperature 1 Physical range low for urea catalys...

Page 100: ...erature upstream DOC signal range check high 4 Sensor error exhaust gas temperature upstream DOC signal range check low 4769 2 Sensor exhaust gas temperature DOC downstream plausibility error 3 Sensor error exhaust gas temperature downstream DOC signal range check high 4 Sensor error exhaust gas temperature downstream DOC signal range check low Sensor exhaust gas temperature downstream DOC plausib...

Page 101: ...nd engine command 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 4 Injector cylinder bank 2 short circuit 23354 64602 12 Injector powerstage output defect 23450 64698 2 Multiple Stage Switch constant speed plausibility error 3 Multiple Stage Switch constant speed short...

Page 102: ...MB Ambient Temperature Sensor 23605 64853 9 Timeout Error of CAN Receive Frame TSC1AE Traction Control 23606 64854 9 Timeout Error of CAN Receive Frame TSC1AR Retarder 23612 64860 12 ECU reported internal software error 14 Softwarereset CPU Internal software error ECU 23613 64861 0 Rail pressure disrupted 1 Minimum rail pressure exceeded RailMeUn3 2 Setpoint of metering unit in overrun mode not pl...

Page 103: ...y primary side open load 12 SCR mainrelay powerstage over temperature only CV56B SCR mainrelay short circuit to battery only CV56B SCR mainrelay short circuit to ground only CV56B SCR mainrelay open load only CV56B 23719 64967 3 SCR heater urea supplymodule short circuit to battery 4 SCR heater urea supplymodule short circuit to ground 5 SCR heater relay urea supply module open load 23720 64968 2 ...

Page 104: ...ate 23793 65041 9 Timeout Error of CAN Receive Frame UAA10 AGS sensor service message 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...

Page 105: ...heck 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 23914 65162 3 Glow plug control short circuit to battery 4 Glow plug control short circuit to ground 5 Glow plug control open lo...

Page 106: ...for airpump pressure shut off regeneration 1 Physical range check low for airpump pressure shut off regeneration 2 Sensor airpump pressure plausibility error 3 Sensor error airpump pressure signal range check high 4 Sensor error airpump pressure signal range check low 23920 65168 0 Physical range check high for exhaustgas back pressure burner shut off regeneration 1 Physical range check low for ex...

Page 107: ...33 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 Transmi...

Page 108: ...50 65198 0 Zerofuel calibration injector 5 in firing order maximum value exceeded 1 Zerofuel calibration injector 5 in firing order minimum value exceeded 23951 65199 0 Zerofuel calibration injector 6 in firing order maximum value exceeded 1 Zerofuel calibration injector 6 in firing order minimum value exceeded 23960 65208 0 EGR cooler downstream temperature out of range system reaction initiated ...

Page 109: ...ontrol integrator injector 8 in firing order minimum value exceeded 23992 65240 9 Timeout Error of CAN Receive 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...

Page 110: ...4019 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 set...

Page 111: ...Slave internal CAN message 24043 65291 9 Timeout error of CAN Receive Frame ComMS_Sys6TO error memory Slave Master Slave internal CAN message 24044 65292 9 CAN message ComMS_Sys7 not received from slave 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 M...

Page 112: ... plausibility error 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 24074 9 NOx sensor downstream SCR CAT sensor internally open load 24075 11 NOx sensor downstream SCR CAT sensor internally short circuit 24076 9 NOx sensor downstream SCR CAT sensor internally open li...

Page 113: ...DPFBrnAirPmpCtl 24103 65351 9 Timeout error of CAN Receive Frame ComRxDPFBrnAirPmp 24104 65352 9 Timeout error of CAN Receive Frame ComRxDPFCtl 24105 65353 9 Timeout error of CAN Transmit Frame ComEGRMsFlw 24106 65354 9 Timeout error of CAN Receive Frame ComRxEGRMsFlw1 24107 65355 9 Timeout error of CAN Receive Frame ComRxEGRMsFlw2 24108 65356 9 Timeout error of CAN Transmit Frame ComEGRTVActr 241...

Page 114: ...e blocked 24147 7 SCR System reverting valve blocked 13 SCR System pressure build up not possible 24152 2 Urea Quality Sensor Timout CAN message 24153 2 Urea tank level urea tank temperature via CAN bus timeout of CAN message 24156 9 Timeout error of CAN Receive Frame ComRxEBC2 24175 0 SCR CAT Nox emissions above minimum threshold 24177 7 SCR System DEF suction line blocked 24178 7 SCR System DEF ...

Page 115: ...d air temperature short to ground 110 3 Engine coolant temperature open short to battery positive 4 Engine coolant temperature short to ground SPN FMI Description 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 tem...

Page 116: ...rt 7 Cylinder 4 injector not responding 678 3 8V DC supply short to battery positive 4 8V DC supply shorted to ground 723 8 Secondary engine speed signal abnormal 1188 5 Turbo wastegate drive current low 1196 9 Machine security system module non communication 1347 5 Fuel rail pump output current low 6 Fuel rail pump output current high 7 Fuel rail pressure valve solenoid not responding 2882 2 Mode...

Page 117: ...fety 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 About This Section There are two groups of schematics in this section Electrical Schematics Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches...

Page 118: ...Repair Manual April 2017 Proximity Switch Legend 108 GTH 1056 Part No 1278145 1 Boom Angle Proximity Switch PX2 under boom pivot pin 2 Boom Extend Proximity Switch PX1 under plate at top of boom tube GTH 1056 only ...

Page 119: ...April 2017 Service and Repair Manual Fuse Panel Layout Part No 1278145 GTH 1056 109 Perkins Engine Circuit Breakers Located in Tank Assembly PCB Board Fuse Panel located in the Cab ...

Page 120: ...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 D Diode ECU Engine Control Unit Item Description F Fuse 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 ...

Page 121: ...le Coil Power ON L24 Forward Shift ON L25 Parking Brake Release OFF L26 Brake Light Power ON L27 Hazard Power ON L28 Not Used Item Description M Motor R Resistor S Switch S1 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 S8 Sway Enable Switch S9 Tilt Enable Switch S...

Page 122: ...A Y77B Auxiliary B Y80 D Transmission Y81 E Transmission Y6 Transmission Forward Y5 Transmission Reverse Y78 4Wheel Steer SVD1A Y79 Crab Steer SVD1B Y75 Left Stabilizer Down Y76 Left Stabilizer Up Y73 Right Stabilizer Down Y74 Right Stabilizer Up Y84 AC Control Wire Color Legend Item Description BL Blue BL BK Blue Black BL RD Blue Red BL WH Blue White BK Black BK RD Black Red BK WH Black White BK ...

Page 123: ...d 0 VDC Battery Negative Device Ground 3 Digital Output 1 12 VDC Engine Run Hour Meter 12V engine run 0V engine off Monitor Engine Hours 4 Digital Output 2 12 VDC Boom Angle Status 12V boom 55 0V 55 Monitor Machine Utilization 5 Digital Output 3 12 VDC Parking Brake 12V active 0V inactive Monitor Machine Utilization 6 Digital Input 1 12 VDC standard or Ground optional Remote Disable Engine Start R...

Page 124: ...gh Schematic standard wiring Telematics Active Low Schematic optional wiring 1 Ignition Start Input 2 Relay 3 Telematics with Active High input 4 Telematics with Active Low input 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 TTE ...

Page 125: ...nal T circuits connect at terminal Circuits crossing no connection Quick disconnect terminal Circuit breaker with amperage Key switch Toggle Switch DPDT Toggle Switch SPDT Pump or Motor Tilt sensor Horn button normally open Emergency Stop button normally closed Resistor with ohm value Battery separator Gauge sending unit Oil temperature switch normally open Coolant temperature switch normally open...

Page 126: ...n 3 way Differential sensing valve Filter with bypass relief valve Relief valve with pressure setting Priority flow regulator valve Solenoid operated proportional valve Directional valve mechanically activated Flow divider combiner valve Pilot operated 3 position 3 way shuttle valve Solenoid operated 2 position 3 way directional valve Counterbalance valve with pressure and pilot ratio Solenoid ope...

Page 127: ...April 2017 Service and Repair Manual Part No 1278145 GTH 1056 117 Harness Map Control System Single Joystick ...

Page 128: ...Service and Repair Manual April 2017 118 Harness Map Control System Ground Single Joystick ...

Page 129: ...April 2017 Service and Repair Manual 119 Harness Map Control System Dual Joystick ...

Page 130: ...Service and Repair Manual April 2017 120 GTH 1056 Part No 1278145 Harness Map Control System Dual Joystick ...

Page 131: ...April 2017 Service and Repair Manual Part No 1278145 GTH 1056 121 Harness Map Deutz TCD3 6 T4F Engine ...

Page 132: ...Service and Repair Manual April 2017 122 Harness Map Deutz 3 6TCD T4F Engine ...

Page 133: ...April 2017 Service and Repair Manual 123 Harness Map Perkins 1204 T4F Engine ...

Page 134: ...Service and Repair Manual April 2017 124 GTH 1056 Part No 1278145 Harness Map Perkins 1204 T4F Engine ...

Page 135: ...April 2017 Service and Repair Manual Part No 1278145 GTH 1056 125 Harness Map Work Lights ...

Page 136: ...Service and Repair Manual April 2017 126 Harness Map Work Lights ...

Page 137: ...April 2017 Service and Repair Manual 127 Harness Map Road Lights ...

Page 138: ...Service and Repair Manual April 2017 128 GTH 1056 Part No 1278145 Harness Map Road Lights ...

Page 139: ...April 2017 Service and Repair Manual Part No 1278145 GTH 1056 129 Harness Map Enclosed Cab with Heat ...

Page 140: ...Service and Repair Manual April 2017 130 Harness Map Enclosed Cab with Heat ...

Page 141: ...April 2017 Service and Repair Manual 131 Harness Map Enclosed Cab with HVAC ...

Page 142: ...Service and Repair Manual April 2017 132 GTH 1056 Part No 1278145 Harness Map Enclosed Cab with HVAC ...

Page 143: ...April 2017 Service and Repair Manual Part No 1278145 GTH 1056 133 Harness Map Auxiliary Hydraulics Beacon and Top Gear Lockout ...

Page 144: ...Service and Repair Manual April 2017 134 Harness Map Auxiliary Hydraulics Beacon and Top Gear Lockout ...

Page 145: ...April 2017 Service and Repair Manual 135 Electrical Schematic ...

Page 146: ...Service and Repair Manual April 2017 136 GTH 1056 Part No 1278145 Electrical Schematic ...

Page 147: ...April 2017 Service and Repair Manual Part No 1278145 GTH 1056 137 Electrical Schematic ...

Page 148: ...Service and Repair Manual April 2017 138 Electrical Schematic ...

Page 149: ...April 2017 Service and Repair Manual 139 Hydraulic Schematic Models with Single Joystick ...

Page 150: ...Service and Repair Manual April 2017 140 GTH 1056 Part No 1278145 Hydraulic Schematic Models with Single Joystick ...

Page 151: ...April 2017 Service and Repair Manual Part No 1278145 GTH 1056 141 Hydraulic Schematic Models with Dual Joystick ...

Page 152: ...Service and Repair Manual April 2017 142 Hydraulic Schematic Models with Dual Joystick GTH 1056 Part No 1278145 Ser vice and R epair M anual April 2017 ...

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