Escolar Documentos
Profissional Documentos
Cultura Documentos
Service
Manual
Serial
Number
Range
Serial
Number
Range
GTH-636
GTH-844
GTH-644
GTH-842
GTH-842
GTH-644
GTH-844
GTH-1048
GTH-1056
from GTH0606A-8418
after GTH05-12345
from GTH0606A-8418
after
GTH05-12345
from GTH0606B-6271
from GTH0806A-8418
after
GTH05-12345
from GTH0806B-6958
from GTH0806A-8418
from GTH0806B-6956
from GTH1006A-8418 to
GTH1007A-11442
from GTH1006A-8418 to
GTH-1007A-11442
Introduction
June 2007
Introduction
Important
Read, understand and obey the safety rules and
operating instructions in the appropriate Operator's
Manual on your machine before attempting any
maintenance or repair procedure.
This manual provides detailed scheduled
maintenance information for the machine owner
and user. It also provides troubleshooting 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 Genie dealer
service center.
Technical Publications
Genie Industries 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:
PO Box 97030
Redmond, WA 98073-9730 USA
www.genieindustries.com
e-mail: techsup@genieind.com
ii
June 2007
INTRODUCTION
A TEREX COMPANY
Genie Industries
18340 NE 76th S treet
Redmond, WA 98052
USA
MODEL: GTH844
SERIAL NUMBER: GTH0806A-8454
ATTACHMENT:
MANUFACTURE DATE:
02/20/06
TH08 06
LIFT CAPACITY(LBS)
AT MAX LIFT HEIGHT: 6000 LBS
OUTRIGGERS UP:
N/A
OUTRIGGERS DOWN: N/A
A - 1234
Model
Serial label
(located inside chassis
upright at cab side of machine)
Sequence
number
Year of
manufacture
Facility code
Serial label
(located inside fork frame)
(models with quick attach frame)
Serial number
stamped on chassis
iii
June 2007
iv
June 2007
Safety Rules
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
operators manual are also safety hazards
when maintenance and repair procedures
are performed.
June 2007
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 symbolused 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.
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.
vi
June 2007
Table of Contents
Introduction
Important Information ......................................................................................... ii
Serial Number Legend ...................................................................................... iii
Section 1
Safety Rules
General Safety Rules ........................................................................................ v
Section 2
Rev
D
Specifications
Machine Specifications ................................................................................ 2 - 1
Performance Specifications ......................................................................... 2 - 3
Hydraulic Specifications ............................................................................... 2 - 4
Manifold Component Specifications ............................................................. 2 - 6
John Deere 4045TF270 Engine ................................................................... 2 - 7
John Deere 4045TF275 Engine ................................................................... 2 - 8
Deutz BF4 2012 Engine ............................................................................... 2 - 9
Perkins 1104C-44T Engine ........................................................................ 2 - 10
Perkins 1104C-44TA Engine ..................................................................... 2 - 11
Dana T12000 Transmission ....................................................................... 2 - 12
Dana T20000 Transmission ....................................................................... 2 - 12
Dana Planetary 212 Drive Axle .................................................................. 2 - 13
Dana Planetary 213 Drive Axle .................................................................. 2 - 13
Hydraulic Hose and Fitting Torque Specifications ...................................... 2 - 14
SAE and Metric Fasteners Torque Charts ................................................. 2 - 15
Section 3
Rev
vii
June 2007
TABLE OF CONTENTS
Section 3
Rev
C
A-2
A-3
A-4
A-5
A-6
A-7
A-8
A-9
Perform Transmission Maintenance GTH-636, GTH-644, GTH-842 and GTH-844 Models ...................... 3 - 13
Checklist B Procedures
B-1
B-2
B-3
B-4
B-5
B-6
B-7
Inspect the Fuel and Hydraulic Tank Cap Venting Systems ............. 3 - 21
B-8
B-9
viii
June 2007
TABLE OF CONTENTS
Section 3
Rev
B
Checklist D Procedures
D-1 Inspect the Forks .............................................................................. 3 - 28
D-2 Adjust the Boom Sequencing Chains ............................................... 3 - 28
D-3 Replace the Hydraulic Tank Return Filter Element ........................... 3 - 31
D-4 Perform Engine Maintenance - Deutz Models .................................. 3 - 32
D-5 Perform Transmission Maintenance ................................................. 3 - 32
D-6 Perform Axle Maintenance ............................................................... 3 - 33
D-7 Perform Engine Maintenance - Perkins Models ................................ 3 - 33
D-8 Perform Engine Maintenance - Deutz Models .................................. 3 - 34
Checklist E Procedures
E-1
E-2
E-3
E-4
E-5
E-6
E-7
E-8
E-9
ix
June 2007
TABLE OF CONTENTS
Section 4
Rev
Repair Procedures
Introduction .................................................................................................. 4 - 1
Boom Components
1-1
1-2
Boom ................................................................................................. 4 - 3
1-3
1-4
1-5
1-6
Operator's Compartment
2-1
2-2
3-2
Engines
4-1
Engines ............................................................................................ 4 - 40
4-2
Transmission
5-1
Hydraulic Pumps
6-1
Transmission .................................................................................... 4 - 42
Manifolds
7-1
7-2
7-3
7-4
7-5
June 2007
TABLE OF CONTENTS
Section 4
Rev
7-7
7-8
7-9
Axle Components
8-1
Outriggers
9-1
Axles ................................................................................................ 4 - 73
Outriggers ........................................................................................ 4 - 76
xi
June 2007
TABLE OF CONTENTS
Section 5
Rev
Troubleshooting
Introduction .................................................................................................. 5 - 1
xii
1-1
1-2
1-3
1-4
1-5
1-6
1-7
June 2007
TABLE OF CONTENTS
Section 6
Rev
Schematics
Introduction .................................................................................................. 6 - 1
Electrical Schematic GTH-644, GTH-842 and GTH-844 with John Deere Power ......................... 6 - 8
Electrical Schematic GTH-644, GTH-842 and GTH-844 with Perkins Power ............................. 6 - 10
Electrical Schematic GTH-644, GTH-842 and GTH-844 with Deutz Power ................................ 6 - 12
Electrical Schematic GTH-1048 and GTH-1056 with John Deere Power .................................... 6 - 14
Hydraulic Schematic GTH-644, GTH-842 and GTH-844 with Single Joystick ............................. 6 - 20
Hydraulic Schematic GTH-644, GTH-842 and GTH-844 with Dual Joysticks .............................. 6 - 21
xiii
June 2007
xiv
Section 2 Specifications
June 2007
Specifications
REV D
Machine Specifications
Fluid capacities
Fuel tank
30 gallons
113.6 liters
Hydraulic tank
48 gallons
181.7 liters
Hydraulic system
(including tank)
66 gallons
249.8 liters
30 gallons
113.6 liters
Hydraulic tank
34 gallons
128.7 liters
Hydraulic system
(including tank)
50 gallons
189.3 liters
2-1
Section 2 Specifications
June 2007
SPECIFICATIONS
REV D
All models
Tire size
13.00 x 24
12
270 lbs
122.5 kg
815 35 lbs
370 16 kg
836 35 lbs
379 16 kg
835 35 lbs
379 16 kg
886 35 lbs
402 16 kg
Tire size
Lug pattern
465 ft-lbs
630 Nm
10 x 13.189
Wheel diameter
24 in
60.1 cm
Wheel width
9 in
22.9 cm
12
270 lbs
122.5 kg
965 35 lbs
438 16 kg
967 35 lbs
439 16 kg
982 35 lbs
445 16 kg
2-2
50 psi
3.45 bar
14.00 x 24
Tire pressure
(models without foam filled tires)
1013 35 lbs
459 16 kg
Section 2 Specifications
June 2007
REV D
SPECIFICATIONS
Performance Specifications
18 mph
29 km/h
17 mph
27.4 km/h
19 mph
30.6 km/h
Boom up
14 to 16 seconds
Boom down
10 to 12 seconds
Boom extend
17 to 19 seconds
Boom retract
13 to 15 seconds
Chassis sway
9 to 12 seconds
Fork tilt up
GTH-636, GTH-644,
GTH-842 and GTH-844
19,200 lbs
8427 kg
26,500 lbs
12045 kg
7 to 9 seconds
GTH-1048
6000 lbs
2727 kg
8000 lbs
3636 kg
10,000 lbs
4545 kg
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
Chassis sway
11 to 13 seconds
Fork tilt up
11 to 13 seconds
GTH-1056
Boom function speeds, maximum
Boom up
17 to 19 seconds
GTH-636
Boom down
23 to 25 seconds
Boom up
12 to 14 seconds
Boom extend
14 to 16 seconds
Boom down
16 to 18 seconds
Boom retract
13 to 15 seconds
Chassis sway
11 to 13 seconds
11 to 13 seconds
Boom extend
6 to 8 seconds
Boom retract
9 to 11 seconds
Fork tilt up
Chassis sway
11 to 13 seconds
All models
Fork tilt up
11 to 13 seconds
11 to 13 seconds
Fork rotate
19 to 21 seconds
2-3
Section 2 Specifications
June 2007
SPECIFICATIONS
REV D
Hydraulic Specifications
Hydraulic Specifications
Chevron Rykon AW
ISO46 equivalent
46
97
15/13
200 ppm
Fire resistant
Mineral based
15/13
200 ppm
Optional Fluids
Biodegradable
Fire resistant
Mineral based
Chevron Rykon MV
Shell Tellus T32
Shell Tellus T46
Chevron Aviation A
Section 2 Specifications
June 2007
REV D
SPECIFICATIONS
Function Pump
GTH-636
Type:
0 to 35 gpm
0 to 132.5 L/min
Pump pressure
(measured at test port GP1)
2800 psi
193 bar
0 to 35 gpm
0 to 132.5 L/min
3000 psi
206.9 bar
GTH-1048
Type:
0 to 35 gpm
0 to 132.5 L/min
3500 psi
206.9 bar
3650 psi
251.7 bar
2250 psi
155 bar
500 psi
34.5 bar
2250 psi
155 bar
400 psi
27.6 bar
1200 psi
82.7 bar
1200 psi
82.7 bar
2000 psi
137.9 bar
2500 psi
172.3 bar
2-5
Section 2 Specifications
June 2007
SPECIFICATIONS
REV D
Manifold Component
Specifications
Plug torque
8 to 10
8 to 10
4 to 6
8 to 10
6.5 to 8.5
7.5 to 9.5
Description
SAE No. 2
50 in-lbs / 6 Nm
SAE No. 4
13 ft-lbs / 18 Nm
SAE No. 6
18 ft-lbs / 24 Nm
SAE No. 8
50 ft-lbs / 68 Nm
SAE No. 10
55 ft-lbs / 75 Nm
SAE No. 12
75 ft-lbs / 102 Nm
Specification
2-6
Section 2 Specifications
June 2007
REV D
SPECIFICATIONS
Injection system
Stanadyne
10,000 psi
690 bar
Displacement
275 cu in
4.5 liters
Number of cylinders
Bore & stroke
4
4.19 x 5 inches
106 x 127 mm
Horsepower
99 @ 2500 rpm
73.8 kw @ 2500 rpm
Firing order
Fuel requirement
For fuel requirements, refer to the engine Operator's
Manual on your machine.
Engine coolant
Capacity
1-3-4-2
Low idle
Frequency
900 rpm
180 Hz
High idle
Frequency
2600 rpm
520 Hz
Compression ratio
17:1
Alternator
Output
0.012 to 0.015 in
0.31 to 0.38 mm
0.016 to 0.019 in
0.41 to 0.48 mm
0.14 in
0.36 mm
0.18 in
0.46 mm
95 A, 14V DC
Battery
Type
Group
2.6 gallons
9.8 liters
12V DC
C31
Quantity
1000A
200 minutes
Lubrication system
Oil pressure
(at rated speed with full load)
5015 psi
3.41 bar
Oil capacity
(including filter)
14 quarts
13.2 liters
2-7
Section 2 Specifications
June 2007
SPECIFICATIONS
REV D
Injection system
Stanadyne
10,000 psi
690 bar
Displacement
275 cu in
4.5 liters
Number of cylinders
Bore & stroke
4
4.19 x 5 inches
106 x 127 mm
Horsepower
Firing order
Fuel requirement
For fuel requirements, refer to the engine Operator's
Manual on your machine.
Engine coolant
Capacity
1-3-4-2
Low idle
Frequency
1000 rpm
200 Hz
Alternator
High idle
Frequency
2600 rpm
520 Hz
Battery
Compression ratio
17:1
Type
Group
Output
0.012 to 0.015 in
0.31 to 0.38 mm
0.016 to 0.019 in
0.41 to 0.48 mm
0.14 in
0.36 mm
0.18 in
0.46 mm
7 gallons
26.5 liters
95 A, 14V DC
12V DC
C31
Quantity
1000A
200 minutes
Lubrication system
Oil pressure
(at rated speed with full load)
5015 psi
3.41 bar
Oil capacity
(including filter)
14 quarts
13.2 liters
2-8
Section 2 Specifications
June 2007
REV D
SPECIFICATIONS
Injection system
Displacement
246 cu in
4 liters
Number of cylinders
Bore and stroke
4
3.97 x 4.96 inches
101 x 126 mm
Horsepower
Firing order
19:1
Low idle
Frequency
1000 rpm
200 Hz
High idle
Frequency
2600 rpm
520 Hz
0.01 in
0.3 mm
Exhaust
0.02 in
0.5 mm
Lubrication system
Oil pressure
20 to 43 psi
1.4 to 3 bar
Oil capacity
(including filter)
12.2 quarts
11.5 liters
3 gallons
11.4 liters
Alternator
Output
Fan belt (pretension / retension)
95 A, 14V DC
101 / 67 11 lbf
450 / 300 50 N
Battery
Type
Intake
3190 psi
220 bar
Fuel requirement
1-3-4-2
Compression ratio
Bosch PFM
Group
12V DC
C31
Quantity
1000A
200 minutes
2-9
Section 2 Specifications
June 2007
REV D
SPECIFICATIONS
Injection system
Displacement
269 cu in
4.4 liters
Number of cylinders
Bore and stroke
4.133 x 5 inches
105 x 127 mm
Fuel requirement
Horsepower
Firing order
1-3-4-2
Compression ratio
18.2:1
Low idle
Frequency
1000 rpm
200 Hz
High idle
Frequency
2520 rpm
504 Hz
Exhaust
Engine coolant
Capacity
4.75 gallons
18 liters
Alternator
Output
Fan belt tension (new belt / used belt)
0.008 in
0.2 mm
Battery
0.018 in
0.45 mm
Group
Type
85 A, 14V DC
120 / 80 lbf
535 / 355 N
12V DC
C31
Quantity
Lubrication system
Oil pressure at high idle, minimum
Oil capacity
(including filter)
43 psi
3 bar
1000A
200 minutes
7 quarts
6.5 liters
2 - 10
4380 psi
302 bar
Delphi
Section 2 Specifications
June 2007
REV D
SPECIFICATIONS
Injection system
Displacement
269 cu in
4.4 liters
Number of cylinders
Bore and stroke
4.133 x 5 inches
105 x 127 mm
Fuel requirement
Horsepower
Firing order
1-3-4-2
Compression ratio
18.2:1
Low idle
Frequency
1000 rpm
200 Hz
High idle
Frequency
2310 rpm
462 Hz
Exhaust
Engine coolant
Capacity
5 gallons
18.9 liters
Alternator
Output
Fan belt tension (new belt / used belt)
0.008 in
0.2 mm
Battery
0.018 in
0.45 mm
Group
Type
85 A, 14V DC
120 / 80 lbf
535 / 355 N
12V DC
C31
Quantity
Lubrication system
Oil pressure at high idle, minimum
Oil capacity
(including filter)
43 psi
3 bar
1000A
200 minutes
8.3 quarts
7.85 liters
4380 psi
302 bar
Delphi
2 - 11
Section 2 Specifications
June 2007
REV D
SPECIFICATIONS
Transmission Type
Transmission Type
Speeds, Forward
Speeds, Forward
Speeds, Reverse
Speeds, Reverse
Torque Converter
Torque Converter
Maximum input
3300 rpm
Maximum input
3100 rpm
Size
11 inches
Size
12 inches
Lubrication
Lubrication
Oil capacity
13.6 quarts
12.9 liters
Oil capacity
20 quarts
18.9 liters
97489
117155
2 - 12
Section 2 Specifications
June 2007
REV D
SPECIFICATIONS
Steering
Steering
Joints
55
Joints
55
Front differential
9 quarts
8.5 liters
1 quart
0.9 liter
Front differential
15 quarts
14.2 liters
2 quarts
1.9 liters
Rear differential
6 quarts
5.7 liters
1 quart
0.9 liter
Rear differential
15 quarts
14.2 liters
2 quarts
1.9 liters
Differential
Differential
Planet ends
Planet ends
2 - 13
Section 2 Specifications
June 2007
REV D
SPECIFICATIONS
JIC 37 Fittings
(swivel nut or hose connection)
Thread Size
Flats
-4
7/16-20
-6
9/16-18
1 1/4
-8
3/4-16
Torque Procedure
-10
7/8-14
JIC 37 fittings
-12
1 1/16-12
-16
1 5/16-12
-20
1 5/8-12
-24
1 7/8-12
b
c
b
a
c
b
a
b
c
d
hydraulic hose
hex nut
reference mark
body hex fitting
a
b
c
2 - 14
Section 2 Specifications
June 2007
REV D
SPECIFICATIONS
SIZE
Grade 5
THREAD
LUBED
20
28
1/4
DRY
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 1/2
LUBED
DRY
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
80
90
9
10.1
100
120
11.3
13.5
110
120
12.4
13.5
140
160
15.8
18
130
140
14.7
15.8
LUBED
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
Grade 8
DRY
LUBED
DRY
LUBED
f t - lbs
Nm
f t - lbs
Nm
f t - lbs
Nm
f t - lbs
Nm
f t - lbs
Nm
13
14
23
26
37
41
57
64
80
90
110
130
200
220
320
350
480
530
590
670
840
930
1460
1640
17.6
19
31.2
35.2
50.1
55.5
77.3
86.7
108.4
122
149
176
271
298
433
474
650
718
800
908
1138
1260
1979
2223
17
19
31
35
49
55
75
85
110
120
150
170
270
300
430
470
640
710
790
890
1120
1240
1950
2190
23
25.7
42
47.4
66.4
74.5
101.6
115
149
162
203
230
366
406
583
637
867
962
1071
1206
1518
1681
2643
2969
18
20
33
37
50
60
80
90
120
130
160
180
280
310
450
500
680
750
970
1080
1360
1510
2370
2670
24
27.1
44.7
50.1
67.8
81.3
108.4
122
162
176
217
244
379
420
610
678
922
1016
1315
1464
1844
2047
3213
3620
25
27
44
49
70
80
110
120
150
170
210
240
380
420
610
670
910
990
1290
1440
1820
2010
3160
3560
33.9
36.6
59.6
66.4
94.7
108.4
149
162
203
230
284
325
515
569
827
908
1233
1342
1749
1952
2467
2725
4284
4826
21
24
38
43
61
68
93
105
130
140
180
200
320
350
510
560
770
840
1090
1220
1530
1700
2670
3000
28.4
32.5
51.5
58.3
82.7
92.1
126
142
176
189
244
271
433
474
691
759
1044
1139
1477
1654
2074
2304
3620
4067
Class 4.6
Size
(m m )
5
6
7
LUBED
DRY
LUBED
Class 10.9
8.8
DRY
LUBED
Class 12.9
10.9
DRY
LUBED
12.9
DRY
in- lbs
Nm
in-lbs
Nm
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
16
19
45
1.8
3.05
5.12
21
36
60
2.4
4.07
6.83
41
69
116
4.63
7.87
13.2
54
93
155
6.18
10.5
17.6
58
100
167
6.63
11.3
18.9
78
132
223
8.84
15
25.2
68
116
1.95
7.75
13.2
22.1
91
155
260
10.3
17.6
29.4
LUBED
8
10
12
14
16
18
20
22
24
Class 8.8
4.6
DRY
LUBED
DRY
LUBED
DRY
LUBED
DRY
f t - lbs
Nm
f t -lbs
Nm
f t - lbs
Nm
f t - lbs
Nm
f t - lbs
Nm
ft - lbs
Nm
f t - lbs
Nm
f t - lbs
Nm
5.4
10.8
18.9
30.1
46.9
64.5
91
124
157
7.41
14.7
25.6
40.8
63.6
87.5
124
169
214
7.2
14.4
25.1
40
62.5
86.2
121
166
210
9.88
19.6
34.1
54.3
84.8
117
165
225
285
14
27.9
48.6
77.4
125
171
243
331
420
19.1
37.8
66
105
170
233
330
450
570
18.8
37.2
64.9
103
166
229
325
442
562
25.5
50.5
88
140
226
311
441
600
762
20.1
39.9
69.7
110
173
238
337
458
583
27.3
54.1
94.5
150
235
323
458
622
791
26.9
53.2
92.2
147
230
317
450
612
778
36.5
72.2
125
200
313
430
610
830
1055
23.6
46.7
81
129
202
278
394
536
682
32
63.3
110
175
274
377
535
727
925
31.4
62.3
108
172
269
371
525
715
909
42.6
84.4
147
234
365
503
713
970
1233
2 - 15
Section 2 Specifications
June 2007
2 - 16
June 2007
Symbols Legend
Safety alert symbolused 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.
Indicates that a specific result is expected after
performing a series of steps.
Indicates that an incorrect result has occurred
after performing a series of steps.
3-1
June 2007
Checklist
A
A+B
A+B+C
A+B+C+D
A+B+C+D+E
3-2
Pre-Delivery Preparation
Fundamentals
Instructions
Pre-Delivery Preparation
Pre-operation inspection
completed
Maintenance items completed
Function tests completed
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Genie Industries USA
18340 NE 76th Street
PO Box 97030
Redmond, WA 98073-9730
(425) 881-1800
Genie UK
The Maltings, Wharf Road
Grantham, Lincolnshire
NG31- 6BH England
(44) 1476-584333
June 2007
3-4
June 2007
Checklist A - Rev C
Y N R
Checklist B - Rev B
B-1 Battery
Inspected by (print)
A-6 Transmission
maintenance
Inspector signature
Serial number
Date
Hour meter
Machine owner
Inspector company
Instructions
Make copies of this report to use for
each inspection.
A+B
A-14 Transmission
maintenance
Comments
Y N R
Y N R
3-5
June 2007
Model
Checklist D - Rev B
Y N R
Checklist E - Rev C
Y N R
D-1 Forks
Date
Hour meter
D-5 Transmission
Serial number
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Instructions
Make copies of this report to use for
each inspection.
A+B
Comments
3-6
June 2007
REV C
Checklist A Procedures
A-1
Inspect the Manuals and Decals
Note: Genie specifications require that this
procedure be performed every 8 hours or daily,
whichever comes first.
Maintaining the operators and safety manuals in
good condition is essential to safe machine
operation. Manuals are included with each
machine and should be stored in the container
provided in the operator's compartment. An
illegible or missing manual will not provide safety
and operational information necessary for a safe
operating condition.
In addition, maintaining all of the safety and
instructional decals in good condition is mandatory
for safe machine operation. Decals alert operators
and personnel to the many possible hazards
associated with using this machine. They also
provide users with operation and maintenance
information. An illegible decal will fail to alert
personnel of a procedure or hazard and could
result in unsafe operating conditions.
3-7
CHECKLIST A
June 2007
PROCEDURES
REV C
A-2
Perform Pre-operation Inspection
A-3
Perform Function Tests
3-8
June 2007
REV C
CHECKLIST A
A-4
Lubricate the Machine
PROCEDURES
a
b
c
d
e
f
g
3-9
CHECKLIST A
June 2007
PROCEDURES
REV C
i
h
a
b
c
d
e
f
g
h
i
3 - 10
June 2007
REV C
CHECKLIST A
PROCEDURES
A-5
Perform Engine Maintenance John Deere and Perkins Models
A-6
Perform Transmission
Maintenance
97489
97492
108444
115025
3 - 11
CHECKLIST A
June 2007
PROCEDURES
REV C
A-7
Perform Engine Maintenance Deutz Models
A-8
Perform 30 Day Service
108746
A-12
B-5
D-3
Deutz models:
B-5
D-3
D-4
Perkins models:
3 - 12
B-5
D-3
June 2007
REV C
CHECKLIST A
A-9
Perform Transmission
Maintenance
PROCEDURES
A-10
Perform Engine Maintenance Perkins Models
97489
3 - 13
CHECKLIST A
June 2007
PROCEDURES
A-11
Perform Axle Maintenance
REV C
A-12
Perform Engine Maintenance John Deere Models
Note: Engine specifications requires that this onetime procedure be performed after 100 hours of
operation.
Required maintenance procedures and additional
engine information is available in the
John Deere 4045T270 Operator's Manual
(John Deere part number OMRG25204) OR the
John Deere 4045T275 Operator's Manual
(John Deere part number OMRG33324).
John Deere 4045T270 Operator's Manual
Genie part number
97492
108444
3 - 14
June 2007
REV C
CHECKLIST A
A-13
Perform Axle Maintenance
PROCEDURES
A-14
Perform Transmission
Maintenance
GTH-636, GTH-644, GTH-842 and GTH-844
97489
3 - 15
CHECKLIST A
PROCEDURES
June 2007
REV C
A-15
Perform Axle Maintenance
3 - 16
June 2007
Checklist B Procedures
REV B
B-1
Inspect the Battery
B-2
Inspect the Electrical Wiring
3 - 17
CHECKLIST B
June 2007
REV B
PROCEDURES
B-3
Check the Exhaust System
Transmission
Manifolds
Chassis
7 Inspect for a liberal coating of dielectric grease
in all connections between the engine,
transmission and the operator's compartment.
8 Install all covers removed in step 5.
9 Remove the lifting strap from the overhead
crane.
10 Start the engine and lower the boom to the
stowed position. Turn the machine off.
3 - 18
June 2007
CHECKLIST B
REV B
B-4
Inspect the Engine Air Filter
PROCEDURES
B-5
Inspect the Tires, Wheels and
Lug Nut Torque
3 - 19
CHECKLIST B
June 2007
PROCEDURES
REV B
B-6
Perform Hydraulic Oil Analysis
valve stem
June 2007
REV B
CHECKLIST B
B-7
Inspect the Fuel and Hydraulic
Tank Cap Venting Systems
PROCEDURES
3 - 21
CHECKLIST B
June 2007
PROCEDURES
B-8
Check the Boom Wear Pads
GTH-644, GTH-842 and GTH-844
REV B
9/16 inch
14.3 mm
3/8 inch
9.5 mm
9/16 inch
14.3 mm
3 - 22
June 2007
REV B
CHECKLIST B
B-9
Lubricate the Driveshafts
PROCEDURES
B-10
Perform Engine Maintenance John Deere Models
Grease Specification
97492
108444
b
a
b
rear driveshaft
front driveshaft
3 - 23
June 2007
Checklist C Procedures
REV B
C-1
Perform Engine Maintenance Deutz Models
C-2
Perform Engine Maintenance John Deere Models
3 - 24
108746
John Deere 4045T270 Operator's Manual
Genie part number
97492
108444
June 2007
REV B
CHECKLIST
C-3
Perform Axle Maintenance
C PROCEDURES
C-4
Perform Transmission
Maintenance
GTH-1048 and GTH-1056
115025
3 - 25
CHECKLIST
June 2007
PROCEDURES
C-5
Perform Engine Maintenance Perkins Models
REV B
C-6
Perform Axle Maintenance
3 - 26
June 2007
REV B
CHECKLIST
C PROCEDURES
C-7
Perform Axle Maintenance
3 - 27
June 2007
Checklist D Procedures
D-1
Inspect the Forks
REV B
D-2
Adjust the Boom Sequencing
Chains
Surface cracks
Straightness of the blade and shank
Fork angle at 90 3 degrees
a
b
3 - 28
shank
blade
June 2007
REV B
CHECKLIST
D PROCEDURES
GTH-1056:
1 Raise the boom to the horizontal position.
2 Extend the boom fully, then retract the boom
approximately 1 inch / 25 mm.
3 On either side of the number 2 boom tube,
estimate the center. Place one end of a
tape measure on the top surface of the
boom directly above the estimated center.
a
GTH-1056
a
b
c
nut
spring
chain anchor
a
b
c
d
e
f
g
h
i
j
k
l
3 - 29
CHECKLIST
June 2007
REV B
PROCEDURES
2
1
nut
spring
chain anchor
3 - 30
June 2007
REV B
CHECKLIST
D-3
Replace Hydraulic Tank Return
Filter Element
D PROCEDURES
3 - 31
CHECKLIST
June 2007
PROCEDURES
REV B
D-4
Perform Engine Maintenance Deutz Models
D-5
Perform Transmission
Maintenance
108746
Dana T12000 Maintenance Manual
Genie part number
97489
3 - 32
115025
June 2007
REV B
CHECKLIST
D-6
Perform Axle Maintenance
D PROCEDURES
D-7
Perform Engine Maintenance Perkins Models
3 - 33
CHECKLIST
PROCEDURES
June 2007
REV B
D-8
Perform Engine Maintenance Deutz Models
3 - 34
108746
June 2007
Checklist E Procedures
REV C
E-1
Test or Replace the Hydraulic Oil
3 - 35
CHECKLIST E
June 2007
PROCEDURES
REV C
E-2
Perform Engine Maintenance John Deere Models
E-3
Perform Engine Maintenance Perkins Models
97492
108444
3 - 36
June 2007
REV C
CHECKLIST E
PROCEDURES
E-4
Perform Engine Maintenance Perkins Models
E-5
Perform Engine Maintenance Perkins Models
3 - 37
CHECKLIST E
June 2007
PROCEDURES
REV C
E-6
Perform Engine Maintenance John Deere Models
E-7
Perform Engine Maintenance Perkins Models
97492
108444
3 - 38
June 2007
REV C
CHECKLIST E
PROCEDURES
E-8
Perform Engine Maintenance Deutz Models
E-9
Perform Engine Maintenance Perkins Models
108746
3 - 39
June 2007
3 - 40
June 2007
Repair Procedures
About This Section
Most of the procedures in this section should only
be performed by a trained service professional
in a suitably equipped workshop. Select the
appropriate repair procedure after troubleshooting
the problem.
4-1
June 2007
Boom Components
1-1
Boom Angle Limit Switch
(all models except GTH-636)
How to Adjust the Limit Switch
Note: Perform this procedure on a firm, level
surface.
1 Start the engine.
2 GTH-1056: Raise the boom to 55. Confirm with
a digital level.
All other models: Raise the boom to 60.
Confirm with a digital level.
3 Working at the pivot end of the boom, locate
and loosen the fasteners of the limit switch
collar on the boom pivot at the exhaust side of
the machine.
a
REV C
boom pivot
4-2
June 2007
REV C
BOOM COMPONENTS
1-2
Boom
4-3
June 2007
BOOM COMPONENTS
REV C
3-section boom
a
b
c
d
e
f
a
b
c
4-4
lift cylinder
rod end pivot pin
barrel end pivot pin
June 2007
REV C
BOOM COMPONENTS
4-5
June 2007
BOOM COMPONENTS
REV C
4-6
a
b
c
d
e
f
g
June 2007
REV C
BOOM COMPONENTS
4-7
June 2007
REV C
BOOM COMPONENTS
4-8
June 2007
REV C
BOOM COMPONENTS
GTH-636
GTH-1048
a
b
c
d
e
f
g
h
i
a
b
c
d
retraction chain
extension chain
fixed chain block
chain tensioner
4-9
June 2007
REV C
BOOM COMPONENTS
4 - 10
June 2007
REV C
BOOM COMPONENTS
GTH-1056:
1 Remove the extension cylinder. See 1-4, How
to Remove the Boom Extension Cylinder.
GTH-1056
a
b
c
d
e
f
g
h
i
j
k
l
m
n
o
p
4 - 11
June 2007
REV C
BOOM COMPONENTS
4 - 12
June 2007
REV C
BOOM COMPONENTS
4 - 13
June 2007
REV C
BOOM COMPONENTS
4 - 14
June 2007
REV C
BOOM COMPONENTS
1-3
Boom Lift Cylinder
How to Remove a Lift Cylinder
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Section 2, Hydraulic Hose and
Fitting Torque Specifications.
1 Attach an overhead 10 ton / 10,000 kg crane to
the boom. Support the boom. Do not apply any
lifting pressure.
2 Tag, disconnect and plug the two larger
hydraulic hoses at the lift cylinder and manifold.
Cap the fittings.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
4 - 15
BOOM COMPONENTS
June 2007
REV C
4 - 16
June 2007
REV C
BOOM COMPONENTS
1-4
Boom Extension Cylinder
How to Remove the
Extension Cylinder
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Section 2, Hydraulic Hose and
Fitting Torque Specifications.
1 Raise the boom to a horizontal position.
2 Extend the boom approximately 1 foot / 30 cm.
3 Attach a lifting strap from an overhead crane to
the extension cylinder. Support the cylinder. Do
not apply any lifting pressure.
a
a
b
c
d
e
f
4 - 17
June 2007
REV C
BOOM COMPONENTS
1-5
Fork Level Cylinder
4 - 18
June 2007
REV C
BOOM COMPONENTS
a
b
c
4 - 19
June 2007
BOOM COMPONENTS
REV C
1-6
Fork Rotate Cylinder (option)
380 ft-lbs
515 Nm
4 - 20
June 2007
REV C
BOOM COMPONENTS
a
b
c
4 - 21
June 2007
REV C
BOOM COMPONENTS
4 - 22
June 2007
Operator's Compartment
REV B
2-1
Operator's Compartment
e
Illustration 1
a
b
c
d
e
f
4 - 23
June 2007
OPERATOR'S COMPARTMENT
REV B
T
1
3
4
TO (T) PORT
ON FOOT BRAKE
VALVE
LIFT UP
BOOM IN
FRONT
STEERING
CYL.
CYL 2
LIFT DOWN
T
BOOM OUT
1
4
MAIN VALVE
ASSEMBLY
PARKING BRAKE
VALVE
TO FRONT AXLE
PARKING BRAKE
CIRCUIT
CONTROL BLOCK
T3
C2
P
L
R
C1
BOTTOM
VIEW
TANK PORT #3
T2 T3 R
TANK PORT #1
Illustration 2
4-way Controller Circuit
CONTROL
BLOCK
T1
ST
C
S PR BK
MANIFOLD
BLOCK
REAR
STEERING
CYL.
Illustration 3
Steer Circuit
4 - 24
June 2007
REV B
OPERATOR'S COMPARTMENT
P
F
BK
FRONT AXLE
TRANSMISSION
TO REAR
LOCK-UP BLOCK
2
1
Illustration 4
Brake/Differential Lock Circuit
a
b
c
d
brake pedal
service brake pressure switch
clutch cut-off pressure switch
brake pedal actuator body
4 - 25
June 2007
OPERATOR'S COMPARTMENT
REV B
4 - 26
June 2007
REV B
OPERATOR'S COMPARTMENT
e
d
Illustration 1
Operator's Compartment
Torque specification
Operator's compartment
mounting fasteners
750 ft-lbs
1017 Nm
a
b
c
d
e
f
g
4 - 27
June 2007
OPERATOR'S COMPARTMENT
REV B
BOOM IN
3
4
BOOM OUT
LIFT UP
LIFT DOWN
TO PORT 2
ON BRAKING
BRAKE VALVE
TO PORT 3
TEE FITTING
ON BRAKING
BRAKE VALVE
TO CONTROLLER
RELIEF VALVE
Illustration 2
Bottom View of 4-way Controller
4 - 28
June 2007
REV B
OPERATOR'S COMPARTMENT
CYL 1
P
R
CYL 2
TOP VIEW
STEERING SELECTOR
TOP VIEW
C2
P
C1
BOTTOM
VIEW
FRONT OF
MACHINE
T2 T3 R
T1 CONTROL
BLOCK
G2
ST
C
G4
G1
G3
S PR BK
SEE BOOM
CIRCUIT
(10 SERIES ONLY)
MANIFOLD
BLOCK
REAR
STEERING
CYLINDER
Illustration 3
Steer Circuit
4 - 29
June 2007
OPERATOR'S COMPARTMENT
REV B
P T
A
TO CLUTCH CUT-OFF
PRESSURE SWITCH
TO BRAKE ACCUMULATOR /
CONTROL BLOCK
Illustration 4
Brake Actuator
4 - 30
June 2007
REV B
OPERATOR'S COMPARTMENT
TO "P" PORT
ON 4-WAY CONTROLLER
TO "T" PORT
ON 4-WAY CONTROLLER
3
2
1
TO "P" PORT
ON 4-WAY CONTROLLER
3
2
1
FRONT
AXLE
TO "PRESSURE" TEE FITTING
ON CONTROLLER RELIEF VALVE
4-WAY CONTROLLER CIRCUIT
Illustration 5
Parking Brake Valve Assembly
4 - 31
June 2007
OPERATOR'S COMPARTMENT
REV B
2-2
Machine Controls
4 - 32
June 2007
REV B
OPERATOR'S COMPARTMENT
4 - 33
June 2007
REV B
OPERATOR'S COMPARTMENT
4 - 34
June 2007
REV B
OPERATOR'S COMPARTMENT
4 - 35
June 2007
REV B
OPERATOR'S COMPARTMENT
4 - 36
June 2007
REV B
OPERATOR'S COMPARTMENT
4 - 37
June 2007
REV C
3-1
Fuel Tank
How to Remove the Fuel Tank
Explosion and fire hazard. Engine
fuels are combustible. Remove the
fuel tank in an open, wellventilated area away from heaters,
sparks, flames and lighted
tobacco. Always have an
approved fire extinguisher within
easy reach.
Explosion and fire hazard. Never
drain or store fuel in an open
container due to the possibility of
fire.
Explosion and fire hazard. When
transferring fuel, connect a
grounding wire between the
machine and pump or container.
1 Disconnect the battery from the machine.
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
4 - 38
June 2007
REV C
3-2
Hydraulic Tank
The primary functions of the hydraulic tank are to
cool, clean and deaerate the hydraulic fluid during
operation. It has an internal return line filter with a
filter condition indicator.
4 - 39
June 2007
Engines
REV B
4-1
Engines
108746
108748
97492
108444
108443
108502
108503
4 - 40
117764
June 2007
REV B
ENGINES
4-2
Engine Fault Codes John Deere 4045TF275 Engine
How to Retrieve Engine Fault
Codes
When an engine malfunction is detected by the
engine Electronic Control Module (ECM), a fault
code is recorded and the blink code light on the
dashboard in the operator's compartment will turn
on.
4 - 41
June 2007
Transmission
5-1
Transmission
How to Remove the Transmission
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Section 2, Hydraulic Hose and
Fitting Torque Specifications.
Note: Perform this procedure with the engine off
and cool.
REV C
4 - 42
June 2007
REV C
TRANSMISSION
97489
115025
4 - 43
June 2007
Hydraulic Pump
6-1
Hydraulic Pump
How to Test the Function Pump
Note: When removing a hose assembly or fitting,
the fitting and/or hose end must be torqued to
specification during installation. Refer to Section 2,
Hydraulic Hose and Fitting Torque Specifications.
1 Tag, disconnect and plug the high pressure
hydraulic hose from the main valve assembly.
Cap the fitting on the main valve.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
Note: The high pressure hose is the smaller of the
two hoses.
2 Connect a 0 to 5000 psi / 0 to 350 bar pressure
gauge to the high pressure hose disconnected
in step 1.
3 Hold the manual fuel shut-off lever on the
engine in the closed position.
REV B
4 - 44
June 2007
REV B
HYDRAULIC PUMP
a
b
pump
DFR valve
4 - 45
June 2007
HYDRAULIC PUMP
REV B
4 - 46
June 2007
REV B
HYDRAULIC PUMP
4 - 47
June 2007
Manifolds
REV C
7-1
Main Valve Manifold Components
The main valve manifold is located on the front of the hydraulic tank at the tailpipe side of the machine.
Index
No.
Description
Schematic
Item
Directional valve, pilot operated ....... AA .......... Boom extend/retract .................................... 88 in-lbs / 10 Nm
Function
Torque
Directional valve, pilot operated ....... AB .......... Lifting fork level ........................................... 88 in-lbs / 10 Nm
Directional valve, pilot operated ...... AC .......... Boom up/down ............................................ 88 in-lbs / 10 Nm
Relief valve, 3650 psi / 251 bar ....... AD .......... Manifold relief ............................................ 73 ft-lbs / 100 Nm
AA
AB
AC
AD
4 - 48
IC
UL
RAANK
D
Y T
June 2007
REV C
MANIFOLDS
7-2
Tilt Limiter Manifold Components
The tilt limiter manifold is located on the front of the hydraulic tank at the tailpipe side of the machine.
Index
No.
Description
Schematic
Item
Relief valve, 1250 psi / 86.2 bar ....... BA .......... Fork level circuit ................................ 30-35 ft-lbs / 45-50 Nm
Function
Torque
BA
IC
UL
RAANK
D
Y T
4 - 49
June 2007
MANIFOLDS
REV C
7-3
Dual Pilot Check Manifold Components
The dual pilot check manifold is located on the front of the hydraulic tank at the tailpipe side of the machine
Index
No.
Description
Schematic
Item
Check valve, pilot operated ............. CA .......... Boom lift circuit .................................. 30-35 ft-lbs / 45-50 Nm
Check valve, pilot operated ............. CB .......... Boom lift circuit .................................. 30-35 ft-lbs / 45-50 Nm
Function
Torque
CB
CA
4 - 50
IC
UL
RAANK
D
Y T
June 2007
REV C
MANIFOLDS
7-4
Boom Activated Rear Lock-up Manifold Components
The rear lock-up manifold is located on the front of the hydraulic tank at the cab side of the machine.
Index
No.
1
Description
Schematic
Item
Function
Torque
Y69
IC
UL
RAANK
D
Y T
4 - 51
June 2007
MANIFOLDS
REV C
7-5
Fork Rotate Speed Manifold Components (option)
The fork rotate speed manifold is located on the front of the hydraulic tank at the cab side of the machine.
Index
No.
Description
Schematic
Item
Function
Torque
Adjustable needle valve ................... EA .......... Fork rotate speed .............................. 30-35 ft-lbs / 40-47 Nm
Adjustment nut ..................................................................................................................... 108 in-lbs / 12 Nm
EA
1
4 - 52
IC
UL
RAANK
D
Y T
June 2007
REV C
MANIFOLDS
7-6
Control Block Manifold Components
The control block manifold is located on the front of the hydraulic tank at the cab side of the machine.
Index
No.
Schematic
Item
Description
Function
Torque
Adjustable needle valve ................... FA .......... Chassis sway speed ......................... 30-35 ft-lbs / 40-47 Nm
Adjustment nut ..................................................................................................................... 108 in-lbs / 12 Nm
Check valve ...................................... FD .......... Brake circuit ...................................... 30-35 ft-lbs / 40-47 Nm
FA
FB
FC
FD
IC
UL
RAANK
D
Y T
4 - 53
June 2007
MANIFOLDS
REV C
7-7
Fork Tilt Manifolds Components
The fork tilt manifolds, used only on machines with single joystick, are located on the front of the hydraulic
tank at the cab side of the machine.
Index
No.
Description
Solenoid valve, 2 position 4 way ..... GA .......... Tilts lifting forks down ................................. 20 ft-lbs / 27 Nm
Solenoid valve, 2 position 4 way ..... GB .......... Tilts lifting forks up ...................................... 20 ft-lbs / 27 Nm
GA
Schematic
Item
Function
Y72A
Torque
Y72B
GB
2
4 - 54
IC
UL
RAANK
D
Y T
IC
UL
RAANK
D
Y T
June 2007
REV C
MANIFOLDS
7-8
Rear Lock-up Manifold Components
The rear lock-up manifold is located on top of the rear axle support bulkhead.
Index
No.
Description
Schematic
Item
Check valve, pilot operated ............. HA .......... Left rear cylinder retract circuit ......... 35-40 ft-lbs / 47-54 Nm
Check valve, pilot operated ............. HB .......... Left rear cylinder extend circuit ......... 35-40 ft-lbs / 47-54 Nm
Check valve, pilot operated ............. HC .......... Right rear cylinder retract circuit ....... 35-40 ft-lbs / 47-54 Nm
Check valve, pilot operated ............. HD .......... Right rear cylinder extend circuit ...... 35-40 ft-lbs / 47-54 Nm
Shuttle valve, 2 position 3 way ........ HE .......... Chassis sway circuit ......................... 25-30 ft-lbs / 34-40 Nm
Directional valve, pilot operated ....... HF .......... Activates rear sway function ............. 35-40 ft-lbs / 47-54 Nm
Directional valve, pilot operated ...... HG .......... Opens check valves .......................... 35-40 ft-lbs / 47-54 Nm
Torque
HB
2
HC
Function
2
HD
HH
HE
HG
HF
4 - 55
June 2007
MANIFOLDS
REV C
7-9
Parking Brake Manifold Components
GTH-644, GTH-842 and GTH-844: The parking brake manifold is the outboard of the two similar
manifolds located on the chassis main tube next to the cab, mounted directly to the chassis.
GTH-636, GTH-1048 and GTH-1056: The parking brake manifold located inside the cab, just to the left of
the operator's seat.
Index
No.
Schematic
Item
Description
Function
Torque
Manually-activated valve,
2 position 3 way
(636, 1048 and 1056 models) .......... IA ........... Activates/releases parking brake ............... 20 ft-lbs / 27 Nm
1
IA
IA
Y67
GTH-636
GTH-1048
GTH-1056
2
1
GTH-644
GTH-842
GTH-844
4 - 56
June 2007
REV C
MANIFOLDS
7-10
Differential Lock-up Manifold Components
(optional on GTH-636 and GTH-644)
The differential lock-up manifold is the inboard of the two similar manifolds located on the chassis main
tube next to the cab, mounted closest to the centerline of the machine.
Index
No.
1
Description
Schematic
Item
Function
Torque
Solenoid valve, 2 position 3 way ...... JA .......... Releases parking brake .............................. 20 ft-lbs / 27 Nm
Coil nut .................................................................................................................................. 40 in-lbs / 4.5 Nm
JA
Y68
4 - 57
June 2007
MANIFOLDS
REV C
7-11
Sway Manifold Components
The sway manifolds are located under an inspection cover on the front axle support bulkhead with the left
sway manifold mounted on the cab side of the machine and the right sway manifold mounted on the
exhaust side of the machine.
Index
No.
Description
Schematic
Item
Check valve, pilot operated .............. KA .......... Left front cylinder extend circuit ........ 30-35 ft-lbs / 40-47 Nm
Function
Torque
Check valve, pilot operated .............. KB .......... Left front cylinder retract circuit ......... 30-35 ft-lbs / 40-47 Nm
Check valve, pilot operated ............. KC .......... Right front cylinder retract circuit ...... 30-35 ft-lbs / 40-47 Nm
Check valve, pilot operated ............. KD .......... Right front cylinder extend circuit ..... 30-35 ft-lbs / 40-47 Nm
2
1
KB
KC
KA
KD
CAB SIDE
3
4
EXHAUST SIDE
4 - 58
June 2007
REV C
MANIFOLDS
7-12
Fork Rotate Manifold Components (option)
If equipped with the fork rotate option, the fork rotate manifold is located under the rear lock-up manifold
on the rear axle support bulkhead at the cab side of the machine.
Index
No.
1
Schematic
Item
Description
Function
Torque
LA
1
4 - 59
June 2007
MANIFOLDS
REV C
7-13
Sway Directional Manifold Components
The sway directional manifold is located under the rear lock-up manifold on the rear axle support bulkhead
at the exhaust side of the machine.
Index
No.
Schematic
Item
Description
Function
Torque
MODELS WITH
SINGLE
JOYSTICK
Y71
MA
Y70
MA
1
MODELS WITH
DUAL
JOYSTICKS
4 - 60
June 2007
REV C
MANIFOLDS
7-14
Outrigger Manifold Components GTH-1048 and GTH-1056
The outrigger manifold is located under the inspection cover on the front axle support bulkhead.
Index
No.
Description
Schematic
Item
Function
Torque
Y75
Y73
Y76
NA
Y74
NB
4 - 61
June 2007
MANIFOLDS
REV C
7-15
Controller Relief (Drop Block) Manifold Components
GTH-636, GTH-1048 and GTH-1056
The controller relief valve manifold is located inside the frame rail between the cab and the rear axle
support bulkhead on the cab side of the machine.
Index
No.
Description
Schematic
Item
Function
Torque
Y77
OA
1
4 - 62
June 2007
REV C
MANIFOLDS
7-16
Boom Lift and Boom Extension Cylinders Manifold Components
The manifolds are located on the respective cylinder(s).
Index
No.
Schematic
Item
Description
Function
Torque
PA
PB
Boom Lift
Cylinder Manifold
QA
QB
Boom Extension
Cylinder Manifold
Note: 'alpha' callouts refer
to corresponding notes on
the hydraulic schematic
4 - 63
June 2007
MANIFOLDS
REV C
7-17
Fork Level Cylinder Manifold Components
If equipped with the fork rotate option, the fork rotate cylinder manifold is located on the cylinder.
Index
No.
Description
Schematic
Item
Check valve, pilot operated ............. RA .......... Fork up circuit ................................... 30-35 ft-lbs / 40-47 Nm
Function
Torque
Counterbalance valve ...................... RB .......... Fork up circuit ................................... 30-35 ft-lbs / 40-47 Nm
Check valve, pilot operated ............. RC .......... Fork down circuit ............................... 30-35 ft-lbs / 40-47 Nm
RA
RB
RC
4 - 64
June 2007
REV C
MANIFOLDS
7-18
Fork Rotate Cylinder Manifold Components (option)
The manifolds are located on the cylinder.
Index
No.
Description
Schematic
Item
Check valve, pilot operated .............. SA .......... Rotate clockwise circuit .................... 30-35 ft-lbs / 40-47 Nm
Check valve, pilot operated .............. SB .......... Rotate counterclockwise circuit ........ 30-35 ft-lbs / 40-47 Nm
Function
Torque
SA
SB
4 - 65
June 2007
MANIFOLDS
REV C
7-19
Pump Destroke Manifold Components
The pump destroke manifold is located on the hydraulic pump next to the DFR valve.
Index
No.
Description
Schematic
Item
Solenoid valve, 2 position 2 way ...... TA .......... Disengages hydraulic pump ....................... 20 ft-lbs / 27 Nm
Function
Torque
TA
Y66
Y66
TA
4 - 66
June 2007
REV C
MANIFOLDS
7-20
Extend Cylinder Relief Manifold Components GTH-636, GTH-1048 and GTH-1056
The extend cylinder relief manifold is located on the dump block at the front of the hydraulic tank.
Index
No.
Schematic
Item
Description
Function
Torque
UA
IC
UL
RAANK
D
Y T
4 - 67
June 2007
MANIFOLDS
REV C
7-21
Boom-activated Sway Lock-up Manifold Components
(models with dual joysticks except GTH-636)
The boom-activated sway lock-up manifold, used on all machines with dual joysticks except the GTH-636,
is mounted on the pilot operated sway directional valve.
Index
No.
Description
Schematic
Item
Solenoid valve, 2 position 2 way ...... VA .......... GTH-644, GTH-842 and GTH-844:
Stops fluid flow to chassis sway circuit
when boom is above 60 ............................. 20 ft-lbs / 27 Nm
Function
Torque
VA
Y84
4 - 68
June 2007
REV C
MANIFOLDS
7-22
Valve Adjustments Control Block Manifold
a
FA
FB
FC
GTH-636
GTH-644
GTH-842
GTH-844
GTH-1048
GTH-1056
a
b
c
d
test port 6
test port 4
test port 3
test port 1
c
b
a
b
c
hydraulic tank
boom lift/extend relief valve
control block manifold
4 - 69
June 2007
MANIFOLDS
REV C
Result:
GTH-636, GTH-644, GTH-842 and GTH-844:
The pressure gauge fails to read
500 psi / 34.5 bar. The pressure setting needs
to be adjusted. Continue to step 5.
GTH-1048 and GTH-1056: The pressure
gauge fails to read 500 psi / 34.5 bar. The
pressure setting needs to be adjusted. Continue
to step 5.
GTH-1048
GTH-1056
a
FA
FB
a
b
c
d
test port 6
test port 4
test port 3
test port 1
FC
a
b
c
4 - 70
hydraulic tank
pilot pressure relief valve
control block manifold
June 2007
REV C
MANIFOLDS
7-23
Valve Adjustments Tilt Limiter Manifold
c
GTH-636
GTH-644
GTH-842
GTH-844
GTH-1048
GTH-1056
a
b
c
d
test port 6
test port 4
test port 3
test port 1
BA
a
b
c
hydraulic tank
tilt limiter manifold
tilt limiter relief valve
4 - 71
MANIFOLDS
June 2007
REV C
7-24
Valve Coils
How to Test a Coil
A properly functioning coil provides an
electromotive force which operates the solenoid
valve. Critical to normal operation is continuity
within the coil that provides this force field.
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
1 Start the engine.
2 While activating the appropriate machine
function, apply a steel wrench to the tip of the
solenoid valve. Release the wrench.
Result: The wrench sticks to the tip of the valve.
The valve coil is functioning correctly.
Result: The wrench does not stick to the valve.
The valve coil is not functioning correctly.
3 Disconnect the wire harness from the valve coil.
4 Using a multimeter set to read DC voltage,
attach the positive lead to one of the terminals
of the valve coil connector.
5 Attach the negative lead to a ground point on
the chassis.
Result: The multimeter displays approximately
13V DC. The wire harness is good. Replace the
valve coil.
Result: The multimeter displays 0V DC. The
valve coil is good; the wire harness is faulty.
Repair or replace the wire harness.
4 - 72
June 2007
Axle
REV D
8-1
Axles
How to Remove the Axle
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant
component damage. Dealer
service is required.
1 Remove the fasteners securing the driveshaft to
the transmission. Lower the end of the
driveshaft to the ground.
2 Remove the fasteners securing the driveshaft to
the axle. remove the driveshaft from the
machine.
3 Loosen the lug nuts of both wheels on the axle
to be removed. Do not remove the lug nuts.
4 Raise the end of the machine until the tires are
off the ground. Place blocks under the chassis
for support.
Crushing hazard. The chassis will
fall if not properly supported.
5 Remove the lug nuts. Remove the tire and
wheel assembly from both ends of the axle.
6 Support and secure the axle to an appropriate
lifting device.
380 ft-lbs
515 Nm
4 - 73
June 2007
AXLE
REV D
4 - 74
June 2007
REV D
AXLE
321 mm
4 - 75
June 2007
Outriggers
REV A
9-1
Outriggers
How to Remove an Outrigger
1 Extend the outrigger until the pad just touches
the ground. Do not rest the weight of the
machine on the outrigger.
2 Tag, disconnect and plug the hydraulic supply
hoses at the outrigger cylinder. Cap the fittings.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
4 - 76
June 2007
REV A
OUTRIGGERS
4 - 77
June 2007
4 - 78
June 2007
Section 5 Troubleshooting
Troubleshooting
Before Troubleshooting:
Read, understand and obey the safety rules
and operating instructions in the appropriate
operator's manual on your machine.
Malfunction
discovered
Identify
symptoms
Troubleshoot
problem
still exists
Return to
service
problem
solved
Inspect
and test
Perform
repair
5-1
Section 5 Troubleshooting
June 2007
REV A
TROUBLESHOOTING
1-1
Engine Fault Codes GTH-1048 and GTH-1056
When an engine malfunction is detected by the
engine Electronic Control Module (ECM), a fault
code is recorded and the blink code light, located
on the dashboard in the operator's compartment,
will turn on.
Warning Lamp
Engine Protection
5-2
Section 5 Troubleshooting
June 2007
REV A
TROUBLESHOOTING
11
12
18
19
21
22
23
24
25
26
28
32
33
37
38
39
42
54
55
62
63
64
65
66
68
69
71
72
73
74
75
76
77
78
79
81
82
83
84
88
5-3
Section 5 Troubleshooting
June 2007
REV A
TROUBLESHOOTING
1-2
Hydraulic Pump
Symptom:
Laboring engine; pump is constantly trying to build
pressure.
Check the Pump
5-4
Section 5 Troubleshooting
June 2007
REV A
TROUBLESHOOTING
GTH-636
GTH-644
GTH-842
GTH-844
GTH-1048
GTH-1056
a
b
c
d
test port 6
test port 4
test port 3
test port 1
5-5
Section 5 Troubleshooting
June 2007
REV B
TROUBLESHOOTING
1-3
Boom Functions
Joystick (4-way) Circuit
Symptom:
Slow or no boom functions
Check the Pilot Pressure
1 GTH-636, GTH-644, GTH-842 and GTH-844:
Install a 0 to 3500 psi / 0 to 250 bar pressure
gauge into test port 3 at the side of the
hydraulic tank.
Note: There are four test ports at the hydraulic
tank. Test port 1 is closest to the tank; test port 4 is
farthest from the tank.
2 GTH-1048 and GTH-1056: Install a
0 to 3500 psi / 0 to 250 bar pressure gauge into
test port 5 at the side of the hydraulic tank.
Note: There are six test ports at the hydraulic tank.
Test port 1 is closest to the tank; test port 6 is
farthest from the tank.
Result:
GTH-636, GTH-644, GTH-842 and GTH-844:
The pressure gauge reads 500 psi / 34.5 bar.
The pressure setting is correct. Proceed to step
4.
GTH-1048 and GTH-1056: The pressure
gauge reads 400 psi / 27.6 bar. The pressure
setting is correct. Proceed to step 4.
Result:
GTH-636, GTH-644, GTH-842 and GTH-844:
The pressure gauge fails to read
500 psi / 34.5 bar. Adjust or replace the
pressure reducing/relief valve (schematic item
FB). Refer to Repair Procedure 7-18, How to
Set the Boom System Pilot Pressure.
GTH-1048 and GTH-1056: The pressure
gauge fails to read 400 psi / 27.6 bar. Adjust or
replace the pressure reducing/relief valve
(schematic item FB). Refer to Repair Procedure
7-18, How to Set the Boom System Pilot
Pressure.
Result: The pressure reading is
200 psi / 13.8 bar or lower. The pressure
reducing/relief valve (schematic item FB) is
faulty. Replace the valve.
4 GTH-636, GTH-1048 and GTH-1056: Stop the
engine. Proceed to step 5.
GTH-644, GTH-842 and GTH-844: Stop the
engine. Proceed to step 13.
GTH-636
GTH-644
GTH-842
GTH-844
GTH-1048
GTH-1056
5-6
a
b
c
d
test port 6
test port 4
test port 3
test port 1
Section 5 Troubleshooting
June 2007
REV B
TROUBLESHOOTING
5-7
Section 5 Troubleshooting
June 2007
REV B
TROUBLESHOOTING
5-8
Section 5 Troubleshooting
June 2007
REV B
TROUBLESHOOTING
5-9
Section 5 Troubleshooting
June 2007
REV B
TROUBLESHOOTING
5 - 10
Section 5 Troubleshooting
June 2007
REV B
TROUBLESHOOTING
Symptom B:
Forks self-level at a faster rate than the boom is
descending.
1 Remove the load from the forks.
2 Start the engine and allow the engine to idle.
3 Level the forks.
4 Stop the engine.
5 - 11
Section 5 Troubleshooting
June 2007
TROUBLESHOOTING
REV B
5 - 12
Section 5 Troubleshooting
June 2007
REV A
TROUBLESHOOTING
1-4
Drive Functions
Symptom:
Back-up alarm doesn't work when transmission in
reverse.
Symptom:
Machine won't drive.
5 - 13
Section 5 Troubleshooting
June 2007
REV A
TROUBLESHOOTING
1-5
Steer Functions
How to Troubleshoot the Steering
Check the Steer Orbitral
1 Tag, disconnect and plug the hoses at orbitral
ports T, R and L. Do not cap the fittings.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
2 Install the hose from port P into port L and
torque to specification. Refer to Section 2,
Specifications.
5 - 14
Section 5 Troubleshooting
June 2007
REV A
TROUBLESHOOTING
5 - 15
Section 5 Troubleshooting
June 2007
REV A
TROUBLESHOOTING
5 - 16
Section 5 Troubleshooting
June 2007
REV A
TROUBLESHOOTING
1-6
Brake Functions
Service Brakes
Symptom:
Brakes dragging (not releasing)
1 Tee in a 0 to 1000 psi / 0 to 100 bar pressure
gauge at port A of the brake actuator at the
brake pedal assembly.
2 Start the engine and allow the engine to idle. Do
not touch the brake pedal.
Result: The gauge indicates 0 psi / 0 bar. The
actuator is good.
Result: The gauge indicates more than
0 psi / 0 bar. The actuator is faulty. Replace the
brake actuator.
Parking Brake
Symptom:
Parking brake does not hold OR does not release
1 Locate the parking brake manifold.
Note: The parking brake manifold is the outboard
of the two manifolds located inside the frame rail
next to the operator's compartment.
2 Tag, disconnect and plug the hydraulic hoses at
ports 1 and 2 of the parking brake manifold.
Cap the fittings.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
Symptom:
Brakes slow to apply OR apply too quickly
5 - 17
Section 5 Troubleshooting
June 2007
TROUBLESHOOTING
REV A
1-7
Sway Functions
Symptom:
When activating the sway function, the rear axle
wont move.
Check the Boom Angle Limit Switch
The GTH-636 is not equipped with
a boom angle limit switch. To
troubleshoot the sway function on
a GTH-636, begin this procedure
with step 7.
1 Remove all weight from the forks.
2 GTH-1056: Lower the boom to below 55. Turn
the machine off.
All other models: Lower the boom to below
60. Turn the machine off.
3 Turn the key switch to the on position. Do not
start the engine.
5 - 18
Section 5 Troubleshooting
June 2007
REV A
TROUBLESHOOTING
5 - 19
Section 5 Troubleshooting
June 2007
REV A
TROUBLESHOOTING
5 - 20
Section 5 Troubleshooting
June 2007
REV A
TROUBLESHOOTING
5 - 21
Section 5 Troubleshooting
June 2007
5 - 22
June 2007
Section 6 Schematics
Schematics
About This Section
There are two groups of schematics in this section.
An illustration legend precedes each group of
drawings.
Electrical Schematics
Hydraulic Schematics
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
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.
Malfunction
discovered
Identify
symptoms
Troubleshoot
problem
still exists
Return to
service
problem
solved
Inspect
and test
Perform
repair
6-1
Section 6 Schematics
June 2007
ABBREVIATION LEGEND
ABBREVIATION LEGEND
ABBREVIATION LEGEND
Item
Description
Item
Description
Item
Description
B1
BN
Battery
Button
BN3 = Cold start
BN5 = Horn
BN77 = Front axle differential lock
BN99 = Pump destroke
BN100 = Fork level
BN101 = Blink code enable
Circuit breaker, system power, 40A
Control relay
CR1 = Engine start
CR5 = Horn relay
CR22 = Head light
CR88 = Fuse block
CR89 = Parking brake
CR90 = Fork tilt
Alternator
Fuse
F18 = Power to blink code light
F19 = Power to ECM
Flashing beacons (option)
Gauge
G1 = Volt meter
G2 = Engine oil pressure
G3 = Engine coolant temperature
G6 = Hour meter
G9 = Transmission oil pressure
G10 = Transmission temperature
G11 = Fuel level
Horn or alarm
H2 = Auto-style horn
H3 = Back-up alarm
KS3
L
Key switch
Light or LED
L30 = Head lights
L31 = Left rear turn/brake
L32 = Right rear turn/brake
L59 = Right front turn signal
L60 = Left front turn signal
L61 = Back-up
L62 = Brake/tail light
L63 = Low brake pressure
L64 = Parking brake On
L65 = Blink code
Boom limit switch
Motor
M3 = Engine starter
M4 = Fuel pump
M9 = Heater fan
M10 = Front wiper
M11 = Circulation fan
Solenoid
Q7 = Fuel enrichment
Q8 = Fuel shut-off
Pressure switch
PS4 = Clutch cut-off
PS5 = Brake light
PS6 = Parking brake
PS7 = Service brake low pressure
Sensor
S1 = Engine coolant temperature
S2 = Engine oil pressure
S11 = Transmission temperature
S12 = Transmission pressure
S13 = Fuel level
SW
Switch
SW23 = Transmission control
SW24 = Parking brake
SW34 = Sway control
SW35 = Auxiliary control
SW36 = Wiper
SW37 = Turn switch
SW38 = Heater
SW39 = Outrigger - RF
SW40 = Outrigger - LF
Toggle switch
TS18 = Head light
Electronic component
U31 = Engine ECM
U34 = Turn flasher
U35 = 12V accessory plug
Solenoid valve coil
Y66 = Pump destroke
Y67 = Parking brake
Y68 = Front axle differential lock
Y69 = Boom actuated lock-up
Y70 = Sway left
Y71 = Sway right
Y72 = Fork level
Y73 = Stabilizer right front down
Y74 = Stabilizer right front up
Y75 = Stabilizer left front down
Y76 = Stabilizer left front up
Y77 = Controller relief
CB2
CR
D1
F
FB1
G
LS2
M
PS
TS
U
6-2
Section 6 Schematics
June 2007
NC
NO
X
P
COM
Battery
Boom up
limit switch
Flasher
2 position 4 way
solenoid valve
3 position 4 way
solenoid valve with
manual override
1
2
3
Button
Motors
12V DC accessory
recepticle
2 position 3 way
solenoid valve
Relief valve
40A
Circuit breaker
Pressure switch
87
86
2 position 2 way
solenoid valve
3 position 7 way
steering valve
Diode
Pilot operated
check valve
85
30
BAT
Sensor
Relay
ACC
Pump
ST
IGN
Key switch
Counterbalance
vavle
T
Flashing beacon,
LED or light
Hydraulic cylinder
Switch
2
Solenoid valves
Joystick
1 2 3 4
Toggle switch
Test ports
Gauge
Pressure switch
D1
10A
10 Amp fuse
Adjustable orifice
Horn or alarm
Alternator
Accumulator
Check valve
6-3
Section 6 Schematics
June 2007
REV C
BATTERY
ALTERNATOR
D1
2/0 BLK
2/0 RED
12 RED
16 RED
B1
16 WHT
16 GRY
12 RED
16 BRN
12 BLK
16 BLK
16 BRN
16 BLU
16 YEL
M3
12 WHT
8 BLK
M4
16 WHT
FUEL PUMP
16 RED
8 RED
STARTER
12 WHT
12 GRN
E
12 PUR
16 BLK
12 RED
16 YEL
12 BLK
16 BLK
12 RED
16 GRN
12 BLK
16 BLK
12 BLK
12 BLK
CLUTCH CUT-OFF
PRESSURE SWITCH
DESTROKE COIL
STARTER
RELAY
16 BLU
12 BLK
PS4
D
8 RED
CR1
16 GRN
12 RED
DIRECTION GEAR
1
FORWARD
Y66
TRANSMISSION
SHIFT COILS
REVERSE
12 PUR
COILS
ACTIVATED
ADE
AE
BDE
BE
B
12 BLK
12 BLK
8 RED
WIRE COLOR
LEGEND
12 WHT
16 GRN
WHT / WHITE
16 ORN
16 GRN
16 BLU
RED / RED
BLK / BLACK
16 BLU
16 GRY
16 GRY
BLU / BLUE
YEL / YELLOW
16 YEL
16 BRN
BRN / BROWN
16 BRN
GRN / GREEN
ORN / ORANGE
GRY / GRAY
PUR / PURPLE
16 BRN/WHT
16 TAN
12 RED
16 PINK
16 WHT
16 GRY
12 RED
TAN / TAN
LT BLU / LIGHT BLUE
16 PUR
16 BRN/WHT
12 PUR
12 GRY (UNUSED)
12 GRY
12 BLU (UNUSED)
12 BLU
16 BLK
16 BLK
BACK-UP
ALARM
16 WHT
H3
L61
16 RED
16 WHT
16 BLK
16 GRY
16 WHT 16 WHT
BACK-UP
LIGHT
16 BRN/WHT
16 WHT
16 RED
S13
12 RED
CR90
16 TAN
85
87A
87
86
BN100
FORK TILT
BUTTON
16 BLK
16 BLK
LEFT
Y70 SWAY
(WHT WIRE)
RIGHT
Y71 SWAY
(BLK WIRE)
MODELS
WITH
SINGLE
JOYSTICK
H2
HORN
FORK TILT
16 BLK
Y72B
30
16 BLK
12 RED
CR5
HORN
FUEL
SENDER
PS6
20 RED
30
FORK TILT
COILS
Y72A
16 BLK
PARKING BRAKE
PRESSURE
SWITCH
12 RED
12 BLK
12 BLK
12 RED
16 PINK
12 BLK
Y77
CONTROLLER
RELIEF
16 PUR
MODELS
WITH
SINGLE JOYSTICK
12 RED
16 GRY
16 BRN/WHT
12 RED
16 RED
16 BLK
12 RED
L62
BRAKE LIGHTS
PRESSURE
SWITCH
16 ORG
PS5
BRAKE/TAIL LIGHT
16 YEL
16 RED
16 PUR
16 PUR
16 BLK
85
20 BLK
87A
87
86
ES0447A
6-4
Section 6 Schematics
June 2007
REV C
L30
HEAD LIGHTS
CR22
TS18
16 BRN
14 WHT
16 BLU
16 BLK
12 BLK
16 YEL
16 RED
12 BLK
16 RED
87
CR88
SW23
8 RED
BAT.
TRANS
CONTROL
12 RED
40A
BAT
ACC.
12 GRN
16 BLK
85
16 WHT
86
ACC
ST
IGN
12 WHT
M9
87
30
KS3
16 BLK
CB2
16 YEL
FUSE BLOCK
RELAY
14 WHT
1 7 8
CR89
KEY SWITCH
PARKING
BRAKE
RELAY
8 YEL
16 ORN
12 YEL
16 BRN/WHT
16 GRN
16 RED
16 BLK
HEAD LIGHT
SWITCH
12 BLK
12 YEL
12 YEL
16 RED
16 BLK
85 16 GRN
86
30
SW38 HEATER
HEATER FAN
16 RED (LOW)
16 PUR
16 ORN (HIGH)
16 ORN
CAB HEATER
(OPTION)
16 BRN
16 RED 16 BRN
M11
8 RED
CIRCULATION FAN
87A
16 BLK
16 BLK
16 ORN
L64
86
G3
ET
G2
EP
16 RED
TP
16 RED
G9
12 WHT
16 RED
8 RED
G6
HM
85
12 WHITE
30
16 RED
12 RED
16 RED
PARKING BRAKE ON
12 BLK
16 PUR
12 GRY
16 ORN
20A
20A
5A
20A
10A
10A
5A
10A
10A
10A
16 GRN
G10
16 BRN
TT
G1
16 RED
16 RED
16 PUR
16 ORN
16 YEL
12 BLU
FUSE BOX
FR AXLE
G11
BN5
HORN
16 PUR
HORN RELAY
16 BRN/WHT
TAIL-LIGHT
12 PUR
Y68
PUMP DESTROKE
16 BLK
16 WHT
FRONT AXLE
DIFFERENTIAL
LOCK (OPTION)
BN3
16 BLK
COLD START
16 BLK
COLD START (ETHER AID)
(JOHN DEERE MODELS)
16 BRN/WHT
SW35
16 GRY
P
12 GRY
16 GRY
SW36
WIPER
16 ORN
16 BRN
16 BLU
16 BLK
SW34
FB1
STROBE LIGHT
16 RED
16 PUR
16 BLK
P FLASHER
L
16 YEL
16 GRY/BLK
16 BLK
16 RED
16 RED
MODELS
WITH
SINGLE
JOYSTICK
16 BLK
16 BLK
16 GRN
LEFT REAR
TURN/BRAKE LIGHT
6
8
16 RED
SW37
L31
TURN SWITCH
5
16 GRY
BRAKE LIGHTS
PRESSURE
SWITCH
16 BLU
16 GRY - HOT
PS5
U34
L60
LEFT FRONT
TURN SIGNAL
16 BRN/WHT
16 RED
SWAY CONTROL
16 GRY
16 RED
M10
16 GRY / WHT
16 BLK
BN99
FRONT WIPER
12 GRY
AUXILIARY CONTROL
16 YEL
12V
ACCESSORY
16 TAN
U35
12 BLK
FL
12 RED
12 PUR
16 BLK
16 YEL
16 BLK
16 RED
16 GRY
16 WHT
12 YEL
5A
16 BLU
12 BLU
16 BRN
L59
L32
RIGHT FRONT
TURN SIGNAL
RIGHT REAR
TURN/BRAKE LIGHT
ES0447A
6-5
Section 6 Schematics
June 2007
REV B
STARTER
85
86
LIFT PUMP
RELAY
CR1
STARTER
RELAY
16 RED/BLK
CR15
A
12 YEL
50A
12 PUR
16 BRN
16 BLU
12 RED
16 BLU
12 BLK
16 BLK
12 RED
16 YEL
12 BLK
16 BLK
12 RED
16 GRN
12 BLK
16 BLK
16 GRN
12 BLK
12 BLK
CLUTCH CUT-OFF
PRESSURE SWITCH
DIRECTION GEAR
1
FORWARD
TRANSMISSION
SHIFT COILS
12 GRN
16 BLK
PS4
D
M4
12 PUR
16 BRN
12 BLK
30
20A
CB3
16 GRY
12 RED
16 YEL
COLD START
85 RELAY
87
86
30
F9
16 RED/BLK
8 BLK
12 WHT
CR94
87
M3
M4
INJECTION PUMP
ADVANCE SENDER
16 GRN/WHT
16 RED
FUEL PUMP
GLOW PLUGS
16 WHT
S1B
8 RED
U32
12 RED/WHT
B1
16 RED/WHT
16 RED
8 RED
2/0 BLK
2/0 RED
12 RED
D1
16 ORN
Q7
BATTERY
ALTERNATOR
Y66
REVERSE
DESTROKE
COIL
COILS
ACTIVATED
ADE
AE
BDE
BE
B
12 BLK
12 BLK
8 RED
8 RED
12 WHT
12 WHT
16 RED/WHT
WIRE COLOR
LEGEND
16 WHT
16 ORN
16 GRN
16 GRN
S12
WHT / WHITE
TRANSMISSION
PRESSURE
SENDER
RED / RED
BLK / BLACK
16 BLU
16 BLU
S1
ENGINE COOLANT
TEMPERATURE SENDER
S2
16 GRY
16 GRY
16 YEL
S11
BLU / BLUE
YEL / YELLOW
16 BRN
TRANSMISSION
TEMPERATURE
SENDER
BRN / BROWN
16 PINK
GRN / GREEN
ORN / ORANGE
GRY / GRAY
16 BLU/WHT
PUR / PURPLE
TAN / TAN
LT BLU / LIGHT BLUE
16 BLK
12 RED
16 GRY
H3
16 TAN
12 RED
BACK-UP
ALARM
16 WHT
16 PUR
16 BRN/WHT
16 WHT 16 WHT
16 BRN/WHT
12 PUR
BACK-UP
LIGHT
L61
16 RED
12 PUR
12 GRY
16 WHT
12 BLU
16 BLK
PS5
BRAKE LIGHTS
PRESSURE SWITCH
16 BLK
BRAKE/TAIL LIGHT
16 WHT
PARKING BRAKE
PRESSURE
SWITCH
BN100
FORK TILT
BUTTON
FORK TILT
12 RED
Y77
16 BLK
Y72A
Y72B
FORK TILT
COIL
FORK TILT
COIL
20 RED
30
85
16 PUR
16 PUR
16 BLK
16 BLK
Y70
CR5
HORN
30
85
86
Y71
SWAY RIGHT (BLK WIRE)
87A
87
86
20 BLK
87A
87
16 BLK
FUEL
SENDER
PS6
CR90
CONTROLLER
RELIEF
16 TAN
16 ORG
S13
16 BLK
12 BLK
12 BLK
12 RED
16 PINK
12 BLK
12 RED
12 BLU (UNUSED)
16 BLK
16 PUR
MODELS
WITH
SINGLE JOYSTICK
12 GRY (UNUSED)
16 RED
16 BRN/WHT
12 RED
16 BLK
12 RED
16 GRY
16 YEL
16 RED
16 RED
12 RED
L62
H2
MODELS
WITH
SINGLE
JOYSTICK
HORN
ES0445A
6-6
Section 6 Schematics
June 2007
REV B
L30
HEAD LIGHTS
CR22
TS18
16 BRN
14 WHT
16 BLU
16 BLK
12 BLK
16 YEL
16 RED
12 BLK
16 RED
87
CR88
SW23
8 RED
+
BAT.
TRANS
CONTROL
12 RED
40A
ACC.
BAT
ACC
ST
12 GRN
16 BLK
85
16 WHT
86
IGN
12 WHT
M9
87
30
KS3
16 BLK
CB2
16 YEL
FUSE BLOCK
RELAY
14 WHT
1 7 8
CR89
KEY SWITCH
PARKING
BRAKE
RELAY
8 YEL
16 ORN
12 YEL
16 BRN/WHT
16 GRN
16 RED
16 BLK
HEAD LIGHT
SWITCH
12 BLK
12 YEL
12 YEL
16 RED
16 BLK
85 16 GRN
86
30
SW38 HEATER
HEATER FAN
16 RED (LOW)
16 PUR
16 ORN (HIGH)
16 ORN
CAB HEATER
(OPTION)
16 BRN
16 RED 16 BRN
M11
8 RED
CIRCULATION FAN
87A
16 BLK
16 BLK
16 ORN
86
L64
PARKING BRAKE ON
12 BLK
85
12 WHITE
30
16 RED
16 RED/WHT
12 GRY
G9
TP
G3
ET
G2
EP
G6
HM
16 RED
16 PUR
16 RED
12 WHT
16 RED
12 RED
16 RED
8 RED
20A
20A
5A
20A
10A
10A
5A
10A
10A
10A
16 BRN
12 YEL
16 PUR
16 ORN
16 YEL
12 BLU
5A
16 ORN
FUSE BOX
16 GRN
FR AXLE
16 GRY
G10
16 BRN
TT
G1
16 RED
16 RED
16 YEL
12 PUR
16 BLK
16 RED
16 BLU
U35
12 BLK
16 YEL
16 BLK
12V
ACCESSORY
Y68
G11
FRONT AXLE
DIFFERENTIAL
LOCK (OPTION)
FL
BN3
16 BLK
16 BLU/WHT
COLD
START
16 BLU/WHT
16 BLU/WHT
16 BRN/WHT
PUMP DESTROKE
12 GRY
12 BLU
AUXILIARY CONTROL
SW35
BN99
16 WHT
12 GRY
PS5
SW34
P FLASHER
L
16 YEL
16 GRY/BLK
SW37
16 GRY
L31
16 BLK
16 RED
16 BLK
16 RED
LEFT REAR
TURN/BRAKE LIGHT
U34
16 GRY - HOT
16 GRY
BRAKE LIGHTS
PRESSURE
SWITCH
SWAY CONTROL
16 PUR
16 BLK
16 GRY / WHT
16 BLK
16 RED
TURN SWITCH
L60
16 RED
12 PUR
FB1
STROBE LIGHT
16 BLU
TAIL-LIGHT
16 ORN
16 GRN
HORN RELAY
16 BRN/WHT
16 BLK
16 BLK
16 PUR
SW36
WIPER
16 RED
BN5
HORN
16 GRY
16 BRN
16 BLU
16 TAN
16 GRY
12 RED
16 BLK
M10
FRONT WIPER
P
LEFT FRONT
TURN SIGNAL
16 RED
16 BLK
16 BRN/WHT
L59
L32
RIGHT FRONT
TURN SIGNAL
RIGHT REAR
TURN/BRAKE LIGHT
MODELS
WITH
SINGLE
JOYSTICK
ES0445A
6-7
Section 6 Schematics
June 2007
Electrical Schematic GTH-644, GTH-842 and GTH-844 with John Deere Power
Page 1 of 2
BATTERY
ALTERNATOR
D1
REV C
2/0 BLK
2/0 RED
12 RED
16 RED
B1
16 WHT
16 GRY
12 RED
16 BRN
12 BLK
16 BLK
16 BRN
16 BLU
16 YEL
FUEL PUMP
M3
12 WHT
8 BLK
M4
16 WHT
16 RED
8 RED
STARTER
12 WHT
12 GRN
E
12 PUR
16 BLK
12 RED
16 YEL
12 BLK
16 BLK
12 RED
16 GRN
12 BLK
16 BLK
16 GRN
12 BLK
12 BLK
CLUTCH CUT-OFF
PRESSURE SWITCH
DESTROKE COIL
STARTER
RELAY
16 BLU
12 BLK
PS4
D
8 RED
CR1
12 RED
DIRECTION GEAR
1
FORWARD
Y66
TRANSMISSION
SHIFT COILS
REVERSE
12 PUR
COILS
ACTIVATED
ADE
AD
BDE
BD
B
12 BLK
12 BLK
8 RED
WIRE COLOR
LEGEND
12 WHT
16 GRN
WHT / WHITE
16 ORN
16 GRN
16 BLU
RED / RED
BLK / BLACK
16 BLU
16 GRY
16 GRY
BLU / BLUE
YEL / YELLOW
16 YEL
16 BRN
BRN / BROWN
16 BRN
GRN / GREEN
16 LT BLU
ORN / ORANGE
GRY / GRAY
PUR / PURPLE
12 RED
16 TAN
16 GRY
16 WHT
TAN / TAN
LT BLU / LIGHT BLUE
16 PUR
16 BRN/WHT
12 PUR
12 GRY (UNUSED)
12 BLU (UNUSED)
16 BLK
BACK-UP
ALARM
16 PINK
H3
16 RED
LOW
BRAKE
PRESSURE
87A
86
87
16 PINK
16 LT BLU
12 GRY
PARKING BRAKE
VALVE
16 RED
Y67
H2
HORN
12 BLU
16 BLK
12 YEL
RIGHT
Y71 SWAY
(BLK WIRE)
L63
30
85
16 BLK
12 BLK
12 RED
LEFT
Y70 SWAY
(WHT WIRE)
FUEL
SENDER
16 RED
16 GRY
16 BRN/WHT
S13
16 WHT
16 RED
16 BLK
HORN
16 BLK
L62
12 RED
BRAKE/TAIL LIGHT
PS6
PARKING BRAKE
PRESSURE
SWITCH
CR5
16 BLK
12 BLK
PS5
16 ORG
16 PUR
16 BLK
16 BLK
BRAKE LIGHTS
PRESSURE SWITCH
16 PUR
16 PUR
16 TAN
16 YEL
16 BLK
12 BLK
16 RED
16 BLK
16 WHT
L61
16 WHT
16 GRY
16 WHT
BACK-UP
LIGHT
12 YEL
16 WHT
PS7
SERVICE BRAKE
LOW PRESSURE
SWITCH
FORK TILT
CR90
12 RED
BN100
12 RED
12 RED
12 BLK
12 BLK
12 RED
FORK TILT
20 BLK
FORK TILT
COILS
Y72A
SW35
87
86
16 BLK
87A
Y72B
85
20 RED
30
SW34
AUXILIARY
CONTROL
SWAY
CONTROL
ES0446A
6-8
Section 6 Schematics
June 2007
Electrical Schematic GTH-644, GTH-842 and GTH-844 with John Deere Power
Page 2 of 2
REV C
L30
HEAD LIGHTS
CR22
TS18
16 BRN
14 WHT
16 BLU
16 BLK
12 BLK
16 YEL
16 RED
12 BLK
16 RED
87
CR88
SW23
8 RED
12 RED
BAT.
TRANS
CONTROL
40A
BAT
ACC.
ACC
ST
12 GRN
16 BLK
85
16 WHT
86
IGN
12 WHT
M9
87
30
KS3
16 BLK
CB2
16 YEL
FUSE BLOCK
RELAY
14 WHT
1 7 8
CR89
KEY SWITCH
PARKING
BRAKE
RELAY
8 YEL
12 YEL
16 BRN/WHT
16 GRN
16 RED
16 BLK
HEAD LIGHT
SWITCH
12 BLK
12 YEL
12 YEL
16 RED
16 BLK
85 16 GRN
86
30
SW38 HEATER
HEATER FAN
16 RED (LOW)
16 PUR
16 ORN (HIGH)
16 ORN
CAB HEATER
(OPTION)
16 BRN
16 RED 16 BRN
M11
8 RED
CIRCULATION FAN
87A
16 BLK
16 ORN
86
85
12 RED
30
G9
12 WHT
TP
G3
ET
G2
EP
G6
HM
16 RED
12 RED
16 RED
8 RED
16 RED
16 RED
16 RED
12 BLK
16 PUR
12 GRY
12 WHT
16 ORN
16 GRN
G10
16 BRN
16 LT BLU
TT
G1
16 RED
16 RED
20A
10A
10A
5A
10A
10A
10A
16 BRN
12 YEL
16 PUR
16 ORN
16 YEL
12 BLU
FUSE BOX
FR AXLE
G11
12 PUR
U35
12 BLK
16 YEL
16 BLK
12V
ACCESSORY
FL
Y68
12 RED
16 TAN
HORN
16 PUR
HORN RELAY
16 BRN/WHT
TAIL-LIGHT
12 PUR
PUMP DESTROKE
BN5
20A
5A
5A
12 YEL
16 RED
16 GRY
16 YEL
16 BLK
16 BLU
20A
16 WHT
FRONT AXLE
DIFFERENTIAL LOCK
(STANDARD ON 842,844)
(OPTIONAL ON 644)
16 BLK
BN3
16 BLK
COLD START
COLD START (ETHER AID)
(JOHN DEERE MODELS)
16 BRN/WHT
FRONT WIPER
P
16 GRY
SW36
WIPER
16 ORN
16 GRY / WHT
FB1
16 PINK
STROBE LIGHT
12 YEL
16 RED
16 PUR
16 BLK
16 YEL
16 GRY/BLK
16 BLK
16 RED
16 BLK
16 GRN
TURN SWITCH
L60
LEFT FRONT
TURN SIGNAL
16 BRN/WHT
Y69
L59
BOOM ACTUATED
LOCK-UP VALVE
L32
NC
12 YEL
12 GRY
NO
COM
RIGHT FRONT
TURN SIGNAL
RIGHT REAR
TURN/BRAKE LIGHT
12 RED
Y84
BOOM ACTUATED
SWAY LOCK-UP
16 RED
12 BLK
16 BLK
12 GRY
6
8
16 RED
SW37
LEFT REAR
TURN/BRAKE LIGHT
12 BLK
16 BLU
16 GRY - HOT
L31
12 GRY
P FLASHER
L
16 GRY
PS5
BRAKE LIGHTS
PRESSURE
SWITCH
U34
16 RED
(INTERNAL CONNECTION)
16 BRN
16 BLU
12 BLK
16 BLK
16 RED
M10
12 GRY
12 BLK
16 BLK
16 GRY / WHT
16 BLK
BN99
SW24
LS2
ES0446A
6-9
Section 6 Schematics
June 2007
REV B
M3
86
85
LIFT PUMP
RELAY
86
30
CR15
COLD START
85 RELAY
87
CR1
STARTER
RELAY
16 RED/BLK
30
12 YEL
50A
12 PUR
16 BRN
16 BLU
12 RED
16 BLU
12 BLK
16 BLK
12 RED
16 YEL
12 BLK
16 BLK
12 RED
16 GRN
12 BLK
16 BLK
16 GRN
12 BLK
12 BLK
CLUTCH CUT-OFF
PRESSURE SWITCH
DIRECTION GEAR
1
FORWARD
TRANSMISSION
SHIFT COILS
12 GRN
16 BLK
M4
12 PUR
16 BRN
12 BLK
PS4
D
20A
CB3
16 GRY
12 RED
16 YEL
F9
16 RED/BLK
12 WHT
8 BLK
M4
CR94
87
16 WHT
STARTER
INJECTION PUMP
ADVANCE SENDER
16 GRN/WHT
16 RED
FUEL PUMP
GLOW PLUGS
16 WHT
S1B
8 RED
U32
12 RED/WHT
B1
16 RED/WHT
16 RED
8 RED
2/0 BLK
2/0 RED
12 RED
D1
16 ORN
Q7
BATTERY
ALTERNATOR
Y66
REVERSE
DESTROKE
COIL
COILS
ACTIVATED
ADE
AD
BDE
BD
B
12 BLK
12 BLK
8 RED
8 RED
12 WHT
12 WHT
16 RED/WHT
WIRE COLOR
LEGEND
16 WHT
16 ORN
16 GRN
16 GRN
S12
WHT / WHITE
TRANSMISSION
PRESSURE
SENDER
RED / RED
BLK / BLACK
16 BLU
16 BLU
S1
ENGINE COOLANT
TEMPERATURE SENDER
S2
16 GRY
16 GRY
16 YEL
S11
BLU / BLUE
YEL / YELLOW
16 BRN
16 LT BLU
TRANSMISSION
TEMPERATURE
SENDER
BRN / BROWN
GRN / GREEN
ORN / ORANGE
16 BLU/WHT
GRY / GRAY
PUR / PURPLE
12 RED
16 GRY
TAN / TAN
16 TAN
16 PUR
16 BRN/WHT
16 BRN/WHT
16 BLK
H3
12 PUR
12 PUR
BACK-UP
ALARM
16 WHT
16 RED
16 WHT 16 WHT
16 RED
16 WHT
16 BLK
PS5
16 PUR
87A
Y71
S13
FUEL
SENDER
12 BLK
16 BLK
FORK TILT
Y72A
FORK TILT
COIL
Y72B
FORK TILT
COIL
16 LT BLU
16 RED
PARKING BRAKE
VALVE
HORN
BN100
12 GRY
SW35
SERVICE BRAKE
LOW PRESSURE
SWITCH
AUXILIARY
CONTROL
Y67
H2
SWAY RIGHT
(BLK WIRE)
12 BLK
16 PINK
12 YEL
SWAY LEFT
(WHT WIRE)
LOW
BRAKE
PRESSURE
PS7
86
16 BLK
87
Y70
PARKING BRAKE
PRESSURE
SWITCH
30
85
12 BLU
HORN
16 RED
16 BLK
12 BLU (UNUSED)
L63
PS6
16 BLK
16 BLK
CR5
12 YEL
12 RED
16 BLK
16 PINK
16 WHT
12 GRY (UNUSED)
16 PUR
16 BRN/WHT
16 TAN
16 BLK
16 YEL
16 GRY
16 BLK
16 RED
12 BLK
L62
16 WHT
BRAKE/TAIL LIGHT
16 RED
BRAKE LIGHTS
PRESSURE SWITCH
16 ORG
L61
16 PUR
BACK-UP
LIGHT
CR90
FORK TILT
20 BLK
87
86
16 BLK
87A
85
20 RED
30
SW34
SWAY
CONTROL
ES0444A
6 - 10
Section 6 Schematics
June 2007
REV B
L30
HEAD LIGHTS
CR22
TS18
16 BRN
14 WHT
16 BLU
16 BLK
12 BLK
16 YEL
16 RED
12 BLK
16 RED
87
CR88
SW23
8 RED
12 RED
BAT.
TRANS
CONTROL
40A
BAT
ACC.
ACC
ST
12 GRN
16 BLK
85
16 WHT
86
IGN
12 WHT
M9
87
30
KS3
16 BLK
CB2
16 YEL
FUSE BLOCK
RELAY
14 WHT
1 7 8
CR89
KEY SWITCH
PARKING
BRAKE
RELAY
8 YEL
12 YEL
16 BRN/WHT
16 GRN
16 RED
16 BLK
HEAD LIGHT
SWITCH
12 BLK
12 YEL
12 YEL
16 RED
16 BLK
85 16 GRN
86
30
SW38 HEATER
HEATER FAN
16 RED (LOW)
16 PUR
16 ORN (HIGH)
16 ORN
CAB HEATER
(OPTION)
16 BRN
16 RED 16 BRN
M11
8 RED
CIRCULATION FAN
87A
16 BLK
16 ORN
86
85
12 RED
30
12 WHT
16 PUR
16 RED/WHT
12 GRY
TP
G3
ET
G2
EP
G6
HM
12 WHT
G9
16 RED
12 RED
16 RED
8 RED
16 RED
16 RED
16 RED
12 BLK
16 ORN
20A
20A
5A
20A
10A
10A
5A
10A
10A
10A
16 BRN
12 YEL
16 PUR
16 ORN
16 YEL
12 BLU
5A
FUSE BOX
16 GRN
G10
16 BRN
16 LT BLU
TT
G1
16 RED
16 RED
16 YEL
16 BLK
16 RED
16 GRY
12 YEL
FR AXLE
16 BLU
12 PUR
U35
12 BLK
16 YEL
16 BLK
12V
ACCESSORY
Y68
G11
FRONT AXLE
DIFFERENTIAL LOCK
(STANDARD ON 842,844)
(OPTIONAL ON 644)
FL
BN3
16 BLK
16 BLU/WHT
16 BLU/WHT
COLD
START
16 BLU/WHT
16 BRN/WHT
HORN
16 PUR
HORN RELAY
16 BRN/WHT
TAIL-LIGHT
12 PUR
PUMP DESTROKE
M10
16 BLK
FRONT WIPER
P
16 GRY / WHT
16 GRY
12 GRY
FB1
STROBE LIGHT
SW24
SW36
WIPER
16 ORN
16 BRN
16 BLU
16 RED
16 PUR
16 BLK
P FLASHER
L
16 PINK
16 YEL
16 GRY/BLK
SW37
12 YEL
L31
16 RED
12 BLK
16 BLK
12 GRY
12 BLK
16 RED
12 GRY
16 BLK
LEFT REAR
TURN/BRAKE LIGHT
4
16 GRN
PS5
BRAKE LIGHTS
PRESSURE
SWITCH
16 GRY / WHT
16 BLK
12 BLK
(INTERNAL CONNECTION)
16 BLU
16 GRY - HOT
16 BLK
U34
12 BLK
16 RED
BN99
TURN SWITCH
5
16 GRY
BN5
L60
16 RED
16 TAN
16 BLK
12 RED
LEFT FRONT
TURN SIGNAL
16 RED
Y69
L59
BOOM ACTUATED
LOCK-UP VALVE
NC
12 YEL
12 GRY
NO
L32
12 RED
Y84
BOOM ACTUATED
SWAY LOCK-UP
16 BLK
16 BRN/WHT
COM
RIGHT FRONT
TURN SIGNAL
RIGHT REAR
TURN/BRAKE LIGHT
LS2
ES0444A
6 - 11
Section 6 Schematics
June 2007
BATTERY
ALTERNATOR
D1
REV B
2/0 BLK
2/0 RED
12 RED
16 RED
B1
16 WHT
16 GRY
12 RED
16 BRN
12 BLK
16 BLK
16 BRN
16 BLU
16 YEL
16 RED
12 WHT
8 RED
Q8
STARTER
M3
12 BLK
12 BLK
12 BLK
FUEL
ENRICHMENT
1
8 BLK
12 WHT
12 GRN
E
12 PUR
STARTER
RELAY
16 BLK
12 RED
16 YEL
12 BLK
16 BLK
12 RED
16 GRN
12 BLK
16 BLK
16 GRN
12 BLK
12 BLK
CLUTCH CUT-OFF
PRESSURE SWITCH
DESTROKE COIL
8 RED
CR1
16 BLU
12 BLK
PS4
Q7
12 RED
DIRECTION GEAR
1
FORWARD
Y66
TRANSMISSION
SHIFT COILS
REVERSE
12 PUR
COILS
ACTIVATED
ADE
AD
BDE
BD
B
12 BLK
12 BLK
8 RED
WIRE COLOR
LEGEND
12 WHT
16 GRN
WHT / WHITE
16 ORN
16 GRN
16 BLU
RED / RED
BLK / BLACK
16 BLU
16 GRY
16 GRY
BLU / BLUE
YEL / YELLOW
16 YEL
16 BRN
BRN / BROWN
16 BRN
GRN / GREEN
16 LT BLU
ORN / ORANGE
GRY / GRAY
PUR / PURPLE
12 RED
16 TAN
16 GRY
16 WHT
TAN / TAN
LT BLU / LIGHT BLUE
16 PUR
16 BRN/WHT
12 PUR
12 GRY (UNUSED)
12 BLU (UNUSED)
16 BLK
BACK-UP
ALARM
16 PINK
H3
16 RED
LOW
BRAKE
PRESSURE
87A
86
87
16 PINK
16 LT BLU
12 GRY
PARKING BRAKE
VALVE
16 RED
Y67
H2
HORN
12 BLU
16 BLK
12 YEL
RIGHT
Y71 SWAY
(BLK WIRE)
L63
30
85
16 BLK
12 BLK
12 RED
LEFT
Y70 SWAY
(WHT WIRE)
FUEL
SENDER
16 RED
16 GRY
16 BRN/WHT
S13
16 WHT
16 RED
16 BLK
HORN
16 BLK
L62
12 RED
BRAKE/TAIL LIGHT
PS6
PARKING BRAKE
PRESSURE
SWITCH
CR5
16 BLK
12 BLK
PS5
16 ORG
16 PUR
16 BLK
16 BLK
BRAKE LIGHTS
PRESSURE SWITCH
16 PUR
16 PUR
16 TAN
16 YEL
16 BLK
12 BLK
16 RED
16 BLK
16 WHT
BACK-UP
LIGHT
16 WHT
16 GRY
16 WHT
L61
12 YEL
16 WHT
PS7
SERVICE BRAKE
LOW PRESSURE
SWITCH
FORK TILT
CR90
12 RED
BN100
12 RED
12 RED
12 BLK
12 BLK
12 RED
FORK TILT
20 BLK
FORK TILT
COILS
Y72A
SW35
87
86
16 BLK
87A
Y72B
85
20 RED
30
SW34
AUXILIARY
CONTROL
SWAY
CONTROL
ES0448A
6 - 12
Section 6 Schematics
June 2007
REV B
L30
HEAD LIGHTS
CR22
TS18
16 BRN
14 WHT
16 BLU
16 BLK
12 BLK
16 YEL
16 RED
12 BLK
16 RED
87
CR88
SW23
8 RED
12 RED
BAT.
TRANS
CONTROL
40A
BAT
ACC.
ACC
ST
12 GRN
16 BLK
85
16 WHT
86
IGN
12 WHT
M9
87
30
KS3
16 BLK
CB2
16 YEL
FUSE BLOCK
RELAY
14 WHT
1 7 8
CR89
KEY SWITCH
PARKING
BRAKE
RELAY
8 YEL
12 YEL
16 BRN/WHT
16 GRN
16 RED
16 BLK
HEAD LIGHT
SWITCH
12 BLK
12 YEL
12 YEL
16 RED
16 BLK
85 16 GRN
86
30
SW38 HEATER
HEATER FAN
16 RED (LOW)
16 PUR
16 ORN (HIGH)
16 ORN
CAB HEATER
(OPTION)
16 BRN
16 RED 16 BRN
M11
8 RED
CIRCULATION FAN
87A
16 BLK
16 ORN
86
85
12 RED
30
G9
12 WHT
TP
G3
ET
G2
EP
G6
HM
16 RED
12 RED
16 RED
8 RED
16 RED
16 RED
16 RED
12 BLK
16 PUR
12 GRY
12 WHT
16 ORN
16 GRN
G10
16 BRN
16 LT BLU
TT
G1
16 RED
16 RED
20A
10A
10A
5A
10A
10A
10A
16 BRN
12 YEL
16 PUR
16 ORN
16 YEL
12 BLU
FUSE BOX
FR AXLE
G11
12 PUR
U35
12 BLK
16 YEL
16 BLK
12V
ACCESSORY
FL
Y68
12 RED
16 TAN
HORN
16 PUR
HORN RELAY
16 BRN/WHT
TAIL-LIGHT
12 PUR
PUMP DESTROKE
BN5
20A
5A
5A
12 YEL
16 RED
16 GRY
16 YEL
16 BLK
16 BLU
20A
FRONT AXLE
DIFFERENTIAL LOCK
(STANDARD ON 842,844)
(OPTIONAL ON 644)
16 BLK
16 BRN/WHT
FRONT WIPER
12 BLK
(INTERNAL CONNECTION)
16 GRY
SW36
WIPER
16 ORN
16 BRN
16 BLU
12 BLK
16 BLK
16 GRY / WHT
FB1
16 PINK
STROBE LIGHT
12 YEL
16 RED
16 PUR
16 BLK
16 YEL
16 GRY/BLK
16 BLK
16 RED
16 BLK
16 GRN
TURN SWITCH
L60
LEFT FRONT
TURN SIGNAL
16 BRN/WHT
Y69
L59
BOOM ACTUATED
LOCK-UP VALVE
L32
NC
12 YEL
12 GRY
NO
COM
RIGHT FRONT
TURN SIGNAL
RIGHT REAR
TURN/BRAKE LIGHT
12 RED
Y84
BOOM ACTUATED
SWAY LOCK-UP
16 RED
12 BLK
16 BLK
12 GRY
6
8
16 RED
SW37
LEFT REAR
TURN/BRAKE LIGHT
12 BLK
16 BLU
16 GRY - HOT
L31
12 GRY
P FLASHER
L
16 GRY
PS5
BRAKE LIGHTS
PRESSURE
SWITCH
U34
16 RED
SW24
16 RED
M10
12 GRY
16 BLK
16 GRY / WHT
16 BLK
BN99
LS2
ES0448A
6 - 13
Section 6 Schematics
June 2007
REV C
16 YEL
REV
FWD
10 BLK
10 RED
8 BLK
10A
8 RED
REVERSE
U31
UR
ENGINE
ECM
Y66
16 GRN/WHT
16 BLU/WHT
390 OHM
RESISTOR
F2
R21
R2
R
16 P
12 PUR
12 PUR
12 RED
BLU / BLUE
12 GRN
DESTROKE COIL
BLK / BLACK
TRANS
CONTROL
COILS
ACTIVATED
F21
DIRECTION GEAR
FORWARD
STARTER
RELAY
SW23
16 WHT
STARTER
CR1
3 2 8
16 GRY
AMP
F19 10
FUSE
WHT / WHITE
16 BLK
12 BLK
RED / RED
16 BLU
16 YEL
BATTERY
WIRE COLOR
LEGEND
16 RED
8 RED
M3
16 BLK
16 BRN
16 BLK
12 BLK
16 GRN
B1
16 GRN
16 BLK
16 BRN
2/0 BLK
2/0 RED
16 RED
1 ST
16 BLK
CLUTCH
CUT-OFF
PRESSURE
SWITCH
ALTERNATOR
12 RED
D1
16 BLU
PS4
2 ND
16 BRN/WHT
16 GRY/WHT
16 ORN/WHT
12 RED/BLK
12 RED/WHT
390 OHM
RESISTOR
S 16 WHT
C 16 YEL/WHT
L
YEL / YELLOW
16 GRN/WHT
M 16 BLU/WHT
BRN / BROWN
P 16 BRN/WHT
GRN / GREEN
N 16 GRY/WHT
ORN / ORANGE
H 16 ORN/WHT
GRY / GRAY
PUR / PURPLE
TAN / TAN
12 RED
16 RED
G 12 RED/BLK
D 12 RED/WHT
16 RED/WHT
16 RED/WHT
16 GRN
16 ORN
16 GRN
16 BLU
16 BLU
16 GRY
16 GRY
16 YEL
16 BRN
16 BRN
12 RED
12 RED
16 TAN
16 PUR
16 BRN/WHT
12 PUR
12 GRY
12 GRY
12 BLU
12 BLU
16 BLK
PS5
FORK TILT
BUTTON
12 RED
12 BLK
16 BRN/WHT
CR90
Y77
12 BLK
CONTROLLER
RELIEF VALVE
FORK TILT
COILS
Y72A
30
16 BLK
87A
85
Y72B
20 RED
86 20 BLK
16 WHT
MODELS
WITH
SINGLE
JOYSTICK
86
85
87
16 BLK
16 BLK
16 BLK
FORK TILT
12 RED
16 BLK
16 PUR
87A
BN100
12 BLK
12 RED
16 BLK
CR5
HORN
30
16 GRY
16 PNK
L62
FUEL
SENDER
PARKING BRAKE
PRESSURE
SWITCH
12 BLK
BRAKE/TAIL
LIGHT
16 RED
S13
PS6
BRAKE LIGHTS
PRESSURE SWITCH
16 TAN
16 RED
16 WHT
16 PUR
16 RED
16 BLK
L61
16 WHT
16 PUR
16 WHT
BACK-UP
LIGHT
16 ORG
16 BLK
16 WHT
16 GRY
H3
16 YEL
16 BLK
BACK-UP
ALARM
H2
HORN
87
LEFT
Y70 SWAY
(WHT WIRE)
RIGHT
Y71 SWAY
(BLK WIRE)
12 RED
ES0450A
6 - 14
Section 6 Schematics
June 2007
REV C
14 WHT
16 BLK
12 RED/WHT
16 RED
12 RED/WHT
ACCELERATOR
PEDAL
A
B
C
16 YEL/WHT
L30
16 GRN/WHT
HEADLIGHTS
16 BLU/WHT
TS18
16 BRN/WHT
16 GRY/WHT
87
86
12 RED/BLK
30
KEY SWITCH
8 YEL
L65
PARKING BRAKE ON
CAB HEATER
(OPTION)
M11
CIRCULATION FAN
12 RED
30
G2
EP
G6
HM
16 RED
ET
16 RED
G3
12 RED
12 GRY
16 GRN
16 RED
16 GRY
16 RED
10A
10A
5A
10A
10A
10A
5A
FL
12 BLK
16 TAN
HORN
16 PUR
HORN RELAY
16 BRN/WHT
TAIL-LIGHT
12 PUR
PUMP DESTROKE
16 BLK
COLD START
COLD START (ETHER AID)
(JOHN DEERE MODELS)
M10
16 GRY / WHT
FRONT WIPER
P
16 GRY
STROBE LIGHT
12 GRY
12 BLK
12 BLK
Y84
BOOM ACTUATED
SWAY LOCK-UP
16 BRN
STABILIZER
VALVES
16 BLK
16 YEL
NC
12 YEL
16 BLK
NO
SW37
LEFT REAR
TURN/BRAKE LIGHT
TURN SWITCH
LEFT FRONT
TURN SIGNAL
L60
12 RED
Y74
12 GRY
16 BLK
L31
Y76
ES0450A
16 GRY/BLK
Y73
16 ORN
L.F. UP
16 YEL
16 GRY
12 GRY
BRAKE LIGHTS
PRESSURE
SWITCH
16 BLK
PS5
16 GRN
SW40
16 BLK
16 PUR
P FLASHER
L
16 GRY - HOT
BOOM ACTUATED
LOCK-UP VALVE
R.F. DOWN
16 BLK
U34
16 GRN
16 RED
Y69
16 PUR
16 BLK
16 BLK
SW40
16 ORN
16 RED
SW39
16 BRN/WHT
SW36
WIPER
16 GRY
FB1
12 YEL
16 PUR
L.F. DOWN
16 BRN
16 BLU
16 GRY
Y75
12 GRY
SW34
BN3
16 BLK
16 BRN/WHT
SW35
16 BLK
16 BLK
SWAY CONTROL
12 BLU
16 RED
16 BLK
16 YEL
16 WHT
FRONT AXLE
DIFFERENTIAL
LOCK (OPTION)
BN99
AUX. CONTROL
16 ORN
12V
ACCESSORY
Y68
12 RED
12 GRY
16 PUR
FR AXLE
BN5
12 YEL
12 PUR
12 YEL
G1
12 GRN
16 BRN
FUSE BOX
G11
16 RED
G10 TT
16 BRN
16 WHT
20A
16 BLK
16 BLU
12 BLU
20A
5A
16 PUR
12 WHT
16 ORN
16 RED
16 RED
TP
16 YEL
20A
16 RED
G9
16 BRN
16 RED 16 BRN
8 RED
16 RED/WHT
8 RED
SW38 HEATER
16 RED
L64
BLINK
CODE
LIGHT
PARKING
BRAKE
RELAY 87A
16 BLK
16 ORN
86
85
16 ORN
COM
LS2
R.F. UP
L32
RIGHT REAR
TURN/BRAKE LIGHT
16 RED
16 ORN
16 BLK
CR89
16 PUR
16 ORN (HIGH)
16 BLU
KS3
16 RED/WHT
16 RED (LOW)
16 BLK
IGN
BLINK
CODE
ENABLE
30
HEATER FAN
16 BLK
ST
M9
BN101
16 BRN/WHT
16 RED
ACC.
40A
16 BLK
85
ACC 16 WHT
16 GRN
16 GRN
BAT.
BAT
8 RED
12 RED
14 WHT
16 RED
CB2
12 RED
CR88
10A
16 RED
12 YEL
16 BLK
85
86
16 YEL
16 BLK
FUSE BLOCK
RELAY
10 AMP
FUSE
16 ORN/WHT
F18
12 RED/WHT
12 YEL
16 BRN/WHT
87
16 RED
16 BLK
16 RED
16 BRN/WHT
16 GRY/WHT
16 ORN/WHT
12 RED/BLK
12 YEL
CR22
HEAD LIGHT
SWITCH
L59
RIGHT FRONT
TURN SIGNAL
6 - 15
Section 6 Schematics
June 2007
REV B
M4
Y66
TRANS
CONTROL
FUEL
LIFT PUMP
16 WHT
12 PUR
12 GRN
12 RED
SW23
PS4
16 GRY
12 YEL
50A
12 BLK
3 2 8
CLUTCH
CUT-OFF
PRESSURE
SWITCH
20A
CB3
12 PUR
12 BLK
85
30
16 GRN/WHT
STARTER
RELAY
12 RED/WHT
16 RED/WHT
16 RED
8 BLK
16 RED/BLK
86
16 RED
16 BLK
CR1
87
85
30
16 BLK
16 BRN
16 BLU
16 YEL
F9
86
16 GRN
16 BLK
M4
87
M3
16 WHT
CR15
16 BLK
FUEL PUMP
STARTER
CR94
1 ST
16 BLK
8 RED
INJECTION PUMP
ADVANCE SENDER
2 ND
16 GRN
S1B
REV
FWD
GLOW PLUGS
16 BRN
B1
14 WHT
16 YEL
U32
16 BLU
16 RED
16 RED/BLK
12 RED
D1
2/0 BLK
2/0 RED
8 RED
BATTERY
ALTERNATOR
16 ORN
Q7
DESTROKE
COIL
COILS
ACTIVATED
F21
FORWARD
REVERSE
F2
R21
R2
R
16 BLU/WHT
12 BLK
12 BLK
8 RED
8 RED
12 WHT
12 WHT
16 RED/WHT
WIRE COLOR
LEGEND
16 ORN
16 GRN
16 GRN
S12
WHT / WHITE
RED / RED
TRANSMISSION
PRESSURE
SENDER
BLK / BLACK
BLU / BLUE
16 BLU
16 BLU
S1
ENGINE COOLANT
TEMPERATURE SENDER
S2
16 GRY
16 GRY
16 YEL
S11
YEL / YELLOW
BRN / BROWN
16 BRN
16 BRN
TRANSMISSION
TEMPERATURE
SENDER
GRN / GREEN
ORN / ORANGE
GRY / GRAY
12 RED
PUR / PURPLE
12 RED
16 TAN
TAN / TAN
LT BLU / LIGHT BLUE
16 PUR
16 BRN/WHT
12 PUR
12 GRY
12 GRY
12 BLU
12 BLU
16 BLK
16 BLK
PS5
FORK TILT
BUTTON
12 RED
12 BLK
16 BRN/WHT
CR90
Y77
12 BLK
CONTROLLER
RELIEF VALVE
FORK TILT
COILS
Y72A
30
16 BLK
87A
85
Y72B
20 RED
86 20 BLK
16 WHT
MODELS
WITH
SINGLE
JOYSTICK
86
85
87
16 BLK
16 BLK
16 BLK
FORK TILT
12 RED
16 BLK
16 PUR
87A
BN100
12 BLK
12 BLK
16 BLK
CR5
HORN
30
16 GRY
16 PNK
L62
FUEL
SENDER
PARKING BRAKE
PRESSURE
SWITCH
12 RED
BRAKE/TAIL
LIGHT
16 RED
S13
PS6
BRAKE LIGHTS
PRESSURE SWITCH
16 TAN
16 RED
16 WHT
16 PUR
16 RED
16 BLK
L61
16 WHT
16 PUR
16 WHT
BACK-UP
LIGHT
16 ORG
16 BLK
16 WHT
16 GRY
H3
16 YEL
BACK-UP
ALARM
H2
HORN
87
LEFT
Y70 SWAY
(WHT WIRE)
RIGHT
Y71 SWAY
(BLK WIRE)
12 RED
ES0449A
6 - 16
Section 6 Schematics
June 2007
REV B
14 WHT
16 BLK
12 BLK
16 RED
12 BLK
L30
HEADLIGHTS
TS18
12 YEL
CR22
HEAD LIGHT
SWITCH
87
CR88
KS3
KEY SWITCH
CB2
12 RED
BAT.
BAT
ACC.
40A
12 WHT
ACC
ST
86
IGN
30
12 GRN
16 RED/WHT
M9
16 BLK
85
16 WHT
16 RED/WHT
8 YEL
CR89
16 BLK
L64
PARKING BRAKE ON
16 RED (LOW)
16 PUR
16 ORN (HIGH)
16 ORN
12 RED
30
G2
EP
G6
HM
12 RED
16 RED
ET
16 RED
G3
20A
5A
20A
10A
10A
5A
10A
12 GRY
10A
10A
5A
5A
16 RED
16 GRY
16 RED
G1
12 YEL
16 PUR
16 ORN
16 YEL
12 BLU
FR AXLE
12 PUR
FL
12 BLK
Y68
12 YEL
G10 TT
16 BRN
16 BRN
FUSE BOX
G11
16 RED
16 YEL
12 GRN
16 BLK
16 BLU
CIRCULATION FAN
20A
16 PUR
16 GRN
16 BRN
M11
8 RED
12 WHT
16 ORN
16 RED
16 RED
TP
SW38 HEATER
16 RED 16 BRN
16 RED
G9
16 BRN/WHT
30
HEATER FAN
PARKING
BRAKE
RELAY 87A
16 BLK
16 ORN
86
85
16 ORN
16 GRN
CAB HEATER
(OPTION)
14 WHT
8 RED
FUSE BLOCK
87 RELAY
16 BLK
12 BLK
16 RED
12 YEL
16 BLK
85
86
16 YEL
16 BLU/WHT
12 YEL
16 BRN/WHT
16 RED
8 RED
16 RED
16 BLK
12V
ACCESSORY
FRONT AXLE
DIFFERENTIAL
LOCK (OPTION)
16 BLK
16 BLU/WHT
HORN RELAY
16 BRN/WHT
TAIL-LIGHT
12 PUR
PUMP DESTROKE
16 BLK
M10
16 GRY / WHT
BN99
P
16 GRY
SW35
FB1
12 YEL
STROBE LIGHT
Y84
BOOM ACTUATED
SWAY LOCK-UP
STABILIZER
VALVES
16 BLK
16 YEL
ES0449A
NC
12 YEL
NO
16 BLU
LEFT FRONT
TURN SIGNAL
L60
12 RED
16 BLK
12 GRY
Y74
TURN SWITCH
16 BLK
SW37
LEFT REAR
TURN/BRAKE LIGHT
Y73
Y76
L.F. UP
L31
16 RED
12 BLK
16 GRN
12 BLK
16 GRY/BLK
16 GRY
12 GRY
16 YEL
16 BLK
12 GRY
BRAKE LIGHTS
PRESSURE
SWITCH
16 BRN
16 ORN
P FLASHER
L
16 RED
PS5
16 GRN
SW40
16 BLK
16 PUR
U34
16 GRY - HOT
BOOM ACTUATED
LOCK-UP VALVE
R.F. DOWN
16 BLK
16 PUR
16 BLK
16 GRN
16 BRN/WHT
Y69
16 ORN
16 RED
SW39
16 PUR
16 ORN L.F. STABILIZER CONTROL
SW36
WIPER
16 GRY
16 BLK
SW34
L.F. DOWN
16 BRN
16 BLU
16 GRY
Y75
12 GRY
16 BLK
SWAY CONTROL
FRONT WIPER
16 RED
AUX. CONTROL
16 BLK
16 WHT
COLD
START
16 BRN/WHT
12 GRY
12 BLU
BN3
16 BLU/WHT
16 RED
16 PUR
BN5
COM
LS2
R.F. UP
L32
RIGHT REAR
TURN/BRAKE LIGHT
16 RED
HORN
16 BLK
16 TAN
16 BLK
12 RED
L59
RIGHT FRONT
TURN SIGNAL
6 - 17
6 - 18
PA
CA
RB
CB
TILT
CYLINDER
RC
BA
PB
TA
LIFT
CYLINDERS
UA
2000 psi
137.9 bar
QB
QA
P1
2800 psi
193 bar
PUMP
KB
MA
KD
0.060 in
1.5 mm
0.060 in
1.5 mm
3650 psi
251 bar
AD
LIFT
TILT
BOOM
RETURN FILTER
SWAY
DIRECTIONAL
VALVE
KC
KA
T1
AC
AB
AA
HYDRAULIC
TANK
PRESSURIZED
FILTER/BREATHER
3 psi / 0.2 bar
RA
EXTENSION
CYLINDER
FD
FA
FC
T3
OA
T2
T1
G2
ST
G4
CONTROLLER
RELIEF
(DROP BLOCK)
1 2 3
FB
GB
NOTE:
ITEM UA WAS REMOVED FROM
THE MACHINE AFTER SERIAL NUMBER
GTH0606A-9022
BK
G3
PR
G1
GA
4-WAY CONTROL
(JOYSTICK)
3
2
P
T
0.040 in
1 mm
FRONT AXLE
JA
2
SB
SA
RT
LT
P TO T = 2WS
P TO C2 = 4WS
P TO C1 = OBLIQUE
C1
STEERING
WHEEL
STEER LEGEND
STEERING
ORBITRAL
C2
LA
HOSE REEL
REAR AXLE
DIFFERENTIAL
LOCK
PARKING BRAKE
PRESSURE SWITCH
250 psi / 17 bar
NORMALLY CLOSED
BRAKE
ACTUATOR
PS6
ROTATE
VALVE
TRANSMISSION
ROTATE SPEED
EA
BRAKE
ACCUMULATOR
IA
PARKING BRAKE
REAR
STEER CYLINDER
STEER SELECTOR
FRONT
STEER CYLINDER
ROTATE
CYLINDER
BRAKE LIGHTS
PRESSURE SWITCH
NORMALLY OPEN
(OPTION)
PS5
PS4
CLUTCH CUTOFF
PRESSURE SWITCH
350 psi / 24 bar
NORMALLY CLOSED
Section 6 Schematics
June 2007
Hydraulic Schematic -
P1-1846
PA
CA
RB
CB
TILT
CYLINDER
RC
BA
PB
TA
LIFT
CYLINDERS
UA
2000 psi
137.9 bar
QB
QA
P1
2800 psi
193 bar
PUMP
KB
KC
KD
SWAY
DIRECTIONAL
VALVE
MA
RETURN FILTER
0.060 in
1.5 mm
0.060 in
1.5 mm
3650 psi
251 bar
AD
LIFT
TILT
BOOM
2
4
2
4
FD
FA
FC
T3
T2
1 2 3
FB
OA
T1
G2
ST
G4
CONTROLLER
RELIEF
(DROP BLOCK)
NOTE:
ITEM UA WAS REMOVED FROM
THE MACHINE AFTER SERIAL NUMBER
GTH0606A-9022
BK
G3
PR
G1
4-WAY CONTROL
(JOYSTICK)
3
2
P
T
0.040 in
1 mm
FRONT AXLE
JA
2
SB
SA
RT
LT
P TO T = 2WS
P TO C2 = 4WS
P TO C1 = OBLIQUE
C1
STEERING
WHEEL
STEER LEGEND
STEERING
ORBITRAL
C2
LA
HOSE REEL
REAR AXLE
DIFFERENTIAL
LOCK
PARKING BRAKE
PRESSURE SWITCH
250 psi / 17 bar
NORMALLY CLOSED
BRAKE
ACTUATOR
PS6
ROTATE
VALVE
TRANSMISSION
ROTATE SPEED
EA
BRAKE
ACCUMULATOR
IA
PARKING BRAKE
REAR
STEER CYLINDER
STEER SELECTOR
FRONT
STEER CYLINDER
ROTATE
CYLINDER
BRAKE LIGHTS
PRESSURE SWITCH
NORMALLY OPEN
(OPTION)
PS5
PS4
CLUTCH CUTOFF
PRESSURE SWITCH
350 psi / 24 bar
NORMALLY CLOSED
REV A
KA
T1
AC
AB
AA
HYDRAULIC
TANK
PRESSURIZED
FILTER/BREATHER
3 psi / 0.2 bar
RA
EXTENSION
CYLINDER
4-WAY CONTROL
(JOYSTICK)
June 2007
Section 6 Schematics
P1-1846
6 - 19
6 - 20
CB
RA
RC
GTH-644 GTH-842
MODELS
NA
CB
GTH-844
MODELS
CA
PA
CA
RB
TILT
CYLINDER
PB
TA
LIFT
CYLINDERS
BA
QB
QA
P1
3000 psi
207 bar
PUMP
MA
KD
SWAY
DIRECTIONAL
VALVE
KC
SWAY
CYLINDERS
KB
KA
RETURN FILTER
0.060 in
1.5 mm
0.060 in
1.5 mm
3650 psi
251 bar
AD
LIFT
TILT
BOOM
AC
AB
AA
HYDRAULIC
TANK
PRESSURIZED
FILTER/BREATHER
3 psi / 0.2 bar
EXTENSION
CYLINDER
T1
TANK
S2
S1
HE
G3
PR
P
A
HF
HH
G1
C1
HB
HD
T3
REAR LOCK-UP
MANIFOLD
HG
DA
BK
FD
FB
T1
G2
ST
R
T2
HA
HC
C2
G4
1 2 3 4
FC
GB
CONTROL BLOCK
MANIFOLD
FA
GA
4-WAY CONTROL
(JOYSTICK)
C4
C3
REAR
LOCK-UP
CYLINDERS
BRAKE
ACCUMULATOR
P
T
PS4
LA
SB
SA
LT
P TO T = 2WS
P TO C2 = 4WS
P TO C1 = OBLIQUE
C1
STEERING
WHEEL
STEER LEGEND
RT
C2
REAR
STEER CYLINDER
STEER SELECTOR
FRONT
STEER CYLINDER
ROTATE
CYLINDER
PS5
BRAKE LIGHTS
PRESSURE SWITCH
NORMALLY OPEN (OPTION)
FRONT AXLE
0.040 in
1 mm
STEERING
ORBITRAL
EA
ROTATE
SPEED
HOSE REEL
REAR AXLE
ROTATE
VALVE
JA
2
PARKING BRAKE
PRESSURE SWITCH
250 psi / 17 bar
NORMALLY CLOSED
BRAKE
ACTUATOR
PS6
DIFFERENTIAL
LOCK
PS7
TRANSMISSION
IA
PARKING BRAKE
Section 6 Schematics
June 2007
Hydraulic Schematic -
P1-1940
P1-1962
P1-1971
GTH-644 GTH-842
MODELS
NA
CB
GTH-844
MODELS
CB
RC
PB
TA
LIFT
CYLINDERS
BA
QB
QA
P1
3000 psi
207 bar
PUMP
KC
SWAY
CYLINDERS
KB
KA
KD
T1
0.060 in
1.5 mm
SWAY DIRECTIONAL VALVE
MA
RETURN FILTER
0.060 in
1.5 mm
3650 psi
251 bar
AD
LIFT
TILT
BOOM
AC
AB
AA
HYDRAULIC
TANK
PRESSURIZED
FILTER/BREATHER
3 psi / 0.2 bar
EXTENSION
CYLINDER
VA
TANK
S2
S1
HE
G3
PR
2
4
HF
HH
G1
C1
HB
HD
T3
FC
FB
T1
G2
ST
R
T2
HA
HC
C2
G4
1 2 3 4
REAR LOCK-UP
MANIFOLD
HG
DA
BK
FD
CONTROL BLOCK
MANIFOLD
FA
4-WAY CONTROL
(JOYSTICK)
C4
C3
REAR
LOCK-UP
CYLINDERS
BRAKE
ACCUMULATOR
P
T
PS4
LA
SB
SA
LT
P TO T = 2WS
P TO C2 = 4WS
P TO C1 = OBLIQUE
C1
STEERING
WHEEL
STEER LEGEND
RT
C2
REAR
STEER CYLINDER
STEER SELECTOR
FRONT
STEER CYLINDER
ROTATE
CYLINDER
PS5
BRAKE LIGHTS
PRESSURE SWITCH
NORMALLY OPEN (OPTION)
FRONT AXLE
0.040 in
1 mm
STEERING
ORBITRAL
EA
ROTATE
SPEED
HOSE REEL
REAR AXLE
ROTATE
VALVE
JA
2
PARKING BRAKE
PRESSURE SWITCH
250 psi / 17 bar
NORMALLY CLOSED
BRAKE
ACTUATOR
PS6
DIFFERENTIAL
LOCK
PS7
TRANSMISSION
IA
PARKING BRAKE
REV A
CA
PA
CA
RB
TILT
CYLINDER
RA
4-WAY CONTROL
(JOYSTICK)
June 2007
Section 6 Schematics
Hydraulic Schematic -
P1-1940
P1-1962
P1-1971
6 - 21
6 - 22
CB
PB
RC
TANK
NA
BA
QB
NB
LIFT
CYLINDERS
UA
QA
GTH-1048
3500 psi / 241 bar
GTH-1056
3000 psi / 207 bar
KA
3650 psi
251 bar
SWAY
CYLINDERS
MA
KC
SWAY
DIRECTIONAL
VALVE
KD
AD
LIFT
TILT
0.060 in
1.5 mm
0.060 in
1.5 mm
RETURN FILTER
PRESSURIZED
FILTER/BREATHER
3 psi / 0.2 bar
T1
BOOM
HYDRAULIC
TANK
P1
AC
AB
AA
PUMP
2500 psi
172.4 bar
TA
EXTENSION
CYLINDER
RA
OUTRIGGERS
PA
CA
RB
TILT
CYLINDER
TANK
S1
HE
GA
P
A
A
FORK
LEVEL
GB
S2
HF
HH
FD
FA
C3
HB
HD
C1
T3
FC
FB
HG
DA
BK
G3
PR
G1
OA
C4
T1
G2
ST
HA
HC
C2
T2
G4
12 3 4 5 6
CONTROLLER
RELIEF
(DROP BLOCK)
4-WAY CONTROL
(JOYSTICK)
REAR LOCK-UP
CYLINDERS
RT
LA
HOSE REEL
SB
SA
LT
P TO T = 2WS
P TO C2 = 4WS
P TO C1 = OBLIQUE
C2
STEER SELECTOR
REAR
STEER CYLINDER
C1
FRONT
STEER CYLINDER
STEERING
WHEEL
ROTATE
CYLINDER
BRAKE LIGHTS
PRESSURE SWITCH
NORMALLY OPEN
(OPTION)
PS5
PS4
CLUTCH CUTOFF
PRESSURE SWITCH
350 psi / 24 bar
NORMALLY CLOSED
0.040 in
1 mm
ROTATE
VALVE
STEER LEGEND
EA
REAR AXLE
ROTATE
SPEED
FRONT AXLE
PS6
PARKING BRAKE
PRESSURE SWITCH
250 psi / 17 bar
NORMALLY CLOSED
BRAKE
ACTUATOR
STEERING
ORBITRAL
BRAKE
ACCUMULATOR
IA
PARKING
BRAKE
JA
DIFFERENTIAL
LOCK
Section 6 Schematics
June 2007
Hydraulic Schematic -
P1-1871
CB
PB
RC
TANK
NB
LIFT
CYLINDERS
GTH-1048
3500 psi / 241 bar
GTH-1056
3000 psi / 207 bar
TA
KA
3650 psi
251 bar
SWAY
CYLINDERS
KC
AD
LIFT
TILT
0.060 in
1.5 mm
KD
0.060 in
1.5 mm
SWAY DIRECTIONAL VALVE
MA
RETURN FILTER
PRESSURIZED
FILTER/BREATHER
3 psi / 0.2 bar
T1
BOOM
HYDRAULIC
TANK
P1
AC
AB
AA
PUMP
2500 psi
172.4 bar
UA
QA
TANK
S1
HE
VA
2
4
3
1
S2
HF
HH
FD
FA
G1
C3
HB
HD
C1
T3
FC
FB
HG
DA
BK
G3
PR
OA
C4
T1
G2
ST
HA
HC
C2
T2
G4
12 3 4 5 6
CONTROLLER
RELIEF
(DROP BLOCK)
4-WAY CONTROL
(JOYSTICK)
REAR LOCK-UP
CYLINDERS
RT
LA
HOSE REEL
SB
SA
LT
P TO T = 2WS
P TO C2 = 4WS
P TO C1 = OBLIQUE
C2
STEER SELECTOR
REAR
STEER CYLINDER
C1
FRONT
STEER CYLINDER
STEERING
WHEEL
ROTATE
CYLINDER
BRAKE LIGHTS
PRESSURE SWITCH
NORMALLY OPEN
(OPTION)
PS5
PS4
CLUTCH CUTOFF
PRESSURE SWITCH
350 psi / 24 bar
NORMALLY CLOSED
0.040 in
1 mm
ROTATE
VALVE
STEER LEGEND
EA
REAR AXLE
ROTATE
SPEED
FRONT AXLE
PS6
PARKING BRAKE
PRESSURE SWITCH
250 psi / 17 bar
NORMALLY CLOSED
BRAKE
ACTUATOR
STEERING
ORBITRAL
BRAKE
ACCUMULATOR
IA
PARKING
BRAKE
JA
DIFFERENTIAL
LOCK
REV A
NA
BA
QB
EXTENSION
CYLINDER
RA
OUTRIGGERS
PA
CA
RB
TILT
CYLINDER
4-WAY CONTROL
(JOYSTICK)
June 2007
Section 6 Schematics
Hydraulic Schematic -
P1-1871
6 - 23
Section 6 Schematics
June 2007
6 - 24
California Proposition 65
Warning
The exhaust from this product
contains chemicals known to
the State of California to
cause cancer, birth defects
or other reproductive harm.
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Phone
Phone
Fax
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Distributed By:
Service Manual
GTH-636 GTH-842GTH-1048
GTH-644 GTH-844GTH-1056
Rev D
Part No.
97487