Terex Genie GTH-1056 Service And Repair Manual
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Terex Genie GTH-1056 Service And Repair Manual

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Service and Repair Manual
GTH
-1056
™
Serial Number Range
from GTH10E-16000
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
Part No. 1303145GT
Rev A
May 2021

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Summary of Contents for Terex Genie GTH-1056

  • Page 1 Service and Repair Manual Serial Number Range -1056 ™ from GTH10E-16000 This manual includes: Repair procedures Fault Codes Electrical and Hydraulic Schematics For detailed maintenance procedures, refer to the appropriate Maintenance Manual for your machine. Part No. 1303145GT Rev A May 2021...

  • Page 2: Introduction

    Copyright © 2018 by Terex Corporation 1303145GT Rev A, May 2021 Fifth Edition, First Printing Genie is a registered trademark of Terex South Dakota, Inc. in the U.S.A. and many other countries. "GTH" is a trademark of Terex South Dakota, Inc.
  • Page 3 May 2021 Service and Repair Manual Introduction Revision History Revision Date Section Procedure / Page / Description 5/2021 Initial Release Reference Examples: Electronic Version Section – Repair Procedure, 4-2 Click on any content or procedure in the Table of Contents to view Section –...

  • Page 4: Serial Number Legend

    Service and Repair Manual May 2021 Introduction Serial Number Legend 1 Model 2 Facility code 3 Sequence number 4 Serial label (located inside fork frame) 5 Serial number (stamped on chassis) 6 Serial label (located inside chassis) ™ -1056 Part No. 1303145GT...

  • Page 5: Safety Rules

    May 2021 Service and Repair Manual Safety Rules General Safety Rules Section 1 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.
  • Page 6 Service and Repair Manual May 2021 Safety Rules Workplace 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. Be sure to keep sparks, flames and lighted tobacco away from flammable and combustible materials like battery gases...

  • Page 7: Table Of Contents

    May 2021 Table of Contents Introduction Introduction ......................ii Important Information ..................... ii Find a Manual for this Model .................. ii Serial Number Legend ..................iv Section 1 Safety Rules ......................v General Safety Rules ..................... v Section 2 Specifications ....................... 1 Machine Specifications ...................
  • Page 8 May 2021 Table of Contents Section 3 Repair Procedures ..................... 15 Introduction ......................15 Boom Components .................... 17 1-1 Boom Proximity Switch .................. 17 How to Test a Proximity Switch ..............17 How to Adjust the Boom Angle Proximity Switch ........... 18 How to Adjust the Boom Extend Proximity Switch .........
  • Page 9 May 2021 Table of Contents Fuel and Hydraulic Tanks .................. 45 3-1 Fuel and HydraulicTanks ................45 Engines ........................ 47 4-1 Engines ......................47 How to Repair the Deutz TCD3.6 Engine ............47 4-2 Engine Fault Codes ..................47 Transmission ...................... 48 5-1 Transmission ....................
  • Page 10 May 2021 Table of Contents Section 4 Fault Codes ......................67 Introduction ......................67 Diagnostic Display ..................... 68 Diagnostic Display ....................68 Deutz TCD3.6 Engine Fault Codes ..............69 ECGenius 150 Transmission Fault Codes ............93 Section 5 Schematics ......................94 Introduction ......................

  • Page 11: Specifications

    May 2021 Service and Repair Manual Specifications Section 2 Specifications Machine Specifications Machine Specifications Fluid capacities Tires and wheels Fuel tank 30 gallons 113,6 liters Tire size 14.00 x 28 Hydraulic tank 27 gallons Tire ply rating 102,2 liters Weight, rough terrain tire 312.5 lbs Hydraulic system 52 gallons...

  • Page 12: Performance Specifications

    Service and Repair Manual May 2021 Specifications Performance Specifications Hydraulic Oil Specifications Performance Specifications Hydraulic Oil Specifications Drive speed, maximum 17 mph Hydraulic Fluid Specifications Standard engine - 120 hp 27,4 km/h Genie specifications require hydraulic oils which are Draw bar pull 25,000 lbs designed to give maximum protection to hydraulic 11340 kg...
  • Page 13 May 2021 Service and Repair Manual Specifications Chevron Rando HD Premium Oil Do not top off with incompatible hydraulic fluids. Hydraulic fluids MV Fluid Properties may be incompatible due to the differences in base additive ISO Grade chemistry. When incompatible Viscosity index fluids are mixed, insoluble materials may form and deposit...
  • Page 14 Service and Repair Manual May 2021 Specifications Chevron 5606A Hydraulic Oil Petro-Canada Environ MV 46 Fluid Properties Fluid Properties ISO Grade ISO Grade Viscosity index Viscosity index Kinematic Viscosity Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 200°F / 100°C 15.0 cSt @ 104°F / 40°C cSt @ 104°F / 40°C...
  • Page 15 May 2021 Service and Repair Manual Specifications UCON Hydrolube HP-5046 Fluid Properties ISO Grade Viscosity index Kinematic Viscosity cSt @ 149°F / 65°C cSt @ 104°F / 40°C cSt @ 0°F / -18°C 1300 Flash point None Pour point -81°F / -63°C Maximum continuous operating 189°F / 87°C temperature...

  • Page 16: Hydraulic Component Specifications

    Service and Repair Manual May 2021 Specifications Hydraulic Component Hydraulic Component Specifications Primary Function Manifold Specifications System relief valve pressure, maximum 3626 psi (measured at test port TP) 350 bar Function pump (ZF Transmission) Boom extend relief valve pressure, 2611 psi maximum 180 bar Type: variable displacement piston pump...

  • Page 17: Manifold Component Specifications

    May 2021 Service and Repair Manual Specifications Manifold Component Manifold Component Specifications DEF Storage Specifications DEF Storage Specifications Specifications Diesel Exhaust Fluid decomposes when exposed to elevated temperatures for an extended period of Plug torque time. Therefore precautions must be taken to SAE No.

  • Page 18: Deutz Tcd3.6 120Hp T4F Engine Specifications

    Service and Repair Manual May 2021 Specifications Deutz TCD3.6 120HP T4F Engine Deutz TCD3.6 120HP T4F Engine Specifications Fuel injection system Injection pump pressure, maximum 23200 psi Displacement 221 cu in 1600 bar 3.62 liters Max fuel consumption 6.5 gph / 24.6 lph Number of cylinders Fuel requirement Bore and Stroke...

  • Page 19: Deutz Tcd3.6 L4 T4F Engine Specifications

    May 2021 Service and Repair Manual Specifications Deutz TCD3.6 74HP T4F Engine Deutz TCD3.6 L4 T4F Engine Specifications Fuel injection system Injection pump pressure, maximum 23200 psi Displacement 221 cu in 1600 bar 3.62 liters Max fuel consumption 6.5 gph / 24.6 lph Number of cylinders Fuel requirement Bore and Stroke...

  • Page 20: Deutz Tcd3.6 Row Engine Specifications

    Service and Repair Manual May 2021 Specifications Deutz TCD3.6 ROW Engine Deutz TCD3.6 ROW Engine Specifications Fuel injection system Injection pump pressure, maximum 23200 psi Displacement 221 cu in 1600 bar 3.62 liters Max fuel consumption 6.5 gph / 24.6 lph Number of cylinders Fuel requirement Bore and Stroke...

  • Page 21: Zf 4 Wg-98 Tsc Transmission Specifications

    May 2021 Service and Repair Manual Specifications ZF 4 WG-98 TSC Transmission ECOMEC CVT 150 Transmission ZF 4 WG-98 TSC Transmission Specifications ECOMEC CVT 150 Transmission Specifications Transmission Type 4 speed powershift converter Transmission Type 2 speed powershift converter Speeds, Forward Speeds, Forward Speeds, Reverse Speeds, Reverse...

  • Page 22: Dana Vdt12000 Transmission Specifications

    Service and Repair Manual May 2021 Specifications Dana VDT12000 Transmission Dana Planetary Drive Axle Dana VDT12000 Transmission Specifications Dana Planetary Drive Axle Specifications (223_212HY) Specifications Steering Integrated steer cylinder Joints Heavy duty double U-joints Transmission Type 3 speed powershift converter Steering angle, maximum 45°...

  • Page 23: Hydraulic Hose And Fitting Torque Specifications

    May 2021 Service and Repair Manual Specifications Hydraulic Hose and Fitting Hydraulic Hose and Fitting Torque Specifications Torque Specifications ORFS Hose End SAE Dash Size Torque Your machine is equipped with Ryco ORFS or 37° JIC fittings and hose ends. Manufactures 10 - 12 ft-lbs / 14 - 16 Nm specifications require that fittings and hose ends 18 - 20 ft-lbs / 24 - 27 Nm...

  • Page 24: Torque Procedure

    Service and Repair Manual May 2021 Specifications Torque Procedure Torque Procedure Code 62 ORFS fittings SAE Dash Size Torque 15 - 18 ft lbs / 20 - 25 Nm Replace the O-ring. The O-ring must be replaced anytime the seal has been broken. 25 - 33 ft lbs / 34 - 45 Nm The O-ring cannot be re-used if the fitting or 41 - 50 ft lbs / 56 - 68 Nm...

  • Page 25: Repair Procedures

    May 2021 Service and Repair Manual Repair Procedures Machine Configuration: Section 3 Repair Procedures Introduction  Unless otherwise specified, perform each repair procedure with the machine in the following configuration: • Machine parked on a firm, level surface • Boom in the stowed position Observe and Obey: •...

  • Page 26: About This Section

    Service and Repair Manual May 2021 Repair Procedures About This Section Most of the procedures in this section should only be performed by trained service professional in a suitably equipped workshop. Select the appropriate repair procedure after troubleshooting the problem. Perform disassembly procedures to the point where repairs can be completed.

  • Page 27: Boom Components

    May 2021 Service and Repair Manual Boom Components How to Test a Proximity Switch Boom Components How to Test a Proximity Switch 1-1 Boom Proximity Switch Boom Proximity Switch Remove the switch from the machine. Do not disconnect the switch wire harness from the The boom angle switch is a proximity switch.

  • Page 28: How To Adjust The Boom Angle Proximity Switch

    Service and Repair Manual May 2021 Boom Components How to Adjust the Boom Angle How to Adjust the Boom Extend How to Adjust the Boom Angle Proximity Switch How to Adjust the Boom Extend Proximity Switch Proximity Switch Proximity Switch The boom angle proximity switch is attached to a The boom extend proximity switch assembly is mounting bracket, located between the boom and...

  • Page 29: Boom

    May 2021 Service and Repair Manual Boom Components How to Remove the Lifting Fork 1-2 Boom How to Remove the Lifting Fork Frame Boom Frame With the boom in the stowed position, attach a How to Replace the Boom Wear Pads How to Replace the Boom Wear lifting strap from an overhead crane to the top Pads...

  • Page 30: How To Remove And Install The Cable Track Assembly

    Service and Repair Manual May 2021 Boom Components How to remove the Cable Track How to Remove and Install the Cable Track Assembly Loosen the retaining fasteners securing the rear hydraulic hose clamp. Do not remove the Assembly retaining fasteners at this time. Note: Perform this procedure on a firm, level surface with the machine in the stowed position and the wheels chocked.
  • Page 31 May 2021 Service and Repair Manual Boom Components Locate the hydraulic hard lines under the 11 Pull the cable track out far enough to mark the boom assembly. Tag, disconnect and plug the hydraulic hoses next to the upper hose clamp hydraulic hoses from the bulkhead fittings.
  • Page 32 Service and Repair Manual May 2021 Boom Components How to Install the Cable Track 14 Loosen fasteners and remove clamp half to on the lower cable track mount in order to free Assembly up the hose loop. Note: Verify the boom is fully retracted. If it is not fully retracted, the twin hydraulic hoses that go to the horse head will kink when the boom fully retracts.
  • Page 33 May 2021 Service and Repair Manual Boom Components Attach narrow hose clamps to the mounting At the front of the horsehead, attach the hose plate. Line up the mark from the previous clamps through the mounting bracket. Do not steps with the face of the clamp that is tighten at this time.
  • Page 34 Service and Repair Manual May 2021 Boom Components 11 Push the cable track with the hydraulic hoses 14 Attach the hydraulic hoses to the hardlines into the boom and loop the hoses that will located at the bottom of the boom. connect to the hardlines up or to the side so that they are out of the way.

  • Page 35: How To Replace The Retract Chains

    May 2021 Service and Repair Manual Boom Components How to Replace the Retract How to Replace the Retract Chains 16 Working at the fork end of the boom, pull on the hydraulic hoses to remove any excess Chains slack in the boom and cable track. Tighten the hose clamps in the horsehead.
  • Page 36 Service and Repair Manual May 2021 Boom Components Secure a rope to the end of the chain being Remove the top, front wear pads that are replaced. between the boom tube number 0, 1, and 2. Note: Verify the rope is securely attached to the Note: This step is not required if only replacing the chain.
  • Page 37 May 2021 Service and Repair Manual Boom Components 10 Use hook or a 3/8-16 UNC threaded rod to 16 Working at the fork end of the boom, use the secure the retract anchors. rope to carefully pull the chain through the boom just until the end of the chain is accessible.

  • Page 38: How To Replace The Extend Chain

    Service and Repair Manual May 2021 Boom Components How to Replace the Extend How to Replace the Extend Chain 22 Use a combination of a forklift pushing on the horsehead and the extend cylinder to fully Chains stow the boom. Note: Perform this procedure with the machine on Note: The loosened extend chains should allow a firm, level surface.
  • Page 39 May 2021 Service and Repair Manual Boom Components Start the machine and retract the boom At the pivot end of the boom, remove 8 inches / 20,3 cm. retaining fasteners securing the step anchors. Note: This step is not required if only replacing the 1-2-3 extend chain.

  • Page 40: How To Remove The Boom

    Service and Repair Manual May 2021 Boom Components How to Remove the Boom How to Remove the Boom 15 Secure the step anchors to the boom. 16 Remove the blocks or shims used to chock up Bodily injury hazard. This the number 2 boom tube.
  • Page 41 May 2021 Service and Repair Manual Boom Components Lower the fork level cylinder onto the chassis. 16 Use a soft metal drift to remove the boom pivot pin. Crushing hazard. Keep hands clear of the cylinder manifold Crushing hazard. The boom will when lowering the cylinder.

  • Page 42: How To Disassemble The Boom

    Service and Repair Manual May 2021 Boom Components How to Disassemble the Boom - How to Disassemble the Boom Remove the fastener securing the fork level cylinder rod-end pivot pin to the fork frame GTH1056 mount. Bodily injury hazard. This Use a soft metal drift to remove the rod-end procedure requires specific repair pivot pin.
  • Page 43 May 2021 Service and Repair Manual Boom Components the hard lines that run under the boom. Cap 14 Working at the pivot end of the boom, remove the fittings. the hose keepers from the hose roller assembly. 18 Working at the fork end of the boom, remove Note: The hose keepers ensure that the hoses do the fasteners securing the twin line clamps to not jump off the hose rollers.
  • Page 44 Service and Repair Manual May 2021 Boom Components the chain tensioners to the bottom of boom 33 Support and slide boom tube number 1 out of tube number 0. boom tube number 0. Place boom tube number 1 on a structure capable of supporting 26 Working at the fork end of the boom, remove the fasteners securing the extension chain rollers to the bottom of boom tube number 1.

  • Page 45: Boom Lift Cylinder

    May 2021 Service and Repair Manual Boom Components 1-3 Boom Lift Cylinder Use a soft metal drift to remove the pivot pin. Boom Lift Cylinder Remove the fasteners securing the lift cylinder rod-end pivot pin to the boom. How to Remove the Lift Cylinder Use a soft metal drift to remove the pivot pin.

  • Page 46: Boom Extension Cylinder

    Service and Repair Manual May 2021 Boom Components 1-4 Boom Extension Cylinder Remove the extension cylinder support loop from the underside of the boom. Boom Extension Cylinder Note: The extension cylinder support loop is located at the fork end of the boom. How to Remove the Extension Remove the fasteners securing the extension Cylinder...

  • Page 47: Fork Level Cylinder

    May 2021 Service and Repair Manual Boom Components 1-5 Fork Level Cylinder Tag, disconnect and plug the fork level cylinder hoses from the cylinder manifolds. Fork Level Cylinder Cap the fittings. Bodily injury hazard. Spraying How to Remove the Fork Level hydraulic oil can penetrate and Cylinder burn skin.

  • Page 48: Hydraulic Hoses

    Service and Repair Manual May 2021 Boom Components 1-6 Hydraulic Hoses Working near the center of the boom assembly, tag, disconnect and plug the Hydraulic Hoses hydraulic hoses from the hydraulic hard lines under boom tube number number 1. Cap the How to Replace the Fork Level and/or Auxiliary Cylinder Hoses How to Replace the Fork Level hard lines.
  • Page 49 May 2021 Service and Repair Manual Boom Components Replace the upper hoses: 10 Working at the fork end of the boom, remove the fasteners securing the cable bridge slider Fully retract the boom. to the cable bridge. Remove the slider from the boom.

  • Page 50: Operator's Compartment

    Service and Repair Manual May 2021 Operator's Compartment Operator's Compartment 2-1 Operator's Compartment Working under the dashboard, locate the hydraulic hose at port L of the steering Operator's Compartment orbitral. Working at the front axle, locate the hydraulic How to Remove the Operator's hose connected to the front axle steer cylinder Compartment at the operator's compartment side of the...

  • Page 51: Machine Controls

    May 2021 Service and Repair Manual Operator's Compartment 2-2 Machine Controls 10 Support and secure the operator's compartment to an adjustable table capable Machine Controls of supporting the weight and that will allow the operator's compartment to remain in an How to Remove the Steering Column How to Remove the Steering upright and stable position.

  • Page 52: How To Remove The Steering Wheel

    Service and Repair Manual May 2021 Operator's Compartment How to Remove the Steering How to Remove the Steer Orbitral How to Remove the Steering Wheel How to Remove the Steer Orbitral Wheel Remove the steering column. Refer to Repair Procedure, How to Remove the Steering Open the access door above the hydraulic Column.

  • Page 53: How To Remove The Joystick - Models With Electronic Joystick

    May 2021 Service and Repair Manual Operator's Compartment How to Remove the Joystick - How to Remove the Brake Pedal How to Remove the Joystick - Models with Electronic Joystick How to Remove the Brake Pedal Assembly Models with Electronic Joystick Assembly Disconnect the battery from the machine.

  • Page 54: How To Remove The Gauge Cluster Assembly

    Service and Repair Manual May 2021 Operator's Compartment How to Remove the Gauge How to Remove the Gauge Cluster Assembly Cluster Assembly Disconnect the battery from the machine. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury.

  • Page 55: Fuel And Hydraulic Tanks

    May 2021 Service and Repair Manual Fuel and Hydraulic Tanks Fuel and Hydraulic Tanks 3-1 Fuel and HydraulicTanks Remove the filler cap from the fuel tank. Fuel and Hydraulic Tanks Place a drain pan or other suitable container under the fuel tank. How to Remove the Fuel and Using an approved hand-operated pump, drain the fuel tank into a container of suitable...
  • Page 56 Service and Repair Manual May 2021 Fuel and Hydraulic Tanks HYDRAULIC TANK Remove the access cover to the hydraulic tank. Remove the filler cap from the hydraulic tank. 10 Place a drain pan or other suitable container under the hydraulic tank. Refer Specifications, Machine Specifications.

  • Page 57: Engines

    May 2021 Service and Repair Manual Engines Engines 4-2 Engine Fault Codes 4-1 Engines Engine Fault Codes Engines How to Repair the Deutz TCD3.6 Engine How to Repair the Deutz TCD3.6 How to Retrieve Engine Fault Engine Codes Maintenance procedures and additional engine When the engine Electronic Control Module (ECM) information is available in the Deutz TCD3.6 detects an abnormal operating condition, a fault...

  • Page 58: Transmission

    Service and Repair Manual May 2021 Transmission Transmission 5-1 Transmission Transmission How to Repair the Transmission How to Repair the Transmission Repair procedures and additional transmission information is available in the ZF WG-98 Transmission Repair Manual. Repair Manual, ZF Transmission, 4 WG-98 TSC Genie part number 1311107GT Repair Manual, CVT 150 Transmission,...

  • Page 59: Hydraulic Pump

    May 2021 Service and Repair Manual Hydraulic Pump Hydraulic Pump 6-1 Hydraulic Pump Observe the pressure gauge while cranking the engine in one second intervals. Hydraulic Pump Result: If the pressure gauge reads 3190 psi / How to Test the Function Pump How to Test the Function Pump 220 bar, immediately stop.

  • Page 60: How To Remove The Function Pump

    Service and Repair Manual May 2021 Hydraulic Pump How to Remove the Function How to Remove the Function Pump Tag, disconnect and plug the large hydraulic pump supply hose at the pump. Cap the fitting Pump on the pump. Bodily injury hazard. This Note: Placing the open end of the pump supply procedure requires specific repair hose below the fluid level in the hydraulic tank...

  • Page 61: How To Install The Function Pump

    May 2021 Service and Repair Manual Hydraulic Pump How to Install the Function Pump How to Prime the Function Pump How to Install the Function Pump How to Prime the Function Pump Carefully install the hydraulic pump onto the Note: When removing a hose assembly or fitting, transmission.

  • Page 62: How To Adjust The Function Pump Standby Pressure

    Service and Repair Manual May 2021 Hydraulic Pump How to Adjust the Function Pump How to Adjust the Function Pump Standby Pressure Remove the plug and slowly fill the case drain port of the pump with hydraulic fluid until the Standby Pressure oil level is even with the bottom of the hole.

  • Page 63: How To Adjust The Function Pump Pressure Compensator

    May 2021 Service and Repair Manual Hydraulic Pump How to Adjust the Function Pump How to Adjust the Function Pump Pressure Compensator Loosen the set screw for the standby pressure adjustment screw. Standby Pressure Note: Two people will be required to perform this procedure.
  • Page 64 Service and Repair Manual May 2021 Hydraulic Pump Loosen the set screw for the pressure Adjust the pressure compensator pressure. compensator adjustment screw. Turn the adjustment screw clockwise to increase the pressure or counterclockwise to decrease the pressure. Tighten the set screw. Component damage hazard.

  • Page 65: Manifolds

    May 2021 Service and Repair Manual Manifolds Manifolds 7-1 PVG Manifold PVG Manifold Components The Proportional Valve Group manifold is located at the rear of the chassis. Index Description Function Assembly, tilt Tilt functions Assembly, lift Lift functions Assembly, auxiliary Auxiliary functions Assembly, extend/retract Extend/retract functions...

  • Page 66: Secondary Function Manifold Components

    Service and Repair Manual May 2021 Manifolds 7-2 Secondary Function Manifold Components Secondary Function Manifold Components The secondary function manifold is located under the manifold inspection cover. Index Schematic Description Function Torque Item Check valve, 4 psi / 0.3 bar Tank return circuit 20-25 ft-lbs / 27-34 Nm Check valve, 4 psi / 0.3 bar...
  • Page 67 May 2021 Service and Repair Manual Manifolds Part No. 1303145GT ™ -1056...

  • Page 68: Brake Manifold Components

    Service and Repair Manual May 2021 Manifolds 7-3 Brake Manifold Components Brake Manifold Components The brake manifold is located under the manifold inspection cover. Index Schematic Description Function Torque Item Pressure switch, 450 psi / 31 bar Service brake 11 ft-lbs / 14.9 Nm ™...

  • Page 69: Valve Adjustments - Secondary Function Manifold

    May 2021 Service and Repair Manual Manifolds 7-4 Valve Adjustments - Secondary Function Manifold Start the engine. Allow the engine to idle. Valve Adjustments - Secondary Result: The pressure gauge reads 400 psi / Function Manifold 27.5 bar. The pressure setting is correct. Proceed to step 11.

  • Page 70: How To Set The Rear Lock-Up System Pressure

    Service and Repair Manual May 2021 Manifolds How to Set the Rear Lock-up How to Set the Rear Lock-up System Pressure Start the engine. Allow the engine to idle. System Pressure Result: The pressure gauge reads 50 psi / 3.4 bar. The pressure setting is correct. Note: Be sure that the hydraulic oil level is visible Proceed to step 11.

  • Page 71: Valve Coils

    May 2021 Service and Repair Manual Manifolds Valve Coil Resistance 7-5 Valve Coils Specification Valve Coils Note: The following coil resistance specifications How to Test a Coil are at an ambient temperature of 68°F / 20°C. As valve coil resistance is sensitive to changes in air A properly functioning coil provides an temperature, the coil resistance will typically electromotive force which operates the solenoid...
  • Page 72 Service and Repair Manual May 2021 Manifolds How to Test a Coil Diode Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes. Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil. Faulty diodes can fail to protect the electrical system, resulting in a tripped circuit breaker or component damage.

  • Page 73: Axle

    May 2021 Service and Repair Manual Axle Axle 8-1 Axles Axles How to Repair the Axle How to Repair the Axle Repair procedures and additional axle information is available in the Dana 212HY and 223 Axle Maintenance and Repair Manual. Dana 212HY and 223 Axle Maintenance and Repair Manual Genie part number...

  • Page 74: Outriggers

    Service and Repair Manual May 2021 Outriggers Outriggers 9-1 Outriggers Use a soft metal drift to remove the outrigger cylinder barrel-end pivot pin. Lower the Outriggers cylinder onto the outrigger. How to Remove an Outrigger How to Remove an Outrigger Crushing hazard.

  • Page 75: How To Remove An Outrigger Cylinder

    May 2021 Service and Repair Manual Outriggers How to Remove an Outrigger How to Remove an Outrigger Cylinder Remove the fasteners securing the outrigger cylinder barrel-end pivot pin to the chassis. Cylinder Use a soft metal drift to remove the pivot pin. Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose Crushing hazard.
  • Page 76 Service and Repair Manual May 2021 This page intentionally left blank. ™ -1056 Part No. 1303145GT...

  • Page 77: Fault Codes

    May 2021 Service and Repair Manual Fault Codes Before Troubleshooting: Section 4 Fault Codes Introduction  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 ...

  • Page 78: Diagnostic Display

    Service and Repair Manual May 2021 Diagnostic Display Diagnostic Display Decoding Fault Codes Diagnostic Display When the engine Electronic Control Module (ECM) The Suspect Parameter Number (SPN) and the detects an abnormal operating condition, a fault Failure Mode Identifier (FMI), when combined, are code is immediately stored in the ECM memory.

  • Page 79: Deutz Tcd3.6 Engine Fault Codes

    May 2021 Service and Repair Manual Deutz TCD3.6 Engine Fault Codes Deutz TCD3.6 Engine Fault Codes SPN = Suspect Parameter Number ASPN = Alternate Suspect Parameter Number FMI = Failure Mode Identifier ASPN FMI Description Handthrottle; signal out of range, short circuit to battery Handthrottle;...
  • Page 80 Service and Repair Manual May 2021 Deutz TCD3.6 Engine Fault Codes SPN = Suspect Parameter Number ASPN = Alternate Suspect Parameter Number FMI = Failure Mode Identifier ASPN FMI Description Air filter differential pressure; system reaction initiated Sensor error airfilter differential pressure; short circuit to battery Sensor error airfilter differential pressure;...
  • Page 81 May 2021 Service and Repair Manual Deutz TCD3.6 Engine Fault Codes SPN = Suspect Parameter Number ASPN = Alternate Suspect Parameter Number FMI = Failure Mode Identifier ASPN FMI Description Oil temperature; out of range, system reaction initiated Physical range check low for oil temperature Oil temperature;...
  • Page 82 Service and Repair Manual May 2021 Deutz TCD3.6 Engine Fault Codes SPN = Suspect Parameter Number ASPN = Alternate Suspect Parameter Number FMI = Failure Mode Identifier ASPN FMI Description Injector 1 (in firing order); short circuit High side to low side short circuit in the injector 1 (in firing order) Injector 1 (in firing order);...
  • Page 83 May 2021 Service and Repair Manual Deutz TCD3.6 Engine Fault Codes SPN = Suspect Parameter Number ASPN = Alternate Suspect Parameter Number FMI = Failure Mode Identifier ASPN FMI Description Cold start aid relay open load Cold start aid relay; over temperature error Timeout Error of CAN-Receive-Frame TSC1TE;...
  • Page 84 Service and Repair Manual May 2021 Deutz TCD3.6 Engine Fault Codes SPN = Suspect Parameter Number ASPN = Alternate Suspect Parameter Number FMI = Failure Mode Identifier ASPN FMI Description 1188 Wastegate; status message from ECU missing Wastegate actuator; blocked Turbo charger wastegate actuator;...
  • Page 85 May 2021 Service and Repair Manual Deutz TCD3.6 Engine Fault Codes SPN = Suspect Parameter Number ASPN = Alternate Suspect Parameter Number FMI = Failure Mode Identifier ASPN FMI Description 2791 EGR actuator, temperature critical high EGR actuator, CAN error EGR actuator supply voltage is above the maximum threshold EGR actuator supply voltage is below minimum threshold EGR actuator current is above maximum threshold...
  • Page 86 Service and Repair Manual May 2021 Deutz TCD3.6 Engine Fault Codes SPN = Suspect Parameter Number ASPN = Alternate Suspect Parameter Number FMI = Failure Mode Identifier ASPN FMI Description 3248 Exhaust gas temperature particulate filter downstream; out of range, system reaction initiated Exhaust gas temperature particulate filter downstream;...
  • Page 87 May 2021 Service and Repair Manual Deutz TCD3.6 Engine Fault Codes SPN = Suspect Parameter Number ASPN = Alternate Suspect Parameter Number FMI = Failure Mode Identifier ASPN FMI Description 4243 SCR system heater diagnostic reports error; shut off SCR-system 4334 Urea pump pressure;...
  • Page 88 Service and Repair Manual May 2021 Deutz TCD3.6 Engine Fault Codes SPN = Suspect Parameter Number ASPN = Alternate Suspect Parameter Number FMI = Failure Mode Identifier ASPN FMI Description 4375 Urea pump motor; short circuit to battery Urea pump motor; short circuit to ground Urea pump motor;...
  • Page 89 May 2021 Service and Repair Manual Deutz TCD3.6 Engine Fault Codes SPN = Suspect Parameter Number ASPN = Alternate Suspect Parameter Number FMI = Failure Mode Identifier ASPN FMI Description 23006 64254 3 Controller mode switch; short circuit to battery Controller mode switch;...
  • Page 90 Service and Repair Manual May 2021 Deutz TCD3.6 Engine Fault Codes SPN = Suspect Parameter Number ASPN = Alternate Suspect Parameter Number FMI = Failure Mode Identifier ASPN FMI Description 23470 64718 2 Pressure Relief Valve (PRV) forced to open Maximum rail pressure in limp home mode exceeded (PRV) Pressure Relief Valve (PRV) error;...
  • Page 91 May 2021 Service and Repair Manual Deutz TCD3.6 Engine Fault Codes SPN = Suspect Parameter Number ASPN = Alternate Suspect Parameter Number FMI = Failure Mode Identifier ASPN FMI Description 23698 64946 11 Shut off request from supervisory monitoring function 23704 Timeout Error of CAN-Transmit_Frame EEC3 23717 64965 12...
  • Page 92 Service and Repair Manual May 2021 Deutz TCD3.6 Engine Fault Codes SPN = Suspect Parameter Number ASPN = Alternate Suspect Parameter Number FMI = Failure Mode Identifier ASPN FMI Description 23723 64971 11 Detection of AdBlue filled SCR system in Init-State 23766 65014 9 Timeout Error of CAN-Receive-Frame Active TSC1AE 23767 65015 9...
  • Page 93 May 2021 Service and Repair Manual Deutz TCD3.6 Engine Fault Codes SPN = Suspect Parameter Number ASPN = Alternate Suspect Parameter Number FMI = Failure Mode Identifier ASPN FMI Description 23911 65159 0 Burner dosing valve (DV2); overcurrent at the end of the injection phase Burner dosing valve (DV2);...
  • Page 94 Service and Repair Manual May 2021 Deutz TCD3.6 Engine Fault Codes SPN = Suspect Parameter Number ASPN = Alternate Suspect Parameter Number FMI = Failure Mode Identifier ASPN FMI Description 23917 65165 0 Physical range check high for DV1 & DV2 upstream pressure; shut off regeneration Physical range check low for DV1 &...
  • Page 95 May 2021 Service and Repair Manual Deutz TCD3.6 Engine Fault Codes SPN = Suspect Parameter Number ASPN = Alternate Suspect Parameter Number FMI = Failure Mode Identifier ASPN FMI Description 23924 Short circuit to ground actuator relay 2 23925 Short cicuit to battery error of actuator relay 3 Short circuit to ground actuator relay 3 23926 Short cirucit to dround actuator relay 4...
  • Page 96 Service and Repair Manual May 2021 Deutz TCD3.6 Engine Fault Codes SPN = Suspect Parameter Number ASPN = Alternate Suspect Parameter Number FMI = Failure Mode Identifier ASPN FMI Description 23943 65191 9 Timeout Error (PCK2PCK) for CAN-Receive-Frame AT1OGCVol2 information; factors & Sensorcalibration for NOX Sensor (SCR-system downstream cat;...
  • Page 97 May 2021 Service and Repair Manual Deutz TCD3.6 Engine Fault Codes SPN = Suspect Parameter Number ASPN = Alternate Suspect Parameter Number FMI = Failure Mode Identifier ASPN FMI Description 23984 UB6; Short circuit to battery error of actuator relay 6 23986 Actuator relay 5;...
  • Page 98 Service and Repair Manual May 2021 Deutz TCD3.6 Engine Fault Codes SPN = Suspect Parameter Number ASPN = Alternate Suspect Parameter Number FMI = Failure Mode Identifier ASPN FMI Description 24011 65259 0 Zerofuel calibration injector 7 (in firing order); maximum value exceeded Zerofuel calibration injector 7 (in firing order);...
  • Page 99 May 2021 Service and Repair Manual Deutz TCD3.6 Engine Fault Codes SPN = Suspect Parameter Number ASPN = Alternate Suspect Parameter Number FMI = Failure Mode Identifier ASPN FMI Description 24035 65283 12 Injector diagnostics; time out error in the SPI communication 24036 65284 12 Injector diagnostics Slave;...
  • Page 100 Service and Repair Manual May 2021 Deutz TCD3.6 Engine Fault Codes SPN = Suspect Parameter Number ASPN = Alternate Suspect Parameter Number FMI = Failure Mode Identifier ASPN FMI Description 24065 Pressure sensor upstream SCR-CAT, pressure above upper physical threashold Pressure sensor upstream SCR-CAT, pressure below lower physical threashold Pressure sensor upstream SCR-CAT, plausibility error Pressure sensor upstream SCR-CAT, short circuit battery or open load...
  • Page 101 May 2021 Service and Repair Manual Deutz TCD3.6 Engine Fault Codes SPN = Suspect Parameter Number ASPN = Alternate Suspect Parameter Number FMI = Failure Mode Identifier ASPN FMI Description 24097 65345 9 Timeout error of CAN-Transmit-Frame DPFBrnAirPmpCtl 24098 65346 9 Timeout error of CAN-Transmit-Frame ComDPFBrnPT 24099 65347 9 Timeout error of CAN-Transmit-Frame ComDPFC0...
  • Page 102 Service and Repair Manual May 2021 Deutz TCD3.6 Engine Fault Codes SPN = Suspect Parameter Number ASPN = Alternate Suspect Parameter Number FMI = Failure Mode Identifier ASPN FMI Description 24116 65364 9 Timeout error of CAN-Transmit-Frame SCR2 24117 65365 9 Timeout error of CAN-Transmit-Frame SCR3 24118 65366 9 Timeout error of CAN-Receive-Frame ComRxCM0...

  • Page 103: Ecgenius 150 Transmission Fault Codes

    May 2021 Service and Repair Manual ECGenius 150 Transmission Fault Codes ECGenius 150 Transmission Fault Codes SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description FMI Signification Transmission Behavior Synchro Position High position error High range disabled Reverse position error Engage if no forward motion CVT Oil Sump Temperature High temperature Alarm...

  • Page 104: Schematics

    Service and Repair Manual May 2021 Schematics About This Section Section 5 Schematics Introduction There are two groups of schematics in this section. Electrical Schematics Electrocution/burn hazard. Contact with electrically charged Observe and Obey: circuits could result in death or serious injury.

  • Page 105: Proximity Switch Legend

    May 2021 Service and Repair Manual Proximity Switch Legend Proximity Switch Legend 1 Boom Angle Proximity Switch PX2 (under boom pivot pin) 2 Boom Extend Proximity Switch PX1 (under plate at top of boom tube) Part No. 1303145GT ™ -1056...

  • Page 106: Fuse Panel Layout (120Hp & Row Engine)

    Service and Repair Manual May 2021 Fuse Panel Layout (120HP & ROW Engine) Fuse Panel Layout (120HP & ROW Engine) BEACON ENCLOSED HARNESS CAB HARNESS F15 1A F14 10A F11 10A F8 5A DOME LT HARNESS DASHBOARD F3 10A F6 5A F17 10A MAX F7 5A HARNESS...

  • Page 107: Fuse Panel Layout (74Hp Engine With Cvt Transmission)

    May 2021 Service and Repair Manual Fuse Panel Layout (74HP Engine with CVT Transmission) Fuse Panel Layout (74HP Engine with CVT Transmission) BEACON ENCLOSED HARNESS CAB HARNESS F15 1A F14 10A F11 10A F8 5A DOME LT HARNESS DASHBOARD F3 10A F6 5A F17 10A MAX F7 5A...

  • Page 108: Deutz Tcd3.6 T4F Module

    Service and Repair Manual May 2021 Deutz TCD3.6 T4F Module Deutz TCD3.6 T4F Module Deutz TCD3.6 T4F Engine only Located inside of chassis by the ECU ™ -1056 Part No. 1303145GT...

  • Page 109: Electrical Component & Wire Color Abbreviation Legend

    May 2021 Service and Repair Manual Electrical Component & Wire Color Abbreviation Legend Electrical Component & Wire Color Abbreviation Legend Item Description Item Description Alternator Diode Battery Engine Management System Main Battery Fuse Circuit Breaker 15 Amp - Break/Shift 50 Amp Circuit Breaker 10 Amp - Aux Hydraulics 30 Amp or 50 Amp Circuit Breaker 10 Amp –...
  • Page 110 Service and Repair Manual May 2021 Electrical Component & Wire Color Abbreviation Legend Item Description Item Description LED Light Switch Ignition Power ON Key Start Switch Accessories Power ON Boom Extend Switch Horn Switch ON Parking Brake Pressure Switch Blinkers ON Service Brake Pressure Switch Light Switch ON Sway Enable Pressure Switch...
  • Page 111 May 2021 Service and Repair Manual Electrical Component & Wire Color Abbreviation Legend Wire Color Legend Item Description Blue Valve Coil BL/BK Blue/Black Sway Left Enable SV1 BL/RD Blue/Red Tilt Up Enable SV2 BL/WH Blue/White Sway Right Enable SV3 Black Tilt Down Enable SV4 BK/RD Black/Red...

  • Page 112: Electrical Symbol Legend

    Service and Repair Manual May 2021 Electrical Symbol Legend Electrical Symbol Legend Battery Coil, solenoid or relay Horn or alarm Flashing beacon Gauge Diode Hour meter Fuse with amperage Foot switch T-circuits connect Limit switch Power relay Coil with suppression Fuel or RPM solenoid T-circuits connect at Circuits crossing no...

  • Page 113: Hydraulic Symbols Legend

    May 2021 Service and Repair Manual Hydraulic Symbols Legend Hydraulic Symbols Legend Orifice with size Check valve Shut off valve Brake Pump, bi-directional Motor, 2 speed bi- Pump, fixed displacement Motor, bi-directional variable displacement directional Pump, prime mover Shuttle valve. 2 position, Cylinder, double acting Differential sensing valve (engine or motor)
  • Page 114 Service and Repair Manual May 2021 This page intentionally left blank. ™ -1056 Part No. 1303145GT...

  • Page 115: Electrical Schematics

    May 2021 Service and Repair Manual Electrical Schematics Electrical Schematic - Deutz T4F 74HP CVT...

  • Page 116: Electrical Schematic - Deutz T4F 74Hp Cvt

    Service and Repair Manual May 2021 Electrical Schematic - Deutz T4F 74HP CVT Electrical Schematic - Deutz T4F 74HP CVT ™ -1056 Part No. 1303145GT...

  • Page 117: Electrical Schematic - Deutz T4F Hp Cvt Transmission

    May 2021 Service and Repair Manual Electrical Schematic - Deutz T4F 74HP CVT Transmission Electrical Schematic - Deutz T4F HP CVT Transmission Part No. 1303145GT ™ -1056...
  • Page 118 Service and Repair Manual May 2021 Electrical Schematic - Deutz T4F 74HP CVT Transmission...
  • Page 119 May 2021 Service and Repair Manual Electrical Schematic- Deutz T4F 74HP Engine Harness...

  • Page 120: Electrical Schematic - Deutz T4F 74Hp Engine Harness

    Service and Repair Manual May 2021 Electrical Schematic - Deutz T4F 74HP Engine Harness Electrical Schematic- Deutz T4F 74HP Engine Harness CVT ™ -1056 Part No. 1303145GT...

  • Page 121: Electrical Schematic - Options Deutz T4F 74Hp

    May 2021 Service and Repair Manual Electrical Schematic- Deutz T4F 74HP Options CVT Electrical Schematic - Options Deutz T4F 74HP Part No. 1303145GT ™ -1056...
  • Page 122 Service and Repair Manual May 2021 Electrical Schematic- Deutz T4F 74HP Options...
  • Page 123 May 2021 Service and Repair Manual Electrical Schematic - Deutz T4F 74HP DANA...

  • Page 124: Electrical Schematic - Deutz T4F 74Hp Dana

    Service and Repair Manual May 2021 Electrical Schematic - Deutz T4F 74HP DANA Electrical Schematic - Deutz T4F 74HP DANA ™ -1056 Part No. 1303145GT...

  • Page 125: Electrical Schematic- Deutz T4F 74Hp Dana Engine Harness

    May 2021 Service and Repair Manual Electrical Schematic- Deutz T4F 74HP DANA Engine Harness Electrical Schematic - Deutz T4F 74HP DANA Engine Harness Part No. 1303145GT ™ -1056...
  • Page 126 Service and Repair Manual May 2021 Electrical Schematic- Deutz T4F 74HP DANA Engine Harness...
  • Page 127 May 2021 Service and Repair Manual Electrical Schematic- Deutz T4F 74HP DANA Options...

  • Page 128: Electrical Schematic - Options Deutz T4F 74Hp Dana

    Service and Repair Manual May 2021 Electrical Schematic - Options Deutz T4F 74HP DANA Electrical Schematic- Deutz T4F 74HP DANA Options ™ -1056 Part No. 1303145GT...

  • Page 129: Electrical Schematic - Deutz T3/T4F 120Hp Zf

    May 2021 Service and Repair Manual Electrical Schematic - Deutz T3/T4F 120HP ZF Electrical Schematic - Deutz T3/T4F 120HP ZF Part No. 1303145GT ™ -1056...
  • Page 130 Service and Repair Manual May 2021 Electrical Schematic - Deutz T3/T4F 120HP ZF...
  • Page 131 May 2021 Service and Repair Manual Base Engine ECM Schematic - Deutz T4F 120HP ZF...

  • Page 132: Base Engine Ecm Schematic - Deutz T4F 120Hp Zf

    Service and Repair Manual May 2021 Base Engine ECM Schematic - Deutz T4F 120HP ZF Base Engine ECM Schematic - Deutz T4F 120HP ZF ™ -1056 Part No. 1303145GT...

  • Page 133: Engine Ecm Schematic - Deutz T3 120Hp Zf

    May 2021 Service and Repair Manual Engine ECM Schematic - Deutz T3 120HP ZF Engine ECM Schematic - Deutz T3 120HP ZF Part No. 1303145GT ™ -1056...
  • Page 134 Service and Repair Manual May 2021 Engine ECM Schematic - Deutz T3 120HP ZF...
  • Page 135 May 2021 Service and Repair Manual EAT ECM Schematic - Deutz T4F 120HP ZF...

  • Page 136: Eat Ecm Schematic - Deutz T4F 120Hp Zf

    Service and Repair Manual May 2021 EAT ECM Schematic - Deutz T4F 120HP ZF EAT ECM Schematic - Deutz T4F 120HP ZF ™ -1056 Part No. 1303145GT...

  • Page 137: Eat Ecm Vec Schematic - Deutz T4F 120Hp Zf

    May 2021 Service and Repair Manual EAT ECM VEC Schematic - Deutz T4F 120HP ZF EAT ECM VEC Schematic - Deutz T4F 120HP ZF Part No. 1303145GT ™ -1056...
  • Page 138 Service and Repair Manual May 2021 EAT ECM VEC Schematic - Deutz T4F 120HP ZF...
  • Page 139 May 2021 Service and Repair Manual Schematic - Deutz T3/T4F 120HP ZF Options...

  • Page 140: Schematic - Options Deutz T3/T4F 120Hp Zf

    Service and Repair Manual May 2021 Schematic - Options Deutz T3/T4F 120HP ZF Schematic - Deutz T3/T4F 120HP ZF Options ™ -1056 Part No. 1303145GT...

  • Page 141: Hydraulic Schematics

    May 2021 Service and Repair Manual Hydraulic Schematics Hydraulic Schematic...

  • Page 142: Hydraulic Schematic

    Service and Repair Manual May 2021 Hydraulic Schematic Hydraulic Schematic BOOM UP / DOWN EXTEND / RETRACT TILT UP / DOWN SWING AUX. HYDRAULICS CHASSIS SWAY UP - 39.5 gpm / 150 L/min EXT - 39.5 gpm / 150 L/min UP - 14 gpm / 53 L/min CARRIAGE 15 gpm / 57 L/min...
  • Page 143 May 2021 Service and Repair Manual Hydraulic Schematic SERVICE BRAKE BRAKE LIGHTS PRESSURE SWITCH PRESSURE SWITCH FRONT STEER REAR STEER REAR LOCK-UP 450 psi / 31 bar 50 psi / 3,4 bar 6 gpm / 23 L/min 6 gpm / 23 L/min 5 gpm / 19 L/min REAR AXLE FRONT AXLE...
  • Page 144 Service and Repair Manual May 2021 Hydraulic Schematic GTH™-1056 Part No. 1303145GT Service and Repair Manual May 2021...

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