Terex GTH10E-12500 Service And Repair Manual
  1. Manuals
  2. Brands
  3. Terex Manuals
  4. Construction Equipment
  5. GTH10E-12500
  6. Service and repair manual

Terex GTH10E-12500 Service And Repair Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Service and Repair Manual
GTH™-1056
Serial Number Range
from GTH10E-12500
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. 1287211GT
Rev A
April 2018

Advertisement

Table of Contents
loading

Related Manuals for Terex GTH10E-12500

Summary of Contents for Terex GTH10E-12500

  • Page 1 Service and Repair Manual Serial Number Range GTH™-1056 This manual includes: from GTH10E-12500 Repair procedures Fault Codes Electrical and Hydraulic Schematics For detailed maintenance procedures, refer to the appropriate Maintenance Manual for your machine. Part No. 1287211GT Rev A April 2018...

  • Page 2: Introduction

    Copyright © 2018 by Terex Corporation 1287211GT Rev A, April 2018 Fourth 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 April 2018 Service and Repair Manual Introduction Revision History Revision Date Section Procedure / Page / Description 4/2018 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 April 2018 Introduction Serial Number Legend To August 31, 2016 1 Model 1 Serial label 2 Model year 2 Serial number (stamped on chassis) 3 Facility code 3 Serial label (located inside fork frame) 4 Sequence number From September 1, 2016 1 Model 1 Serial label...

  • Page 5: Safety Rules

    April 2018 Service and Repair Manual Safety Rules Section 1 Safety R ules Danger Failure to obey the instructions and safety rules in this manual and the appropriate Operator's Manual on your machine will result in death or serious injury. Many of the hazards identified in the operator's manual are also safety hazards when maintenance and repair procedures are performed.
  • Page 6 Service and Repair Manual April 2018 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

    April 2018 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 April 2018 Table of Contents How to Remove the Lifting Fork Frame ............18 How to Remove the Cable Bridge Assembly ..........19 How to Replace the Retraction Chain ............20 How to Replace the Extension Chains ............22 How to Remove the Boom ................24 How to Disassemble the Boom - GTH-1056 ..........
  • Page 9 April 2018 Table of Contents 6-1 Hydraulic Pump ....................45 How to Test the Function Pump ..............45 How to Remove the Function Pump ............... 46 How to Install the Function ................47 How to Prime the Function Pump ..............47 How to Adjust the Function Pump Standby Pressure ........
  • Page 10 Harness Map - Deutz HVAC Option ..............122 Harness Map - Perkins HVAC Option ..............123 Harness Map - Heater Option ................126 Electrical Schematic (from GTH10E-12500) ............130 Electrical Schematic- Deutz T4F Engine Harness ..........134 Hydraulic Schematics ..................141 Hydraulic Schematic ..................

  • Page 11: Specifications

    April 2018 Service and Repair Manual Specifications Section 2 Specific ati ons Machine Specifications Fluid capacities Tires and wheels Fuel tank 35 gallons 132.5 liters Tire size 14.00 x 24 Hydraulic tank 44 gallons Tire ply rating 166.5 liters Weight, rough terrain tire 315 lbs Hydraulic system 55 gallons...

  • Page 12: Performance Specifications

    Service and Repair Manual April 2018 Specifications Performance Specifications Hydraulic Oil Specifications Drive speed, maximum 18 mph Hydraulic Fluid Specifications 29 km/h Genie specifications require hydraulic oils which are Draw bar pull 29,000 lbs designed to give maximum protection to hydraulic 13,154 kg systems, have the ability to perform over a wide temperature range, and the viscosity index should...
  • Page 13 April 2018 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 April 2018 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 cSt @ 104°F / 40°C 15.0 cSt @ 104°F / 40°C...

  • Page 15: Hydraulic Component Specifications

    April 2018 Service and Repair Manual Specifications Hydraulic Component UCON Hydrolube HP-5046 Fluid Specifications Properties Function pump Type: variable displacement piston pump ISO Grade Displacement 0 to 3.66 cu in Viscosity index 0 to 60 cc Kinematic Viscosity Flow rate @ 2400 rpm 38 gpm cSt @ 149°F / 65°C 144 L/min...

  • Page 16: Manifold Component Specifications

    Service and Repair Manual April 2018 Specifications Manifold Component 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 avoid SAE No. 2 50 in-lbs / 6 Nm prolonged exposure to elevated temperatures.

  • Page 17: Deutz Tcd3.6 L4 Engine Specifications

    April 2018 Service and Repair Manual Specifications Deutz TCD3.6 L4 Engine Fuel injection system Injection pump pressure, maximum 23200 psi Displacement 221 cu in 1600 bar 3.62 liters Fuel requirement Number of cylinders For fuel requirements, refer to the engine Operator Bore and Stroke 3.86 x 4.72 inches Manual for your engine.

  • Page 18: Deutz Tcd3.6 L4 T4F Engine Specifications

    Service and Repair Manual April 2018 Specifications Deutz TCD3.6 L4 T4F Engine 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 3.86 x 4.72 inches...

  • Page 19: Perkins 1104D-E44Ta Engine Specifications

    April 2018 Service and Repair Manual Specifications Perkins 1104D-E44TA Engine Fuel requirement For fuel requirements, refer to the engine Operator Displacement 269 cu. in Manual for your engine. 4.4 liters Fuel injection pressure, minimum 23700 psi Number of cylinders 1635 bar Bore and Stroke 4.13 x 5 inches Starter motor...

  • Page 20: Perkins 1204E-E44Ta Engine Specifications

    Service and Repair Manual April 2018 Specifications Perkins 1204E-E44TA Engine Fuel requirement For fuel requirements, refer to the engine Operator Displacement 268.5 cu. in Manual for your engine. 4.4 liters Fuel injection pressure, minimum 23000 psi Number of cylinders 1585 bar Bore and Stroke 4.13 x 4.99 inches Starter motor...

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

    April 2018 Service and Repair Manual Specifications ZF 4 WG-98 TC Transmission Dana Planetary Drive Axle Transmission Type 4 speed powershift converter Steering Integrated steer cylinder Joints Speeds, Forward Heavy duty double U-joints Steering angle, maximum Speeds, Reverse 45° Torque Converter Front Axle Lubrication- Dana 223 Maximum input 2600 rpm...

  • Page 22: Hydraulic Hose And Fitting Torque Specifications

    Service and Repair Manual April 2018 Specifications Hydraulic Hose and Fitting Torque Specifications SAE O-ring Boss Port (tube fitting - installed into Aluminum) Your machine is equipped with Parker Seal-Lok™ (all types) ORFS or 37° JIC fittings and hose ends. Genie SAE Dash Size Torque specifications require that fittings and hose ends be...

  • Page 23: Torque Procedure

    April 2018 Service and Repair Manual Specifications Torque Procedure JIC 37° fittings Seal-Lok™ fittings Align the tube flare (hex nut) against the nose of the fitting body (body hex fitting) and tighten Replace the O-ring. The O-ring must be the hex nut to the body hex fitting to hand tight, replaced anytime the seal has been broken.
  • Page 24 Service and Repair Manual April 2018 Specifications Working clockwise on the body hex fitting, make a second mark with a permanent ink marker to indicate the proper tightening position. Refer to Illustration 2. Note: Use the JIC 37° Fitting table in this section to determine the correct number of flats, for the proper tightening position.

  • Page 25: Repair Procedures

    April 2018 Service and Repair Manual Repair Procedures Machine Configuration: Section 3 Repair Pr oc edures  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 Service and Repair Manual April 2018 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

    April 2018 Service and Repair Manual Boom Components How to Adj ust the Boom Angle Proximity Swi tch How to Adjust the Boom Angle Proximity Switch Boom Proximity Switch The boom angle proximity switch is attached to a The boom angle switch is a proximity switch. This mounting bracket, located between the boom and switch functions by sensing a change in the the chassis directly beneath the boom pivot pin.

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

    Service and Repair Manual April 2018 Boom Components How to Adj ust the Boom Ex tend Proximity Switc h How to Adjust the Boom Extend Proximity Switch Boom The boom extend proximity switch assembly is How to Replace the Boom Wear How to R eplac e the Boom W ear Pads secured to the top surface of the number 0 boom Pads...

  • Page 29: How To Remove The Cable Bridge Assembly

    April 2018 Service and Repair Manual Boom Components How to R emove the Cable Bridge Ass embly How to Remove the Cable Bridge Working at the pivot end of the boom, remove the fasteners securing the hose roller Assembly assembly to boom tube number 1. Remove Inside the four-section boom, a cable bridge is the hose roller assembly from the boom.

  • Page 30: How To Replace The Retraction Chain

    Service and Repair Manual April 2018 Boom Components How to R eplac e the R etraction C hain How to Replace the Retraction Chain Note: Perform this procedure on a firm, level surface with the boom in the stowed position and the wheels chocked.
  • Page 31 April 2018 Service and Repair Manual Boom Components Locate the two chain anchors of the boom 14 Working at the fork end of the boom, securely retraction chains where they attach to the connect a 30 foot / 10 m length of rope to the chain anchor mount at the lower side of boom end of the chain.

  • Page 32: How To Replace The Extension Chains

    Service and Repair Manual April 2018 Boom Components How to R eplac e the Extension C hai ns How to Replace the Extension 19 Working at the pivot end of the boom, route the chain over the roller and install the chain Chains onto the boom assembly using the pivot pin removed in step 10.
  • Page 33 April 2018 Service and Repair Manual Boom Components Select a chain tensioner. Remove the bow tie clip securing the chain anchor pin to the chain assembly. Remove the chain anchor pin from the assembly and remove the chain anchor from the tensioner assembly. Repeat this procedure, beginning with step 8, for the other chains.

  • Page 34: How To Remove The Boom

    Service and Repair Manual April 2018 Boom Components How to R emove the Boom How to Remove the Boom 16 Working at the fork end of the boom, use the rope to carefully pull the chain through the Bodily injury hazard. This boom just until the end of the chain is procedure requires specific repair accessible.
  • Page 35 April 2018 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 36: How To Disassemble The Boom - Gth1056

    Service and Repair Manual April 2018 Boom Components How to Dis ass embl e the Boom - GTH-1056 How to Disassemble the Boom - Remove the fastener securing the fork level cylinder rod-end pivot pin to the fork frame GTH1056 mount.
  • Page 37 April 2018 Service and Repair Manual Boom Components 14 Working at the pivot end of the boom, remove 17 Working at the pivot end of the boom, remove the hose keepers from the hose roller the fasteners securing the hose roller assembly.
  • Page 38 Service and Repair Manual April 2018 Boom Components 21 Working at the pivot end of the boom, carefully 30 Working at the pivot end of the boom, remove remove the cable bridge from the boom. the fasteners securing the chain roller to boom tube number 2.

  • Page 39: Boom Lift Cylinder

    April 2018 Service and Repair Manual Boom Components 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 40: Boom Extension Cylinder

    Service and Repair Manual April 2018 Boom Components 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 Cylinder Remove the fasteners securing the extension cylinder pivot pins to the boom.

  • Page 41: Fork Level Cylinder

    April 2018 Service and Repair Manual Boom Components 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 42: Hydraulic Hoses

    Service and Repair Manual April 2018 Boom Components 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 How to R eplac e the F ork Lev el and/or Auxiliary Cyli nder H oses , GTH-1056 hard lines.
  • Page 43 April 2018 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 44: Operator's Compartment

    Service and Repair Manual April 2018 Operator's Compartment Working under the dashboard, locate the hydraulic hose at port L of the steering orbitral. Operator's Compartment Working at the front axle, locate the hydraulic hose connected to the front axle steer cylinder How to Remove the Operator's at the operator's compartment side of the Compartment...

  • Page 45: Machine Controls

    April 2018 Service and Repair Manual Operator's Compartment 10 Support and secure the operator's compartment to an adjustable table capable of Machine Controls supporting the weight and that will allow the operator's compartment to remain in an How to Remove the Steering How to R emove the Steering Col um n upright and stable position.

  • Page 46: How To Remove The Steering Wheel

    Service and Repair Manual April 2018 Operator's Compartment How to R emove the Steering Wheel How to Remove the Steering How to R emove the Steer Or bitral 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 47: How To Remove The Joystick - Models With Electronic Joystick

    April 2018 Service and Repair Manual Operator's Compartment How to R emove the Joy stick - Models with El ectr onic J oystick How to Remove the Joystick - How to R emove the Brake Pedal Ass embly How to Remove the Brake Pedal Models with Electronic Joystick Assembly Disconnect the battery from the machine.

  • Page 48: How To Remove The Gauge Cluster Assembly

    Service and Repair Manual April 2018 Operator's Compartment How to R emove the Gauge Clus ter Ass em bly How to Remove the Gauge Cluster Assembly Disconnect the battery from the machine. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury.

  • Page 49: Fuel And Hydraulic Tanks

    April 2018 Service and Repair Manual Fuel and Hydraulic Tanks Remove the battery from the machine. Fuel and Hydraulic Tanks Tag and disconnect the wire harness from the fuel level terminals. Remove the filler cap from the hydraulic tank. How to Remove the Fuel and Hydraulic Tank Assembly Place a drain pan or other suitable container under the hydraulic tank.
  • Page 50 Service and Repair Manual April 2018 Fuel and Hydraulic Tanks 10 Tag, disconnect and plug the fuel supply and return hoses. Cap the fittings. 11 Tag, disconnect and plug the supply and return hoses from the hydraulic tank. Cap the fittings.

  • Page 51: Engines

    April 2018 Service and Repair Manual Engines How to R emove the Engi ne How to Remove the Engine Engines Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose How to Repair the Perkins How to R epair the Perki ns 1104D-E44T A Engi ne end must be replaced.

  • Page 52: Engine Fault Codes

    Service and Repair Manual April 2018 Engines John Deere models: Open the engine access cover at the tank side of the machine. Locate Engine Fault Codes the fuel supply line where it is attached to the fuel filter/water separator. How to Retrieve Engine Fault Tag, disconnect and plug the fuel supply hose Codes at the fuel filter/water separator.

  • Page 53: Transmission

    April 2018 Service and Repair Manual Transmission lace a drain pan or other suitable container under the hydraulic tank. Refer to Transmission Specifications, Machine Specifications. Remove the drain plug from the hydraulic tank and completely drain the tank. How to R epair the Tr ansmissi on How to Repair the Transmission Bodily injury hazard.
  • Page 54 Service and Repair Manual April 2018 Transmission Tag, disconnect and plug the hydraulic pump high pressure line at the function manifold. Cap the fitting. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually.

  • Page 55: Hydraulic Pump

    April 2018 Service and Repair Manual 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 T est the Func tion Pum p 220 bar, immediately stop.

  • Page 56: How To Remove The Function Pump

    Service and Repair Manual April 2018 Hydraulic Pump How to R emove the Functi on Pum p How to Remove the Function Tag, disconnect and plug the large hydraulic pump supply hose at the pump. Cap the fitting Pump on the pump. Bodily injury hazard.

  • Page 57: How To Install The Function

    April 2018 Service and Repair Manual Hydraulic Pump How to Ins tall the F uncti on How to Install the Function Pump How to Prime the F uncti on Pump How to Prime the Function Pump Note: When removing a hose assembly or fitting, Carefully install the hydraulic pump onto the the O-ring (if equipped) on the fitting and/or hose transmission.

  • Page 58: How To Adjust The Function Pump Standby Pressure

    Service and Repair Manual April 2018 Hydraulic Pump How to Adj ust the Functi on Pum p Standby Pr ess ure How to Adjust the Function Pump 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 59: How To Adjust The Function Pump Pressure Compensator

    April 2018 Service and Repair Manual Hydraulic Pump How to Adj ust the Functi on Pum p Press ure Com pens ator How to Adjust the Function Pump Loosen the set screw for the standby pressure adjustment screw. Standby Pressure Note: Two people will be required to perform this procedure.
  • Page 60 Service and Repair Manual April 2018 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 61: Manifolds

    April 2018 Service and Repair Manual Manifolds PVG Manifold Components The Proportional Valve Group manifold is located at the rear of the chassis. Index Description Function Assembly, lift Lift functions Assembly, extend/retract Extend/retract functions Assembly, tilt Tilt functions Assembly, sway Sway functions Assembly, auxiliary Auxiliary functions...

  • Page 62: Secondary Function Manifold Components

    Service and Repair Manual April 2018 Manifolds Secondary Function Manifold Components The secondary function manifold is located under the manifold inspection cover. Index Schematic Description Function Torque Item DO3 valve, 3 position 4 way SVD1 Steer left/right 60 in-lbs / 6.8 Nm Pressure reducing/relief valve, 50 psi / Rear lock-up circuit 30-35 ft-lbs / 41-47.5 Nm...
  • Page 63 April 2018 Service and Repair Manual Manifolds Part No. 1287211GT GTH-1056...

  • Page 64: Outrigger Manifold Components

    Service and Repair Manual April 2018 Manifolds Outrigger Manifold Components The outrigger manifold is located under the outrigger inspection cover. Index Schematic Description Function Torque Item Solenoid valve, 3 position 4 way Left outrigger 40 ft-lbs / 54 Nm extend/retract Solenoid valve, 3 position 4 way Right outrigger 40 ft-lbs / 54 Nm...
  • Page 65 April 2018 Service and Repair Manual Manifolds Part No. 1287211GT GTH-1056...

  • Page 66: Brake Manifold Components

    Service and Repair Manual April 2018 Manifolds 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 Clutch cut-off pressure 11 ft-lbs / 14.9 Nm Pressure switch, 50 psi / 3.4 bar Brake light pressure (option) 11 ft-lbs / 14.9 Nm...

  • Page 67: Ac Hydraulic Manifold Components

    April 2018 Service and Repair Manual Manifolds AC Hydraulic Manifold Components The AC Hydraulic manifolds are located under the manifold inspection cover. Index Schematic Description Function Torque Item Solenoid valve, 2 position 2 way Controls motor 20 ft-lbs / 27.1 Nm Flow control valve, 3 gpm/ 11.3 lpm Regulates flow 33-37 ft-lbs / 45-50 Nm...

  • Page 68: Valve Adjustments - Secondary Function Manifold

    Service and Repair Manual April 2018 Manifolds 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. How to Set the Parking Brake How to Set the Parki ng Br ake Sy stem Pr ess ure Result: The pressure gauge fails to read...

  • Page 69: How To Set The Differential Lock/Joystick System Pressure

    April 2018 Service and Repair Manual Manifolds How to Set the Differ enti al Lock/J oysti ck System Press ure How to Set the Differential Start the engine. Allow the engine to idle. Lock/Joystick System Pressure Result: The pressure gauge reads 400 psi / 27.5 bar.

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

    Service and Repair Manual April 2018 Manifolds How to Set the R ear Lock-up Sys tem Pressur e How to Set the Rear Lock-up Start the engine. Allow the engine to idle. System Pressure Result: The pressure gauge reads 50 psi / 3.4 bar.

  • Page 71: Valve Coils

    April 2018 Service and Repair Manual Manifolds Valve Coil Resistance 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 April 2018 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

    April 2018 Service and Repair Manual Axle Support and secure the axle to an appropriate lifting device. Axles Remove the fasteners securing the sway How to Remove the Axle How to R emove the Axl e cylinder rod-end pivot pin to the chassis. Use a soft metal drift to remove the pivot pin.

  • Page 74: Outriggers

    Service and Repair Manual April 2018 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 R emove an Outrigger Crushing hazard. The cylinder may become unbalanced and fall Extend the outrigger until the pad just touches if not properly supported when...

  • Page 75: How To Remove An Outrigger Cylinder

    April 2018 Service and Repair Manual Outriggers How to R emove an Outrigger Cyli nder How to Remove an Outrigger 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: Fault Codes

    Service and Repair Manual April 2018 Fault Codes Before Troubleshooting: Section 4 Faul t Codes  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.

  • Page 77: Diagnostic Display

    April 2018 Service and Repair Manual Diagnostic Display When the engine Electronic Control Module (ECM) Decoding Fault Codes detects an abnormal operating condition, a fault The Suspect Parameter Number (SPN) and the code is immediately stored in the ECM memory. Failure Mode Identifier (FMI), when combined, are The fault code is displayed on the LCD display the basis for an engine fault code.

  • Page 78: Deutz Tcd3.6 Engine Fault Codes

    Service and Repair Manual April 2018 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; signal out of range, short circuit to ground Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8);...
  • Page 79 April 2018 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 Air filter differential pressure; system reaction initiated Sensor error airfilter differential pressure; short circuit to battery Sensor error airfilter differential pressure;...
  • Page 80 Service and Repair Manual April 2018 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 81 April 2018 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 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 82 Service and Repair Manual April 2018 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 83 April 2018 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 1188 Wastegate; status message from ECU missing Wastegate actuator; blocked Turbo charger wastegate actuator;...
  • Page 84 Service and Repair Manual April 2018 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 85 April 2018 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 3248 Exhaust gas temperature particulate filter downstream; out of range, system reaction initiated Exhaust gas temperature particulate filter downstream;...
  • Page 86 Service and Repair Manual April 2018 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 87 April 2018 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 4375 Urea pump motor; short circuit to battery Urea pump motor; short circuit to ground Urea pump motor;...
  • Page 88 Service and Repair Manual April 2018 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 89 April 2018 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 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 90 Service and Repair Manual April 2018 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 91 April 2018 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 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 92 Service and Repair Manual April 2018 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 93 April 2018 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 23917 65165 0 Physical range check high for DV1 & DV2 upstream pressure; shut off regeneration Physical range check low for DV1 &...
  • Page 94 Service and Repair Manual April 2018 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 95 April 2018 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 23943 65191 9 Timeout Error (PCK2PCK) for CAN-Receive-Frame AT1OGCVol2 information; factors & Sensorcalibration for NOX Sensor (SCR-system downstream cat;...
  • Page 96 Service and Repair Manual April 2018 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 97 April 2018 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 24011 65259 0 Zerofuel calibration injector 7 (in firing order); maximum value exceeded Zerofuel calibration injector 7 (in firing order);...
  • Page 98 Service and Repair Manual April 2018 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 99 April 2018 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 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 100 Service and Repair Manual April 2018 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 101 April 2018 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 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 102: Perkins 1104 Engine Fault Codes

    Service and Repair Manual April 2018 Perkins 1104 Engine Fault Codes FMI Description SPN = Suspect Parameter Number Fuel rail pressure open/short to battery FMI = Failure Mode Identifier positive (+) FMI Description Fuel rail pressure short to ground Incorrect throttle switch inputs System voltage high Throttle position sensor: voltage above System voltage low...
  • Page 103 April 2018 Service and Repair Manual Perkins 1104 Engine Fault Codes SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Cylinder #3 injector data incorrect Cylinder #3 injector open circuit Cylinder #3 injector short Cylinder #3 injector not responding Cylinder #4 injector data incorrect Cylinder #4 injector open circuit Cylinder #4 injector short...

  • Page 104: Schematics

    Service and Repair Manual April 2018 Schematics About This Section Section 5 Schem atics 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

    April 2018 Service and Repair Manual 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, GTH-1056 only) Part No. 1287211GT GTH-1056...

  • Page 106: Fuse Panel Layout

    Service and Repair Manual April 2018 Fuse Panel Layout Deutz T3 - Perkins T3 – Perkins T4i CB1- 50A- Control System Power CB3- 60A- Glow Plugs Perkins T4i *CB2 50A- Engine Power / ECM Deutz T3 - Perkins T3 *CB2 30A- Engine Power / ECM Deutz T4F CB4 50A-EAT Power CB2 50A- ECM Power...

  • Page 107: Deutz Tcd3.6 T4F Module

    April 2018 Service and Repair Manual Deutz TCD3.6 T4F Module Deutz TCD3.6 T4F Engine only Located in the Tank Assembly with the circuit breaker panel Part No. 1287211GT GTH-1056...

  • Page 108: Electrical Component & Wire Color Abbreviation Legend

    Service and Repair Manual April 2018 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 30 Amp or 50 Amp Circuit Breaker 10 Amp - Aux Hydraulics 30 Amp or 50 Amp Circuit Breaker 10 Amp –...
  • Page 109 April 2018 Service and Repair Manual Electrical Component & Wire Color Abbreviation Legend Item Description Item Description LED Light Switch Ignition Power ON Key Start Switch Options Power Relay ON Boom Extend Switch Horn Relay ON Parking Brake Pressure Switch Turn Signal ON Service Brake Pressure Switch Road Lights, Work Lights ON...
  • Page 110 Service and Repair Manual April 2018 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 111: Telematics Connector Pin Legend

    April 2018 Service and Repair Manual Telematics Connector Pin Legend Genie installed Telematics connector is wired with an Active High digital input. Circuit Type Circuit Properties Genie Machine Function(s) Telematics Use Case System Power 12 VDC Battery Positive – constant power Supply power to device 5 Amp Max.
  • Page 112 Service and Repair Manual April 2018 Telematics Connector Pin Legend Remote Disable Engine Start Relay Configuration Telematics Active High - Schematic Telematics Active Low - Schematic (standard wiring) (optional wiring) Ignition Start Input Relay Telematics with Active High input Telematics with Active Low input Wireless Certifications Telematic device(s) should comply with specific wireless carrier certifications where applicable and comply with the following:...

  • Page 113: Electrical Symbol Legend

    April 2018 Service and Repair Manual 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 Quick disconnect...

  • Page 114: Hydraulic Symbols Legend

    Service and Repair Manual April 2018 Hydraulic Symbols Legend Orifice with size Check valve Shut off valve Brake Pump, bi-directional Motor, 2 speed Pump, fixed displacement Motor, bi-directional variable displacement bi-directional Pump, prime mover (engine Shuttle valve. 2 position, Cylinder, double acting Differential sensing valve or motor) 3 way...

  • Page 115: Electrical Schematics

    April 2018 Service and Repair Manual Harness Map - Harness Legend...

  • Page 116: Harness Map - Wire Harness Legend

    Service and Repair Manual April 2018 Harness Map - Harness Legend GTH-1056 Part No. 1287211GT...

  • Page 117: Harness Map - Control System Electronic Joystick

    April 2018 Service and Repair Manual Harness Map - Control System- Electronic Joystick Part No. 1287211GT GTH-1056...
  • Page 118 Service and Repair Manual April 2018 Harness Map - Control System- Electronic Joystick...
  • Page 119 April 2018 Service and Repair Manual Harness Map - Deutz T4F Engine...
  • Page 120 Service and Repair Manual April 2018 Harness Map - Deutz T4F Engine GTH-1056 Part No. 1287211GT...

  • Page 121: Harness Map - Deutz T3 Engine

    April 2018 Service and Repair Manual Harness Map - Deutz T3 Engine Part No. 1287211GT GTH-1056...
  • Page 122 Service and Repair Manual April 2018 Harness Map - Deutz T3 Engine...
  • Page 123 April 2018 Service and Repair Manual Harness Map - Perkins T4i Engine...

  • Page 124: Harness Map - Perkins T4I Engine

    Service and Repair Manual April 2018 Harness Map - Perkins T4i Engine GTH-1056 Part No. 1287211GT...

  • Page 125: Harness Map - Perkins T3 Engine

    April 2018 Service and Repair Manual Harness Map - Perkins T3 Engi Part No. 1287211GT GTH-1056...
  • Page 126 Service and Repair Manual April 2018 Harness Map - Perkins T3 Engine...
  • Page 127 April 2018 Service and Repair Manual Harness Map - Road Lights...

  • Page 128: Harness Map - Road Light Option

    Service and Repair Manual April 2018 Harness Map - Road Lights GTH-1056 Part No. 1287211GT...

  • Page 129: Harness Map - Work Light Option

    April 2018 Service and Repair Manual Harness Map - Work Lights Part No. 1287211GT GTH-1056...
  • Page 130 Service and Repair Manual April 2018 Harness Map - Work Lights...
  • Page 131 April 2018 Service and Repair Manual Harness Map - Deutz HVAC Option...

  • Page 132: Harness Map - Deutz Hvac Option

    Service and Repair Manual April 2018 Harness Map - Deutz HVAC Option GTH-1056 Part No. 1287211GT...

  • Page 133: Harness Map - Perkins Hvac Option

    April 2018 Service and Repair Manual Harness Map - Perkins HVAC Option Part No. 1287211GT GTH-1056...
  • Page 134 Service and Repair Manual April 2018 Harness Map - Perkins HVAC Option...
  • Page 135 April 2018 Service and Repair Manual Harness Map - Enclosed Cab Heater...

  • Page 136: Harness Map - Heater Option

    Service and Repair Manual April 2018 Harness Map - Enclosed Cab Heater GTH-1056 Part No. 1287211GT...
  • Page 137 April 2018 Service and Repair Manual Harness Map - Proximity Sensor, Beacon, Lockout Options Part No. 1287211GT GTH-1056...
  • Page 138 Service and Repair Manual April 2018 Harness Map - Proximity Sensor, Beacon, Lockout Options...
  • Page 139 April 2018 Service and Repair Manual Electrical Schematic- View 1...

  • Page 140: Electrical Schematic (From Gth10E-12500)

    Service and Repair Manual April 2018 Electrical Schematic- View 1 GTH-1056 Part No. 1287211GT...
  • Page 141 April 2018 Service and Repair Manual Electrical Schematic- View 2 500) Part No. 1287211GT GTH-1056...
  • Page 142 Service and Repair Manual April 2018 Electrical Schematic- View 2...
  • Page 143 April 2018 Service and Repair Manual Electrical Schematic- Deutz T4F Eng Harness...

  • Page 144: Electrical Schematic- Deutz T4F Engine Harness

    Service and Repair Manual April 2018 Electrical Schematic- Deutz T4F Eng Harness Page 1 of 3 GTH-1056 Part No. 1287211GT...
  • Page 145 April 2018 Service and Repair Manual Electrical Schematic- Deutz T4F Eng Harness Page 2 of 3 Part No. 1287211GT GTH-1056...
  • Page 146 Service and Repair Manual April 2018 Electrical Schematic- Deutz T4F Eng Harness...
  • Page 147 April 2018 Service and Repair Manual Electrical Schematic- Deutz T4F Eng Harness...
  • Page 148 Service and Repair Manual April 2018 Electrical Schematic- Deutz T4F Eng Harness Page 3 of 3 GTH-1056 Part No. 1287211GT...
  • Page 149 April 2018 Service and Repair Manual Electrical Schematic- Deutz Tier 3 Eng Harness Part No. 1287211GT GTH-1056...
  • Page 150 Service and Repair Manual April 2018 Electrical Schematic- Deutz T3 Eng Harness...

  • Page 151: Hydraulic Schematics

    April 2018 Service and Repair Manual Hydraulic Schematic...

  • Page 152: Hydraulic Schematic

    Service and Repair Manual April 2018 Hydraulic Schematic GTH-1056 Part No. 1287211GT...
  • Page 153 April 2018 Service and Repair Manual Hydraulic Schematic Part No. 1287211GT GTH-1056...
  • Page 154 Service and Repair Manual April 2018 Hydraulic Schematic GTH-1056 Part No. 1287211GT Servic e and R epair M anual April 2018...

This manual is also suitable for:

Genie gth-1056

Table of Contents