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

Terex Genie GTH -1056 Service And Repair Manual

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Service and Repair Manual
GTH
-1056
™
Serial Number Range
From GTH1016E-11305 to
f
GTH1016E-11799
includes GTH1016E-11281
GTH1016E-11282
GTH1016E-11286
from GTH10E-11800 to
GTH10E-12499
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
Part No. 1278145
Rev B2
April 2018

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Summary of Contents for Terex Genie GTH -1056

  • Page 1 Service and Repair Manual Serial Number Range -1056 ™ From GTH1016E-11305 to This manual includes: GTH1016E-11799 Repair procedures includes GTH1016E-11281 GTH1016E-11282 Fault Codes GTH1016E-11286 Electrical and from GTH10E-11800 to Hydraulic Schematics GTH10E-12499 For detailed maintenance procedures, refer to the appropriate Maintenance Manual for your machine.

  • Page 2: Find A Manual For This Model

    Copyright © 2016 by Terex Corporation 1278145 Rev B1, April 2018 Second 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 3/2016 Initial Release 4/2016 Repair Revise manifold torque values 8/2017 Specifications added T4F specifications Repair added ZF transmission repair manual Schematics updated fuse panel layout; updated electrical component legend;...

  • 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 Cable Bridge Assembly ..........21 How to Replace the Retraction Chain ............. 22 How to Replace the Extension Chains ............24 How to Remove the Boom ................26 How to Disassemble the Boom - GTH-1056 ........... 28 1-3 Boom Lift Cylinder ..................
  • Page 9 April 2018 Table of Contents Hydraulic Pump ....................47 6-1 Hydraulic Pump ....................47 How to Test the Function Pump ..............47 How to Remove the Function Pump ............... 48 How to Install the Function ................49 How to Prime the Function Pump ..............49 How to Adjust the Function Pump Standby Pressure ........
  • Page 10 April 2018 Table of Contents Deutz TCD3.6 Engine Fault Codes ..............81 Perkins 1104 Engine Fault Codes ..............105 Section 5 Schematics ......................107 Introduction ......................107 Proximity Switch Legend ..................108 Fuse Panel Layout ....................109 Deutz TCD3.6 T4F Module................. 110 Electrical Component &...

  • 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 Primary Function Manifold System relief valve pressure, maximum 3500 psi Specifications (measured at test port TP) 241 bar Plug torque Boom extend relief valve pressure, 3500 psi maximum 241 bar SAE No. 2 50 in-lbs / 6 Nm Fork tilt relief valve pressure, maximum 3500 psi...

  • Page 17: Def Storage Specifications

    April 2018 Service and Repair Manual Specifications DEF Storage Specifications Diesel Exhaust Fluid decomposes when exposed to elevated temperatures for an extended period of time. Therefore precautions must be taken to avoid prolonged exposure to elevated temperatures. Temperature Estimated Useful Life 32°F / 0°C Indefinite 50°F / 10°C...

  • Page 18: Deutz Tcd3.6 L4 Engine Specifications

    Service and Repair Manual April 2018 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 19: Deutz Tcd3.6 L4 T4F Engine Specifications

    April 2018 Service and Repair Manual 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 20: Perkins 1104D-E44Ta Engine Specifications

    Service and Repair Manual April 2018 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 21: Perkins 1204E-E44Ta Engine Specifications

    April 2018 Service and Repair Manual 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 22: Zf 4 Wg-98 Tc Transmission Specifications

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

  • Page 23: Hydraulic Hose And Fitting Torque Specifications

    April 2018 Service and Repair Manual 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 24: Torque Procedure

    Service and Repair Manual April 2018 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 25 April 2018 Service and Repair Manual 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 26: Repair Procedures

    Service and Repair Manual April 2018 Repair Procedures Section 3 Repair Pr oc edures Machine Configuration: 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 27 April 2018 Service and Repair Manual 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 28: Boom Components

    Service and Repair Manual April 2018 Boom Components How to T est a Pr oxi mity Switc h How to Test a 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 29: How To Adjust The Boom Angle Proximity Switch

    April 2018 Service and Repair Manual Boom Components How to Adj ust the Boom Angle Proxi mity Swi tch How to Adj ust the Boom Extend Proxi mity Switc h How to Adjust the Boom Angle How to Adjust the Boom Extend Proximity Switch Proximity Switch The boom angle proximity switch is attached to a...

  • Page 30: Boom

    Service and Repair Manual April 2018 Boom Components How to R emove the Lifting F or k Fr ame How to Remove the Lifting Fork Boom Frame With the boom in the stowed position, attach a How to R eplac e the Boom Wear Pads How to Replace the Boom Wear lifting strap from an overhead crane to the top Pads...

  • Page 31: How To Remove The Cable Bridge Assembly

    April 2018 Service and Repair Manual Boom Components How to R emove the C able Bridg e Assembl y 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.

  • Page 32: 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 33 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 34: How To Replace The Extension Chains

    Service and Repair Manual April 2018 Boom Components How to R eplac e the Extensi on 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 onto Chains the boom assembly using the pivot pin removed in step 10.
  • Page 35 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 36: 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 37 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 38: 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 39 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 40 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 41: 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. Use a soft metal drift to remove the pivot pin. How to Remove the Lift Cylinder Crushing hazard.

  • Page 42: 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 Remove the fasteners securing the extension Cylinder cylinder pivot pins to the boom.

  • Page 43: Fork Level Cylinder

    April 2018 Service and Repair Manual Boom Components Tag, disconnect and plug the fork level cylinder hoses from the cylinder manifolds. Cap the Fork Level Cylinder fittings. Bodily injury hazard. Spraying How to Remove the Fork Level hydraulic oil can penetrate and Cylinder burn skin.

  • Page 44: 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 R eplac e the F or k Level and/or Auxili ar y C ylinder Hoses , GTH-1056 How to Replace the Fork Level hard lines.
  • Page 45 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 46: Operator's Compartment

    Service and Repair Manual April 2018 Operator's Compartment Locate the brake manifold under the manifold inspection cover. Tag, disconnect and plug the Operator's Compartment hydraulic hose at the underside of the brake manifold. Cap the fitting. Refer to Brake Manifold Components. How to Remove the Operator's Working under the dashboard, locate the Compartment...
  • Page 47 April 2018 Service and Repair Manual Operator's Compartment 11 Models with dual joystick: Tag, disconnect 17 Support and secure the operator's and plug the hydraulic hoses at ports JT2, JT4, compartment to an adjustable table capable of JS3 and JS1 of the primary function manifold. supporting the weight and that will allow the Cap the fittings.

  • Page 48: Machine Controls

    Service and Repair Manual April 2018 Operator's Compartment How to R emove the Steering Wheel How to Remove the Steering Machine Controls Wheel Open the access door above the hydraulic How to R emove the Steering Col umn How to Remove the Steering tank.

  • Page 49: How To Remove The Steer Orbitral

    April 2018 Service and Repair Manual Operator's Compartment How to R emove the Steer Or bitral How to R emove the Joystic k - Models with Si ngle J oys tic k How to Remove the Steer Orbitral How to Remove the Joystick - Models with Single Joystick Remove the steering column.

  • Page 50: How To Remove The Joystick - Models With Dual Joysticks

    Service and Repair Manual April 2018 Operator's Compartment How to R emove the Joystic k - Models with Dual J oys tic ks How to R emove the Brake Pedal Ass embl y How to Remove the Joystick - How to Remove the Brake Pedal Models with Dual Joysticks Assembly Disconnect the battery from the machine.

  • Page 51: How To Remove The Gauge Cluster Assembly

    April 2018 Service and Repair Manual Operator's Compartment How to R emove the Gauge Clus ter Ass embl y How to R emove the Di agnostic Displ ay How to Remove the Gauge How to Remove the Gauge Cluster Assembly Cluster Assembly Disconnect the battery from the machine.

  • Page 52: Fuel And Hydraulic Tanks

    Service and Repair Manual April 2018 Fuel and Hydraulic Tanks Place a drain pan or other suitable container under the hydraulic tank. Refer to Fuel and Hydraulic Tanks Specifications, Machine Specifications. Remove the drain plug from the hydraulic tank How to Remove the Fuel and and completely drain the tank.

  • Page 53: Engines

    April 2018 Service and Repair Manual Engines How to R emove the Engine 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 R epair the Per ki ns 1104D-E44T A Engi ne How to Repair the Perkins end must be replaced.

  • Page 54: 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 55: Transmission

    April 2018 Service and Repair Manual Transmission Bodily injury hazard. Spraying hydraulic oil can penetrate and Transmission burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate How to R epair the Trans missi on How to Repair the Transmission gradually.
  • Page 56 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 57: 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 T est the Func tion Pump 220 bar, immediately stop. The pump is good. How to Test the Function Pump Result: If the pressure fails to reach 3190 psi / Note: When removing a hose assembly or fitting,...

  • Page 58: How To Remove The Function Pump

    Service and Repair Manual April 2018 Hydraulic Pump How to R emove the Functi on Pump 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 59: How To Install The Function

    April 2018 Service and Repair Manual Hydraulic Pump How to Ins tall the F uncti on How to Prime the F uncti on 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 60: How To Adjust The Function Pump Standby Pressure

    Service and Repair Manual April 2018 Hydraulic Pump How to Adj ust the Functi on Pump 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 oil Standby Pressure level is even with the bottom of the hole.

  • Page 61: How To Adjust The Function Pump Pressure Compensator

    April 2018 Service and Repair Manual Hydraulic Pump How to Adj ust the Functi on Pump Press ure Compens 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 62 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.
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  • Page 64: Manifolds

    Service and Repair Manual April 2018 Manifolds Primary Function Manifold Components - Models with Single Joystick The primary function manifold is located under the manifold inspection cover. Index Schematic Description Function Torque Item Solenoid valve, 2 position 4 way Function select -boom extend and 40 ft-lbs / 54 Nm sway left Directional valve, 3 position 4 way,...
  • Page 65 April 2018 Service and Repair Manual Manifolds Part No. 1278145 TH-1056...
  • Page 66 Service and Repair Manual April 2018 Manifolds Primary Function Manifold Components - Models with Single Joystick The primary function manifold is located under the manifold inspection cover. Index Schematic Description Function Torque Item Check valve, 5 psi / 0.3 bar Boom extend circuit 20 ft-lbs / 27 Nm Check valve, 5 psi / 0.3 bar...
  • Page 67 April 2018 Service and Repair Manual Manifolds Part No. 1278145 TH-1056...

  • Page 68: Primary Function Manifold Components - Models With Dual Joysticks

    Service and Repair Manual April 2018 Manifolds Primary Function Manifold Components - Models with Dual Joysticks The primary function manifold is located under the manifold inspection cover. Index Schematic Description Function Torque Item Directional valve, 3 position 4 way, pilot Sway left/right 50 ft-lbs / 68 Nm operated...
  • Page 69 April 2018 Service and Repair Manual Manifolds Part No. 1278145 TH-1056...
  • Page 70 Service and Repair Manual April 2018 Manifolds Primary Function Manifold Components - Models with Dual Joysticks The primary function manifold is located under the manifold inspection cover. Index Schematic Description Function Torque Item Check valve, 5 psi / 0.3 bar Sway right circuit 20 ft-lbs / 27.1 Nm Check valve, 5 psi / 0.3 bar...
  • Page 71 April 2018 Service and Repair Manual Manifolds Part No. 1278145 TH-1056...

  • Page 72: 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 Steer left/right 60 in-lbs / 6.8 Nm Pressure reducing/relief valve, 50 psi / Rear lock-up circuit 35 ft-lbs / 47.5 Nm...
  • Page 73 April 2018 Service and Repair Manual Manifolds Part No. 1278145 TH-1056...

  • Page 74: 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 75 April 2018 Service and Repair Manual Manifolds Part No. 1278145 TH-1056...

  • Page 76: Auxiliary Manifold Components (Option)

    Service and Repair Manual April 2018 Manifolds Auxiliary Manifold Components (option) The auxiliary manifold is located under the transmission inspection cover. Index Schematic Description Function Torque Item Check valve, 5 psi / 0.3 bar Auxiliary 'A1' circuit 12-14 ft-lbs / 16-19 Nm DO3 valve, 3 position 4 way Auxiliary function enable 60 in-lbs / 6.8 Nm...

  • Page 77: Brake Manifold Components

    April 2018 Service and Repair Manual 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 78: Ac Hydraulic Manifold Components

    Service and Repair Manual April 2018 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 79: Valve Adjustments - Secondary Function Manifold

    April 2018 Service and Repair Manual Manifolds Start the engine. Allow the engine to idle. Valve Adjustments - Secondary Fully turn and hold the steering wheel in the left direction and allow the wheels to fully turn to Function Manifold the left.

  • Page 80: How To Set The Parking Brake System Pressure

    Service and Repair Manual April 2018 Manifolds How to Set the Par ki ng Brake System Pr ess ure How to Set the Parking Brake Start the engine. Allow the engine to idle. System Pressure Result: The pressure gauge reads 400 psi / 27.5 bar.

  • Page 81: How To Set The Differential Lock/Joystick System Pressure

    April 2018 Service and Repair Manual Manifolds How to Set the Differ enti al Loc k/J oystic k 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 82: How To Set The Rear Lock-Up System Pressure

    Service and Repair Manual April 2018 Manifolds How to Set the R ear Loc k-up System 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 83: Valve Coils

    April 2018 Service and Repair Manual Manifolds Valve Coil Resistance Specification Valve Coils Note: The following coil resistance specifications are at an ambient temperature of 68°F / 20°C. As How to Test a Coil 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 84 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 85: 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 R emove the Axl e cylinder rod-end pivot pin to the chassis. How to Remove the Axle Use a soft metal drift to remove the pivot pin.

  • Page 86: 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 R emove an Outrigger How to Remove 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 87: 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 88 Service and Repair Manual April 2018 This page intentionally left blank. TH-1056 Part No. 1278145...

  • Page 89: Fault Codes

    April 2018 Service and Repair Manual Fault Codes Section 4 Faul t Codes 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.

  • Page 90: Diagnostic Display

    Service and Repair Manual April 2018 Diagnostic Display Stored fault codes are the cumulative history of fault codes which the ECM has detected. These fault When the engine Electronic Control Module (ECM) codes may be recalled by service personnel at a detects an abnormal operating condition, a fault later time even if the condition which caused the code is immediately stored in the ECM memory.

  • Page 91: Deutz Tcd3.6 Engine Fault Codes

    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 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 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 Air filter differential pressure; system reaction initiated Sensor error airfilter differential pressure; short circuit to battery Sensor error airfilter differential pressure;...
  • 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 Oil temperature; out of range, system reaction initiated Physical range check low for oil temperature Oil temperature;...
  • 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 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 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 Cold start aid relay open load Cold start aid relay; over temperature error Timeout Error of CAN-Receive-Frame TSC1TE;...
  • 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 1188 Wastegate; status message from ECU missing Wastegate actuator; blocked Turbo charger wastegate actuator;...
  • 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 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 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 3248 Exhaust gas temperature particulate filter downstream; out of range, system reaction initiated Exhaust gas temperature particulate filter downstream;...
  • 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 4243 SCR system heater diagnostic reports error; shut off SCR-system 4334 Urea pump pressure;...
  • 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 4375 Urea pump motor; short circuit to battery Urea pump motor; short circuit to ground Urea pump motor;...
  • 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 23006 64254 3 Controller mode switch; short circuit to battery Controller mode switch;...
  • Page 102 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 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 103 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 23698 64946 11 Shut off request from supervisory monitoring function 23704 Timeout Error of CAN-Transmit_Frame EEC3 23717 64965 12...
  • Page 104 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 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 105 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 23911 65159 0 Burner dosing valve (DV2); overcurrent at the end of the injection phase Burner dosing valve (DV2);...
  • Page 106 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 23917 65165 0 Physical range check high for DV1 & DV2 upstream pressure; shut off regeneration Physical range check low for DV1 &...
  • Page 107 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 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 108 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 23943 65191 9 Timeout Error (PCK2PCK) for CAN-Receive-Frame AT1OGCVol2 information; factors & Sensorcalibration for NOX Sensor (SCR-system downstream cat;...
  • Page 109 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 23984 UB6; Short circuit to battery error of actuator relay 6 23986 Actuator relay 5;...
  • Page 110 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 24011 65259 0 Zerofuel calibration injector 7 (in firing order); maximum value exceeded Zerofuel calibration injector 7 (in firing order);...
  • Page 111 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 24035 65283 12 Injector diagnostics; time out error in the SPI communication 24036 65284 12 Injector diagnostics Slave;...
  • Page 112 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 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 113 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 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 114 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 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 115: Perkins 1104 Engine Fault Codes

    April 2018 Service and Repair Manual 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 116 Service and Repair Manual April 2018 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 117: Schematics

    April 2018 Service and Repair Manual Schematics Section 5 Schematics About This Section 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. Remove all rings, Troubleshooting and repair procedures shall be watches and other jewelry.

  • Page 118: Proximity Switch Legend

    Service and Repair Manual April 2018 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) TH-1056 Part No. 1278145...

  • Page 119: Fuse Panel Layout

    April 2018 Service and Repair Manual Fuse Panel Layout Circuit Breakers located in the tank assembly All Engine Options CB4- 60A- Glow Plugs CB3- 500A- Control System Power Deutz T3; Perkins T3 CB1- 30A- ECM Power CB2 not used Perkins T4i CB1- 50A- ECM Power CB2 not used Deutz T4F...

  • Page 120: Deutz Tcd3.6 T4F Module

    Service and Repair Manual April 2018 Deutz TCD3.6 T4F Module Deutz TCD3.6 T4F Engine only Located in the Tank Assembly with the circuit breaker panel TH-1056 Part No. 1278145...

  • Page 121: Electrical Component & Wire Color Abbreviation Legend

    April 2018 Service and Repair Manual 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 50 Amp Circuit Breaker 10 Amp –...
  • Page 122 Service and Repair Manual April 2018 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 123 April 2018 Service and Repair Manual Electrical Component & Wire Color Abbreviation Legend Item Description Wire Color Legend 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 124: Telematics Connector Pin Legend

    Service and Repair Manual April 2018 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 125 April 2018 Service and Repair Manual 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 126: Electrical Symbol Legend

    Service and Repair Manual April 2018 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 127: Hydraulic Symbols Legend

    April 2018 Service and Repair Manual 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 128 Service and Repair Manual April 2018 This page intentionally left blank. TH-1056 Part No. 1278145...

  • Page 129: Electrical Schematics

    April 2018 Service and Repair Manual Electrical Schematic (before GTH10E-11890)

  • Page 130: Electrical Schematic (To Gth10E-11889)

    Service and Repair Manual April 2018 Electrical Schematic (before GTH10E-11890) TH-1056 Part No. 1278145...
  • Page 131 April 2018 Service and Repair Manual Electrical Schematic (before GTH10E-11890) Part No. 1278145 TH-1056...
  • Page 132 Service and Repair Manual April 2018 Electrical Schematic (before GTH10E-11890)
  • Page 133 April 2018 Service and Repair Manual Electrical Schematic (from GTH10E-11890 to 12499)

  • Page 134: Electrical Schematic (From Gth10E-11890 To 12499)

    Service and Repair Manual April 2018 Electrical Schematic (from GTH10E-11890 to 12499) TH-1056 Part No. 1278145...
  • Page 135 April 2018 Service and Repair Manual Electrical Schematic (from GTH10E-11890 to 12499) Part No. 1278145 TH-1056...
  • Page 136 Service and Repair Manual April 2018 Electrical Schematic (from GTH10E-11890 to 12499)
  • Page 137 April 2018 Service and Repair Manual Electrical Schematic (from GTH10E-11890 to 12499) Enclosed Cab Option...
  • Page 138 Service and Repair Manual April 2018 Electrical Schematic (from GTH10E-11890 to 12499) Enclosed Cab Option TH-1056 Part No. 1278145...
  • Page 139 April 2018 Service and Repair Manual Electrical Schematic (from GTH10E-11890 to GTH10E-12499)
  • Page 140 Service and Repair Manual April 2018 Electrical Schematic- Deutz T4F Eng Harness...

  • Page 141: Electrical Schematic- Deutz T4F Engine Harness

    April 2018 Service and Repair Manual Electrical Schematic- Deutz T4F Eng Harness Page 1 of 3 Part No. 1278145 TH-1056...
  • Page 142 Service and Repair Manual April 2018 Electrical Schematic- Deutz T4F Eng Harness Page 2 of 3 TH-1056 Part No. 1278145...
  • Page 143 April 2018 Service and Repair Manual Electrical Schematic- Deutz T4F Eng Harness...
  • Page 144 Service and Repair Manual April 2018 Electrical Schematic- Deutz T4F Eng Harness...
  • Page 145 April 2018 Service and Repair Manual Electrical Schematic- Deutz T4F Eng Harness Page 3 of 3 Part No. 1278145 TH-1056...
  • Page 146 Service and Repair Manual April 2018 Electrical Schematic- Deutz Tier 3 Eng Harness TH-1056 Part No. 1278145...

  • Page 147: Electrical Schematic- Deutz T3 Engine Harness

    April 2018 Service and Repair Manual Electrical Schematic- Deutz T3 Eng Harness...

  • Page 148: Hydraulic Schematics

    Service and Repair Manual April 2018 Hydraulic Schematic - Models with Single Joystick...

  • Page 149: Hydraulic Schematic - Models With Single Joystick (To Sn Gth10E-12499)

    April 2018 Service and Repair Manual Hydraulic Schematic - Models with Single Joystick Part No. 1278145 TH-1056...

  • Page 150: Hydraulic Schematic - Models With Dual Joystick (To Sn Gth10E-12499)

    Service and Repair Manual April 2018 Hydraulic Schematic - Models with Dual Joystick TH-1056 Part No. 1278145...
  • Page 151 April 2018 Service and Repair Manual Hydraulic Schematic - Models with Dual Joystick...
  • Page 152 Service and Repair Manual April 2018 TH-1056 Part No. 1278145 Ser vic e and R epair M anual April 2018...

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