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Terex GTH08E-11500 Service And Repair Manual

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Service and Repair Manual
GTH
-844
™
Serial Number Range
from GTH08E-11500
from GTH08T-14101
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. 1288232GT
Rev B
September 2021

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Summary of Contents for Terex GTH08E-11500

  • Page 1 Service and Repair Manual Serial Number Range -844 ™ from GTH08E-11500 This manual includes: from GTH08T-14101 Repair procedures Fault Codes Electrical and Hydraulic Schematics For detailed maintenance procedures, refer to the appropriate Maintenance Manual for your machine. Part No. 1288232GT...

  • Page 2: Introduction

    Copyright © 2016 by Terex Corporation 1288232GT Rev B, September 2021 First Edition, Second 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 September 2021 Service and Repair Manual Introduction Revision History Revision Date Section Procedure / Page / Description 4/2018 Initial Release 9/2021 Specification Hydraulic Component Specifications Machine Component Weights Repair 2-1, 7-2, 7-3, 7-4 Schematics Harness Maps, Electrical, Hydraulic Reference Examples: Electronic Version Section –...

  • Page 4: Serial Number Legend

    Service and Repair Manual September 2021 Introduction Serial Number Legend GTH08 E - 12345 MODEL: SERIAL NUMBER: GTH08E-12345 ATTACHMENT: YEAR OF MANUFACTURE: TOTAL TRUCK WEIGHT: lbs/ kg MAX. LIFT CAPACITY : 1 Model 4 Serial label (located inside fork frame) 2 Facility code 5 Serial number (stamped on chassis) 3 Sequence number...

  • Page 5: Safety Rules

    September 2021 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...
  • Page 6 Service and Repair Manual September 2021 Safety Rules Personal Safety Workplace Safety Any person working on or around a machine must Any person working on or around a machine must be aware of all known safety hazards. Personal be aware of all known safety hazards. Personal safety and the continued safe operation of the safety and the continued safe operation of the machine should be your top priority.

  • Page 7: Table Of Contents

    September 2021 Table of Contents Introduction Introduction ......................ii Important Information ..................... ii Find a Manual for this Model .................. ii Serial Number Legend ..................iv Section 1 Safety Rules ......................v General Safety Rules ..................... v Section 2 Specifications ....................... 1 Machine Specifications ...................
  • Page 8 September 2021 Table of Contents Section 3 Repair Procedures ..................... 16 Introduction ......................16 Boom Components .................... 18 1-1 Boom Proximity Switch .................. 18 How to Test a Proximity Switch ..............18 How to Adjust the Boom Angle Proximity Switch ........... 19 1-2 Boom ......................
  • Page 9 September 2021 Table of Contents Engines ........................ 39 4-1 Engines ......................39 How to Repair the Perkins 1104D-E44TA Engine .......... 39 How to Repair the Perkins 854E-34TA Engine ..........39 How to Repair the Deutz TCD3.6 Engine ............39 4-2 Engine Fault Codes ..................40 Transmission ......................
  • Page 10 Harness Map - Options Enclosed Cab with Heater ........... 108 Harness Map - Options Enclosed Cab with HVAC ..........109 Electrical Schematics ..................111 Electrical Schematic [from GTH08E-11500 to 13228] ........112 Electrical Schematic [from GTH08E-11500 to 13228] ........113 Electrical Schematic [from GTH08E-13229] ............116 Electrical Schematic [from GTH08E-13229] ............

  • Page 11: Specifications

    September 2021 Service and Repair Manual Specifications Section 2 Specific ati ons Machine Specifications Fluid capacities Fuel tank 32 gallons Tires and wheels 121.1 liters Tire size 13.00 x 24 Hydraulic tank 19 gallons 71.9 liters Tire ply rating Hydraulic system 34 gallons Weight, rough terrain tire 315 lbs...

  • Page 12: Performance Specifications

    Service and Repair Manual September 2021 Specifications Performance Specifications Boom function speeds, maximum Boom up 12 to 14 seconds Drive speed, maximum Boom down 9 to 11 seconds Deutz TCD3.6 T3/T4F Engines 15 mph Boom extend 13 to 15 seconds 24.1 km/h Boom retract 8 to 10 seconds...

  • Page 13: Hydraulic Oil Specifications

    September 2021 Service and Repair Manual Specifications Hydraulic Oil Specifications Do not top off with incompatible hydraulic fluids. Hydraulic fluids may be incompatible due to the Hydraulic Fluid Specifications differences in base additive Genie specifications require hydraulic oils which are chemistry.
  • Page 14 Service and Repair Manual September 2021 Specifications Chevron Rando HD Premium Oil Chevron 5606A Hydraulic Oil MV 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 33.5 cSt @ 104°F / 40°C...
  • Page 15 September 2021 Service and Repair Manual Specifications Petro-Canada Environ MV 46 UCON Hydrolube HP-5046 Fluid Fluid Properties Properties ISO Grade ISO Grade Viscosity index Viscosity index Kinematic Viscosity Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 149°F / 65°C cSt @ 104°F / 40°C 44.4 cSt @ 104°F / 40°C...

  • Page 16: Hydraulic Component Specifications

    Service and Repair Manual September 2021 Specifications Hydraulic Component Manifold Component Specifications Specifications Function pump Plug torque Type: variable displacement piston pump SAE No. 2 50 in-lbs / 6 Nm Displacement 0 to 3.1 cu in SAE No. 4 13 ft-lbs / 18 Nm 0 to 51 cc SAE No.

  • Page 17: Machine Component Weights

    September 2021 Service and Repair Manual Specifications Machine Component Weights Primary boom 6062 lbs 2750 kg Primary boom lift cylinder 622 lbs 282 kg Primary boom extend cylinder 438 lbs 199 kg Counterweight 1231 lbs (each) 558 kg Drive chassis assembly 4732 lbs 2146 kg 371 lbs...

  • Page 18: Deutz Tcd3.6 L4 Engine Specifications

    Service and Repair Manual September 2021 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 3.86 x 4.72 inches Bore and Stroke Manual for your engine.

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

    September 2021 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 3.86 x 4.72 inches Bore and Stroke...

  • Page 20: Perkins 1104D-E44Ta Engine Specifications

    Service and Repair Manual September 2021 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 23700 psi Number of cylinders 1635 bar 4.13 x 5 inches Bore and Stroke Starter motor...

  • Page 21: Perkins 854E-E34Ta Engine Specifications

    September 2021 Service and Repair Manual Specifications Perkins 854E-E34TA Engine Fuel injection system Injection pressure 23000 psi / Displacement 207 cu. in (1600 bar) 3.4 liters Fuel requirement Number of cylinders For fuel requirements, refer to the engine Operator 3.9 x 4.3 inches Bore and Stroke Manual for your engine.

  • Page 22: Dana Vdt12000 Transmission Specifications

    Service and Repair Manual September 2021 Specifications Dana VDT12000 Transmission Dana 212 Drive Axle Specifications Specifications Transmission Type 3 speed powershift converter Steering Integrated steer cylinder Speeds, Forward Joints Heavy duty double U-joints Speeds, Reverse Steering angle, maximum 45° Torque Converter Front Axle Lubrication Maximum input 3100 rpm...

  • Page 23: Hydraulic Hose And Fitting Torque Specifications

    September 2021 Service and Repair Manual Specifications Hydraulic Hose and Fitting SAE O-ring Boss Port Torque Specifications (tube fitting - installed into Aluminum) (all types) Your machine is equipped with Parker Seal-Lok™ SAE Dash Size Torque ORFS or 37° JIC fittings and hose ends. Genie specifications require that fittings and hose ends 14 ft-lbs / 19 Nm be torqued to specification when they are removed...

  • Page 24: Torque Procedure

    Service and Repair Manual September 2021 Specifications Torque Procedure JIC 37° fittings Align the tube flare (hex nut) against the nose Seal-Lok™ fittings of the fitting body (body hex fitting) and tighten the hex nut to the body hex fitting to Replace the O-ring.
  • Page 25 September 2021 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 September 2021 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 27 September 2021 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 September 2021 Boom Components How to T est a Pr oximity 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

    September 2021 Service and Repair Manual Boom Components How to Adj ust the Boom Angle Proximity Switch How to Adjust the Boom Angle Proximity Switch Boom The boom angle proximity switch is attached to a How to Replace the Boom Wear How to R eplac e the Boom W ear Pads mounting bracket, located between the boom and Pads...

  • Page 30: How To Remove The Lifting Fork Frame

    Service and Repair Manual September 2021 Boom Components How to R emove the Lifting F ork Fr ame How to Remove the Lifting Fork How to R eplac e the R etraction C hain How to Replace the Retraction Frame Chain With the boom in the stowed position, attach a Note: Perform this procedure on a firm, level...
  • Page 31 September 2021 Service and Repair Manual Boom Components Remove the inspection cover from the pivot 13 Now pull the chain carefully toward the pivot end of the boom. Locate the chain anchor of end until the mounting holes of the chain the boom retraction chain where it attaches to anchor line up with the holes on the boom the chain anchor mount at the lower side of...

  • Page 32: How To Replace The Extension Chains

    Service and Repair Manual September 2021 Boom Components How to R eplac e the Extension C hai ns How to Replace the Extension Select a chain tensioner. Remove the bow tie clip securing the chain anchor pin to the chain Chains assembly.

  • Page 33: How To Remove The Boom

    September 2021 Service and Repair Manual Boom Components How to R emove the Boom How to Remove the Boom 15 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 34 Service and Repair Manual September 2021 Boom Components Lower the fork level cylinder onto the chassis. 15 Using a suitable tool, remove the boom pivot pin. Crushing hazard. Keep hands clear of the cylinder manifold Crushing hazard. The boom will when lowering the cylinder.

  • Page 35: How To Disassemble The Boom

    September 2021 Service and Repair Manual Boom Components How to Dis ass embl e the Boom How to Disassemble the Boom Remove the fastener securing the fork level cylinder rod-end pivot pin to the fork frame Bodily injury hazard. This mount.
  • Page 36 Service and Repair Manual September 2021 Boom Components 15 Working at the pivot end of the boom, remove 23 Working at the fork end of the boom, remove the clamps securing the hoses to the inside of the wear pads from boom tube number 2. boom tube number 3.

  • Page 37: Boom Lift Cylinder

    September 2021 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 38: Boom Extension Cylinder

    Service and Repair Manual September 2021 Boom Components Boom Extension Cylinder Fork Level Cylinder How to Remove the Extension How to Remove the Fork Level Cylinder Cylinder Note: When removing a hose assembly or fitting, Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose the O-ring (if equipped) on the fitting and/or hose end must be replaced.

  • Page 39: Hydraulic Hoses

    September 2021 Service and Repair Manual Boom Components Tag, disconnect and plug the fork level cylinder hoses from the cylinder manifolds. Hydraulic Hoses Cap the fittings. How to Adjust the Fork Level How to Adj ust the Fork Lev el Cylinder and/or Auxiliary Hos e Bodily injury hazard.

  • Page 40: How To Replace The Fork Level Cylinder And/Or Auxiliary Hoses

    Service and Repair Manual September 2021 Boom Components How to R eplac e the F ork Lev el Cyli nder and/or Auxili ary H oses How to Replace the Fork Level Securely connect a 30 feet / 10 m length of rope to each end of the hoses disconnected in Cylinder and/or Auxiliary Hoses steps 5 and 6.
  • Page 41 September 2021 Service and Repair Manual Boom Components 10 Select one of the hoses. Pull the hose out of the boom. Note: Rope coming loose from either end of the hose or the boom during hose removal may result in a difficult reassembly. Be sure each section of rope is securely attached to both the hose and the boom structure before pulling the hose out of the boom.

  • Page 42: Operator's Compartment

    Service and Repair Manual September 2021 Operator's Compartment Locate the brake manifold under the manifold inspection cover. Tag, disconnect and plug Operator's Compartment the hydraulic hose at the underside of the brake manifold. Cap the fitting. How to Remove the Operator's Working under the dashboard, locate the hydraulic hose at port L of the steering Compartment...

  • Page 43: Machine Controls

    September 2021 Service and Repair Manual Operator's Compartment Support and secure the operator's compartment to an adjustable table capable Machine Controls of supporting the weight and that will allow the operator's compartment to remain in an How to Remove the Steering How to R emove the Steering C olum n upright and stable position.

  • Page 44: How To Remove The Steering Wheel

    Service and Repair Manual September 2021 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 45: How To Remove The Joystick - Models With Electronic Joystick

    September 2021 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 46: How To Remove The Gauge Cluster Assembly

    Service and Repair Manual September 2021 Operator's Compartment How to R emove the Gauge Cluster 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 47: Fuel And Hydraulic Tanks

    September 2021 Service and Repair Manual Fuel and Hydraulic Tanks HYDRAULIC TANK Fuel and Hydraulic Tanks Remove the access cover to the hydraulic tank. How to Remove the Fuel and Remove the filler cap from the hydraulic tank. Hydraulic Tank Assembly Place a drain pan or other suitable container under the hydraulic tank.
  • Page 48 Service and Repair Manual September 2021 Fuel and Hydraulic Tanks FUEL TANK Remove the access cover above the fuel tank and the access door above the filler cap. 10 Tag and disconnect the wire harness from the fuel level terminals. 11 Remove the filler cap from the fuel tank.

  • Page 49: Engines

    September 2021 Service and Repair Manual Engines How to R epair the Perki ns 854E-34TA Engi ne How to Repair the Perkins 854E- 34TA Engine Engines Repair procedures and additional engine How to R epair the Perki ns 1104D-E44T A Engi ne How to Repair the Perkins 1104D- information is available in the Perkins 854 E44TA Engine...

  • Page 50: Engine Fault Codes

    Service and Repair Manual September 2021 Engines Engine Fault Codes How to Retrieve Engine Fault Codes When the engine Electronic Control Module (ECM) detects an abnormal operating condition, a fault code is immediately stored in the ECM memory. At the same time, a colored warning lamp is illuminated.

  • Page 51: Transmission

    September 2021 Service and Repair Manual Transmission Transmission How to Repair the Transmission Repair procedures and additional transmission information is available in the Dana VDT12000 Service Manual. Dana VDT12000 Service Manual Genie part number 218706 Part No. 1288232GT -844 ™...

  • Page 52: Hydraulic Pump

    Service and Repair Manual September 2021 Hydraulic Pump Start the engine and fully retract the boom. Continue to hold the joystick in the boom Hydraulic Pump retract position and observe the pressure gauge. How to T est the Func tion Pum p How to Test the Function Pump Result: If the pressure gauge reads 3200 psi / 220 bar, immediately stop.

  • Page 53: How To Remove The Function Pump

    September 2021 Service and Repair Manual 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 54: How To Install The Function Pump

    Service and Repair Manual September 2021 Hydraulic Pump How to Ins tall the F uncti on Pump 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 transmission.

  • Page 55: How To Adjust The Function Pump Standby Pressure

    September 2021 Service and Repair Manual Hydraulic Pump How to Adj ust the Functi on Pum p Standby Pr ess ure How to Adjust the Function Pump Adjust the function pump standby pressure. Turn the adjustment screw clockwise to Standby Pressure increase the pressure or counterclockwise to decrease the pressure.

  • Page 56: How To Adjust The Function Pump Pressure Compensator

    Service and Repair Manual September 2021 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 pressure compensator adjustment screw. Standby Pressure Note: Two people will be required to perform this procedure.

  • Page 57: Manifolds

    September 2021 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, auxiliary Auxiliary functions Assembly, extend/retract Extend/retract functions Assembly, tilt Tilt functions Assembly, sway Sway functions Assembly, lift Lift functions...

  • Page 58: Secondary Function Manifold Components

    Service and Repair Manual September 2021 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 50 ft-lbs / 68 Nm...
  • Page 59 September 2021 Service and Repair Manual Manifolds Part No. 1288232GT -844 ™...

  • Page 60: Brake Manifold Components

    Service and Repair Manual September 2021 Manifolds Brake Manifold Components The auxiliary manifold is located under the transmission 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 61: Valve Adjustments - Secondary Function Manifold

    September 2021 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 Function Manifold to the left. Continue holding the steering while observing the pressure reading on the How to Set the Steer System Pres sur e pressure gauge.

  • Page 62: How To Set The Parking Brake System Pressure

    Service and Repair Manual September 2021 Manifolds How to Set the Parki ng Br ake Sy stem Pr ess ure How to Set the Parking Brake Start the engine. Allow the engine to idle. System Pressure Result: The pressure gauge reads 350 psi / 24.1.

  • Page 63: How To Set The Rear Lock-Up System Pressure

    September 2021 Service and Repair Manual 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 64: Valve Coils

    Service and Repair Manual September 2021 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 65 September 2021 Service and Repair Manual 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 66: Axle

    Service and Repair Manual September 2021 Axle Raise the end of the machine until the tires are off the ground. Place blocks under the Axles chassis for support. Crushing hazard. The chassis How to Remove the Axle will fall if not properly supported. Bodily injury hazard.

  • Page 67: Fault Codes

    September 2021 Service and Repair Manual 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 68: Diagnostic Display

    Service and Repair Manual September 2021 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 69: Deutz Tcd3.6 Engine Fault Codes

    September 2021 Service and Repair Manual Deutz TCD3.6 Engine Fault Codes SPN = Suspect Parameter Number ASPN = Alternate Suspect Parameter Number FMI = Failure Mode Identifier ASPN FMI Description 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 70 Service and Repair Manual September 2021 Deutz TCD3.6 Engine Fault Codes SPN = Suspect Parameter Number ASPN = Alternate Suspect Parameter Number FMI = Failure Mode Identifier ASPN FMI Description Air filter differential pressure; system reaction initiated Sensor error airfilter differential pressure; short circuit to battery Sensor error airfilter differential pressure;...
  • Page 71 September 2021 Service and Repair Manual Deutz TCD3.6 Engine Fault Codes SPN = Suspect Parameter Number ASPN = Alternate Suspect Parameter Number FMI = Failure Mode Identifier ASPN FMI Description Oil temperature; out of range, system reaction initiated Physical range check low for oil temperature Oil temperature;...
  • Page 72 Service and Repair Manual September 2021 Deutz TCD3.6 Engine Fault Codes SPN = Suspect Parameter Number ASPN = Alternate Suspect Parameter Number FMI = Failure Mode Identifier ASPN FMI Description Injector 1 (in firing order); short circuit High side to low side short circuit in the injector 1 (in firing order) Injector 1 (in firing order);...
  • Page 73 September 2021 Service and Repair Manual Deutz TCD3.6 Engine Fault Codes SPN = Suspect Parameter Number ASPN = Alternate Suspect Parameter Number FMI = Failure Mode Identifier ASPN FMI Description Cold start aid relay open load Cold start aid relay; over temperature error Timeout Error of CAN-Receive-Frame TSC1TE;...
  • Page 74 Service and Repair Manual September 2021 Deutz TCD3.6 Engine Fault Codes SPN = Suspect Parameter Number ASPN = Alternate Suspect Parameter Number FMI = Failure Mode Identifier ASPN FMI Description 1188 Wastegate; status message from ECU missing Wastegate actuator; blocked Turbo charger wastegate actuator;...
  • Page 75 September 2021 Service and Repair Manual Deutz TCD3.6 Engine Fault Codes SPN = Suspect Parameter Number ASPN = Alternate Suspect Parameter Number FMI = Failure Mode Identifier ASPN FMI Description 2791 EGR actuator, temperature critical high EGR actuator, CAN error EGR actuator supply voltage is above the maximum threshold EGR actuator supply voltage is below minimum threshold EGR actuator current is above maximum threshold...
  • Page 76 Service and Repair Manual September 2021 Deutz TCD3.6 Engine Fault Codes SPN = Suspect Parameter Number ASPN = Alternate Suspect Parameter Number FMI = Failure Mode Identifier ASPN FMI Description 3248 Exhaust gas temperature particulate filter downstream; out of range, system reaction initiated Exhaust gas temperature particulate filter downstream;...
  • Page 77 September 2021 Service and Repair Manual Deutz TCD3.6 Engine Fault Codes SPN = Suspect Parameter Number ASPN = Alternate Suspect Parameter Number FMI = Failure Mode Identifier ASPN FMI Description 4243 SCR system heater diagnostic reports error; shut off SCR-system 4334 Urea pump pressure;...
  • Page 78 Service and Repair Manual September 2021 Deutz TCD3.6 Engine Fault Codes SPN = Suspect Parameter Number ASPN = Alternate Suspect Parameter Number FMI = Failure Mode Identifier ASPN FMI Description 4375 Urea pump motor; short circuit to battery Urea pump motor; short circuit to ground Urea pump motor;...
  • Page 79 September 2021 Service and Repair Manual Deutz TCD3.6 Engine Fault Codes SPN = Suspect Parameter Number ASPN = Alternate Suspect Parameter Number FMI = Failure Mode Identifier ASPN FMI Description 23006 64254 3 Controller mode switch; short circuit to battery Controller mode switch;...
  • Page 80 Service and Repair Manual September 2021 Deutz TCD3.6 Engine Fault Codes SPN = Suspect Parameter Number ASPN = Alternate Suspect Parameter Number FMI = Failure Mode Identifier ASPN FMI Description 23470 64718 2 Pressure Relief Valve (PRV) forced to open Maximum rail pressure in limp home mode exceeded (PRV) Pressure Relief Valve (PRV) error;...
  • Page 81 September 2021 Service and Repair Manual Deutz TCD3.6 Engine Fault Codes SPN = Suspect Parameter Number ASPN = Alternate Suspect Parameter Number FMI = Failure Mode Identifier ASPN FMI Description 23698 64946 11 Shut off request from supervisory monitoring function 23704 Timeout Error of CAN-Transmit_Frame EEC3 23717 64965 12...
  • Page 82 Service and Repair Manual September 2021 Deutz TCD3.6 Engine Fault Codes SPN = Suspect Parameter Number ASPN = Alternate Suspect Parameter Number FMI = Failure Mode Identifier ASPN FMI Description 23723 64971 11 Detection of AdBlue filled SCR system in Init-State 23766 65014 9 Timeout Error of CAN-Receive-Frame Active TSC1AE 23767 65015 9...
  • Page 83 September 2021 Service and Repair Manual Deutz TCD3.6 Engine Fault Codes SPN = Suspect Parameter Number ASPN = Alternate Suspect Parameter Number FMI = Failure Mode Identifier ASPN FMI Description 23911 65159 0 Burner dosing valve (DV2); overcurrent at the end of the injection phase Burner dosing valve (DV2);...
  • Page 84 Service and Repair Manual September 2021 Deutz TCD3.6 Engine Fault Codes SPN = Suspect Parameter Number ASPN = Alternate Suspect Parameter Number FMI = Failure Mode Identifier ASPN FMI Description 23917 65165 0 Physical range check high for DV1 & DV2 upstream pressure; shut off regeneration Physical range check low for DV1 &...
  • Page 85 September 2021 Service and Repair Manual Deutz TCD3.6 Engine Fault Codes SPN = Suspect Parameter Number ASPN = Alternate Suspect Parameter Number FMI = Failure Mode Identifier ASPN FMI Description 23924 Short circuit to ground actuator relay 2 23925 Short cicuit to battery error of actuator relay 3 Short circuit to ground actuator relay 3 23926 Short cirucit to dround actuator relay 4...
  • Page 86 Service and Repair Manual September 2021 Deutz TCD3.6 Engine Fault Codes SPN = Suspect Parameter Number ASPN = Alternate Suspect Parameter Number FMI = Failure Mode Identifier ASPN FMI Description 23943 65191 9 Timeout Error (PCK2PCK) for CAN-Receive-Frame AT1OGCVol2 information; factors & Sensorcalibration for NOX Sensor (SCR-system downstream cat;...
  • Page 87 September 2021 Service and Repair Manual Deutz TCD3.6 Engine Fault Codes SPN = Suspect Parameter Number ASPN = Alternate Suspect Parameter Number FMI = Failure Mode Identifier ASPN FMI Description 23984 UB6; Short circuit to battery error of actuator relay 6 23986 Actuator relay 5;...
  • Page 88 Service and Repair Manual September 2021 Deutz TCD3.6 Engine Fault Codes SPN = Suspect Parameter Number ASPN = Alternate Suspect Parameter Number FMI = Failure Mode Identifier ASPN FMI Description 24011 65259 0 Zerofuel calibration injector 7 (in firing order); maximum value exceeded Zerofuel calibration injector 7 (in firing order);...
  • Page 89 September 2021 Service and Repair Manual Deutz TCD3.6 Engine Fault Codes SPN = Suspect Parameter Number ASPN = Alternate Suspect Parameter Number FMI = Failure Mode Identifier ASPN FMI Description 24035 65283 12 Injector diagnostics; time out error in the SPI communication 24036 65284 12 Injector diagnostics Slave;...
  • Page 90 Service and Repair Manual September 2021 Deutz TCD3.6 Engine Fault Codes SPN = Suspect Parameter Number ASPN = Alternate Suspect Parameter Number FMI = Failure Mode Identifier ASPN FMI Description 24065 Pressure sensor upstream SCR-CAT, pressure above upper physical threashold Pressure sensor upstream SCR-CAT, pressure below lower physical threashold Pressure sensor upstream SCR-CAT, plausibility error Pressure sensor upstream SCR-CAT, short circuit battery or open load...
  • Page 91 September 2021 Service and Repair Manual Deutz TCD3.6 Engine Fault Codes SPN = Suspect Parameter Number ASPN = Alternate Suspect Parameter Number FMI = Failure Mode Identifier ASPN FMI Description 24097 65345 9 Timeout error of CAN-Transmit-Frame DPFBrnAirPmpCtl 24098 65346 9 Timeout error of CAN-Transmit-Frame ComDPFBrnPT 24099 65347 9 Timeout error of CAN-Transmit-Frame ComDPFC0...
  • Page 92 Service and Repair Manual September 2021 Deutz TCD3.6 Engine Fault Codes SPN = Suspect Parameter Number ASPN = Alternate Suspect Parameter Number FMI = Failure Mode Identifier ASPN FMI Description 24116 65364 9 Timeout error of CAN-Transmit-Frame SCR2 24117 65365 9 Timeout error of CAN-Transmit-Frame SCR3 24118 65366 9 Timeout error of CAN-Receive-Frame ComRxCM0...

  • Page 93: Perkins 1104 Engine Fault Codes

    September 2021 Service and Repair Manual Perkins 1104 Engine Fault Codes SPN = Suspect Parameter Number FMI Description FMI = Failure Mode Identifier Fuel rail pressure open/short to battery FMI Description positive (+) Incorrect throttle switch inputs Fuel rail pressure short to ground Throttle position sensor: voltage above System voltage high normal or shorted high...
  • Page 94 Service and Repair Manual September 2021 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 95: Schematics

    September 2021 Service and Repair Manual 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 96: Fuse Panel Layout

    Service and Repair Manual September 2021 Fuse Panel Layout Deutz 74HP - Perkins T3 - Perkins CB1- 50A- Control System Power *CB2 30A- Engine Power / ECM Deutz 74HP; Perkins T3 *CB2 50A Perkins T4i CB3 60A- Glow Plugs *CB4 20A- Fuel Pump Deutz 74HP Deutz 99HP CB4 50A-EAT Power...

  • Page 97: Deutz Tcd3.6 T4F Module

    September 2021 Service and Repair Manual Deutz TCD3.6 T4F Module Deutz TCD3.6 T4F Engine only Part No. 1288232GT -844 ™...

  • Page 98: Electrical Component & Wire Color Abbreviation Legend

    Service and Repair Manual September 2021 Electrical Component & Wire Color Abbreviation Legend Item Description Item Description Alternator Diode Battery Engine Management System Main Battery, 12V Fuse Circuit Breaker 15 Amp - Parking Brake Switch 50 Amp Circuit Breaker, ECS Power 10 Amp - Stabilizer Power 30 Amp Circuit Breaker, Engine ECM 10 Amp –...
  • Page 99 September 2021 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 Parking Brake Switch Horn Relay ON Boom Angle Switch Blinkers / Pilot Light ON Parking Brake Pressure Switch Road Lights, Work Lights ON Service Brake Pressure Switch...
  • Page 100 Service and Repair Manual September 2021 Electrical Component & Wire Color Abbreviation Legend Item Description Valve Coil Sway Left Enable SV1 Tilt Up Enable SV2 Sway Right Enable SV3 Tilt Down Enable SV4 Parking Brake Release SV5 Differential Lock SV6 Rear Axle Float SV7 Rear Axle Fast SV8 Sway Enable SV9...
  • Page 101 September 2021 Service and Repair Manual Electrical Component & Wire Color Abbreviation Legend Wire Color Legend Blue BL/BK Blue/Black BL/RD Blue/Red BL/WH Blue/White Black BK/RD Black/Red BK/WH Black/White BK/YL Black/Yellow Brown Green GR/BK Green/Black GR/WH Green/White RD/BK Red/Black RD/WH Red/White Orange OR/BK Orange/Black...

  • Page 102: Electrical Symbol Legend

    Service and Repair Manual September 2021 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 Connection - no T-circuits connect at Circuits crossing no...

  • Page 103: Hydraulic Symbols Legend

    September 2021 Service and Repair Manual Hydraulic Symbols Legend Orifice with size Check valve Shut off valve Brake Pump, bi-directional Motor, 2 speed bi- Pump, fixed displacement Motor, bi-directional variable displacement directional Pump, prime mover Shuttle valve. 2 position, Cylinder, double acting Differential sensing valve (engine or motor) 3 way...

  • Page 104: Harness Map Legend

    Service and Repair Manual September 2021 Harness Map Legend Base Harnesses Work Light Option Harnesses (included In all models) Item Description Item Description Harness, Light, Led, Clear, 5" Round Harness, Dashboard Harness Cab Light Power Harness, Secondary Manifold Harness, Backup Light Harness, Transmission Harness, Boom Light Power Harness, Boom Angle Switch...

  • Page 105: Electrical Schematics - Harness Maps

    September 2021 Service and Repair Manual Harness Map - Control System Power- Electronic Joystick...

  • Page 106: Harness Map - Control System Ground Electronic Joystick

    Service and Repair Manual September 2021 Harness Map - Control System Ground Electronic Joystick -844 Part No. 1288232GT ™...

  • Page 107: Harness Map - Beacon, Proximity Alarm And 3Rd Gear Lockout

    September 2021 Service and Repair Manual Harness Map - Beacon, Proximity Alarm and 3rd Gear Lockout Part No. 1288232GT -844 ™...
  • Page 108 Service and Repair Manual September 2021 Harness Map - Beacon, Proximity Alarm and 3rd Gear Lockout...
  • Page 109 September 2021 Service and Repair Manual Harness Map - Deutz TCD3.6 Engine Battery Power and Ground...

  • Page 110: Harness Map - Deutz Tcd3.6 Engine Battery Power And Ground

    Service and Repair Manual September 2021 Harness Map - Deutz TCD3.6 Engines Battery Power and Ground -844 Part No. 1288232GT ™...

  • Page 111: Harness Map - Perkins Engine Battery Power And Ground

    September 2021 Service and Repair Manual Harness Map - Perkins Engines Battery Power and Ground Part No. 1288232GT -844 ™...
  • Page 112 Service and Repair Manual September 2021 Harness Map - Perkins Engines Battery Power and Ground...
  • Page 113 September 2021 Service and Repair Manual Harness Map - Options Work Lights...

  • Page 114: Harness Map - Options Work Lights

    Service and Repair Manual September 2021 Harness Map - Options Work Lights -844 Part No. 1288232GT ™...

  • Page 115: Harness Map - Options Road Lights

    September 2021 Service and Repair Manual Harness Map - Options Road Lights Part No. 1288232GT -844 ™...
  • Page 116 Service and Repair Manual September 2021 Harness Map - Options Road Lights...
  • Page 117 September 2021 Service and Repair Manual Harness Map - Options Enclosed Cab with Heater...

  • Page 118: Harness Map - Options Enclosed Cab With Heater

    Service and Repair Manual September 2021 Harness Map - Options Enclosed Cab with Heater -844 Part No. 1288232GT ™...

  • Page 119: Harness Map - Options Enclosed Cab With Hvac

    September 2021 Service and Repair Manual Harness Map - Options Enclosed Cab with HVAC Part No. 1288232GT -844 ™...
  • Page 120 Service and Repair Manual September 2021 Harness Map - Options Enclosed Cab with HVAC...

  • Page 121: Electrical Schematics

    September 2021 Service and Repair Manual Electrical Schematic (from GTH08E-11500 to 13228)

  • Page 122: Electrical Schematic [From Gth08E-11500 To 13228]

    Service and Repair Manual September 2021 Electrical Schematic (from GTH08E-11500 to 13228) -844 Part No. 1288232GT ™...

  • Page 123: Electrical Schematic [From Gth08E-11500 To 13228]

    September 2021 Service and Repair Manual Electrical Schematic (from GTH08E-11500 to 13228) Part No. 1288232GT -844 ™...
  • Page 124 Service and Repair Manual September 2021 Electrical Schematic (from GTH08E-11500 to 13228)
  • Page 125 September 2021 Service and Repair Manual Electrical Schematic (from GTH08E-13229)

  • Page 126: Electrical Schematic [From Gth08E-13229]

    Service and Repair Manual September 2021 Electrical Schematic (from GTH08E-13229) -844 Part No. 1288232GT ™...

  • Page 127: Electrical Schematic [From Gth08E-13229]

    September 2021 Service and Repair Manual Electrical Schematic (from GTH08E-13229) 2>7 2>4 3>7 3>4 Part No. 1288232GT -844 ™...
  • Page 128 Service and Repair Manual September 2021 Electrical Schematic (from GTH08E-13229)
  • Page 129 September 2021 Service and Repair Manual Electrical Schematic (from GTH08E-13229)

  • Page 130: Electrical Schematic, Option [From Gth08E-13229]

    Service and Repair Manual September 2021 Electrical Schematic (from GTH08E-13229) VALVE -844 Part No. 1288232GT ™...

  • Page 131: Electrical Schematic - Deutz T3 Eng Harness

    September 2021 Service and Repair Manual Electrical Schematic - Deutz T3 Eng Harness Part No. 1288232GT -844 ™...
  • Page 132 Service and Repair Manual September 2021 Electrical Schematic - Deutz T3 Eng Harness...
  • Page 133 September 2021 Service and Repair Manual Electrical Schematic - Deutz T4F Eng Harness...

  • Page 134: Electrical Schematic - Deutz T4F Eng Harness

    Service and Repair Manual September 2021 Electrical Schematic - Deutz T4F Eng Harness -844 Part No. 1288232GT ™...

  • Page 135: Electrical Schematic - Deutz T4F Eng Harness

    September 2021 Service and Repair Manual Electrical Schematic - Deutz T4F Eng Harness Part No. 1288232GT -844 ™...
  • Page 136 Service and Repair Manual September 2021 Electrical Schematic - Deutz T4F Eng Harness...
  • Page 137 September 2021 Service and Repair Manual Electrical Schematic - Deutz T4F Eng Harness...

  • Page 138: Electrical Schematic - Deutz T4F Eng Harness

    Service and Repair Manual September 2021 Electrical Schematic - Deutz T4F Eng Harness -844 Part No. 1288232GT ™...

  • Page 139: Hydraulic Schematics

    September 2021 Service and Repair Manual Hydraulic Schematic (from GTH08E-11500 to 13228)

  • Page 140: Hydraulic Schematic [From Gth08E-11500 To 13228]

    Service and Repair Manual September 2021 Hydraulic Schematic (from GTH08E-11500 to 13228) -844 Part No. 1288232GT ™...

  • Page 141: Hydraulic Schematic [From Gth08E-13229]

    September 2021 Service and Repair Manual Hydraulic Schematic (from GTH08E-13229) STRG. WHL. HS021 C Part No. 1288232GT -844 ™...
  • Page 142 Service and Repair Manual September 2021 Hydraulic Schematic (from GTH08E-13229) GTH™-844 Part No. 1288232GT Servic e and R epair M anual September 2021...

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