Terex GTH12T-10101 Service And Repair Manual
  1. Manuals
  2. Brands
  3. Terex Manuals
  4. Boom Lifts
  5. GTH12T-10101
  6. Service and repair manual
Terex GTH12T-10101 Service And Repair Manual

Terex GTH12T-10101 Service And Repair Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Service and Repair Manual
GTH
-1256
™
Serial Number Range
from GTH12T-10101
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
Original Instructions
Part No. 1310135GT
Rev A
November 2022

Advertisement

Table of Contents
loading

Related Manuals for Terex GTH12T-10101

Summary of Contents for Terex GTH12T-10101

  • Page 1 Service and Repair Manual Serial Number Range -1256 ™ from GTH12T-10101 This manual includes: Repair procedures Fault Codes Electrical and Hydraulic Schematics For detailed maintenance procedures, refer to the appropriate Maintenance Manual for your machine. Original Instructions Part No. 1310135GT...

  • Page 2: Introduction

    Copyright © 2021 by Terex Corporation 1310135GT Rev A, November 2022 Third 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 November 2022 Service and Repair Manual Introduction Revision History Revision Date Section Procedure / Page / Description 11/2022 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 November 2022 Introduction Serial Number Legend GTH12 T - 12345 MODEL: SERIAL NUMBER: GTH12T-12345 ATTACHMENT: YEAR OF MANUFACTURE: TOTAL T CK WEIGHT: lbs/ kg MAX. LIFT CAPACITY : 1 Model 2 Facility code 3 Sequence number 4 Serial label (located inside fork frame) 5 Serial number (stamped on chassis) 6 Serial label (located inside chassis)

  • Page 5: Safety Rules

    November 2022 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 November 2022 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

    November 2022 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 November 2022 Table of Contents Section 3 Repair Procedures ..................... 12 Introduction ......................12 Boom Components .................... 14 1-1 Boom Proximity Switch .................. 14 How to Test a Proximity Switch ..............14 How to Adjust the Boom Angle Proximity Switch ........... 15 How to Adjust the Boom Extend Proximity Switch .........
  • Page 9 November 2022 Table of Contents Fuel and Hydraulic Tanks .................. 39 3-1 Fuel and HydraulicTanks ................39 Engines ........................ 41 4-1 Engines ......................41 How to Repair the Deutz TCD3.6 Engine ............41 4-2 Engine Fault Codes ..................41 Transmission ...................... 42 5-1 Transmission ....................
  • Page 10 November 2022 Table of Contents Section 4 Fault Codes ......................61 Introduction ......................61 Diagnostic Display ..................... 62 Diagnostic Display....................62 Deutz TCD3.6 Engine Fault Codes ..............63 Section 5 Schematics ......................87 Introduction ......................87 Proximity Switch Legend ..................88 Fuse Panel Layout (120HP &...

  • Page 11: Specifications

    November 2022 Service and Repair Manual Specifications Section 2 Specific ati ons Machine Specifications Performance Specifications Tires and wheels Drive speed, maximum 17 mph 27,4 km/h Tire size 14.00 x 28 Draw bar pull 25000 lbs Tire ply rating 11340 kg 380 lbs Weight, rough terrain tire Lift capacity, maximum...

  • Page 12: Hydraulic Oil Specifications

    Service and Repair Manual November 2022 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 13 November 2022 Service and Repair Manual Specifications Chevron Rando HD Premium Oil Chevron 5606A Hydraulic Oil MV Fluid Properties Fluid Properties ISO Grade ISO Grade Viscosity index, maximum Viscosity index, maximum Kinematic Viscosity, maximum Kinematic Viscosity, maximum cSt @ 200°F / 100°C cSt @ 200°F / 100°C cSt @ 104°F / 40°C 33.5...

  • Page 14: Hydraulic Component Specifications

    Service and Repair Manual November 2022 Specifications Shell Tellus S4 VX Fluid Hydraulic Component Properties Specifications ISO Grade Function Pump (ZF Transmission) Viscosity index, maximum Type: variable displacement piston pump Kinematic Viscosity, maximum Displacement 0 - 3.97 cu in cSt @ 200°F / 100°C 0 - 65 cc cSt @ 104°F / 40°C 33.8...

  • Page 15: Manifold Component Specifications

    November 2022 Service and Repair Manual 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 SAE No. 2 50 in-lbs / 6 Nm avoid prolonged exposure to elevated temperatures.

  • Page 16: Deutz Tcd3.6 120Hp Engine Specifications

    Service and Repair Manual November 2022 Specifications Deutz TCD3.6 120HP Engine Fuel injection system Injection pump pressure, maximum 23200 psi Displacement 221 cu in 1600 bar 3,62 liters Maximum fuel consumption 6.5 gph / 24,6 lph Number of cylinders Fuel requirement Bore and Stroke 3.86 x 4.72 in For fuel requirements, refer to the engine Operator...

  • Page 17: Deutz Tcd3.6 Row Engine Specifications

    November 2022 Service and Repair Manual Specifications Deutz TCD3.6 120HP ROW Fuel injection system Engine Injection pump pressure, maximum 23200 psi 1600 bar Displacement 221 cu in Maximum fuel consumption 6.5 gph / 24,6 lph 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...

  • Page 18: Zf 4 Wg-98 Tsc Transmission Specifications

    Service and Repair Manual November 2022 Specifications ZF 4 WG-98 TSC Transmission Dana Planetary Drive Axle Transmission type Steering 4 speed powershift converter Integrated steer cylinder Speeds, Forward Joints Heavy duty double U-joints Speeds, Reverse Steering angle, maximum 45° Torque converter Differential Type Limited Slip 45% Maximum input...

  • Page 19: Machine Component Weights

    November 2022 Service and Repair Manual Specifications Machine Component Weights 10000 lbs Primary boom assembly 4536 kg Primary boom lift cylinder 750 lbs 340 kg Primary boom extend cylinder 1050 lbs 476 kg Lock cylinder 75 lbs 34 kg Sway cylinder 90 lbs 41 kg Tilt cylinder...

  • Page 20: Hydraulic Hose And Fitting Torque Specifications

    Service and Repair Manual November 2022 Specifications Hydraulic Hose and Fitting ORFS Hose End Torque Specifications SAE Dash Size Torque 10 - 12 ft-lbs / 14 - 16 Nm Your machine is equipped with Ryco ORFS or 37° JIC fittings and hose ends. Manufactures 18 - 20 ft-lbs / 24 - 27 Nm specifications require that fittings and hose ends 32 - 35 ft-lbs / 43 - 47 Nm...

  • Page 21: Torque Procedure

    November 2022 Service and Repair Manual Specifications Torque Procedure SAE Flange Clamp Bolts Code 61 ORFS fittings SAE Dash Size Torque Replace the O-ring. The O-ring must be 15 - 18 ft lbs / 20 - 25 Nm replaced anytime the seal has been broken. 21 - 29 ft lbs / 28 - 40 Nm The O-ring cannot be re-used if the fitting or 27 - 35 ft lbs / 37 - 48 Nm...

  • Page 22: Repair Procedures

    Service and Repair Manual November 2022 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 23: About This Section

    November 2022 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 24: Boom Components

    Service and Repair Manual November 2022 Boom Components How to Test a Proximity Switch How to T est a Pr oximity Switc h 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 25: How To Adjust The Boom Angle Proximity Switch

    November 2022 Service and Repair Manual Boom Components How to Adjust the Boom Angle How to Adjust the Boom Extend How to Adj ust the Boom Angle Proximity Swi tch How to Adj ust the Boom Ex tend Proximity Switc h Proximity Switch Proximity Switch The boom angle proximity switch is attached to a...

  • Page 26: Boom

    Service and Repair Manual November 2022 Boom Components How to Remove the Lifting Fork How to R emove the Lifting F ork Fr ame Boom Frame With the boom in the stowed position, attach a How to Replace the Boom Wear How to R eplac e the Boom W ear Pads lifting strap from an overhead supporting Pads...

  • Page 27: How To Remove And Install The Cable Track Assembly

    November 2022 Service and Repair Manual Boom Components How to remove the Cable Track How to R emove and Install the Cabl e Track Ass embly Loosen the retaining fasteners securing the rear hydraulic hose clamp. Do not remove the Assembly retaining fasteners at this time.
  • Page 28 Service and Repair Manual November 2022 Boom Components 12 Remove the bracket attached to the cable Working at the pivot end of the boom, pull the track and lower hose clamp. hydraulic hoses out of the boom tube. Remove the four retaining fasteners securing the cable track mount to the boom.
  • Page 29 November 2022 Service and Repair Manual Boom Components How to Install the Cable Track Attach narrow hose clamps to the mounting plate. Line up the mark from the previous Assembly steps with the face of the clamp that is farthest away from the cable track. Note: Verify the boom is fully retracted.
  • Page 30 Service and Repair Manual November 2022 Boom Components Attach the hose clamps to the lower cable At the front of the horsehead, attach the hose track mount. clamps through the mounting bracket. Do not tighten at this time. 10 Fasten the cable track mount to the top mounting plate.

  • Page 31: How To Replace The Retract Chains

    November 2022 Service and Repair Manual Boom Components 15 Install the top cable track boom mount to the How to Replace the Retract How to R eplac e the R etract C hai ns brackets in the middle of the small boom. Chains Note: There should be some tension on the Note: Perform this procedure with the machine on...
  • Page 32 Service and Repair Manual November 2022 Boom Components Secure a rope to the end of the chain being Remove the top, front wear pads that are replaced. between the boom tube number 0, 1, and 2. Note: Verify the rope is securely attached to the Note: This step is not required if only replacing the chain.
  • Page 33 November 2022 Service and Repair Manual Boom Components 10 Use hook or a 3/8-16 UNC threaded rod to 16 Working at the fork end of the boom, use the rope to carefully pull the chain through the secure the retract anchors. boom just until the end of the chain is accessible.

  • Page 34: How To Replace The Extend Chain

    Service and Repair Manual November 2022 Boom Components How to Replace the Extend How to R eplac e the Extend C hain 22 Use a combination of a forklift pushing on the horsehead and the extend cylinder to fully Chains stow the boom.
  • Page 35 November 2022 Service and Repair Manual Boom Components Start the machine and retract the boom At the pivot end of the boom, remove 8 inches / 20,3 cm. retaining fasteners securing the step anchors. Note: This step is not required if only replacing the 1-2-3 extend chain.

  • Page 36: How To Remove The Boom

    Service and Repair Manual November 2022 Boom Components How to Remove the Boom How to R emove the Boom 15 Secure the step anchors to the boom. 16 Remove the blocks or shims used to chock up Bodily injury hazard. This the number 2 boom tube.
  • Page 37 November 2022 Service and Repair Manual Boom Components Lower the fork level cylinder onto the chassis. 14 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

    Service and Repair Manual November 2022 Boom Components How to Disassemble the Boom How to Dis ass embl e the Boom Remove the inspection cover at the pivot end of the boom. Bodily injury hazard. This Working at the pivot end of the boom, remove procedure requires specific repair the hose keepers from the hose roller skills, lifting equipment and a...
  • Page 39 November 2022 Service and Repair Manual Boom Components 10 Working at the pivot end of the boom, remove 18 Support and slide boom tube number 4 out of the fasteners securing the cable track mount boom tube number 3. Place boom tube brackets to the boom assembly.

  • Page 40: Boom Lift Cylinder

    Service and Repair Manual November 2022 Boom Components 24 Support and slide boom tube number 3 out of boom tube number 2. Place boom tube Boom Lift Cylinder number 3 on a structure capable of supporting How to Remove the Lift Cylinder Crushing hazard.

  • Page 41: Boom Extension Cylinder

    November 2022 Service and Repair Manual Boom Components Use a soft metal drift to remove the pivot pin. Boom Extension Cylinder Remove the fasteners securing the lift cylinder rod-end pivot pin to the boom. How to Remove the Boom Use a soft metal drift to remove the pivot pin. Extension Cylinder Crushing hazard.

  • Page 42: Fork Tilt Cylinder

    Service and Repair Manual November 2022 Boom Components Remove the extension cylinder support loop from the top of the boom. Fork Tilt Cylinder Note: The extension cylinder support loop is located at the fork end of the boom. How to Remove the Fork Tilt Remove the fasteners securing the extension Cylinder cylinder pivot pins to the boom.

  • Page 43: Hydraulic Hoses

    November 2022 Service and Repair Manual Boom Components Hydraulic Hoses How to Replace the Fork Tilt How to R eplac e the F ork Lev el and/or Auxiliary Cyli nder H oses and/or Auxiliary Cylinder Hoses Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced.

  • Page 44: Operator's Compartment

    Service and Repair Manual November 2022 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, tag, disconnect Compartment and plug the hydraulic hoses from the steer...

  • Page 45: Machine Controls

    November 2022 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 Col um n upright and stable position.

  • Page 46: How To Remove The Steering Wheel

    Service and Repair Manual November 2022 Operator's Compartment How to Remove the Steering How to Remove the Steer Orbitral How to R emove the Steering Wheel How to R emove the Steer Or bitral 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

    November 2022 Service and Repair Manual Operator's Compartment How to Remove the Joystick How to Remove the Brake Pedal How to R emove the Joy stick - Models with El ectr onic J oystick How to R emove the Brake Pedal Ass embly Assembly Disconnect the battery from the machine.

  • Page 48: How To Remove The Gauge Cluster Assembly

    Service and Repair Manual November 2022 Operator's Compartment How to Remove the Gauge How to R emove the Gauge Clus ter Ass em bly 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

    November 2022 Service and Repair Manual Fuel and Hydraulic Tanks FUEL TANK Fuel and Hydraulic Tanks Remove the filler cap from the fuel tank. Place a drain pan or other suitable container How to Remove the Fuel and under the fuel tank. Hydraulic Tank Assembly Using an approved hand-operated pump, drain the fuel tank into a container of suitable...
  • Page 50 Service and Repair Manual November 2022 Fuel and Hydraulic Tanks HYDRAULIC TANK Remove the access cover to the hydraulic tank. Remove the filler cap from the hydraulic tank. Place a drain pan or other suitable container under the hydraulic tank. Refer Specifications, Machine Specifications.

  • Page 51: Engines

    November 2022 Service and Repair Manual Engines Engine Fault Codes Engines How to Repair the Deutz TCD3.6 How to R epair the D eutz TCD 3.6 Engine How to Retrieve Engine Fault Engine Codes Maintenance procedures and additional engine When the engine Electronic Control Module (ECM) information is available in the Deutz TCD3.6 detects an abnormal operating condition, a fault Workshop Manual.

  • Page 52: Transmission

    Service and Repair Manual November 2022 Transmission Transmission How to Repair the Transmission How to R epair the Tr ansmissi on Repair procedures and additional transmission information is available in the ZF WG-98 Transmission Repair Manual. Repair Manual, ZF Transmission, 4 WG-98 TSC Genie part number 1311107GT -1256...

  • Page 53: Hydraulic Pump

    November 2022 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 220 bar, immediately stop. The pump is good. How to T est the Func tion Pum p Result: If the pressure fails to reach 3190 psi / Note: When removing a hose assembly or fitting,...

  • Page 54: How To Remove The Function Pump

    Service and Repair Manual November 2022 Hydraulic Pump How to Remove the Function How to R emove the Functi on Pum p Tag, disconnect and plug the large hydraulic pump supply hose at the pump. Cap the fitting Pump on the pump. Bodily injury hazard.

  • Page 55: How To Install The Function Pump

    November 2022 Service and Repair Manual Hydraulic Pump How to Install the Function Pump How to Prime the Function Pump How to Ins tall the F uncti on Pump How to Prime the F uncti on Pump Carefully install the hydraulic pump onto the Note: When removing a hose assembly or fitting, transmission.

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

    Service and Repair Manual November 2022 Hydraulic Pump How to Adjust the Function Pump How to Adj ust the Functi on Pum p Standby Pr ess ure 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 57: How To Adjust The Function Pump Pressure Compensator

    November 2022 Service and Repair Manual Hydraulic Pump How to Adjust the Function Pump How to Adj ust the Functi on Pum p Press ure Com pens ator Loosen the set screw for the standby pressure adjustment screw. Pressure Compensator Note: Two people will be required to perform this procedure.
  • Page 58 Service and Repair Manual November 2022 Hydraulic Pump Loosen the set screw for the pressure Adjust the pressure compensator pressure. Turn the adjustment screw clockwise to compensator adjustment screw. increase the pressure or counterclockwise to decrease the pressure. Tighten the set screw. Component damage hazard.

  • Page 59: Manifolds

    November 2022 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, tilt Tilt functions Assembly, lift Lift functions Assembly, auxiliary Auxiliary functions Assembly, extend/retract Extend/retract functions Assembly, sway Sway functions...

  • Page 60: Secondary Function Manifold Components

    Service and Repair Manual November 2022 Manifolds Secondary Function Manifold Components The secondary function manifold is located under the manifold inspection cover. Index Schematic Description Function Torque Item Rear lockup extend 20-25 ft-lbs / 27-34 Nm Check valve, 4 psi / 0,3 bar circuit Solenoid valve, 2 position 2 way Rear lockup circuit...
  • Page 61 November 2022 Service and Repair Manual Manifolds Part No. 1310135GT -1256 ™...

  • Page 62: Brake Manifold Components

    Service and Repair Manual November 2022 Manifolds Brake Manifold Components The brake manifold is mounted next to the secondary manifold located under the manifold inspection cover. Index Schematic Description Function Torque Item Pressure switch, 450 psi / 31 bar Service brake 11 ft-lbs / 14.9 Nm -1256 Part No.

  • Page 63: Valve Adjustments - Secondary Function Manifold

    November 2022 Service and Repair Manual 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 64: How To Set The Rear Lock-Up System Pressure

    Service and Repair Manual November 2022 Manifolds How to Set the Rear Lock-up How to Set the R ear Lock-up Sys tem Pressur e Start the engine. Allow the engine to idle. System Pressure Result: The pressure gauge reads 50 psi / 3.4 bar.

  • Page 65: Valve Coils

    November 2022 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 66 Service and Repair Manual November 2022 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 67: Axle

    November 2022 Service and Repair Manual Axle Axles How to Repair the Axle How to R epair the Axle Repair procedures and additional axle information is available in the Dana 223 Axle Service Manual. Dana 223 Axle Service Manual Genie part number 1284290GT Part No.

  • Page 68: Outriggers

    Service and Repair Manual November 2022 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 69: How To Remove An Outrigger Cylinder

    November 2022 Service and Repair Manual Outriggers How to Remove an Outrigger How to R emove an Outrigger Cyli nder 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 70 Service and Repair Manual November 2022 This page intentionally left blank. -1256 Part No. 1310135GT ™...

  • Page 71: Fault Codes

    November 2022 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 ...

  • Page 72: Diagnostic Display

    Service and Repair Manual November 2022 Diagnostic Display Decoding Fault Codes When the engine Electronic Control Module (ECM) 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 basis for an engine fault code.

  • Page 73: Deutz Tcd3.6 Engine Fault Codes

    November 2022 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 74 Service and Repair Manual November 2022 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 75 November 2022 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 76 Service and Repair Manual November 2022 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 77 November 2022 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 78 Service and Repair Manual November 2022 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 79 November 2022 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 80 Service and Repair Manual November 2022 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 81 November 2022 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 82 Service and Repair Manual November 2022 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 83 November 2022 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 84 Service and Repair Manual November 2022 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 85 November 2022 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 86 Service and Repair Manual November 2022 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 87 November 2022 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 88 Service and Repair Manual November 2022 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 89 November 2022 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 90 Service and Repair Manual November 2022 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 91 November 2022 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 92 Service and Repair Manual November 2022 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 93 November 2022 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 94 Service and Repair Manual November 2022 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 95 November 2022 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 96 Service and Repair Manual November 2022 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 97: Schematics

    November 2022 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 98: Proximity Switch Legend

    Service and Repair Manual November 2022 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) -1256 Part No. 1310135GT ™...

  • Page 99: Fuse Panel Layout (120Hp & Row Engine)

    November 2022 Service and Repair Manual Fuse Panel Layout (120HP & ROW Engine) BEACON ENCLOSED HARNESS CAB HARNESS F15 1A F14 10A F11 10A F8 5A DOME LT HARNESS DASHBOARD F3 10A F6 5A F17 10A MAX F7 5A HARNESS Deutz 74HP T4F CB4 20A-EAT Power F4 10A...

  • Page 100: Deutz Tcd3.6 T4F Module

    Service and Repair Manual November 2022 Deutz TCD3.6 T4F Module Deutz TCD3.6 T4F Engine only Located inside of chassis by the ECU -1256 Part No. 1310135GT ™...

  • Page 101: Electrical Component & Wire Color Abbreviation Legend

    November 2022 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 50 Amp Circuit Breaker 10 Amp - Aux Hydraulics 30 Amp or 50 Amp Circuit Breaker 10 Amp –...
  • Page 102 Service and Repair Manual November 2022 Electrical Component & Wire Color Abbreviation Legend Item Description Item Description LED Light Switch Ignition Power ON Key Start Switch Accessories Power ON Boom Extend Switch Horn Switch ON Parking Brake Pressure Switch Blinkers ON Service Brake Pressure Switch Light Switch ON Sway Enable Pressure Switch...
  • Page 103 November 2022 Service and Repair Manual Electrical Component & Wire Color Abbreviation Legend Wire Color Legend Item Description Blue Valve Coil BL/BK Blue/Black Sway Left Enable SV1 BL/RD Blue/Red Tilt Up Enable SV2 BL/WH Blue/White Sway Right Enable SV3 Black Tilt Down Enable SV4 BK/RD Black/Red...

  • Page 104: Electrical Symbol Legend

    Service and Repair Manual November 2022 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 105: Hydraulic Symbols Legend

    November 2022 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 106 Service and Repair Manual November 2022 This page intentionally left blank. -1256 Part No. 1310135GT ™...

  • Page 107: Electrical Schematics

    November 2022 Service and Repair Manual Electrical Schematic, Deutz T3/T4F 120HP ZF Base System...

  • Page 108: Electrical Schematic, Deutz T3/T4F 120Hp Zf Base System

    Service and Repair Manual November 2022 Electrical Schematic, Deutz T3/T4F 120HP ZF Base System C38-7 C38-9 C38-4 OR/BK C38-6 C38-2 WH/RD C38-8 C38-5 C75-1 C75-2 C38-11 C38-3 C38-10 2>7 2>4 C85-2 3>7 3>4 C85-1 120Ω 120Ω -1256 Part No. 1310135GT ™...

  • Page 109: Electrical Schematic, Deutz T3/T4F 120Hp Zf Options

    November 2022 Service and Repair Manual Electrical Schematic, Deutz T3/T4F 120HP ZF Options C75-1 C46-1 C75-2 C46-2 C38-1 C38-2 P48LPS WH/RD C99-1 C101-1 C38-3 P32PS WH/RD C109-2 C110-2 C109-1 C110-1 C38-4 C32RET WH/RD C99-2 C38-5 R49LPS WH/BK C38-6 P277LPS OR/BK C38-7 P278LPS GR/BK C38-8...
  • Page 110 Service and Repair Manual November 2022 Electrical Schematic, Deutz T3/T4F 120HP ZF Options...
  • Page 111 November 2022 Service and Repair Manual Electrical Schematic, Deutz T3 120HP ZF Engine ECM...

  • Page 112: Electrical Schematic, Deutz T3 120Hp Zf Engine Ecm

    Service and Repair Manual November 2022 Electrical Schematic, Deutz T3 120HP ZF Engine ECM ENGINE BLOCK GROUND GLOW PLUGS -1256 Part No. 1310135GT ™...

  • Page 113: Electrical Schematic, Deutz T4F 120Hp Zf Engine Ecm

    November 2022 Service and Repair Manual Electrical Schematic, Deutz T4F 120HP ZF Engine ECM ENGINE BLOCK GROUND GLOW PLUGS Part No. 1310135GT -1256 ™...
  • Page 114 Service and Repair Manual November 2022 Electrical Schematic, Deutz T4F 120HP ZF Engine ECM...
  • Page 115 November 2022 Service and Repair Manual Electrical Schematic, Deutz T4F 120HP ZF Engine EAT / ECM...

  • Page 116: Electrical Schematic, Deutz T4F 120Hp Zf Engine Eat / Ecm

    Service and Repair Manual November 2022 Electrical Schematic, Deutz T4F 120HP ZF Engine EAT / ECM -1256 Part No. 1310135GT ™...

  • Page 117: Electrical Schematic, Deutz T4F 120Hp Zf Engine Eat / Ecm / Vec

    November 2022 Service and Repair Manual Electrical Schematic, Deutz T4F 120HP ZF Engine EAT / ECM / VEC Part No. 1310135GT -1256 ™...
  • Page 118 Service and Repair Manual November 2022 Electrical Schematic, Deutz T4F 120HP Engine EAT / ECM / VEC...

  • Page 119: Hydraulic Schematics

    November 2022 Service and Repair Manual Hydraulic Schematic...

  • Page 120: Hydraulic Schematic

    Service and Repair Manual November 2022 Hydraulic Schematic OPTIONS STEERING PRESSURE 3481 psi 240 bar STEERING PRIORITY PUMP PRESSURE 3481 psi 240 bar INLET TILT LIFT EXTEND LSa = 2611 psi LSb = 2611 psi SWAY PRIORITY INLET SECONDARY 180 bar 180 bar PRESSURE PRESSURE...
  • Page 121 November 2022 Service and Repair Manual Hydraulic Schematic SVD1 ORF1 ORF2 50 psi 3,5 bar 400 psi 27,6 bar STEERING PRESSURE STEERING PRIORITY PUMP PRESSURE SECONDARY PRESSURE LOAD SENSE PRESSURE LOAD SENSE DRAIN PRIMARY TANK LINE HS0285A Part No. 1310135GT -1256 ™...
  • Page 122 Service and Repair Manual November 2022 Hydraulic Schematic...
  • Page 123 November 2022 Service and Repair Manual Hydraulic Schematic, Options...

  • Page 124: Hydraulic Schematic, Options

    Service and Repair Manual November 2022 Hydraulic Schematic, Options OPTIONS OPTIONS HS0285A GTH™-1256 Part No. 1310135GT Servic e and R epair M anual Novem ber 2022 -1256 Part No. 1310135GT ™...

This manual is also suitable for:

Gth-1256

Table of Contents