Terex GTH250614-101 Service Manual
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Terex GTH250614-101 Service Manual

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Service Manual
GTH-2506
(Deutz Stage IIIA - IIIB)
GTH-3007
(Deutz Stage IIIA - IIIB)
Serial Number Range
From GTH250614-101
to GTH250619M-1000
From GTH300716M-101
to GTH300719M-500
Part No. 57.4400.9214
Rev
C
July 2018

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Summary of Contents for Terex GTH250614-101

  • Page 1 Service Manual Serial Number Range GTH-2506 From GTH250614-101 to GTH250619M-1000 (Deutz Stage IIIA - IIIB) GTH-3007 From GTH300716M-101 to GTH300719M-500 (Deutz Stage IIIA - IIIB) Part No. 57.4400.9214 July 2018...
  • Page 2 Therefore, product specifications are subject to change without notice. "Genie" and "GTH" are registered trademarks of Terex South Dakota, Inc. in the USA and many other Readers are encouraged to notify Genie of errors countries. and send in suggestions for improvement. All...

  • Page 3: Revision History

    July 2018 Revision History Revision Date Section Procedure / Schematic Page / Description 04/2014 Initial Release 05/2016 Added GTH-3007 information 07/2018 Section 7 Update, Electrical Schematic REFERENCE EXAMPLES: Electronic Version Deutz Engine_Section 2_Specifications. A-6,B-3,C-7_Section 3_Maintenance Procedure. Click on any procedure or page number 3-2, 6-4, 9-1_Section 4_Repair Procedure.
  • Page 4 July 2018 REVISION HISTORY, CONTINUED Revision Date Section Procedure / Schematic Page / Description REFERENCE EXAMPLES: Electronic Version Deutz Engine_Section 2_Specifications. A-6,B-3,C-7_Section 3_Maintenance Procedure. Click on any procedure or page number 3-2, 6-4, 9-1_Section 4_Repair Procedure. highlighted in blue to view the update. Fault Codes_Section 5.

  • Page 5: Serial Number Legend

    July 2018 INTRODUCTION Serial Number legend A TEREX BRAND A TEREX BRAND Model Name: Model Name: GTH-2506 GTH-3007 Model Year: Current Year Model Year: Current Year Designation: Designation: ROUGH TERRAIN VARIABLE REACH TRUCK ROUGH TERRAIN VARIABLE REACH TRUCK Serial Number:...
  • Page 6 July 2018 This page intentionally left blank. GTH-2506 GTH-3007 Part No. 57.4400.9214...

  • Page 7: Safety Rules

    July 2018 Section 1 • Safety Rules Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the appropriate Operator's Manual on your machine will result in death or serious injury. Many of the hazards identified in the Operator’s Manual are also safety hazards when maintenance and repair procedures are performed.
  • Page 8 Section 1 • Safety Rules July 2018 SAFETY RULES Personal Safety Workplace Safety Any person working on or around a machine must Be sure to keep sparks, flames and be aware of all known safety hazards. Personal lighted tobacco away from flammable and safety and the continued safe operation of the combustible materials like battery gases machine should be your top priority.

  • Page 9: Table Of Contents

    July 2018 Table of Contents Introduction Important Information .................. ii Revision History...................iii Serial Number Legend................. v Section 1 Safety Rules General Safety Rules .................vii Section 2 Specifications Machine Specifications ................2 - 1 Performance Specifications ..............2 - 2 Hydraulic Specifications .................2 - 3 Hydraulic Component Specifications ............2 - 4 Function Manifold Specifications ............2 - 5 Air Conditioner Refrigerant Specifications ..........2 - 5...
  • Page 10 July 2018 TABLE OF CONTENTS Section 3 Scheduled Maintenance Procedures, continued Checklist A Procedures Inspect the Manuals and Decals ..........3 - 5 Perform Pre-operation Inspection ..........3 - 6 Perform Function Tests ..............3 - 6 Lubricate the Boom ..............3 - 7 Perform Engine Maintenance ............3 - 7 Safety Devices ................3 - 8 Perform 30 Day Service ...............3 - 8...
  • Page 11 July 2018 TABLE OF CONTENTS Section 3 Scheduled Maintenance Procedures, continued Checklist C Procedures Perform Engine Maintenance .............3 - 16 Checklist D Procedures Inspect the Forks ................3 - 17 Replace the Hydraulic Tank Return Filter Element ....3 - 18 Perform Engine Maintenance .............3 - 19 Perform Axle Maintenance ............3 - 19 Inspect the Engine Air Filter ............3 - 20 Perform Engine Maintenance .............3 - 21...
  • Page 12 July 2018 TABLE OF CONTENTS Section 4 Repair Procedures Introduction .....................4 - 1 Boom Components Boom ....................4 - 2 Boom Lift Cylinder ................4 - 6 Boom Extend Cylinder..............4 - 7 Fork Level Cylinder ..............4 - 8 Fork Tilt Cylinder ................4 - 9 Operator's compartment Operator’s Compartment ............4 - 12 Machine Controls ...............4 - 14...
  • Page 13 July 2018 TABLE OF CONTENTS Section 4 Repair Procedures, continued Miscellaneaous Parking Brake Reducing Valve...........4 - 41 Section 5 Settings Introduction .....................5 - 1 How to Calibrate the Load Cell ...............5 - 2 Section 6 Fault Codes Introduction .....................6 - 1 Diagnostic Display ..................6 - 2 Engine Fault Codes - Models with Deutz TD 2.9 L4.......6 - 3 Section 7...
  • Page 14 July 2018 TABLE OF CONTENTS This page intentionally left blank. GTH-2506 GTH-3007 Part No. 57.4400.9214...

  • Page 15: Specifications

    July 2018 Section 2 • Specifications Specifications Machine Specifications Tires and wheels GTH-2506 Tire size 12 x 16.5 Tire ply rating Fluid Capacities GTH-2506 Weight, rough terrain tire wheel 106 lbs (air filled) 48 kg Fuel Tank 15.9 gallons Weight, rough terrain tire wheel 320 lbs 60 liters (foam filled)

  • Page 16: Performance Specifications

    Section 2 • Specifications July 2018 SPECIFICATIONS Performance Specifications Boom function speeds, maximum GTH-2506 Boom up 8 seconds Boom down 7 seconds GTH-2506 Boom extend 8 seconds Drive speed, maximum 14 mph Boom retract 4 seconds 23 km/h Fork tilt up 5 seconds Draw bar pull 9200 lbs...

  • Page 17: Hydraulic Specifications

    July 2018 Section 2 • Specifications SPECIFICATIONS Hydraulic Specifications Optional fluids Biodegradable Petro Canada Environ MV46 Hydraulic Oil Specification Statoil Hydra Way Bio Pa 32 BP Biohyd SE-S Hydraulic oil type Chevron Rando HD equivalent Fire resistant UCON Hydroluble HP-5046 Viscosity grade Multi-viscosity Quintolubric 822...

  • Page 18: Hydraulic Component Specifications

    Section 2 • Specifications July 2018 SPECIFICATIONS Hydraulic Components Hydrostatic Transmission Pump Specifications Type: variable displacement piston pump Displacement 0 to 2.75 cu in Boom and Steering Functions Pump 0 to 45 cc GTH-2506 Flow rate @ 2300 rpm 27.34 gpm 103.5 L/min Type: fixed displacement gear...

  • Page 19: Function Manifold Specifications

    July 2018 Section 2 • Specifications SPECIFICATIONS Function Manifold Air Conditioner Refrigerant Specifications Specifications Function Manifold System Full Charge System relief valve pressure, maximum 4060 psi R134a 750 g (measured at test port TP1) 280 bar 1 lbs 10 oz Fork tilt relief valve pressure, maximum 4350 psi (measured at test port TP1)

  • Page 20: Deutz Td 2.9 L4 Engine

    Section 2 • Specifications July 2018 SPECIFICATIONS Deutz TD 2.9 L4 Engine Fuel requirements For fuel requirements, refer to the engine Operation Manual on your machine. Displacement 2925 cm Fuel injection pressure 1595 psi Number of cylinders 110 bar Bore and stroke 3.62 x 4.33 inches Engine coolant 92 x 110 mm...

  • Page 21: Comer Axle

    July 2018 Section 2 • Specifications SPECIFICATIONS Comer Axles Dana Axles Steering Integrated steer cylinder Steering Integrated steer cylinder Joints Heavy duty double Joints Heavy duty double U-joints U-joints Steering angle, 40 ° Steering angle, 40 ° maximum maximum Front Axle Lubrication Front Axle Lubrication Front differential 6.34 quarts...

  • Page 22: Hydraulic Hose And Fitting Torque Specifications

    Section 2 • Specifications July 2018 SPECIFICATIONS Hydraulic Hose and Fitting SAE O-ring Boss Port Torque Specifications (tube fitting - installed into Aluminum) (all types) SAE Dash size Torque Your machine is equipped with Parker Seal-Lok™ ORFS or 37° JIC fittings and hose ends. 14 ft-lbs / 19 Nm Genie specifications require that fittings and hose 23 ft-lbs / 31.2 Nm...

  • Page 23: Torque Procedure

    July 2018 Section 2 • Specifications SPECIFICATIONS Torque Procedure Seal-Lok fittings 1 Replace the O-ring. The O-ring must be replaced anytime the seal has been broken. The O-ring cannot be re-used if the fitting or hose end has been tightened beyond finger Figure 1 tight.
  • Page 24 Section 2 • Specifications July 2018 SPECIFICATIONS SAE FASTENER TO RQ UE C HART • Thi s chart i s t o be used as a gui de onl y unl ess not ed el sew here i n t hi s m anual • A 574 Hi gh St rengt h G r ade 5 G r ade 8...

  • Page 25: Scheduled Maintenance Procedures

    July 2018 Section 3 • Scheduled Maintenance Procedures Scheduled Maintenance Procedures About This Section This section contains detailed procedures for each scheduled maintenance inspection. Each procedure includes a description, safety warnings and step-by-step instructions. Observe and Obey: Symbols Legend Maintenance inspections shall be completed Safety alert symbol—used to by a person trained and qualified on the alert personnel to potential...

  • Page 26: Pre-Delivery Preparation Report

    Section 3 • Scheduled Maintenance Procedures July 2018 SCHEDULED MAINTENANCE PROCEDURES Maintenance Symbols Legend Pre-delivery Preparation Report Note: The following symbols have been used The pre-delivery preparation report contains in this manual to help communicate the intent checklists for each type of scheduled inspection. of the instructions.
  • Page 27 500 Oak Wood Road The Maltings, Wharf Road Inspector company PO Box 1150 Grantham, Lincolnshire Watertown, SD 57201-6150 NG31- 6BH England (605) 882-4000 (44) 1476-584333 Copyright © 2011 Terex Corporation. Genie® is a registered trademark of Terex South Dakota, Inc. 133192 Rev D...

  • Page 28: Maintenance Inspection Report

    Section 3 • Scheduled Maintenance Procedures July 2018 Maintenance Inspection Report Model Checklist A Checklist D Serial number Manuals and decals Forks Date Pre-operation inspect Hydraulic return filter Hour meter Function tests Engine maintenance Machine owner Lubricate the boom Axle maintenance Inspected by (print) Engine maintenance Inspect the engine...

  • Page 29: Checklist A Procedures

    July 2018 Section 3 • Scheduled Maintenance Procedures Checklist A Procedures Result: The operator's manual is not appropriate for the machine or all manuals are Inspect the Manuals and not in good condition or is illegible. Remove Decals the machine from service until the manual is replaced.

  • Page 30: Perform Pre-Operation Inspection

    Section 3 • Scheduled Maintenance Procedures July 2018 CHECKLIST A PROCEDURES Perform Pre-operation Perform Function Tests Inspection Genie specifications require that this procedure be performed every 8 hours or daily, whichever Genie specifications require that this procedure comes first. be performed every 8 hours or daily, whichever comes first.

  • Page 31: Lubricate The Boom

    July 2018 Section 3 • Scheduled Maintenance Procedures CHECKLIST A PROCEDURES Lubricate the Boom Perform Engine Maintenance Genie specifications require that this procedure Engine specifications require that this procedure be performed every 8 hours or daily, whichever be performed every 8 hours or daily, whichever comes first.

  • Page 32: Safety Devices

    Section 3 • Scheduled Maintenance Procedures July 2018 CHECKLIST A PROCEDURES Safety Devices Perform 30 Day Service 1 Moment Limiting System Load a weight of 2205 lbs / 1000 kg. Raise the boom about 11.8 in / 30 cm above The 30 day maintenance procedure is a one-time the ground.

  • Page 33: Perform Axle Maintenance

    July 2018 Section 3 • Scheduled Maintenance Procedures CHECKLIST A PROCEDURES Perform Axle Maintenance Perform Axle Maintenance GTH-2506 Comer Axle Axle specifications require that this procedure be GTH-2506 Comer Axle performed after first 100 hours. Axle specifications require that this procedure be performed after first 200 hours.

  • Page 34: Perform Axle Maintenance

    Section 3 • Scheduled Maintenance Procedures July 2018 CHECKLIST A PROCEDURES A-10 Perform Axle Maintenance GTH-2506 Comer Axle Axle specifications require that this procedure be performed every 200 hours. GTH-2506 and GTH-3007 Dana Axle Axle specifications require that this procedure be performed first time after 10 working hours, then weekly.

  • Page 35: Checklist B Procedures

    July 2018 Section 3 • Scheduled Maintenance Procedures Checklist B Procedures 4 Attach a lifting strap from an overhead crane to the boom. Support the boom. Do not apply any Inspect the Electrical Wiring lifting pressure. 5 Remove all engine covers and chassis covers. Crushing hazard.

  • Page 36: Check The Exhaust System

    Section 3 • Scheduled Maintenance Procedures July 2018 CHECKLIST B PROCEDURES Check the Exhaust System Inspect the Tires, Wheels and Lug Nut Torque Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes Genie requires that the first inspection be first.

  • Page 37: Perform Hydraulic Oil Analysis

    July 2018 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES Perform Hydraulic Oil Analysis Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first. Replacement or testing of the hydraulic oil is essential for good machine performance and service life.

  • Page 38: Check The Boom Wear Pads

    Section 3 • Scheduled Maintenance Procedures July 2018 CHECKLIST B PROCEDURES Check the Boom Wear Pads Genie specifications require that this procedure be performed every 250 hours of operation. Any boom section is fitted with adjustable pads located on the four sides of the profile. These pads are secured to both fixed and mobile part of every section.

  • Page 39: Perform Axle Maintenance

    July 2018 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES Perform Axle Maintenance Perform Axle Maintenance GTH-2506 Comer Axle Axle specifications require that this procedure be Genie specifications require that this procedure be performed after first 400 hours. performed every 300 hours or quarterly, whichever comes first.
  • Page 40 Section 3 • Scheduled Maintenance Procedures July 2018 Checklist C Procedures Perform Engine Maintenance Engine specifications require that this procedure be performed every 500 hours. Deutz TD 2.9 L4 Lubricating oil - change (when using Deutz approved oil rated DCQ III or better) Lubricating oil filter - change Coolant (additive concentration) - check Intake air pipes - check for damage...
  • Page 41 July 2018 Section 3 • Scheduled Maintenance Procedures Checklist D Procedures Inspect the Forks Genie specifications require that this procedure be performed every 1000 hours or annually, whichever comes first OR whenever permanent deformation of the forks is suspected. Maintaining the lifting forks in good condition is essential to safe operation and good machine performance.
  • Page 42 Section 3 • Scheduled Maintenance Procedures July 2018 CHECKLIST D PROCEDURES Replace Hydraulic Tank Return 10 Inspect the filter assembly to be sure that there Filter Element are no leaks. 11 Clean up any oil that may have spilled during the installation procedure.
  • Page 43 July 2018 Section 3 • Scheduled Maintenance Procedures CHECKLIST D PROCEDURES Perform Engine Maintenance Perform Axle Maintenance Engine specifications require that this procedure Axle specifications require that this procedure be performed every 1000 hours. be performed every 1000 hours or annually, whichever comes first.

  • Page 44: Inspect The Engine Air Filter

    Section 3 • Scheduled Maintenance Procedures July 2018 CHECKLIST D PROCEDURES 5 Blow out with dry compressed air (max. pressure: 72,5 psi / 5 bar) from the inside to the Inspect the Engine Air Filter outside if soiling is only slight. 6 Renew the filter element if heavily soiled.

  • Page 45: Perform Engine Maintenance

    July 2018 Section 3 • Scheduled Maintenance Procedures CHECKLIST D PROCEDURES Perform Engine Maintenance Engine specifications require that this procedure be performed every year. Deutz TD 2.9 L4 Engine monitor - warning system Maintenance only to be carried out by authorised service personnel Fuel pre-filter - replace Required maintenance procedures and additional...

  • Page 46: Checklist E Procedures

    Section 3 • Scheduled Maintenance Procedures July 2018 Checklist E Procedures 4 Remove oil cap from top of hydraulic tank. Test or Replace the Hydraulic 5 Using an approved hand-operated pump, drain the hydraulic tank into a suitable container. Refer to Section 2, Specifications. Bodily injury hazard.

  • Page 47: Perform Engine Maintenance

    July 2018 Section 3 • Scheduled Maintenance Procedures CHECKLIST E PROCEDURES Perform Engine Maintenance Perform Engine Maintenance Engine specifications require that this procedure Engine specifications require that this procedure be performed every 2 years. be performed every 3000 hours. Deutz TD 2.9 L4 Deutz TD 2.9 L4 Dry air filter - replace V-rib belt and tensioning pulley - replace...

  • Page 48: Perform Engine Maintenance

    Section 3 • Scheduled Maintenance Procedures July 2018 CHECKLIST E PROCEDURES Perform Engine Maintenance Engine specifications require that this procedure be performed every 6000 hours. Deutz TD 2.9 L4 General engine overhaul Required maintenance procedures and additional engine information is available in the Deutz TD 2.9 L4 Operation and Maintenance Manual (Deutz part number 0312 3893).
  • Page 49 July 2018 Section 4 • Repair Procedures Repair Procedures About This Section Most of the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop. Select the appropriate repair procedure after troubleshooting the problem.

  • Page 50: Boom Components

    Section 4 • Repair Procedures July 2018 Boom Components How to Remove the Lifting Boom Fork Frame 1 With the boom in the stowed position, attach a How to Replace the lifting strap from an overhead crane to the top Boom Wear Pads of the lifting fork frame at the front of the boom.
  • Page 51 July 2018 Section 4 • Repair Procedures BOOM COMPONENTS How to Remove the Boom 8 Flip the slave cylinder towards the cab. 9 Using a soft metal drift, remove the lift cylinder Bodily injury hazard. This WARNING locking pin, boom side. procedure requires specific repair skills, lifting equipment 10 Operate the 2 overhead cranes at the same...
  • Page 52 Section 4 • Repair Procedures July 2018 BOOM COMPONENTS How to Disassemble the Boom Note: When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during Bodily injury hazard. This WARNING installation.
  • Page 53 July 2018 Section 4 • Repair Procedures BOOM COMPONENTS 3 Remove the extend cylinder from inside the 13 Remove all pads "g" from the second section boom. Refer to Repair Procedure 1-3, How to "b". Remove the Extend Cylinder. 14 Remove the pipes from the first boom section 4 Remove the hydraulic hoses from inside the "a".

  • Page 54: Boom Lift Cylinder

    Section 4 • Repair Procedures July 2018 BOOM COMPONENTS 5 Place a suitably dimensioned wooden block before the hydraulic oil tank. This block will be Boom Lift Cylinder used to support the weight of the lift cylinder first, and the boom afterwards. How to Remove the Lift 6 Remove the fasteners securing the lift cylinder Cylinder...

  • Page 55: Boom Extend Cylinder

    July 2018 Section 4 • Repair Procedures BOOM COMPONENTS 3 Tag, disconnect and plug the pipes from the cylinder shutoff valve. Cap the cylinder fittings. Boom Extend Cylinder Bodily injury hazard. Spraying WARNING hydraulic oil can penetrate and How to Remove the Extend burn skin.

  • Page 56: Fork Level Cylinder

    Section 4 • Repair Procedures July 2018 BOOM COMPONENTS 6 Remove the retaining fasteners securing the level cylinder barrel end pivot pin. Fork Level Cylinder 7 Using a soft metal drift and a hammer, remove the pivot pin using the holes on the chassis on How to Remove the Fork Level the rear left side of the machine.

  • Page 57: Fork Tilt Cylinder

    July 2018 Section 4 • Repair Procedures BOOM COMPONENTS 6 Remove the protective guard "a" of the shut-off valve. Fork Tilt Cylinder 7 Place a container of suitable size under the hydraulic hoses before disconnecting. How to Remove the Fork Tilt Cylinder 8 Tag, disconnect and plug the hydraulic hoses from the level cylinder.
  • Page 58 Section 4 • Repair Procedures July 2018 BOOM COMPONENTS How to Replace the Fork Tilt from the rear side of the boom. 6 Before replacing a hydraulic hose, thoroughly Cylinder Hoses clean the machine. GHT-2506 to S.N. GTH250615B-231 7 Remove the protective guard "c" of the shut-off Note: When removing a hose assembly or fitting, valve.
  • Page 59 July 2018 Section 4 • Repair Procedures BOOM COMPONENTS 9 Securely attach a resistant guide rope (length 14 Pull hoses "e" and "f" outward - one at a time - about 33 feet / 10 m) to the hydraulic hose, one until they come out completely.
  • Page 60 Section 4 • Repair Procedures July 2018 How to Replace the Fork Tilt 6 Remove the protective guard "c" of the shut-off valve. Cylinder Hoses GHT-2506 from S.N. GTH250615B-232 7 Tag, disconnect and plug the hydraulic hoses GTH-3007 from S.N. GTH300716M-101 from the fork tilt cylinder.
  • Page 61 July 2018 Section 4 • Repair Procedures 8 Securely attach a resistant guide rope (length 12 Pull hoses "e" outward until it comes out about 33 feet / 10 m) to the hydraulic hose. completely. This will be used to install the new double- hose.

  • Page 62: Operator's Compartment

    Section 4 • Repair Procedures July 2018 Operator's Compartment 3 Remove the protective cover next to the cab - inner side of the machine. Operator's Compartment 4 Cut the plastic fasteners fixing the electrical cables, then disconnect all of the electrical How to Remove the Operator's wires.
  • Page 63 July 2018 Section 4 • Repair Procedures OPERATOR'S COMPARTMENT 8 Remove the 4 retaining fasteners "a-b"of the cabin. 9 Install and secure two eyebolts to the top the cabin in the special seats. 10 Using a sling chain and an overhead crane, slowly raise the cabin away from the machine and set it on a supporting device.

  • Page 64: Machine Controls

    Section 4 • Repair Procedures July 2018 OPERATOR'S COMPARTMENT How to Remove the Steering Machine Controls Wheel 1 Get behind the front right wheel and disconnect How to Remove the Steering the battery from the machine. Column Electrocution/burn hazard. WARNING Contact with electrically charged circuits could result in death or 1 Get behind the front right wheel and disconnect...
  • Page 65 July 2018 Section 4 • Repair Procedures OPERATOR'S COMPARTMENT How to Remove the Steer Rotation Actuator 1 Remove the steering column. See 2-2, How to Remove the Steering Column. 2 Working under the dashboard, locate the hydraulic hoses of the steer rotation actuator. 3 Tag, disconnect and cap the hydraulic hoses and steer rotation actuator holes.
  • Page 66 Section 4 • Repair Procedures July 2018 OPERATOR'S COMPARTMENT How to Remove the Joystick How to Remove the Brake Pedal Assembly 1 Get behind the front right wheel and disconnect the battery from the machine. 1 Remove the front dashboard, lower part. Electrocution/burn hazard.
  • Page 67 July 2018 Section 4 • Repair Procedures OPERATOR'S COMPARTMENT How to Remove the Gauge Cluster Assembly 1 Get behind the front right wheel and disconnect the battery from the machine. Electrocution/burn hazard. WARNING Contact with electrically charged circuits could result in death or serious injury.

  • Page 68: Fuel And Hydraulic Tanks

    Section 4 • Repair Procedures July 2018 Fuel and Hydraulic Tanks 1 Get behind the front right wheel and disconnect the battery from the machine. Fuel Tank Electrocution/burn hazard. WARNING Contact with electrically charged How to Remove the Fuel Tank circuits could result in death or serious injury.

  • Page 69: Hydraulic Tank

    July 2018 Section 4 • Repair Procedures FUEL AND HYDRAULIC TANKS 7 Go under the machine and remove the drive shaft. Hydraulic Tank 8 Loosen all the clamps and pull out the hoses. How to Remove the Hydraulic 9 Disconnect the electrical harnesses. Tank 10 Remove the wire harness from bulb on the hydraulic filter.

  • Page 70: Engines

    Section 4 • Repair Procedures July 2018 Engines Engines Engine Fault Codes How to Repair the How to Retrieve Engine Fault Deutz TD 2.9 L4 Engine Codes Repair procedures and additional engine When the engine Electronic Control Module information is available in the (ECM) detects an abnormal operating condition, Deutz TD 2.9 L4 Workshop Manual a fault code is immediately stored in the ECM...

  • Page 71: Disabled Machine

    July 2018 Section 4 • Repair Procedures Axle When the machine shall absolutely be towed and the front axle can NOT be lifted: Disabled Machine 1 Use a rigid drawbar. How to Move a Disabled 2 Unlock the parking brake. Machine 3 Select two wheel steer mode.
  • Page 72 Section 4 • Repair Procedures July 2018 AXLE 7 If the towing distance is greater than 164ft Unlock the negative brakes - GTH-2506 Comer inches / 50m, remove the hydraulic motor from Axle the axle. 1 Completely undo the n.2 screws "a" on the beam "c".
  • Page 73 July 2018 Section 4 • Repair Procedures AXLE Unlock the negative brakes - GTH-2506 and GTH-3007 Dana Axle 1. On both sides unscrew the nuts (5) approximately 10 mm nearby the bolt head. 2. Screw in the brake release bolts (6a) and (6b). The screw must be tightened 1/4 WARNING turn at a time, in sequence, until the...
  • Page 74 Section 4 • Repair Procedures July 2018 AXLE 5 Raise the end of the machine until the tires are off the ground. Place blocks under the chassis Axle for support. Crushing hazard. The chassis WARNING How to Remove the Axle will fall if not properly supported.

  • Page 75: Hydraulic Pumps

    July 2018 Section 4 • Repair Procedures Hydraulic Pumps Boom and Steering Function Pump How to Test the Boom and Steering Function Pump 1 Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to port TP1. 2 Start the engine.
  • Page 76 Section 4 • Repair Procedures July 2018 HYDRAULIC PUMPS How to Remove the Boom and 4 Tag, disconnect and plug the hoses located at the right side of the pump. Cap the fitting on the Steering Function Pump pump. Bodily injury hazard. This WARNING Bodily injury hazard.
  • Page 77 July 2018 Section 4 • Repair Procedures HYDRAULIC PUMPS How to Install the Boom and 6 Check the hydraulic fluid level in the hydraulic tank. Add fluid if needed. Steering Function Pump 7 Start the engine and prime the pump. See 6-1, Bodily injury hazard.
  • Page 78 Section 4 • Repair Procedures July 2018 HYDRAULIC PUMPS How to Prime the Boom and Steering Function Pump 1 Start the engine, allow the engine to run at low idle for 15 seconds then shut off the engine. 2 Wait 15 seconds, then start the engine again. 3 Allow the engine to run at low idle for 15 seconds and then shut off the engine.

  • Page 79: Hydrostatic Transmission Pump

    July 2018 Section 4 • Repair Procedures HYDRAULIC PUMPS 5 Engage forward or reverse gear. Hydrostatic Transmission Result: the pressure gauge connected to test Pump port TP2 reads 725 psi / 50 bar. Pressure is not within specification. How to Test the Hydrostatic Adjust the high pressure relief valve "a"...
  • Page 80 Section 4 • Repair Procedures July 2018 HYDRAULIC PUMPS How to Remove the Hydrostatic 4 Tag, disconnect and plug the hoses that are connected to the hydrostatic transmission Transmission Pump pump. Cap the fittings. Bodily injury hazard. This WARNING Bodily injury hazard. Spraying WARNING procedure requires specific hydraulic oil can penetrate and...
  • Page 81 July 2018 Section 4 • Repair Procedures HYDRAULIC PUMPS How to Install the Hydrostatic 7 Connect the hoses to the pump. Bodily injury hazard. Spraying Transmission Pump WARNING hydraulic oil can penetrate and Bodily injury hazard. This WARNING burn skin. Loosen hydraulic procedure requires specific connections very slowly to allow repair skills, lifting equipment...
  • Page 82 Section 4 • Repair Procedures July 2018 HYDRAULIC PUMPS How to Prime the Hydrostatic 7 Shift the transmission into reverse. Release the brake pedal and slowly increase the engine Transmission Pump rpm until the machine starts to move. Apply the brake.

  • Page 83: Function Manifolds

    July 2018 Section 4 • Repair Procedures Manifold Function Manifold How to Test the Boom Telescopic Cylinder Relief Valve 1 Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to port TP1 on the function manifold (boom and steering functions hydraulic test port).
  • Page 84 Section 4 • Repair Procedures July 2018 MANIFOLD How to Test the Fork Tilt Relief 8 Act on the pressure relief valve "c", until the pressure gauge connected to port TP1, reads Valves 280 bar. 1 Connect a 0 to 5000 psi / 0 to 350 bar pressure 9 Turn the machine off.
  • Page 85 July 2018 Section 4 • Repair Procedures MANIFOLD How to Remove the Function 5 Remove the retaining fasteners securing the function manifold. Manifold 6 Remove the function manifold. Bodily injury hazard. This WARNING procedure requires specific Crushing hazard. The function WARNING repair skills, lifting equipment manifold will fall if not properly...
  • Page 86 Section 4 • Repair Procedures July 2018 MANIFOLD How to Test the Function Manifold 1 Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to port TP1 (boom and steering functions hydraulic circuit test port). 2 Start the engine. 3 Increase the engine speed to maximum rpm.
  • Page 87 July 2018 Section 4 • Repair Procedures MANIFOLD Function Manifold Components Description Schematic ITEM Pos. Function Boom in/out Hydraulic proportional control A3 - B3 Hydraulic proportional control A4 - B4 Auxiliary Circuit Fork tilt Hydraulic proportional control A2 - B2 Boom up/down Hydraulic proportional control A1 - B1...

  • Page 88: Valve Coils

    Section 4 • Repair Procedures July 2018 MANIFOLD Valve Coil Resistance Valve Coils Specification 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 temperature, the coil resistance will typically A properly functioning coil provides an increase or decrease by 4% for each 18°F / 20°C...
  • Page 89 July 2018 Section 4 • Repair Procedures MANIFOLD How to Test a Coil Diode COIL Genie incorporates spike suppressing diodes in all MULTI- of its coils. Properly functioning coil diodes protect METER the electrical circuit by suppressing voltage spikes. Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil.

  • Page 90: Lmi (Overload System)

    Section 4 • Repair Procedures July 2018 LMI (Overload System) How to Install the Load Cell The extensometer and the axle NOTICE must be stored at a similar How to Remove a Load Cell temperature before the mounting operation. The time is linked to the thermal inertia of both 1 Go to the back of the machine.
  • Page 91 July 2018 Section 4 • Repair Procedures 3 It means that the axle must see high shocks before calibration. 4 We suggest driving fast 10 times on a beam fixed to the ground. 5 After this operation, it is recommended to let the machine set unused for 12 hours before calibration.

  • Page 92: Miscellaneaous

    Section 4 • Repair Procedures July 2018 Miscellaneaous Parking Brake Reducing Valve How to Test the Parking Brake Reducing Valve 1 Connect a 0 to 870 psi / 0 to 60 bar pressure gauge to test port TP5. 2 Start the engine and let it run at low idle. 3 Engage the parking brake.

  • Page 93: Settings

    July 2018 Section 5 Settings Settings Before Repairs Start: 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 parts are Observe and Obey: available and ready for use. Use only Genie approved replacement parts.

  • Page 94: How To Calibrate The Load Cell

    Section 5 • Settings July 2018 SETTINGS How to Calibrate the Load Cell 6 Install the forks, load a weight of 5500 lbs / 2500 kg, bring the forks as close as possible to the ground and start extending the boom slowly 1 Release the parking brake.

  • Page 95: Fault Codes

    July 2018 Section 6 Fault Codes Fault 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 Observe and Obey: equipment are available and ready for use. Be aware of the following hazards and follow Troubleshooting and repair procedures shall be generally accepted safe workshop practices.

  • Page 96: Diagnostic Display

    Section 6 • Fault Codes July 2018 FAULT CODES Diagnostic Display Stored fault codes are the cumulative history of fault codes which the ECM has detected. These fault codes may be recalled by service personnel When the engine Electronic Control Module (ECM) at a later time even if the condition which caused detects an abnormal operating condition, a fault the engine fault has ceased to exist.

  • Page 97: Engine Fault Codes - Models With Deutz Td 2.9 L4

    July 2018 Section 6 Fault Codes FAULT CODES Engine Fault Codes - Models with Deutz TD 2.9 L4 Short Text Detail Air flow sensor load correction factor exceeding the maximum drift limit; plausibility error Air flow sensor load correction factor exceeding drift limit; plausibility error Air flow sensor low idle correction factor exceeding the maximum drift limit Air flow sensor load correction factor exceeding the maximum drift limit Sensor ambient air temperature;...
  • Page 98 Section 6 • Fault Codes July 2018 FAULT CODES Short Text Detail 523914 Glow plug control; short circuit to battery 523914 Glow plug control; short circuit to ground CAN-Bus 0 "BusOff-Status" 1231 CAN-Bus 1 "BusOff-Status" 1235 CAN-Bus 2 "BusOff-Status" Charged air pressure above warning threshold Charged air pressure above shut off threshold Sensor error coolant temperature;...
  • Page 99 July 2018 Section 6 Fault Codes FAULT CODES Short Text Detail 523938 Timeout Error (BAM to packet) for CAN-Receive-Frame AT1IGCVol1 information; factors & Sensorcalibration for NOX Sensor (SCR-system upstream cat; DPF-system downstream cat) 523939 Timeout Error (BAM to BAM) for CAN-Receive-Frame AT1IGCVol1 information; factors & Sensorcalibration for NOX Sensor (SCR-system upstream cat;...
  • Page 100 Section 6 • Fault Codes July 2018 FAULT CODES Short Text Detail 523606 Timeout Error of CAN-Receive-Frame TSC1AR; Retarder Timeout Error of CAN-Receive-Frame TSC1TE; Setpoint Timeout Error of CAN-Receive-Frame TSC1TR; Setpoint 523867 Timeout Error of CAN-Transmit-Frame UAA1 on CAN 2; Burner Air Pump Control 523982 Powerstage diagnosis disabled;...
  • Page 101 July 2018 Section 6 Fault Codes FAULT CODES Short Text Detail Fan actuator (PWM output); short circuit to ground 1639 Sensor error fan speed; signal range check high 1639 Sensor error fan speed; signal range check low 523602 High fan speed; warning threshold exceeded 523602 High fan speed;...
  • Page 102 Section 6 • Fault Codes July 2018 FAULT CODES Short Text Detail 523918 Sensor error DV1 & DV2 upstream temperature; signal range check low Cold start aid relay error. Cold start aid relay open load Cold start aid relay open load Cold start aid relay;...
  • Page 103 July 2018 Section 6 Fault Codes FAULT CODES Short Text Detail 523615 Metering unit (Fuel-System); short circuit to battery highside 523615 Metering unit (Fuel-System); short circuit to ground high side 523615 Metering unit (Fuel-System); short circuit to battery low side 523615 Metering Unit (Fuel-System);...
  • Page 104 Section 6 • Fault Codes July 2018 FAULT CODES Short Text Detail Low oil pressure; shut off threshold exceeded Sensor oil temperature; plausibility error Sensor oil temperature; plausibility error oil temperature too high Physical range check high for oil temperature Physical range check low for oil temperature Sensor error oil temperature;...
  • Page 105 July 2018 Section 6 Fault Codes FAULT CODES Short Text Detail 3253 Sensor error differential pressure (DPF); signal range check low 523009 Pressure Relief Valve (PRV) reached maximun allowed opening count 523470 Pressure Relief Valve (PRV) forced to open; performed by pressure increase 523470 Pressure Relief Valve (PRV) forced to open;...
  • Page 106 Section 6 • Fault Codes July 2018 FAULT CODES Short Text Detail 523633 Nox conversion rate insufficient (SCR-Cat defect, bad AdBule quality); temperature range 2 3234 Nox Sensor downstream of SCR Catalysator; plausibility error "stuk in range" 3224 Nox sensor upstream of SCR Catalysator; low signal not plausible 4345 Sensor backflow line pressure (SCR);...
  • Page 107 July 2018 Section 6 Fault Codes FAULT CODES Short Text Detail Accelerator pedal dutycycle PWM signal; signal range check low Acceleration pedal cycle duration PWM signal; signal range check low Sensor error accelerator pedal; signal range check low Sensor error handthrottle sensor; signal range check low 523921 Sensor error burner temperature;...
  • Page 108 Section 6 • Fault Codes July 2018 FAULT CODES Short Text Detail 523921 Physical range check low for burner temperature Sensor error charged air temperature; signal range check high Sensor error charged air temperature; signal range check low High charged air cooler temperature; warning threshold exceeded High charged air cooler temperature;...
  • Page 109 July 2018 Section 6 Fault Codes FAULT CODES Short Text Detail 1180 Sensor error exhaust gas temperature upstream turbine; signal range check low 4360 Physical range check high for urea catalyst upstream temperature 4360 Physical range low for urea catalyst upstream temperature 4360 Sensor error urea catalyst exhaust gas temperature upstream;...
  • Page 110 Section 6 • Fault Codes July 2018 FAULT CODES Short Text Detail 4366 SCR tank heating valve primary side; open load 4366 SCR-heater relay urea tank powerstage output; over temperature 4366 SCR Tank heating valve; short circuit to battery 4366 SCR Tank heating valve;...
  • Page 111 July 2018 Section 6 Fault Codes FAULT CODES Short Text Detail 523612 Internal software error ECU Customer oiltemperature: signal unplausible 523973 SCR Tamper detection; derating timer below limit 1 523974 SCR Tamper detection; derating timer below limit 2 523975 Urea quality; derating timer below limit 1 523976 Urea qulaity;...
  • Page 112 Section 6 • Fault Codes July 2018 FAULT CODES Short Text Detail 523988 Charging lamp; short circuit to battery 523988 Charging lamp; short circuit to ground 524019 Air Pump; air lines blocked 523910 Air Pump; CAN communication lost 523910 Air pump; CAN communication interrupted no purge function available 523910 Air Pump;...
  • Page 113 July 2018 Section 6 Fault Codes FAULT CODES Short Text Detail 524045 Master-Slave CAN; Message-Counter-Error of CAN-Receive-Frame ComMSMoFOvR 524046 Master-Slave CAN; Checksum-Error of CAN-Receive-Frame ComMSMoFOvR 524047 Master-Slave CAN; Messsage-Length-Error of CAN-Receive-Frame ComMSMoFOvR 524048 Timeout error CAN message ComMSMoFOvR1TO error memory Slave 524049 Message copy error in the Master / Slave data transfer 523788...
  • Page 114 Section 6 • Fault Codes July 2018 FAULT CODES Short Text Detail Rail pressure safety function is not executed correctly 523922 Burner Shut Off Valve; open load 523922 Burner Shut Off Valve; powerstage over temperature 523922 Burner Shut Off Valve; short circuit to ground 523921 Sensor burner temperature;...
  • Page 115 July 2018 Section 6 Fault Codes FAULT CODES Short Text Detail 524034 Disc separator; short circuit to battery 524034 Disc separator; short circuit to ground 524030 EGR actuator; internal error 524031 EGR actuator; calibration error 524032 EGR actuator; status message "EGRCust" is missing 524033 EGR actuator;...
  • Page 116 Section 6 • Fault Codes July 2018 FAULT CODES Short Text Detail 523718 SCR mainrelay; short circuit to ground (only CV56B) 4376 SCR reversing valve; open load 4376 SCR reversing valve; over temperature 4376 SCR reversing valve; short circuit to ground 524057 Electric fuel pump;...
  • Page 117 July 2018 Section 6 Fault Codes FAULT CODES Short Text Detail EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); short circuit to battery Position sensor error of actuator EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); signal range check high EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); short circuit to battery (A02) EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8);...
  • Page 118 Section 6 • Fault Codes July 2018 FAULT CODES Short Text Detail Sensor error water in fuel; signal range check high Sensor error water in fuel; signal range check low Water in fuel level prefilter; maximum value exceeded High oil pressure; warning threshold exceeded High oil pressure;...
  • Page 119 July 2018 Section 6 Fault Codes FAULT CODES Short Text Detail Physikal range check high for battery voltage Physikal range check low for battery voltage High battery voltage; warning threshold exceeded Low battery voltage; warning threshold exceeded Sensor error battery voltage; signal range check high Sensor error battery voltage;...
  • Page 120 Section 6 • Fault Codes July 2018 FAULT CODES Short Text Detail Engine speed above warning threshold (Overrun Mode) Camshaft-and Crankshaft speed sensor signal not available on CAN Physical range check high for differential pressure Venturiunit (EGR) Physical range check low for differential pressure Venturiunit (EGR) Sensor error differential pressure Venturiunit (EGR);...
  • Page 121 July 2018 Section 6 Fault Codes FAULT CODES Short Text Detail Injector 6 (in firing order); short circuit High side to low side short circuit in the injector 6 (in firing order) Injector 6 (in firing order); interruption of electric connection Cold start aid relay error.
  • Page 122 Section 6 • Fault Codes July 2018 FAULT CODES Short Text Detail 1176 Sensor error pressure sensor downstream turbine; signal range check high 1180 Physical range check high for exhaust gas temperature upstream turbine 1180 Turbocharger Wastegate CAN feedback; warning threshold exceeded 1180 Exhaust gas temperature upstream turbine;...
  • Page 123 July 2018 Section 6 Fault Codes FAULT CODES Short Text Detail 2621 Flush valve burner (EPV DPF-System); powerstage over temperature 2659 Physical range check high for EGR exhaust gas mass flow 2659 Physical range check low for EGR exhaust gas mass flow 2659 Exhaust gas recirculation AGS sensor;...
  • Page 124 Section 6 • Fault Codes July 2018 FAULT CODES Short Text Detail 3248 Sensor exhaust gas temperature downstream DPF; plausibility error 3248 Sensor error particle filter downstream temperature; signal range check low 3251 Physical range check high for differential pressure (DPF); shut off regeneration 3251 Physical range check low for differential pressure (DPF);...
  • Page 125 July 2018 Section 6 Fault Codes FAULT CODES Short Text Detail 4343 General pressure check error (SCR) 4345 SCR heater urea returnline; short circuit to battery 4345 SCR heater urea returnline; short circuit to ground 4345 SCR heater relay urea returnline sekondary side; open load 4345 SCR heater relay urea returnline primary side;...
  • Page 126 Section 6 • Fault Codes July 2018 FAULT CODES FAULT CODES Short Text Detail 4768 Sensor exhaust gas temperature upstream (DOC); plausibility error 4768 Sensor error exhaust gas temperature upstream (DOC); signal range check high 4768 Sensor error exhaust gas temperature upstream (DOC); signal range check low 4769 Sensor exhaust gas temperature downstream (DOC);...
  • Page 127 July 2018 Section 6 Fault Codes FAULT CODES Short Text Detail 523470 Rail pressure out of tolerance range 523470 Open Pressure Relief Valve (PRV); shut off condition 523470 Open Pressure Relief Valve (PRV); warning condition 523470 Pressure Relief Valve (PRV) is open 523550 T50 start switch active for too long 523601...
  • Page 128 Section 6 • Fault Codes July 2018 FAULT CODES Short Text Detail 523613 Railsystem leakage detected (RailMeUn10) 523613 Maximum negative deviation of rail pressure in metering unit exceeded (RailMeUn2) 523613 Negative deviation of rail pressure second stage (RailMeUn22) 523613 Maximum rail pressure exceeded (RailMeUn4) 523613 Minimum rail pressure exceeded (RailMeUn3) 523613...
  • Page 129 July 2018 Section 6 Fault Codes FAULT CODES Short Text Detail 523720 Sensor urea supply module heater temperature; plausibility error (normal condition) 523720 Sensor urea supply module heater temperature; plausibility error (cold start condition) 523720 Urea supply module heater temperature; duty cycle in failure range 523720 Urea supply module heater temperature;...
  • Page 130 Section 6 • Fault Codes July 2018 FAULT CODES Short Text Detail 523899 check of missing injector adjustment value programming (IMA) injector 5 (in firing order) 523900 check of missing injector adjustment value programming (IMA) injector 6 (in firing order) 523910 Air Pump;...
  • Page 131 July 2018 Section 6 Fault Codes FAULT CODES Short Text Detail 523915 HCI dosing valve (DV1); blocked closed 523915 HCI dosing valve (DV1); blocked open 523915 HCI dosing valve (DV1); short circuit high side powerstage 523915 HCI dosing valve (DV1); powerstage over temperature 523916 Physical range check high for HCI dosing valve (DV1) downstream pressure;...
  • Page 132 Section 6 • Fault Codes July 2018 FAULT CODES Short Text Detail 523921 Sensor error burner temperature; signal range check high 523921 Sensor error burner temperature; signal range check low 523921 Sensor burner temperature; plausibility error 523922 Burner shut of valve; short circuit to battery 523922 Burner shut of valve;...
  • Page 133 July 2018 Section 6 Fault Codes FAULT CODES Short Text Detail 523942 Timeout Error (BAM to BAM) for CAN-Receive-Frame AT1OGCVol2 information; factors & Sensorcalibration for NOX Sensor (SCR-system downstream cat; DPF-system downstream cat) 523943 Timeout Error (PCK2PCK) for CAN-Receive-Frame AT1OGCVol2 information; factors & Sensorcalibration for NOX Sensor (SCR-system downstream cat;...
  • Page 134 Section 6 • Fault Codes July 2018 FAULT CODES Short Text Detail 523989 Fuel Balance Control integrator injector 7 (in firing order); minimum value exceeded 523990 Fuel Balance Control integrator injector 8 (in firing order); maximum value exceeded 523990 Fuel Balance Control integrator injector 8 (in firing order); minimum value exceeded 523992 Timeout Error of CAN-Receive-Frame DM19Vol1;...
  • Page 135 July 2018 Section 6 Fault Codes FAULT CODES Short Text Detail 524023 DPF wasn´t regenerated, warning condition (manuell regeneration mode) 524024 Deviation of the exhaust gas temperature setpoint to actual value downstream (DOC) too high 524025 DPF system; operating voltage error 524025 Particulate filter;...
  • Page 136 Section 6 • Fault Codes July 2018 FAULT CODES Short Text Detail 524055 Spark Plug Control Unit (SPCU); short circuit to ground 524057 Electric fuel pump; fuel pressure build up error 524062 Regeneration inhibit switch not available; ComInhSwtNA 524062 Regeneration release switch not available; ComRegSwtNA 524068 Master ECU and Slave ECU have been identified as the same types 524069...

  • Page 137: Schematics

    July 2018 Section 7 • Schematics Schematics About This Section There are two groups of schematics in this section. Electrical Schematics Electrocution/burn hazard. WARNING 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 138: Electrical And Hydraulic Symbol Legends

    Section 7 • Schematics July 2018 Electrical and Hydraulic Symbols Legends Electrical Schematic Symbols Hydraulic Schematic Symbols Pressure switch Hydraulic cylinder Axle START STARTER SWITCH Key switch Engine start Orifice Adjustable orifice Filter Control relay Alternator Check valve Flow regulator Relief valve Fuse Circuit breaker...
  • Page 139 July 2018 Section 7 • Schematics Electrical Schematic Sheet 1 of 9 GTH-2506 From GTH250614-101 To GTH250616M-244 Part No. 57.4400.9214 GTH-2506 GTH-3007...
  • Page 140 Section 7 • Schematics July 2018 ELECTRICAL SCHEMATIC GTH-2506 From GTH250614-101 To GTH250616M-244 Sheet 2 of 9 GTH-2506 GTH-3007 Part No. 57.4400.9214...
  • Page 141 July 2018 Section 7 • Schematics ELECTRICAL SCHEMATIC GTH-2506 From GTH250614-101 To GTH250616M-244 Sheet 3 of 9 Part No. 57.4400.9214 GTH-2506 GTH-3007...
  • Page 142 Section 7 • Schematics July 2018 ELECTRICAL SCHEMATIC GTH-2506 From GTH250614-101 To GTH250616M-244 Sheet 4 of 9 GTH-2506 GTH-3007 Part No. 57.4400.9214...
  • Page 143 July 2018 Section 7 • Schematics ELECTRICAL SCHEMATIC GTH-2506 From GTH250614-101 To GTH250616M-244 Sheet 5 of 9 Part No. 57.4400.9214 GTH-2506 GTH-3007...
  • Page 144 Section 7 • Schematics July 2018 ELECTRICAL SCHEMATIC GTH-2506 From GTH250614-101 To GTH250616M-244 Sheet 6 of 9 GTH-2506 GTH-3007 Part No. 57.4400.9214...
  • Page 145 July 2018 Section 7 • Schematics ELECTRICAL SCHEMATIC GTH-2506 From GTH250614-101 To GTH250616M-244 Sheet 7 of 9 Part No. 57.4400.9214 GTH-2506 GTH-3007...
  • Page 146 Section 7 • Schematics July 2018 ELECTRICAL SCHEMATIC GTH-2506 From GTH250614-101 To GTH250616M-244 Sheet 8 of 9 7-10 GTH-2506 GTH-3007 Part No. 57.4400.9214...
  • Page 147 July 2018 Section 7 • Schematics ELECTRICAL SCHEMATIC GTH-2506 From GTH250614-101 To GTH250616M-244 Sheet 9 of 9 Part No. 57.4400.9214 GTH-2506 GTH-3007 7-11...

  • Page 148: Electrical Schematic

    Section 7 • Schematics July 2018 ELECTRICAL SCHEMATIC GTH-2506 From GTH250616M-245 To GTH250616M-422 Sheet 1 of 9 GENIE a Terex brand GENIE °C ENGINE RPM hour °C 7-12 GTH-2506 GTH-3007 Part No. 57.4400.9214...
  • Page 149 July 2018 Section 7 • Schematics ELECTRICAL SCHEMATIC GTH-2506 From GTH250616M-245 To GTH250616M-422 Sheet 2 of 9 Part No. 57.4400.9214 GTH-2506 GTH-3007 7-13...
  • Page 150 Section 7 • Schematics July 2018 ELECTRICAL SCHEMATIC GTH-2506 From GTH250616M-245 To GTH250616M-422 Sheet 3 of 9 7-14 GTH-2506 GTH-3007 Part No. 57.4400.9214...
  • Page 151 July 2018 Section 7 • Schematics ELECTRICAL SCHEMATIC GTH-2506 From GTH250616M-245 To GTH250616M-422 Sheet 4 of 9 Optional Part Part No. 57.4400.9214 GTH-2506 GTH-3007 7-15...
  • Page 152 Section 7 • Schematics July 2018 ELECTRICAL SCHEMATIC GTH-2506 From GTH250616M-245 To GTH250616M-422 Sheet 5 of 9 Optional Part 7-16 GTH-2506 GTH-3007 Part No. 57.4400.9214...
  • Page 153 July 2018 Section 7 • Schematics ELECTRICAL SCHEMATIC GTH-2506 From GTH250616M-245 To GTH250616M-422 Sheet 6 of 9 Optional Part Part No. 57.4400.9214 GTH-2506 GTH-3007 7-17...
  • Page 154 Section 7 • Schematics July 2018 ELECTRICAL SCHEMATIC GTH-2506 From GTH250616M-245 To GTH250616M-422 Sheet 7 of 9 Optional Part 7-18 GTH-2506 GTH-3007 Part No. 57.4400.9214...
  • Page 155 July 2018 Section 7 • Schematics ELECTRICAL SCHEMATIC GTH-2506 From GTH250616M-245 To GTH250616M-422 Sheet 8 of 9 Part No. 57.4400.9214 GTH-2506 GTH-3007 7-19...
  • Page 156 Section 7 • Schematics July 2018 ELECTRICAL SCHEMATIC GTH-2506 From GTH250616M-245 To GTH250616M-422 Sheet 9 of 9 F 01 F 11 F 02 F 12 F 03 F 13 F 14 F 04 F 15 F 05 F 16 F 06 F 17 F 07 F 08...
  • Page 157 July 2018 Section 7 • Schematics ELECTRICAL SCHEMATIC GTH-2506 From GTH250616M-423 to GTH250619M-1000 & Sheet 1 of 9 GTH-3007 From GTH300716M-101 to GTH300719M-500 Part No. 57.4400.9214 GTH-2506 GTH-3007 7-21...
  • Page 158 Section 7 • Schematics July 2018 ELECTRICAL SCHEMATIC GTH-2506 From GTH250616M-423 to GTH250619M-1000 & Sheet 2 of 9 GTH-3007 From GTH300716M-101 to GTH300719M-500 7-22 GTH-2506 GTH-3007 Part No. 57.4400.9214...
  • Page 159 July 2018 Section 7 • Schematics ELECTRICAL SCHEMATIC GTH-2506 From GTH250616M-423 to GTH250619M-1000 & Sheet 3 of 9 GTH-3007 From GTH300716M-101 to GTH300719M-500 Part No. 57.4400.9214 GTH-2506 GTH-3007 7-23...
  • Page 160 Section 7 • Schematics July 2018 ELECTRICAL SCHEMATIC GTH-2506 From GTH250616M-423 to GTH250619M-1000 & Sheet 4 of 9 GTH-3007 From GTH300716M-101 to GTH300719M-500 7-24 GTH-2506 GTH-3007 Part No. 57.4400.9214...
  • Page 161 July 2018 Section 7 • Schematics ELECTRICAL SCHEMATIC GTH-2506 From GTH250616M-423 to GTH250619M-1000 & Sheet 5 of 9 GTH-3007 From GTH300716M-101 to GTH300719M-500 Part No. 57.4400.9214 GTH-2506 GTH-3007 7-25...
  • Page 162 Section 7 • Schematics July 2018 ELECTRICAL SCHEMATIC GTH-2506 From GTH250616M-423 to GTH250619M-1000 & Sheet 6 of 9 GTH-3007 From GTH300716M-101 to GTH300719M-500 7-26 GTH-2506 GTH-3007 Part No. 57.4400.9214...
  • Page 163 July 2018 Section 7 • Schematics ELECTRICAL SCHEMATIC GTH-2506 From GTH250616M-423 to GTH250619M-1000 & Sheet 7 of 9 GTH-3007 From GTH300716M-101 to GTH300719M-500 Part No. 57.4400.9214 GTH-2506 GTH-3007 7-27...
  • Page 164 Section 7 • Schematics July 2018 ELECTRICAL SCHEMATIC GTH-2506 From GTH250616M-423 to GTH250619M-1000 & Sheet 8 of 9 GTH-3007 From GTH300716M-101 to GTH300719M-500 7-28 GTH-2506 GTH-3007 Part No. 57.4400.9214...
  • Page 165 July 2018 Section 7 • Schematics ELECTRICAL SCHEMATIC GTH-2506 From GTH250616M-423 to GTH250619M-1000 & Sheet 9 of 9 GTH-3007 From GTH300716M-101 to GTH300719M-500 Part No. 57.4400.9214 GTH-2506 GTH-3007 7-29...
  • Page 166 Section 7 • Schematics July 2018 This page intentionally left blank. 7-30 GTH-2506 GTH-3007 Part No. 57.4400.9214...
  • Page 167 Section 7 • Schematics July 2018 Hydraulic Schematic 7-31 7-32...
  • Page 168 Section 7 • Schematics July 2018 Hydraulic Schematic - GTH-2506 From GTH250614-101 Service brake pressure switch Service brake Inching valve (optional) activating pressure: circuit reservoir 2,8-6,3 bar 100 bar Service brake Service brake circuit test port pedal pump Pp Tp...
  • Page 169 Section 7 • Schematics July 2018 Hydraulic Schematic - GTH-3007 From GTH300716M-101 Service brake pressure switch Service brake Inching valve (optional) activating pressure: circuit reservoir 2,8-6,3 bar 100 bar Service brake Service brake circuit test port pedal pump Pp Tp max operating pressure: 80 bar Front axle...

This manual is also suitable for:

Genie gth-3007Genie gth-2506Gth250619m-1000Gth300716m-101Gth300719m-500

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