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Terex GTH0615H-10001 Service And Repair Manual
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Terex GTH0615H-10001 Service And Repair Manual

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Service and Repair Manual
GTH
-636
™
Serial Number Range
from GTH0615H-10001 to
GTH0616H-10742
from GTH0615E-10000 to
GTH0616E-10999
from GTH06E-11000 to
GTH06E-11749
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
Part No. 1272853
Rev A3
April 2018

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Summary of Contents for Terex GTH0615H-10001

  • Page 1 Service and Repair Manual Serial Number Range -636 ™ from GTH0615H-10001 to This manual includes: GTH0616H-10742 Repair procedures Fault Codes from GTH0615E-10000 to Electrical and GTH0616E-10999 Hydraulic Schematics from GTH06E-11000 to GTH06E-11749 For detailed maintenance procedures, refer to the appropriate Maintenance Manual for your machine.

  • Page 2: Find A Manual For This Model

    Copyright © 2016 by Terex Corporation 1272853 Rev A3, April 2018 First 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: Revision History

    April 2018 Service and Repair Manual Introduction Revision History Revision Date Section Procedure / Page / Description 3/2016 Initial Release 9/2016 Introduction Serial Number Legend 4/2017 Repair Revise manifold torque values Schematics Hydraulic schematics 4/2018 Add ES and HS Schematics; Deutz engine harnesses Move ES and HS Schematics to new SRM;...

  • Page 4: Serial Number Legend

    Service and Repair Manual April 2018 Introduction Serial Number Legend To August 31, 2016 1 Model 1 Serial label (located inside riser, cab side) 2 Model year 2 Serial number (stamped on chassis) 3 Facility code 3 Serial label (inside fork frame) 4 Sequence number From September 1, 2016 1 Model...

  • Page 5: Safety Rules

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

  • Page 6: Personal Safety

    Service and Repair Manual April 2018 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

    April 2018 Table of Contents Introduction Introduction ......................ii Important Information ..................... ii Find a Manual for this Model .................. ii Serial Number Legend ..................iv Section 1 Safety Rules ......................v General Safety Rules ..................... v Section 2 Specifications ....................... 1 Machine Specifications ...................
  • Page 8 April 2018 Table of Contents How to Adjust the Fork Level Cylinder and/or Auxiliary Hose ......26 How to Replace the Fork Level Cylinder and/or Auxiliary Hoses ....27 Operator's Compartment ................... 29 2-1 Operator's Compartment ................29 2-2 Machine Controls ................... 31 How to Remove the Steering Column ............
  • Page 9 April 2018 Table of Contents How to Set the Parking Brake System Pressure ..........54 How to Set the Differential Lock/Joystick System Pressure ......55 7-6 Valve Coils ..................... 56 Axle ........................58 8-1 Axles ....................... 58 Section 4 Fault Codes ......................59 Introduction ......................
  • Page 10 April 2018 Table of Contents Electrical Schematics ..................105 Electrical Schematic - View 1 (to SN GTH06E-11749) ........106 Electrical Schematic - View 2 (to SN GTH06E-11749) ........107 Electrical Schematic - Deutz T4F Eng Harness ..........110 Hydraulic Schematics ..................111 Hydraulic Schematic - Single Joystick (to SN GTH06E-11749) ......

  • Page 11: Specifications

    April 2018 Service and Repair Manual Specifications Section 2 Specific ati ons Machine Specifications Fluid capacities Tires and wheels Fuel tank 27 gallons 102.2 liters Tire size 13.00 x 28 Hydraulic tank 34 gallons Tire ply rating 128.7 liters Weight, rough terrain tire 335 lbs Hydraulic system 46.5 gallons...

  • Page 12: Performance Specifications

    Service and Repair Manual April 2018 Specifications Performance Specifications Boom function speeds, maximum Boom up 10 to 12 seconds Drive speed, maximum Boom down 8 to 10 seconds Deutz TD2.9 Engines 18 mph Boom extend 11 to 13 seconds 29.0 km/h Boom retract 9 to 11 seconds Draw bar pull...

  • Page 13: Hydraulic Oil Specifications

    April 2018 Service and Repair Manual Specifications Hydraulic Oil Specifications Do not top off with incompatible hydraulic fluids. Hydraulic fluids may be incompatible due to the Hydraulic Fluid Specifications differences in base additive Genie specifications require hydraulic oils which are chemistry.
  • Page 14 Service and Repair Manual April 2018 Specifications Chevron Rando HD Premium Oil Chevron 5606A Hydraulic Oil MV Fluid Properties Fluid Properties ISO Grade ISO Grade Viscosity index Viscosity index Kinematic Viscosity Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 200°F / 100°C cSt @ 104°F / 40°C 33.5 cSt @ 104°F / 40°C...
  • Page 15 April 2018 Service and Repair Manual Specifications Petro-Canada Environ MV 46 UCON Hydrolube HP-5046 Fluid Fluid Properties Properties ISO Grade Viscosity index ISO Grade Kinematic Viscosity Viscosity index cSt @ 200°F / 100°C Kinematic Viscosity cSt @ 104°F / 40°C 44.4 cSt @ 149°F / 65°C Flash point...

  • Page 16: Hydraulic Component Specifications

    Service and Repair Manual April 2018 Specifications Hydraulic Component Primary Function Manifold Specifications System relief valve pressure, maximum 3200 psi (measured at test port TP) 221 bar Function pump Fork tilt relief valve pressure, maximum 3500 psi 241 bar Type: variable displacement piston pump Flow regulator, Sway circuit 2 gpm Displacement...

  • Page 17: Manifold Component Specifications

    April 2018 Service and Repair Manual Specifications Manifold Component Air Conditioner Refrigerant Specifications Specifications Plug torque System Full Charge SAE No. 2 50 in-lbs / 6 Nm R134a SAE No. 4 13 ft-lbs / 18 Nm SAE No. 6 18 ft-lbs / 24 Nm SAE No.

  • Page 18: Deutz Td 2.9 Engine Specifications

    Service and Repair Manual April 2018 Specifications Deutz TD 2.9 L4 Engine Oil temperature switch Installation torque 8 - 18 ft-lbs Displacement 177 cu. in 11 - 24 Nm 2.9 liters Temperature switch point 275°F Number of cylinders 135°C Bore and Stroke 3.6 x 4.3 inches Oil Pressure switch 92 x 110 mm...

  • Page 19: Dana Vdt12000 Transmission Specifications

    April 2018 Service and Repair Manual Specifications Dana VDT12000 Transmission Dana 212 Drive Axle Specifications Specifications Transmission Type 3 speed powershift converter Steering Integrated steer cylinder Speeds, Forward Joints Heavy duty double U-joints Speeds, Reverse Steering angle, maximum 45° Torque Converter Front Axle Lubrication Maximum input 3100 rpm...

  • Page 20: Hydraulic Hose And Fitting Torque Specifications

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

  • Page 21: Torque Procedure

    April 2018 Service and Repair Manual Specifications Torque Procedure JIC 37° fittings Seal-Lok™ fittings Align the tube flare (hex nut) against the nose of the fitting body (body hex fitting) and tighten Replace the O-ring. The O-ring must be the hex nut to the body hex fitting to hand tight, replaced anytime the seal has been broken.
  • Page 22 Service and Repair Manual April 2018 Specifications Working clockwise on the body hex fitting, make a second mark with a permanent ink marker to indicate the proper tightening position. Refer to Illustration 2. Note: Use the JIC 37° Fitting table in this section to determine the correct number of flats, for the proper tightening position.

  • Page 23: Observe And Obey

    April 2018 Service and Repair Manual Repair Procedures Section 3 Repair Pr oc edures Machine Configuration: Unless otherwise specified, perform each repair procedure with the machine in the following configuration: · Machine parked on a firm, level surface · Boom in the stowed position Observe and Obey: ·...

  • Page 24: About This Section

    Service and Repair Manual April 2018 Repair Procedures About This Section Most of the procedures in this section should only be performed by trained service professional in a suitably equipped workshop. Select the appropriate repair procedure after troubleshooting the problem. Perform disassembly procedures to the point where repairs can be completed.

  • Page 25: Boom Components

    April 2018 Service and Repair Manual Boom Components How to Us e the Quic k Attac hment How to Use the Quick Attachment Boom Remove the quick attach lock pin. Tilt the forks forward to pivot the quick attach connector How to R eplac e the Boom Wear Pads How to Replace the Boom Wear back.

  • Page 26: How To Replace The Retraction Chain

    Service and Repair Manual April 2018 Boom Components How to R eplac e the R etraction C hain How to Replace the Retraction Tilt the forks back to pivot the quick attach into the attachment. Chain Note: Perform this procedure on a firm, level surface with the boom in the stowed position and the wheels chocked.
  • Page 27 April 2018 Service and Repair Manual Boom Components 10 Remove the chain anchors from each end of 13 Now pull the chain carefully toward the pivot the chain and install them on the new chain. end until the mounting holes of the chain anchor line up with the holes on the boom Note: Always use new cotter pins when installing a tube.

  • Page 28: How To Replace The Extension Chains

    Service and Repair Manual April 2018 Boom Components How to R eplac e the Extensi on C hai ns How to Replace the Extension Working at the fork end of the boom, loosen the fasteners securing the single-chain Chains tensioners to the top of boom tube number 1. After noting the orientation and assembly order Note: Perform this procedure on a firm, level of the components, remove the fasteners and...
  • Page 29 April 2018 Service and Repair Manual Boom Components Repeat this procedure, beginning with step 6, 12 Working at the pivot end of the boom, pull the for the other chain. chain out of the boom. Working at the fork end of the boom, select a Note: Rope coming loose from the chain during chain.

  • Page 30: How To Remove The Boom

    Service and Repair Manual April 2018 Boom Components How to R emove the Boom How to Remove the Boom 20 Install the inspection cover, removed in step 9, onto the boom. Install and securely tighten the Bodily injury hazard. This fasteners.
  • Page 31 April 2018 Service and Repair Manual Boom Components Use a soft metal drift to remove the fork level 14 Using a suitable tool, remove the boom pivot cylinder pivot pin. pin. Lower the fork level cylinder onto the chassis. Crushing hazard. The boom will fall if not properly supported Crushing hazard.

  • Page 32: How To Disassemble The Boom

    Service and Repair Manual April 2018 Boom Components How to Dis ass embl e the Boom How to Disassemble the Boom Working at the pivot end of the boom, remove the fasteners securing the hose roller Bodily injury hazard. This assembly to boom tube number 2.

  • Page 33: Boom Lift Cylinder

    April 2018 Service and Repair Manual Boom Components Note: During removal, the overhead crane strap will need to be adjusted for proper balancing. Boom Lift Cylinder How to Remove the Lift Cylinder Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced.

  • Page 34: Boom Extension Cylinder

    Service and Repair Manual April 2018 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. Use a soft metal drift to remove the pivot pin. How to Remove the Extension Cylinder Crushing hazard.

  • Page 35: Fork Level Cylinder

    April 2018 Service and Repair Manual Boom Components Support the extension cylinder with a suitable lifting device and begin removing from the Fork Level Cylinder boom assembly. Before the cylinder can be removed from the How to Remove the Fork Level boom assembly, loosen the upper wearpad Cylinder mount retaining fastener.

  • Page 36: Hydraulic Hoses

    Service and Repair Manual April 2018 Boom Components Tag, disconnect and plug the fork level cylinder hoses from the cylinder manifolds. Cap the Hydraulic Hoses fittings. How to Adj ust the For k Level C ylinder and/or Auxiliar y H os e How to Adjust the Fork Level Bodily injury hazard.

  • Page 37: How To Replace The Fork Level Cylinder And/Or Auxiliary Hoses

    April 2018 Service and Repair Manual Boom Components How to R eplac e the F or k Level C yli nder and/or Auxili ar y Hoses How to Replace the Fork Level Disconnect and plug the fork level cylinder supply hoses at the cylinder manifold or the Cylinder and/or Auxiliary Hoses auxiliary supply hoses at the quick connect fittings.
  • Page 38 Service and Repair Manual April 2018 Boom Components Securely connect a 30 feet / 10 m length of 13 Install the new hose assembly into the boom in rope to each end of the hoses disconnected in the same manner the hose was removed. steps 5 and 6.

  • Page 39: Operator's Compartment

    April 2018 Service and Repair Manual Operator's Compartment Working under the dashboard, locate the hydraulic hose at port L of the steering orbitral. Operator's Compartment Working at the front axle, locate the hydraulic hose connected to the front axle steer cylinder How to Remove the Operator's at the operator's compartment side of the machine.
  • Page 40 Service and Repair Manual April 2018 Operator's Compartment 10 Models with dual joystick: Tag, disconnect 17 Support and secure the operator's and plug the hydraulic hoses at ports JT2, JT4, compartment to an adjustable table capable of JS3 and JS1 of the primary function manifold. supporting the weight and that will allow the Cap the fittings.

  • Page 41: Machine Controls

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

  • Page 42: How To Remove The Steer Orbitral

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

  • Page 43: How To Remove The Joystick - Models With Dual Joysticks

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

  • Page 44: How To Remove The Gauge Cluster Assembly

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

  • Page 45: Fuel And Hydraulic Tanks

    April 2018 Service and Repair Manual Fuel and Hydraulic Tanks Tag and disconnect the wire harness from the fuel level terminals. Fuel and Hydraulic Tanks Remove the filler cap from the fuel tank. Using an approved hand-operated pump, drain How to Remove the Fuel and the fuel tank into a container of suitable Hydraulic Tank Assembly capacity.
  • Page 46 Service and Repair Manual April 2018 Fuel and Hydraulic Tanks HYDRAULIC TANK Note: The fuel tank must be removed before removing the hydraulic tank. Remove the access cover to the hydraulic tank. 10 Remove the filler cap from the hydraulic tank. 11 Place a drain pan or other suitable container under the hydraulic tank.

  • Page 47: Engines

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

  • Page 48: Transmission

    Service and Repair Manual April 2018 Transmission Transmission How to Repair the Transmission Repair procedures and additional transmission information is available in the Dana VDT12000 Service Manual. Dana VDT12000 Service Manual Genie part number 218706 GTH-636 Part No. 1272853...

  • Page 49: Hydraulic Pump

    April 2018 Service and Repair Manual Hydraulic Pump Start the engine and fully retract the boom. Continue to hold the joystick in the boom Hydraulic Pump retract position and observe the pressure gauge. How to T est the Func tion Pump How to Test the Function Pump Result: If the pressure gauge reads 3200 psi / Note: When removing a hose assembly or fitting,...

  • Page 50: How To Remove The Function Pump

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

  • Page 51: How To Install The Function

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

  • Page 52: How To Adjust The Function Pump Standby Pressure

    Service and Repair Manual April 2018 Hydraulic Pump How to Adj ust the Functi on Pump Standby Pr ess ure How to Adjust the Function Pump Adjust the function pump standby pressure. Turn the adjustment screw clockwise to Standby Pressure increase the pressure or counterclockwise to decrease the pressure.

  • Page 53: How To Adjust The Function Pump Pressure Compensator

    April 2018 Service and Repair Manual Hydraulic Pump How to Adj ust the Functi on Pump Press ure Compens ator How to Adjust the Function Pump Loosen the set screw for the pressure compensator adjustment screw. Standby Pressure Note: Two people will be required to perform this procedure.

  • Page 54: Manifolds

    Service and Repair Manual April 2018 Manifolds Primary Function Manifold Components - Models with Single Joystick The primary function manifold is located under the manifold inspection cover. Index Schematic Description Function Torque Item Solenoid valve, 2 position 4 way Function select -boom retract 19-21 ft-lbs / 25.8-28.6 Nm and sway right Directional valve,proportional...
  • Page 55 April 2018 Service and Repair Manual Manifolds Part No. 1272853 GTH-636...
  • Page 56 Service and Repair Manual April 2018 Manifolds Primary Function Manifold Components - Models with Single Joystick The primary function manifold is located under the manifold inspection cover. Index Schematic Description Function Torque Item Check valve, 5 psi / 0.3 bar Boom up circuit 20 ft-lbs / 27.1 Nm Check valve, 5 psi / 0.3 bar...
  • Page 57 April 2018 Service and Repair Manual Manifolds Part No. 1272853 GTH-636...

  • Page 58: Primary Function Manifold Components - Models With Dual Joysticks

    Service and Repair Manual April 2018 Manifolds Primary Function Manifold Components - Models with Dual Joysticks The primary function manifold is located under the manifold inspection cover. Index Schematic Description Function Torque Item Directional valve, proportional Boom extend/retract 70 ft-lbs / 95 Nm Directional valve, proportional Boom up/down 70 ft-lbs / 95 Nm...
  • Page 59 April 2018 Service and Repair Manual Manifolds Part No. 1272853 GTH-636...

  • Page 60: Secondary Function Manifold Components

    Service and Repair Manual April 2018 Manifolds Secondary Function Manifold Components The secondary function manifold is located under the manifold inspection cover. Index Schematic Description Function Torque Item DO3 valve, 3 position 4 way SVD1 Steer left/right 60 in-lbs / 6.8 Nm Pressure reducing/relief valve, Differential lock-up circuit 50 ft-lbs / 68 Nm...
  • Page 61 April 2018 Service and Repair Manual Manifolds Part No. 1272853 GTH-636...

  • Page 62: Auxiliary Manifold (Option) And Brake Manifold Components

    Service and Repair Manual April 2018 Manifolds Auxiliary Manifold (option) and Brake Manifold Components The auxiliary manifold is located under the transmission inspection cover. Index Schematic Description Function Torque Item Check valve, 5 psi / 0.3 bar Auxiliary 'A1' circuit 13 ft-lbs / 18 Nm DO3 valve, 3 position 4 way SVD1...

  • Page 63: Valve Adjustments - Secondary Function Manifold

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

  • Page 64: How To Set The Parking Brake System Pressure

    Service and Repair Manual April 2018 Manifolds How to Set the Par ki ng Brake System Pr ess ure How to Set the Parking Brake Start the engine. Allow the engine to idle. System Pressure Result: The pressure gauge reads 350 psi / 24.1.

  • Page 65: How To Set The Differential Lock/Joystick System Pressure

    April 2018 Service and Repair Manual Manifolds How to Set the Differ enti al Loc k/J oystic k System Press ure How to Set the Differential Start the engine. Allow the engine to idle. Lock/Joystick System Pressure Result: The pressure gauge reads 400±20 psi / 27.5 ±1.4 bar.

  • Page 66: Valve Coils

    Service and Repair Manual April 2018 Manifolds Valve Coil Resistance Specification Valve Coils Note: The following coil resistance specifications are at an ambient temperature of 68°F / 20°C. As How to Test a Coil valve coil resistance is sensitive to changes in air A properly functioning coil provides an temperature, the coil resistance will typically electromotive force which operates the solenoid...

  • Page 67: How To Test A Coil Diode

    April 2018 Service and Repair Manual Manifolds How to Test a Coil Diode Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes. Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil. Faulty diodes can fail to protect the electrical system, resulting in a tripped circuit breaker or component damage.

  • Page 68: Axle

    Service and Repair Manual April 2018 Axle Raise the end of the machine until the tires are off the ground. Place blocks under the chassis Axles for support. Crushing hazard. The chassis How to Remove the Axle will fall if not properly supported. Bodily injury hazard.

  • Page 69: Observe And Obey

    April 2018 Service and Repair Manual Fault Codes Section 4 Faul t Codes Before Troubleshooting: Read, understand and obey the safety rules and operating instructions in the appropriate operator's manual on your machine. Be sure that all necessary tools and test equipment are available and ready for use.

  • Page 70: Diagnostic Display

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

  • Page 71: Deutz Td 2.9 L4 Engine Fault Codes

    April 2018 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes SPN FMI Description SPN = Suspect Parameter Number Actuator error EGR-Valve; signal range FMI = Failure Mode Identifier check high SPN FMI Description Actuator EGR-Valve; over current EGR-Valve, short circuit to battery Actuator error EGR-Valve;...
  • Page 72 Service and Repair Manual April 2018 Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier Sensor error ambient air press.; signal range check high SPN FMI Description Sensor error ambient air press.; signal High oil pressure;...
  • Page 73 April 2018 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier High low fuel temperature; warning threshold exceeded SPN FMI Description High Low fuel temperature; shut off Physical range check high for battery threshold exceeded voltage...
  • Page 74 Service and Repair Manual April 2018 Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier Sensor error EGR cooler downstream temperature; signal range check high SPN FMI Description Sensor error EGR cooler downstream Sensor crankshaft speed;...
  • Page 75 April 2018 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier Starter relay high side; short circuit to battery SPN FMI Description Starter relay low side; short circuit to Injector 1 (in firing order);...
  • Page 76 Service and Repair Manual April 2018 Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 1180 1 Exhaust gas temperature upstream turbine; shut off threshold exceeded SPN FMI Description 1180 3 Sensor error exhaust gas temperature 1109 2...
  • Page 77 April 2018 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number Description FMI = Failure Mode Identifier 2798 Injector diagnostics; timeout error of short circuit to ground measurement cyl. SPN FMI Description Bank 1 1237 2 Override switch;...
  • Page 78 Service and Repair Manual April 2018 Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI Description FMI = Failure Mode Identifier 23008 Timeout error in Manipulation control FMI Description 23009 Pressure Relief Valve (PRV) reached maximun allowed opening count 4766 Physical range check high for exhaust gas temperature downstream (DOC)
  • Page 79 April 2018 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI Description FMI = Failure Mode Identifier 23612 Internal ECU monitoring detection FMI Description reported error 23470 Maximum rail pressure in limp home 23612 Internal ECU monitoring detection mode exceeded (PRV)
  • Page 80 Service and Repair Manual April 2018 Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI Description FMI = Failure Mode Identifier 23615 Metering unit (Fuel-System); short FMI Description circuit to battery low side 23612 Internal ECU monitoring detection 23615 Metering unit (Fuel-System);...
  • Page 81 April 2018 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI Description FMI = Failure Mode Identifier 23897 check of missing injector adjustment value programming (IMA) injector 3 (in FMI Description firing order) 23768 Timeout Error of CAN-Receive-Frame 23898...
  • Page 82 Service and Repair Manual April 2018 Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI Description FMI = Failure Mode Identifier 23936 Timeout Error of CAN-Transmit-Frame FMI Description EEC3VOL2; Engine send messages 23922 Burner Shut Off Valve; blocked closed 23946 Zerofuel calibration injector 1 (in firing order);...
  • Page 83 April 2018 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI Description FMI = Failure Mode Identifier 24016 Amount of air is not plausible to pump FMI Description speed 23960 High exhaust gas temperature EGR 24016 Calculated amount of air is not plausible cooler downstream;...
  • Page 84 Service and Repair Manual April 2018 Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number Description FMI = Failure Mode Identifier 24108 Timeout error of CAN-Transmit-Frame Description ComEGRTVActr 24035 Injector diagnostics; time out error in the 24109 Timeout error of CAN-Receive-Frame SPI communication ComRxEGRTVActr...

  • Page 85: Schematics

    April 2018 Service and Repair Manual Schematics Section 5 Schematics About This Section There are two groups of schematics in this section. Electrical Schematics Electrocution/burn hazard. Contact with electrically charged Observe and Obey: circuits could result in death or serious injury. Remove all rings, Troubleshooting and repair procedures shall be watches and other jewelry.

  • Page 86: Fuse Panel Layout

    Service and Repair Manual April 2018 Fuse Panel Layout Circuit Breakers located on the Battery Tray CB1- Telehandler Control System Power CB2- Engine Power / ECM CB3- Glow Plugs Fuse Board located in the Cab GTH-636 Part No. 1272853...

  • Page 87: Electrical Component & Wire Color Abbreviation Legend

    April 2018 Service and Repair Manual Electrical Component & Wire Color Abbreviation Legend Item Description Item Description Alternator Diode Battery Engine Management System Main Battery Fuse Circuit Breaker 15 Amp - Break/Shift 50 Amp Circuit Breaker 10 Amp - Aux Hydraulics 30 Amp Circuit Breaker 10 Amp –...
  • Page 88 Service and Repair Manual April 2018 Electrical Component & Wire Color Abbreviation Legend Item Description Item Description LED Light Switch Ignition Power ON Key Start Switch Options Power Relay ON Boom Extend Switch Horn Relay ON Parking Brake Pressure Switch Turn Signal ON Service Brake Pressure Switch Road Lights, Work Lights ON...
  • Page 89 April 2018 Service and Repair Manual Electrical Component & Wire Color Abbreviation Legend Item Description Wire Color Legend Blue Valve Coil BL/BK Blue/Black Sway Left Enable SV1 BL/RD Blue/Red Y72A Tilt Up Enable SV2 BL/WH Blue/White Sway Right Enable SV3 Black Y72B Tilt Down Enable SV4...

  • Page 90: Telematics Connector Pin Legend

    Service and Repair Manual April 2018 Telematics Connector Pin Legend Genie installed Telematics connector is wired with an Active High digital input. Circuit Type Circuit Properties Genie Machine Function(s) Telematics Use Case System Power 12 VDC Battery Positive – constant power Supply power to device 5 Amp Max.
  • Page 91 April 2018 Service and Repair Manual Telematics Connector Pin Legend Remote Disable Engine Start Relay Configuration Telematics Active High - Schematic Telematics Active Low - Schematic (standard wiring) (optional wiring) Ignition Start Input Relay Telematics with Active High input Telematics with Active Low input Wireless Certifications Telematic device(s) should comply with specific wireless carrier certifications where applicable and comply with the following:...

  • Page 92: Electrical Symbol Legend

    Service and Repair Manual April 2018 Electrical Symbol Legend Battery Coil, solenoid or relay Horn or alarm Flashing beacon Gauge Diode Hour meter Fuse with amperage Foot switch T-circuits connect Limit Switch Power relay Coil with suppression Fuel or RPM solenoid T-circuits connect at Circuits crossing no Quick disconnect...

  • Page 93: Hydraulic Symbols Legend

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

  • Page 94: Harness Map Legend

    Service and Repair Manual April 2018 Harness Map Legend Base Harnesses Work Light Option Harnesses (included In all models) Item Part Description Item Part Description 1258527 Harness, Light, Led, Clear, 5" Round 1256695 Harness, Dashboard 1258775 Harness Cab Light Power 826147 Harness, Secondary Manifold 1256520...

  • Page 95: Electrical Schematics - Harness Maps

    April 2018 Service and Repair Manual Harness Map - Control System Power Single Joystick...

  • Page 96: Harness Map - Control System Power Single Joystick

    Service and Repair Manual April 2018 Harness Map - Control System Power Single Joystick GTH-636 Part No. 1272853...

  • Page 97: Harness Map - Control System Ground Single Joystick

    April 2018 Service and Repair Manual Harness Map - Control System Ground Single Joystick Part No. 1272853 GTH-636...
  • Page 98 Service and Repair Manual April 2018 Harness Map - Control System Ground Single Joystick...
  • Page 99 April 2018 Service and Repair Manual Harness Map - Control System Power Dual Joystick...

  • Page 100: Harness Map - Control System Power Dual Joystick

    Service and Repair Manual April 2018 Harness Map - Control System Power Dual Joystick GTH-636 Part No. 1272853...

  • Page 101: Harness Map - Control System Ground Dual Joystick

    April 2018 Service and Repair Manual Harness Map - Control System Ground Dual Joystick Part No. 1272853 GTH-636...
  • Page 102 Service and Repair Manual April 2018 Harness Map - Control System Ground Dual Joystick...
  • Page 103 April 2018 Service and Repair Manual Harness Map - Deutz TD2.9 Engine Battery Power and Ground...

  • Page 104: Harness Map - Deutz Td2.9 Engine Battery Power And Ground

    Service and Repair Manual April 2018 Harness Map - Deutz TD2.9 Engine Battery Power and Ground GTH-636 Part No. 1272853...

  • Page 105: Harness Map - Options Auxiliary Hydraulics, Beacon And 3Rd Gear Lockout

    April 2018 Service and Repair Manual Harness Map - Options Auxiliary Hydraulics, Beacon and 3rd Gear Lockout Part No. 1272853 GTH-636...
  • Page 106 Service and Repair Manual April 2018 Harness Map - Options Auxiliary Hydraulics, Beacon and 3rd Gear Lockout...
  • Page 107 April 2018 Service and Repair Manual Harness Map - Options Work Lights...

  • Page 108: Harness Map - Options Work Lights

    Service and Repair Manual April 2018 Harness Map - Options Work Lights GTH-636 Part No. 1272853...

  • Page 109: Harness Map - Options Road Lights

    April 2018 Service and Repair Manual Harness Map - Options Road Lights Part No. 1272853 GTH-636...
  • Page 110 Service and Repair Manual April 2018 Harness Map - Options Road Lights...
  • Page 111 April 2018 Service and Repair Manual Harness Map - Options Enclosed Cab with Heater...

  • Page 112: Harness Map - Options Enclosed Cab With Heater

    Service and Repair Manual April 2018 Harness Map - Options Enclosed Cab with Heater GTH-636 Part No. 1272853...

  • Page 113: Harness Map - Options Enclosed Cab With Hvac

    April 2018 Service and Repair Manual Harness Map - Options Enclosed Cab with HVAC Part No. 1272853 GTH-636...
  • Page 114 Service and Repair Manual April 2018 Harness Map - Options Enclosed Cab with HVAC...

  • Page 115: Electrical Schematics

    April 2018 Service and Repair Manual Electrical Schematic - View 1...

  • Page 116: Electrical Schematic - View 1 (To Sn Gth06E-11749)

    Service and Repair Manual April 2018 Electrical Schematic - View 1 (to SN GTH06E-11749) GTH-636 Part No. 1272853...

  • Page 117: Electrical Schematic - View 2 (To Sn Gth06E-11749)

    April 2018 Service and Repair Manual Electrical Schematic - View 2 (to SN GTH06E-11749) Part No. 1272853 GTH-636...
  • Page 118 Service and Repair Manual April 2018 Electrical Schematic - View 2...
  • Page 119 April 2018 Service and Repair Manual Electrical Schematic - Deutz T4F Eng Harness...

  • Page 120: Electrical Schematic - Deutz T4F Eng Harness

    Service and Repair Manual April 2018 Electrical Schematic - Deutz T4F Eng Harness GTH-636 Part No. 1272853...

  • Page 121: Hydraulic Schematics

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

  • Page 122: Hydraulic Schematic - Single Joystick (To Sn Gth06E-11749)

    Service and Repair Manual April 2018 Hydraulic Schematic - Single Joystick (to SN GTH06E-11749) GTH-636 Part No. 1272853...

  • Page 123: Hydraulic Schematic - Dual Joysticks (To Sn Gth06E-11749)

    April 2018 Service and Repair Manual Hydraulic Schematic - Dual Joysticks (to SN GTH06E-11749) Part No. 1272853 GTH-636...
  • Page 124 Service and Repair Manual April 2018 Hydraulic Schematic - Dual Joysticks...
  • Page 125 GTH-636 Part No. 1272853 Ser vic e and R epair M anual April 2018...

This manual is also suitable for:

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