Terex Genie GTH -1056 Installations- und Betriebsanleitung

Service and Repair Manual

Serial Number Range

GTH™-1056

From GTH1016E-11305 to

GTH1016E-

11799

includes GTH1016E-

11281

GTH1016E-

11282

GTH1016E-

11286

from GTH10E-11800

GTH10E-

12499

This manual includes:

Repair procedures

Fault Codes

Electrical and

Hydraulic Schematics

For detailed maintenance

procedures, refer to the

appropriate Maintenance

Manual for your machine.

Part No. 1278145

v B2

April 2018

Service and Repair Manual April 2018

Introduction

ii TH-1056 Part No. 1278145

Intr oduct io n Intr oduct io n

Important

Read, understand and obey the safety rules and

operating instructions in the appropriate Operator's

Manual on your machine before attempting any

procedure.

This manual provides troubleshooting and repair

procedures for qualified service professionals.

Basic mechanical, hydraulic and electrical skills are

required to perform most procedures. However,

several procedures require specialized skills, tools,

lifting equipment and a suitable workshop. In these

instances, we strongly recommend that

maintenance and repair be performed at an

authorized Genie dealer service center.

Compliance

Machine Design Life

Unrestricted with proper operation, inspection and

scheduled maintenance.

Technical Publications

Genie has endeavored to deliver the highest

degree of accuracy possible. However, continuous

improvement of our products is a Genie policy.

Therefore, product specifications are subject to

change without notice.

Readers are encouraged to notify Genie of errors

and send in suggestions for improvement. All

communications will be carefully considered for

future printings of this and all other manuals.

Internet: www.genielift.com

E-mail: awp.techpub@terex.com

Find a Manual for this Model

Go to http://www.genielift.com

Use the links to locate Service Manuals,

Maintenance Manuals, Service and Repair

Manuals, Parts Manuals and Operator's Manuals.

1278145 Rev B1, April 2018

Second Edition, First Printing

Genie is a registered trademark of Terex South Dakota, Inc. in

the U.S.A. and many other countries.

"GTH" is a trademark of Terex South Dakota, Inc.

April 2018 Service and Repair Manual

Introduction

Part No. 1278145 TH-1056 iii

Revision History

Revision

Date

Section

Procedure / Page / Description

A 3/2016

Initial Release

A1 4/2016 Repair Revise manifold torque values

B 8/2017 Specifications added T4F specifications

Repair added ZF transmission repair manual

Schematics updated fuse panel layout; updated electrical component

legend; added ES0466B; updated HS0201H and HS0202H

4/2018

Schematics

Added ES0603; added Deutz Engine Harness: added

HS0212

4/2018

Moved ES603 and HS0212 to new SRM; added final serial

number

Reference Examples: Electronic Version

Click on any content or procedure in the Table of Contents to view

the update.

Section – Repair Procedure, 4-2

Section – Fault Codes, All charts

Section – Schematics, Legends and schematics

Service and Repair Manual April 2018

Introduction

iv TH-1056 Part No. 1278145

Serial Number Legend

To August 31, 2016

1 Model

2 Model year

3 Facility code

4 Sequence number

1 Serial label

2 Serial number (stamped on chassis)

3 Serial label (located inside fork frame)

From September 1, 2016

1 Model

2 Facility code

3 Sequence number

1 Serial label

2 Serial number (stamped on chassis)

3 Serial label (located inside fork frame)

April 2018 Service and Repair Manual

Safety Rules

Part No. 1278145 TH-1056 v

Section 1 Safet y Rul es

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.

Do Not Perform Maintenance

Unless:

RYou are trained and qualified to perform

maintenance on this machine.

RYou read, understand and obey:

•manufacturer's instructions and safety rules

•employer's safety rules and worksite

regulations

•applicable governmental regulations

RYou have the appropriate tools, lifting

equipment and a suitable workshop.

Service and Repair Manual April 2018

Safety Rules

vi TH-1056 Part No. 1278145

Workplace Safety

Any person working on or around a machine must

be aware of all known safety hazards. Personal

safety and the continued safe operation of the

machine should be your top priority.

Be sure to keep sparks, flames and lighted

tobacco away from flammable and

combustible materials like battery gases

and engine fuels. Always have an

approved fir

e extinguisher within easy

reach.

Be sure that all tools and working areas

are properly maintained and ready for

use. Keep work surfaces clean and free of

debris that could get into machine

components and cause damage.

Be sure any forklift, overhead

crane or

other lifting or supporting device is fully

capable of supporting and stabilizing the

weight to be lifted. Use only chains or

straps that are in good condition and of

ample capacity.

Be sure that fasteners intended for one

time use (i.e., cotte

r pins and self-locking

nuts) are not reused. These components

may fail if they are used a second time.

Be sure to properly dispose of old oil or

other fluids. Use an approved container.

Please be environmentally safe.

Be sure that your workshop or

work area

is properly ventilated and well lit.

April 2018

Table of Contents

Part No. 1278145 TH-1056 vii

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...........................................................................................1

Performance Specifications ...................................................................................2

Hydraulic Oil Specifications....................................................................................2

Hydraulic Component Specifications .....................................................................5

Manifold Component Specifications.......................................................................6

Air Conditioner Refrigerant Specifications .............................................................6

DEF Storage Specifications ...................................................................................7

Deutz TCD3.6 L4 Engine Specifications................................................................8

Deutz TCD3.6 L4 T4F Engine Specifications ........................................................9

Perkins 1104D-E44TA Engine Specifications......................................................10

Perkins 1204E-E44TA Engine Specifications......................................................11

ZF 4 WG-98 TC Transmission Specifications......................................................12

Dana Planetary Drive Axle Specifications (223_212HY) .....................................12

Hydraulic Hose and Fitting Torque Specifications ...............................................13

Torque Procedure ................................................................................................14

Section 3 Repair Procedures .............................................................................................16

Introduction...........................................................................................................16

Boom Components............................................................................................18

1-1 Boom Proximity Switch ..................................................................................18

How to Test a Proximity Switch ......................................................................18

How to Adjust the Boom Angle Proximity Switch............................................19

How to Adjust the Boom Extend Proximity Switch..........................................19

1-2 Boom..............................................................................................................20

How to Replace the Boom Wear Pads ...........................................................20

How to Remove the Lifting Fork Frame..........................................................20

April 2018

Table of Contents

viii TH-1056 Part No. 1278145

How to Remove the Cable Bridge Assembly..................................................21

How to Replace the Retraction Chain.............................................................22

How to Replace the Extension Chains............................................................24

How to Remove the Boom ..............................................................................26

How to Disassemble the Boom - GTH-1056...................................................28

1-3 Boom Lift Cylinder..........................................................................................31

1-4 Boom Extension Cylinder...............................................................................32

1-5 Fork Level Cylinder ........................................................................................33

1-6 Hydraulic Hoses.............................................................................................34

How to Replace the Fork Level and/or Auxiliary Cylinder Hoses, GTH-1056.34

Operator's Compartment...................................................................................36

2-1 Operator's Compartment................................................................................36

2-2 Machine Controls ...........................................................................................38

How to Remove the Steering Column.............................................................38

How to Remove the Steering Wheel...............................................................38

How to Remove the Steer Orbitral ..................................................................39

How to Remove the Joystick - Models with Single Joystick............................39

How to Remove the Joystick - Models with Dual Joysticks ............................40

How to Remove the Brake Pedal Assembly ...................................................40

How to Remove the Gauge Cluster Assembly................................................41

How to Remove the Diagnostic Display..........................................................41

Fuel and Hydraulic Tanks..................................................................................42

3-1 Fuel and Hydraulic Tanks...............................................................................42

Engines................................................................................................................43

4-1 Engines ..........................................................................................................43

How to Repair the Perkins 1104D-E44TA Engine ..........................................43

How to Repair the Deutz TCD3.6 Engine .......................................................43

How to Remove the Engine.............................................................................43

4-2 Engine Fault Codes........................................................................................44

Transmission ......................................................................................................45

5-1 Transmission..................................................................................................45

How to Repair the Transmission.....................................................................45

How to Remove the Transmission ..................................................................45

April 2018

Table of Contents

Part No. 1278145 TH-1056 ix

Hydraulic Pump..................................................................................................47

6-1 Hydraulic Pump..............................................................................................47

How to Test the Function Pump......................................................................47

How to Remove the Function Pump...............................................................48

How to Install the Function..............................................................................49

How to Prime the Function Pump...................................................................49

How to Adjust the Function Pump Standby Pressure.....................................50

How to Adjust the Function Pump Pressure Compensator ............................51

Manifolds.............................................................................................................54

7-1 Primary Function Manifold Components - Models with Single Joystick ........54

7-2 Primary Function Manifold Components - Models with Dual Joysticks.........58

7-3 Secondary Function Manifold Components...................................................62

7-4 Outrigger Manifold Components....................................................................64

7-5 Auxiliary Manifold Components (option)........................................................66

7-6 Brake Manifold Components..........................................................................67

7-7 AC Hydraulic Manifold Components..............................................................68

7-8 Valve Adjustments - Secondary Function Manifold .......................................69

How to Set the Steer System Pressure ..........................................................69

How to Set the Parking Brake System Pressure............................................70

How to Set the Differential Lock/Joystick System Pressure...........................71

How to Set the Rear Lock-up System Pressure.............................................72

7-9 Valve Coils .....................................................................................................73

Axle......................................................................................................................75

8-1 Axles ..............................................................................................................75

How to Remove the Axle ................................................................................75

How to Repair the Axle ...................................................................................75

Outriggers...........................................................................................................76

9-1 Outriggers ......................................................................................................76

How to Remove an Outrigger .........................................................................76

How to Remove an Outrigger Cylinder...........................................................77

Section 4 Fault Codes.........................................................................................................79

Introduction...........................................................................................................79

Diagnostic Display.............................................................................................80

April 2018

Table of Contents

x TH-1056 Part No. 1278145

Deutz TCD3.6 Engine Fault Codes....................................................................81

Perkins 1104 Engine Fault Codes...................................................................105

Section 5 Schematics........................................................................................................107

Introduction.........................................................................................................107

Proximity Switch Legend....................................................................................108

Fuse Panel Layout..............................................................................................109

Deutz TCD3.6 T4F Module.................................................................................110

Electrical Component & Wire Color Abbreviation Legend..................................111

Telematics Connector Pin Legend .....................................................................114

Electrical Symbol Legend...................................................................................116

Hydraulic Symbols Legend.................................................................................117

Electrical Schematics.......................................................................................119

Electrical Schematic (to GTH10E-11889) ..........................................................120

Electrical Schematic (from GTH10E-11890 to 12499).......................................124

Electrical Schematic (from GTH10E-12500)......... Error! Bookmark not defined.

Electrical Schematic- Deutz T4F Engine Harness .............................................131

Electrical Schematic- Deutz T3 Engine Harness................................................139

Hydraulic Schematics......................................................................................138

Hydraulic Schematic - Models with Single Joystick (to SN GTH10E-12499).....139

Hydraulic Schematic - Models with Dual Joystick (to SN GTH10E-12499) .......140

Hydraulic Schematic - Electronic Joystick (from SN GTH10E-12500)...........Error!

Bookmark not defined.

Hydraulic Schematic - Electronic Joystick (from SN GTH10E-12500)...............142

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