Terex Genie GTH1056 Installations- und Betriebsanleitung

Service and Repair Manual

Serial Number Range

GTH™-1056

from GTH10E-16000

This manual includes:

Repair procedures

Fault Codes

Electrical and

Hydraulic Schematics

or detailed maintenance

procedures, refer to the

appropriate Maintenance

Manual for your machine.

Part No. 1303145GT

Rev A

May 2021

Service and Repair Manual May 2021

Introduction

ii GTH™-1056 Part No. 1303145GT

Introducti on Introduction

Important Information

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.

1303145GT Rev A, May 2021

Fifth 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.

May 2021 Service and Repair Manual

Introduction

Part No. 1303145GT GTH™-1056 iii

Revision History

Revision Date Section Procedure / Page / Description

A 5/2021

Initial Release

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 May 2021

Introduction

iv GTH™-1056 Part No. 1303145GT

Serial Number Legend

1 Model

2 Facility code

3 Sequence number

4 Serial label (located inside fork frame)

5 Serial number (stamped on chassis)

6 Serial label (located inside chassis)

May 2021 Service and Repair Manual

Safety Rules

Part No. 1303145GT GTH™-1056 v

Section 1 Safety Rul es GeneralSaf ety 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.

Do not modify or alter a Telehandler without prior

written permission from the manufacture.

Do Not Perform Maintenance

Unless:

You are trained and qualified to perform

maintenance on this machine.

You read, understand and obey:

•manufacturer's instructions and safety rules

•employer's safety rules and worksite

regulations

•applicable governmental regulations

You have the appropriate tools, lifting

equipment and a suitable workshop.

Service and Repair Manual May 2021

Safety Rules

vi GTH™-1056 Part No. 1303145GT

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 fire 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

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 goo

d condition and of

ample capacity.

Be sure t

hat fasteners intended for one

time use (i.e., cotter 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 fl

uids. Use an approved container.

Please be

environmentally safe.

Be sure that your workshop or work area

is properly ventilated and well lit.

May 2021

Table of Contents

Part No. 1303145GT GTH™-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 .....................................................................6

Manifold Component Specifications.......................................................................7

Air Conditioner Refrigerant Specifications .............................................................7

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

Deutz TCD3.6 120HP T4F Engine Specifications..................................................8

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

Deutz TCD3.6 ROW Engine Specifications .........................................................10

ZF 4 WG-98 TSC Transmission Specifications....................................................11

ECOMEC CVT 150 Transmission Specifications.................................................11

Dana VDT12000 Transmission Specifications.....................................................12

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

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

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

May 2021

Table of Contents

viii GTH™-1056 Part No. 1303145GT

Section 3 Repair Procedures ............................................................................................. 15

Introduction .......................................................................................................... 15

Boom Components............................................................................................ 17

1-1 Boom Proximity Switch .................................................................................. 17

How to Test a Proximity Switch ...................................................................... 17

How to Adjust the Boom Angle Proximity Switch ........................................... 18

How to Adjust the Boom Extend Proximity Switch ......................................... 18

1-2 Boom.............................................................................................................. 19

How to Replace the Boom Wear Pads ........................................................... 19

How to Remove the Lifting Fork Frame.......................................................... 19

How to Remove and Install the Cable Track Assembly.................................. 20

How to Replace the Retract Chains................................................................ 25

How to Replace the Extend Chain.................................................................. 28

How to Remove the Boom.............................................................................. 30

How to Disassemble the Boom....................................................................... 32

1-3 Boom Lift Cylinder ......................................................................................... 35

1-4 Boom Extension Cylinder .............................................................................. 36

1-5 Fork Level Cylinder........................................................................................ 37

1-6 Hydraulic Hoses............................................................................................. 38

How to Replace the Fork Level and/or Auxiliary Cylinder Hoses ................... 38

Operator's Compartment................................................................................... 40

2-1 Operator's Compartment ............................................................................... 40

2-2 Machine Controls........................................................................................... 41

How to Remove the Steering Column ............................................................ 41

How to Remove the Steering Wheel .............................................................. 42

How to Remove the Steer Orbitral.................................................................. 42

How to Remove the Joystick - Models with Electronic Joystick ..................... 43

How to Remove the Brake Pedal Assembly................................................... 43

How to Remove the Gauge Cluster Assembly ............................................... 44

May 2021

Table of Contents

Part No. 1303145GT GTH™-1056 ix

Fuel and Hydraulic Tanks..................................................................................45

3-1 Fuel and HydraulicTanks ...............................................................................45

Engines................................................................................................................47

4-1 Engines ..........................................................................................................47

How to Repair the Deutz TCD3.6 Engine .......................................................47

4-2 Engine Fault Codes........................................................................................47

Transmission ......................................................................................................48

5-1 Transmission..................................................................................................48

How to Repair the Transmission.....................................................................48

Hydraulic Pump ..................................................................................................49

6-1 Hydraulic Pump..............................................................................................49

How to Test the Function Pump......................................................................49

How to Remove the Function Pump ...............................................................50

How to Install the Function Pump ...................................................................51

How to Prime the Function Pump ...................................................................51

How to Adjust the Function Pump Standby Pressure.....................................52

How to Adjust the Function Pump Pressure Compensator ............................53

Manifolds.............................................................................................................55

7-1 PVG Manifold .................................................................................................55

7-2 Secondary Function Manifold Components...................................................56

7-3 Brake Manifold Components..........................................................................58

7-4 Valve Adjustments - Secondary Function Manifold .......................................59

How to Set the Parking Brake System Pressure ............................................59

How to Set the Rear Lock-up System Pressure .............................................60

7-5 Valve Coils .....................................................................................................61

Axle ......................................................................................................................63

8-1 Axles...............................................................................................................63

How to Repair the Axle ...................................................................................63

Outriggers ...........................................................................................................64

9-1 Outriggers.......................................................................................................64

How to Remove an Outrigger..........................................................................64

How to Remove an Outrigger Cylinder ...........................................................65

May 2021

Table of Contents

x GTH™-1056 Part No. 1303145GT

Section 4 Fault Codes......................................................................................................... 67

Introduction .......................................................................................................... 67

Diagnostic Display............................................................................................. 68

Diagnostic Display ............................................................................................... 68

Deutz TCD3.6 Engine Fault Codes ................................................................... 69

ECGenius 150 Transmission Fault Codes....................................................... 93

Section 5 Schematics ......................................................................................................... 94

Introduction .......................................................................................................... 94

Proximity Switch Legend...................................................................................... 95

Fuse Panel Layout (120HP & ROW Engine) ....................................................... 96

Fuse Panel Layout (74HP Engine with CVT Transmission) ................................ 97

Deutz TCD3.6 T4F Module .................................................................................. 98

Electrical Component & Wire Color Abbreviation Legend ................................... 99

Electrical Symbol Legend .................................................................................. 102

Hydraulic Symbols Legend ................................................................................ 103

Electrical Schematics ...................................................................................... 105

Electrical Schematic - Deutz T4F 74HP CVT .................................................... 106

Electrical Schematic - Deutz T4F HP CVT Transmission.................................. 107

Electrical Schematic - Deutz T4F 74HP Engine Harness.................................. 110

Electrical Schematic - Options Deutz T4F 74HP ............................................... 111

Electrical Schematic - Deutz T4F 74HP DANA ................................................. 114

Electrical Schematic - Deutz T4F 74HP DANA Engine Harness....................... 115

Electrical Schematic - Options Deutz T4F 74HP DANA.................................... 118

Electrical Schematic - Deutz T3/T4F 120HP ZF................................................ 119

Base Engine ECM Schematic - Deutz T4F 120HP ZF ...................................... 122

Engine ECM Schematic - Deutz T3 120HP ZF.................................................. 123

EAT ECM Schematic - Deutz T4F 120HP ZF.................................................... 126

EAT ECM VEC Schematic - Deutz T4F 120HP ZF ........................................... 127

Schematic - Options Deutz T3/T4F 120HP ZF .................................................. 130

Hydraulic Schematics...................................................................................... 131

Hydraulic Schematic .......................................................................................... 132

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