Terex GTH10E-12500 Installations- und Betriebsanleitung

Service and Repair Manual

Serial Number Range

GTH™-1056

from GTH10E-

12500

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. 1287211GT

Rev A

April 2018

Service and Repair Manual April 2018

Introduction

ii GTH-1056 Part No. 1287211GT

Intr od ucti o n Intr od ucti o 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.

1287211GT Rev A, April 2018

Fourth 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. 1287211GT GTH-1056 iii

Revision History

Revision

Date

Section

Procedure / Page / Description

A 4/2018

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 April 2018

Introduction

iv GTH-1056 Part No. 1287211GT

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. 1287211GT GTH-1056 v

Section 1 Safet y R ul 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:

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 April 2018

Safety Rules

vi GTH-1056 Part No. 1287211GT

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 a

nd 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 t

o 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., 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 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. 1287211GT 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......................................................................5

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

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

DEF Storage Specifications ...................................................................................6

Deutz TCD3.6 L4 Engine Specifications ................................................................7

Deutz TCD3.6 L4 T4F Engine Specifications.........................................................8

Perkins 1104D-E44TA Engine Specifications ........................................................9

Perkins 1204E-E44TA Engine Specifications ......................................................10

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

Dana Planetary Drive Axle Specifications (223_212HY) .....................................11

Hydraulic Hose and Fitting Torque Specifications ...............................................12

Torque Procedure ................................................................................................13

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............................................17

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

1-2 Boom ..............................................................................................................18

How to Replace the Boom Wear Pads ...........................................................18

April 2018

Table of Contents

viii GTH-1056 Part No. 1287211GT

How to Remove the Lifting Fork Frame .......................................................... 18

How to Remove the Cable Bridge Assembly.................................................. 19

How to Replace the Retraction Chain ............................................................ 20

How to Replace the Extension Chains ........................................................... 22

How to Remove the Boom.............................................................................. 24

How to Disassemble the Boom - GTH-1056 .................................................. 26

1-3 Boom Lift Cylinder ......................................................................................... 29

1-4 Boom Extension Cylinder .............................................................................. 30

1-5 Fork Level Cylinder ........................................................................................ 31

1-6 Hydraulic Hoses............................................................................................. 32

How to Replace the Fork Level and/or Auxiliary Cylinder Hoses, GTH-1056 32

Operator's Compartment................................................................................... 34

2-1 Operator's Compartment ............................................................................... 34

2-2 Machine Controls ........................................................................................... 35

How to Remove the Steering Column ............................................................ 35

How to Remove the Steering Wheel .............................................................. 36

How to Remove the Steer Orbitral.................................................................. 36

How to Remove the Joystick - Models with Electronic Joystick ..................... 37

How to Remove the Brake Pedal Assembly................................................... 37

How to Remove the Gauge Cluster Assembly ............................................... 38

Fuel and Hydraulic Tanks ................................................................................. 39

3-1 Fuel and Hydraulic Tanks .............................................................................. 39

Engines ............................................................................................................... 41

4-1 Engines .......................................................................................................... 41

How to Repair the Perkins 1104D-E44TA Engine.......................................... 41

How to Repair the Deutz TCD3.6 Engine....................................................... 41

How to Remove the Engine ............................................................................ 41

4-2 Engine Fault Codes ....................................................................................... 42

Transmission...................................................................................................... 43

5-1 Transmission.................................................................................................. 43

How to Repair the Transmission..................................................................... 43

How to Remove the Transmission.................................................................. 43

Hydraulic Pump.................................................................................................. 45

April 2018

Table of Contents

Part No. 1287211GT GTH-1056 ix

6-1 Hydraulic Pump..............................................................................................45

How to Test the Function Pump......................................................................45

How to Remove the Function Pump ...............................................................46

How to Install the Function..............................................................................47

How to Prime the Function Pump ...................................................................47

How to Adjust the Function Pump Standby Pressure .....................................48

How to Adjust the Function Pump Pressure Compensator ............................49

Manifolds.............................................................................................................51

7-1 PVG Manifold .................................................................................................51

7-2 Secondary Function Manifold Components ...................................................52

7-4 Outrigger Manifold Components ....................................................................54

7-6 Brake Manifold Components..........................................................................56

7-7 AC Hydraulic Manifold Components ..............................................................57

7-8 Valve Adjustments - Secondary Function Manifold .......................................58

How to Set the Parking Brake System Pressure ............................................58

How to Set the Differential Lock/Joystick System Pressure ...........................59

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

7-9 Valve Coils .....................................................................................................61

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

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

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

Section 4 Fault Codes .........................................................................................................66

Introduction...........................................................................................................66

Diagnostic Display .............................................................................................67

Diagnostic Display ................................................................................................67

Deutz TCD3.6 Engine Fault Codes....................................................................68

Perkins 1104 Engine Fault Codes.....................................................................92

April 2018

Table of Contents

x GTH-1056 Part No. 1287211GT

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

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

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

Fuse Panel Layout ............................................................................................... 96

Deutz TCD3.6 T4F Module .................................................................................. 97

Electrical Component & Wire Color Abbreviation Legend ................................... 98

Telematics Connector Pin Legend..................................................................... 101

Electrical Symbol Legend .................................................................................. 103

Hydraulic Symbols Legend ................................................................................ 104

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

Harness Map - Wire Harness Legend................................................................ 106

Harness Map - Control System Electronic Joystick ........................................... 107

Harness Map - Deutz T3 Engine........................................................................ 111

Harness Map - Perkins T4i Engine .................................................................... 114

Harness Map - Perkins T3 Engine ..................................................................... 115

Harness Map - Road Light Option ..................................................................... 118

Harness Map - Work Light Option...................................................................... 119

Harness Map - Deutz HVAC Option .................................................................. 122

Harness Map - Perkins HVAC Option................................................................ 123

Harness Map - Heater Option ............................................................................ 126

Electrical Schematic (from GTH10E-12500)...................................................... 130

Electrical Schematic- Deutz T4F Engine Harness............................................. 134

Hydraulic Schematics...................................................................................... 141

Hydraulic Schematic .......................................................................................... 142

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