Terex Genie GTH1056 Service And Repair Manual Download

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April 2018

Service and Repair Manual

Part No. 1287211GT

GTH-1056

123

Harness Map - Perkins HVAC Option

Summary of Contents for Genie GTH1056

Page 1: ... 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 ...

Page 2: ...peration 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 carefull...

Page 3: ...ory 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 ...

Page 4: ...t 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 ...

Page 5: ... 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 ...

Page 6: ...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 on...

Page 7: ...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...

Page 8: ... 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 ...

Page 9: ...s 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 Out...

Page 10: ...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 Schemat...

Page 11: ...ugh terrain tire foam filled 967 35 lbs 439 16 kg Weight rock lug tire foam filled 1013 35 lbs 459 16 kg Tire pressure models with air filled tires 50 psi 3 45 bar Lug nut torque 465 ft lbs 630 Nm Lug Pattern 10 x 13 189 Wheel diameter 24 in 60 1 cm Wheel width 9 in 22 9 cm Fluid capacities Fuel tank 35 gallons 132 5 liters Hydraulic tank 44 gallons 166 5 liters Hydraulic system including tank 55 ...

Page 12: ...ditioning and foam and aeration suppression properties Cleanliness level minimum ISO 15 13 Water content maximum 250 ppm Recommended Hydraulic Fluid Hydraulic oil type Chevron Rando HD Premium Viscosity grade 32 Viscosity index 200 Optional Hydraulic Fluids Mineral based Shell Tellus S2 V 32 Shell Tellus S2 V 46 Shell Tellus S4 VX 32 Shell Shell Donax TG Dexron III Chevron 5606A Biodegradable Petr...

Page 13: ...F 49 C Hydraulic Fluid Temperature Range Ambient air temperature 1 Chevron hydraulic oil 5606A 2 Petro Canada Environ MV 46 3 UCON Hydrolube HP 5046D 4 Chevron Rando HD premium oil MV Chevron Rando HD Premium Oil MV Fluid Properties ISO Grade 32 Viscosity index 200 Kinematic Viscosity cSt 200 F 100 C cSt 104 F 40 C 7 5 33 5 Brookfield Viscosity cP 4 F 20 C cP 22 F 30 C 1040 3310 Flash point 375 F ...

Page 14: ...em is used Continued use of Chevron 5606A hydraulic fluid or equivalent when ambient temperatures are consistently above 32 F 0 C may result in component damage Petro Canada Environ MV 46 Fluid Properties ISO Grade 46 Viscosity index 154 Kinematic Viscosity cSt 200 F 100 C cSt 104 F 40 C 8 0 44 4 Flash point 482 F 250 C Pour point 49 F 45 C Maximum continuous operating temperature 180 F 82 C Shell...

Page 15: ...ry Function Manifold System relief valve pressure maximum measured at test port TP 3500 psi 241 bar Boom extend relief valve pressure maximum 3500 psi 241 bar Fork tilt relief valve pressure maximum 3500 psi 241 bar Flow regulator Fork tilt circuit 14 gpm 53 L min Flow regulator Sway circuit 2 gpm 7 5 L min Flow regulator Pilot pressure bleed circuit 0 1 gpm 1 4 L min Secondary Function Manifold S...

Page 16: ...lbs 102 Nm Air Conditioner Refrigerant Specifications System Full Charge R134a 1 lb 14 oz DEF Storage Specifications Diesel Exhaust Fluid decomposes when exposed to elevated temperatures for an extended period of time Therefore precautions must be taken to avoid prolonged exposure to elevated temperatures Temperature Estimated Useful Life 32 F 0 C Indefinite 50 F 10 C 75 years 68 F 20 C 11 years 8...

Page 17: ... 9 liters Oil viscosity requirements Unit ships with 15W 40 API CJ4 low ash oil Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Manual for your engine Fuel injection system Injection pump pressure maximum 23200 psi 1600 bar Fuel requirement For fuel requirements refer to the engine Operator Manual for your engine Engin...

Page 18: ...imum oil pressure warm at low idle 23 5 psi 1 6 bar Oil capacity including filter Low Emission Oil 9 5 quarts 9 liters Oil viscosity requirements Unit ships with 15W 40 API CJ4 low ash oil Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Manual for your engine Fuel injection system Injection pump pressure maximum 23200 ...

Page 19: ... liters Oil viscosity requirements Unit ships with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Manual for your engine Fuel requirement For fuel requirements refer to the engine Operator Manual for your engine Fuel injection pressure minimum 23700 psi 1635 bar Starter motor Normal load 68A Relay max 50A Relay...

Page 20: ...ity requirements Units ship with 15W 40 API CJ4 low ash oil Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operation and Maintenance Manual on your machine Fuel requirement For fuel requirements refer to the engine Operator Manual for your engine Fuel injection pressure minimum 23000 psi 1585 bar Starter motor Normal load 155A...

Page 21: ...F Transmission 4 WG 98 TC Genie part number 1284042GT Dana Planetary Drive Axle Steering Integrated steer cylinder Joints Heavy duty double U joints Steering angle maximum 45 Front Axle Lubrication Dana 223 Front differential 13 7 quarts 13 liters Axle planetary end each 2 quarts 1 9 liters Rear Axle Lubrication Dana 212 Rear differential 8 2 quarts 7 8 liters Axle planetary end each 2 2 quarts 2 ...

Page 22: ...8 14 1 12 1 1 16 12 1 16 1 5 16 12 1 20 1 5 8 12 1 24 1 7 8 12 1 SAE O ring Boss Port tube fitting installed into Aluminum all types SAE Dash Size Torque 4 14 ft lbs 19 Nm 6 23 ft lbs 31 2 Nm 8 36 ft lbs 54 2 Nm 10 62 ft lbs 84 Nm 12 84 ft lbs 114 Nm 16 125 ft lbs 169 5 Nm 20 151 ft lbs 204 7 Nm 24 184 ft lbs 249 5 Nm Adjustable Fitting Non adjustable fitting 1 jam nut SAE O ring Boss Port tube fi...

Page 23: ...and retained properly 4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight 5 Tighten the nut or fitting to the appropriate torque Refer to the appropriate torque chart in this section 6 Operate all machine functions and inspect the hose fittings and related components to confirm there are no leaks JIC 37 fittings 1 Align the tube flare hex nut a...

Page 24: ...number of flats for the proper tightening position Note The marks indicate the correct tightening positions have been determined Use the second mark on the body hex fitting to properly tighten the joint after it has been loosened Illustration 2 1 body hex fitting 2 reference mark 3 second mark 4 Tighten the hex nut until the mark on the hex nut is aligned with the second mark on the body hex fitti...

Page 25: ...derstand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all necessary tools and parts are available and ready for use Use only Genie approved replacement parts Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Machine Configuration Unless otherwise specified per...

Page 26: ...t personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates a imminently hazardous situation which if not avoided will result in death or serious injury Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous situation which if not avo...

Page 27: ...imit switch assembly is not illuminated 4 Move the switch close to any ferrous or metallic object Result The light of the proximity switch assembly turns on The switch is functioning correctly How to Adj ust the Boom Angle Proximity Swi tch How to Adjust the Boom Angle Proximity Switch The boom angle proximity switch is attached to a mounting bracket located between the boom and the chassis direct...

Page 28: ... from the boom 3 Lubricate the wear surface of the new pads Refer to Maintenance Procedure in the appropriate Service or Maintenance Manual for your machine Lubricate the Boom Note Do not lubricate the side wear pads 4 Install the wear pads Install and securely tighten the fasteners Do not over tighten How to R emove the Lifting Fork Fr ame How to Remove the Lifting Fork Frame 1 With the boom in t...

Page 29: ...rd lines of the cable bridge Cap the fittings 4 Working at the pivot end of the boom remove the fasteners securing the hose roller assembly to boom tube number 1 Remove the hose roller assembly from the boom 5 Working at the fork end of the boom remove the fasteners securing the cable track mount bracket to boom tube number 3 6 Working at the fork end of the boom remove the fasteners securing the ...

Page 30: ...boom loosen the fasteners securing the dual chain tensioner to the top of boom tube number 1 After noting the orientation and assembly order of the components remove the fasteners and pull the tensioner free of the boom 1 tube 3 extension chains 2 dual chain tensioner 3 tube 2 extension chains 4 single chain tensioner 5 boom tube number 0 6 boom tube number 1 7 boom tube number 2 8 boom tube numbe...

Page 31: ...or access to the chain anchor bolts 14 Working at the fork end of the boom securely connect a 30 foot 10 m length of rope to the end of the chain Securely tie off the other end of the rope to the boom structure 15 Working at the pivot end of the boom pull the chain out of the boom Note Rope coming loose from the chain during removal may result in a difficult reassembly Be sure the rope is securely...

Page 32: ...ighten the chain tensioners to the top of the boom tube until they are securely tightened 24 Adjust the chains Refer to Maintenance Procedure in the appropriate Service or Maintenance Manual for your machine Adjust the Boom Sequencing Chains Component damage hazard Chains can be damaged if the boom is used while the chains are out of adjustment Do not return the machine to use until the chains hav...

Page 33: ...chains 9 Working at the fork end of the boom select a chain Securely connect a 30 foot 10 m length of rope to the end of the chain Securely tie off the other end of the rope to the boom structure 10 Remove the inspection cover from the pivot end of the boom and locate the chain anchors of the extension chains at the top of boom tubes 2 and 3 11 Remove the fasteners securing the extension chain anc...

Page 34: ...aintenance Procedure in the appropriate Service or Maintenance Manual for your machine Adjust the Boom Sequencing Chains Component damage hazard Chains can be damaged if the boom is used while the chains are out of adjustment Do not return the machine to use until the chains have been correctly adjusted How to R emove the Boom How to Remove the Boom Bodily injury hazard This procedure requires spe...

Page 35: ...3 Tag disconnect and plug the hydraulic hoses at the hydraulic hard line connections at the pivot end of the boom Cap the fittings 14 Using the overhead crane raise the boom to a horizontal position Crushing hazard The lift cylinder will fall if not properly supported when the boom is raised 15 Remove the fasteners securing the boom pivot pin to the chassis 16 Use a soft metal drift to remove the ...

Page 36: ... remove the lift cylinder rod end pivot pin Remove the cylinder from the boom Crushing hazard The cylinder could become unbalanced and fall if not properly supported when removed from the machine 6 Repeat this procedure beginning with step 3 for the other lift cylinder 7 Remove the fastener securing the fork level cylinder rod end pivot pin to the fork frame mount 8 Use a soft metal drift to remov...

Page 37: ...he cable bridge Cap the fittings 17 Working at the pivot end of the boom remove the fasteners securing the hose roller assembly to boom tube number 1 Remove the hose roller assembly from the boom 18 Working at the fork end of the boom remove the fasteners securing the cable track mount bracket to boom tube number 3 1 cable bridge mount bracket 2 cable track mount bracket 3 cable bridge slider 19 W...

Page 38: ...ring the extension chain rollers to the top of boom tube number 1 Remove the chain rollers from the boom 29 Working at the pivot end of the boom remove the fasteners securing the retraction chain block pivot pin to boom tube number 2 Remove the pivot pin 30 Working at the pivot end of the boom remove the fasteners securing the chain roller to boom tube number 2 Remove the chain roller from the boo...

Page 39: ...oosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Component damage hazard Hoses can be damaged if they are kinked or pinched 3 Attach a lifting strap from an overhead crane to the rod end of the lift cylinder Support the cylinder Do not apply any lifting pressure 4 Remove the fasteners securing the lift cylinder barrel end ...

Page 40: ...ns very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Component damage hazard Hoses can be damaged if they are kinked or pinched 3 Attach a lifting strap from an overhead crane to the center point of the boom extension cylinder Support the cylinder Do not apply any lifting pressure 4 Remove the extension cylinder support loop from the underside of the ...

Page 41: ...move the pivot pin 4 Attach a lifting strap from an overhead crane to the barrel end of the fork level cylinder Support the cylinder Do not apply any lifting pressure 5 Tag disconnect and plug the fork level cylinder hoses from the cylinder manifolds Cap the fittings Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pr...

Page 42: ... Working near the center of the boom assembly tag disconnect and plug the hydraulic hoses from the hydraulic hard lines under boom tube number number 1 Cap the hard lines 8 Securely connect a 30 feet 10 m length of rope to the end of each hose disconnected in steps 6 and 7 Securely tie off the other end of each section of rope to the boom structure 9 Working at the pivot end of the boom select one...

Page 43: ... Working at the fork end of the boom remove the fasteners securing the cable bridge slider to the cable bridge Remove the slider from the boom Note Pay attention to how the hoses are routed before removing the slider from the boom Note During reassembly it may be helpful to use tape to secure the bolts to the cable bridge when installing the cable bridge slider 11 Remove the fasteners securing the...

Page 44: ...tion manifold Cap the fittings 3 Locate the brake manifold under the manifold inspection cover Tag disconnect and plug the hydraulic hose at the underside of the brake manifold Cap the fitting 4 Working under the dashboard locate the hydraulic hose at port L of the steering orbitral 5 Working at the front axle locate the hydraulic hose connected to the front axle steer cylinder at the operator s c...

Page 45: ...ue specification Operator s cab mounting bolts 750 ft lbs 1017 Nm 2 2 Machine Controls How to R emove the Steering Col um n How to Remove the Steering Column 1 Disconnect the battery from the machine Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 2 Remove the fasteners securing the transmission...

Page 46: ...w to Remove the Steering Column 2 Working under the dashboard locate the hydraulic hose at port L of the steering orbitral 3 Follow the hydraulic hose from port L of the steer orbitral to its connection at the front axle of the machine Tag disconnect and plug the hydraulic hose at the front axle Cap the fitting 4 Tag disconnect and plug the hydraulic hoses at ports SUP SUR and SUT of the secondary...

Page 47: ... hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 2 Fully press and release the brake pedal a minimum of 10 times to release the hydraulic pressure in the brake system 3 Tag disconnect and plug the hydraulic hoses at ports BP and BT of the secondary hydraulic manifold Cap the fittings Bodily injury hazard Spraying ...

Page 48: ...Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 2 Remove the fasteners securing the transmission control lever to the column Carefully separate the lever from the column 3 Grasp the edge of the dash cluster and pull the cluster through the opening in the dashboard 4 Tag and disconnect the wire harness from the dash clust...

Page 49: ...ts could result in death or serious injury Remove all rings watches and other jewelry 2 3 Remove the battery from the machine 4 Tag and disconnect the wire harness from the fuel level terminals 5 Remove the filler cap from the hydraulic tank 6 Place a drain pan or other suitable container under the hydraulic tank Refer to Specifications Machine Specifications 7 Remove the drain plug from the hydra...

Page 50: ...connect and plug the supply and return hoses from the hydraulic tank Cap the fittings 12 Support and secure the tank assembly to an appropriate lifting device 13 Remove the fasteners securing the tank assembly to the chassis Remove the tank from the machine Crushing hazard The tank assembly could become unbalanced and fall if not properly supported when removed from the machine ...

Page 51: ...ne How to Remove the Engine Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications All Models 1 Open the access door above the hydraulic tank 2 Disconnect the battery from the machine Electrocutio...

Page 52: ...d interfere with the removal of the engine from the chassis 10 Remove the fasteners securing the driveshaft to the transmission Secure the bearing caps onto the universal joint of the driveshaft Note Using adhesive tape to secure the caps to the universal joint may be helpful 11 Remove the fasteners securing the engine tray to the chassis 12 Support and secure the engine tray to a forklift of adeq...

Page 53: ...e access door above the hydraulic tank 2 Disconnect the battery from the machine Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 3 4 lace a drain pan or other suitable container under the hydraulic tank Refer to Specifications Machine Specifications 5 Remove the drain plug from the hydraulic tan...

Page 54: ...lug the hydraulic pump supply line at the pump Cap the orifice on the pump 9 Remove the fasteners securing the transmission mounting flange to the chassis 10 Tag and disconnect the driveshafts from the transmission Note To avoid damage to the driveshaft universal joints secure the driveshafts to the chassis 11 Tag and disconnect the wiring harness from the transmission 12 Attach a lifting strap fr...

Page 55: ... disconnected in step 1 3 Hold the manual fuel shut off lever on the engine in the closed position 4 Observe the pressure gauge while cranking the engine in one second intervals Result If the pressure gauge reads 3190 psi 220 bar immediately stop The pump is good Result If the pressure fails to reach 3190 psi 220 bar the pump needs to be adjusted OR or the pump or pump coupling is faulty and will ...

Page 56: ...in hose at the top of the pump Cap the fitting on the pump Note Placing the open end of the case drain hose below the hydraulic oil level in the hydraulic tank will result in excessive hydraulic fluid leaking from the hose Do not lower the open end of the case drain hose to below the fluid level of the hydraulic tank until the hose is plugged 5 Tag disconnect and plug the large hydraulic pump supp...

Page 57: ... install the wire harness onto the pump 8 Check the level of the hydraulic fluid in the hydraulic tank Add fluid if needed 9 Prime the pump Refer to Repair Procedure How to Prime the Function Pump 10 Start the engine and inspect for leaks 11 Turn the machine off 12 Adjust the pump pressure Refer to Repair Procedures How to Adjust the Function Pump Standby Pressure and How to Adjust the Function Pu...

Page 58: ... off the engine 5 Check for hydraulic leaks and clean up any oil that may have spilled How to Adj ust the Functi on Pum p Standby Pr essure How to Adjust the Function Pump Standby Pressure 1 Connect a 0 to 1000 psi 0 to 100 bar pressure gauge to test port TP on the primary function manifold Refer to Primary Function Manifold Components 2 Start the engine and allow the engine to run at low idle 3 O...

Page 59: ... to dissipate gradually Do not allow oil to squirt or spray How to Adj ust the Functi on Pum p Pressure Com pensator How to Adjust the Function Pump Standby Pressure Note Two people will be required to perform this procedure 1 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to test port TP on the primary function manifold Refer to Primary Function Manifold Components 2 Start the engine and all...

Page 60: ... pressure Turn the adjustment screw clockwise to increase the pressure or counterclockwise to decrease the pressure Tighten the set screw Component damage hazard Do not adjust the pressure compensator higher than specified 7 Turn the engine off and remove the pressure gauge Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the...

Page 61: ...ponents The Proportional Valve Group manifold is located at the rear of the chassis Index No Description Function 1 Assembly lift Lift functions 2 Assembly extend retract Extend retract functions 3 Assembly tilt Tilt functions 4 Assembly sway Sway functions 5 Assembly auxiliary Auxiliary functions ...

Page 62: ...circuit 33 37 ft lbs 45 50 Nm 5 Check valve 4 psi 0 3 bar CV3 Brake circuit 20 25 ft lbs 27 34 Nm 6 Check valve 4 psi 0 3 bar CV4 Rear lockup extend circuit 20 25 ft lbs 27 34 Nm 7 Check valve 4 psi 0 3 bar Check valve CV2 Tank circuit 20 25 ft lbs 27 34 Nm 8 Check valve 4 psi 0 3 bar Check valve CV5 Drive brake circuit 20 25 ft lbs 27 34 Nm 9 Solenoid valve 2 position 3 way SV8 Rear cylinder floa...

Page 63: ...April 2018 Service and Repair Manual Manifolds Part No 1287211GT GTH 1056 53 ...

Page 64: ... DB Right outrigger extend retract 40 ft lbs 54 Nm 3 Flow regulator valve 6 gpm 22 7 L min DC Right outrigger circuit 45 50 ft lbs 61 67 8 Nm 4 Flow regulator valve 6 gpm 22 7 L min DD Left outrigger circuit 45 50 ft lbs 61 67 8 Nm 5 Check valve 5 psi 0 3 bar DE Left outrigger extend circuit 13 ft lbs 17 6 Nm 6 Check valve 5 psi 0 3 bar DF Right outrigger extend circuit 13 ft lbs 17 6 Nm 7 Check v...

Page 65: ...April 2018 Service and Repair Manual Manifolds Part No 1287211GT GTH 1056 55 ...

Page 66: ...old Components The brake manifold is located under the manifold inspection cover Index No Description Schematic Item Function Torque 1 Pressure switch 450 psi 31 bar PS4 Clutch cut off pressure 11 ft lbs 14 9 Nm 2 Pressure switch 50 psi 3 4 bar PS5 Brake light pressure option 11 ft lbs 14 9 Nm ...

Page 67: ...c Manifold Components The AC Hydraulic manifolds are located under the manifold inspection cover Index No Description Schematic Item Function Torque 1 Solenoid valve 2 position 2 way FA Controls motor 20 ft lbs 27 1 Nm 2 Flow control valve 3 gpm 11 3 lpm FB Regulates flow 33 37 ft lbs 45 50 Nm ...

Page 68: ...enetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 5 Install a 0 to 1000 psi 0 to 100 bar pressure gauge into test port TPB at the top of the secondary function manifold Refer to Secondary Function Manifold Components 6 Start the engine Allow the engine to idle Result The pressure gauge reads 400 psi ...

Page 69: ... Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 5 Install a 0 to 1000 psi 0 to 100 bar pressure gauge into test port TJ at the top of the secondary function manifold Refer to Secondary Function Manifold Components 6 Start the engine Allow the engine to idle Result The pressure gauge reads 400 psi 27 5 bar The pressure s...

Page 70: ...sen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 5 Install a 0 to 500 psi 0 to 50 bar pressure gauge into test port TR at the top of the secondary function manifold Refer to Secondary Function Manifold Components 6 Start the engine Allow the engine to idle Result The pressure gauge reads 50 psi 3 4 bar The pressure setting i...

Page 71: ...2 Test the coil resistance Result The resistance should be within specification plus or minus 30 Result If the resistance is not within specification plus or minus 30 replace the coil Valve Coil Resistance Specification Note The following coil resistance specifications are at an ambient temperature of 68 F 20 C As valve coil resistance is sensitive to changes in air temperature the coil resistance...

Page 72: ...the coil Resistor 10Ω Genie part number 27287 Note The battery should read 9V DC or more when measured across the terminals 1 multimeter 2 9v DC battery 3 10Ω resistor 4 coil Note Dotted lines in illustration indicate a reversed connection as specified in step 6 3 Set a multimeter to read DC current Note The multimeter when set to read DC current should be capable of reading up to 800 mA 4 Connect...

Page 73: ...support Crushing hazard The chassis will fall if not properly supported 6 Remove the lug nuts Remove the tire and wheel assembly from both ends of the axle 7 Support and secure the axle to an appropriate lifting device 8 Remove the fasteners securing the sway cylinder rod end pivot pin to the chassis 9 Use a soft metal drift to remove the pivot pin 10 Remove the fasteners securing the axle to the ...

Page 74: ... overhead crane to the barrel end of the fork level cylinder Support the cylinder Do not apply any lifting pressure 4 Remove the fasteners securing the outrigger cylinder barrel end pivot pin to the machine 5 Use a soft metal drift to remove the outrigger cylinder barrel end pivot pin Lower the cylinder onto the outrigger Crushing hazard The cylinder may become unbalanced and fall if not properly ...

Page 75: ...ic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Component damage hazard Hoses can be damaged if they are kinked or pinched 3 Attach a lifting strap from an overhead crane to the barrel end of the outrigger cylinder Support the cylinder Do not apply any lifting pressure 4 Remove the fasteners securing the outrigger cylinder barrel end ...

Page 76: ... stowed position Key switch in the off position with the key removed Wheels chocked 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 Read each appropriate fault code thoroughly Attempting short cuts may produce hazardous...

Page 77: ...e fault codes are detected scroll through them using the diagnostic button Active Codes vs Stored Codes Active fault codes indicating an engine condition or conditions which have not been corrected are displayed at the moment the fault is detected Stored fault codes are the cumulative history of fault codes which the ECM has detected These fault codes may be recalled by service personnel at a late...

Page 78: ... speed plausibility error 91 3 Sensor error accelerator pedal signal range check high 4 Sensor error accelerator pedal signal range check low 11 Plausibility error between APP1 and APP2 or APP1 and idle switch 94 1 Low fuel pressure system reaction initiated 3 Sensor error low fuel pressure signal range check high 4 Sensor error low fuel pressure signal range check low 97 3 Sensor error water in f...

Page 79: ...rail pressure signal range check low 164 2 Rail pressure safety function is not executed correctly 168 0 Physikal range check high for battery voltage 1 Physikal range check low for battery voltage 2 High battery voltate warning threshold exceeded 2 Battery voltage system reaction initiated 3 Sensor error battery voltage signal range check high 3 Sensor error battery voltage signal range check hig...

Page 80: ...out of range signal disrupted 14 Speed detection out of range signal disrupted 411 0 Physical range check high for differential pressure Venturiunit EGR 1 Physical range check low for differential pressure Venturiunit EGR 3 Sensor error differential pressure Venturiunit EGR signal range check high 4 Physical range check low for EGR differential pressure Sensor error differential pressure Venturiun...

Page 81: ...ion of electric connection 654 3 Injector 4 in firing order short circuit 4 High side to low side short circuit in the injector 4 in firing order 5 Injector 4 in firing order interruption of electric connection 655 3 Injector 5 in firing order short circuit 4 High side to low side short circuit in the injector 5 in firing order 5 Injector 5 in firing order interruption of electric connection 656 3...

Page 82: ... temperature 1 Physikal range check low for ECU temperature 3 Sensor error ECU temperature signal range check high 4 Sensor error ECU temperature signal range check low 1176 3 Sensor error pressure sensor upstream turbine signal range check high 4 Sensor error pressure sensor downstream turbine signal range check high 1180 0 Exhaust gas temperature turbine upstream out of range system reaction ini...

Page 83: ... firing order 1325 12 Too many recognized misfires in cylinder 3 in firing order 1326 12 Too many recognized misfires in cylinder 4 in firing order 1327 12 Too many recognized misfires in cylinder 5 in firing order 1328 12 Too many recognized misfires in cylinder 6 in firing order 1639 0 Sensor error fan speed signal range check high 1 Sensor error fan speed signal range check low 1761 14 Urea tan...

Page 84: ...ctuator temperature high 2797 4 Injector diagnostics timeout error of short circuit to ground measurement cyl Bank 0 2798 4 Injector diagnostics short circuit Bank 0 Bank 1 Injector diagnostics timeout error of short circuit to ground measurement cyl Bank 1 3031 0 AdBlue Tank temperature maximum exceeded 1 DEF Tank temperature below minimum 3 Sensor error urea tank temperature short circuit to bat...

Page 85: ...ressure DPF signal range check low 3361 3 Urea dosing valve short circuit to battery 4 Urea dosing valve short circuit to ground 7 AdBlue dosing valve blocked SCR 3519 3 DEF quality sensor internal temperature sensor short circuit to battery or open lead 4 DEF quality sensor internal temperature sensor short circuit to ground 12 DEF tank temperature temperature too high 13 Temperature at UQS inval...

Page 86: ...R heater relay urea pressureline open load 11 General pressure check error SCR 4345 3 SCR heater urea returnline short circuit to battery 4 SCR heater urea returnline short circuit to ground 5 SCR heater relay urea returnline open load 11 Sensor backflow line pressure SCR plausibility error 4360 0 Physical range check high for urea catalyst upstream temperature 1 Physical range low for urea cataly...

Page 87: ...perature upstream DOC signal range check high 4 Sensor error exhaust gas temperature upstream DOC signal range check low 4769 2 Sensor exhaust gas temperature DOC downstream plausibility error 3 Sensor error exhaust gas temperature downstream DOC signal range check high 4 Sensor error exhaust gas temperature downstream DOC signal range check low Sensor exhaust gas temperature downstream DOC plausi...

Page 88: ...and engine command 23240 64488 9 Timeout CAN message FunModCtl Function Mode Control 23330 64578 14 Immobilizer status fuel blocked 23350 64598 4 Injector cylinder bank 1 short circuit 23352 64600 4 Injector cylinder bank 2 short circuit 23354 64602 12 Injector powerstage output defect 23450 64698 2 Multiple Stage Switch constant speed plausibility error 3 Multiple Stage Switch constant speed shor...

Page 89: ...AMB Ambient Temperature Sensor 23605 64853 9 Timeout Error of CAN Receive Frame TSC1AE Traction Control 23606 64854 9 Timeout Error of CAN Receive Frame TSC1AR Retarder 23612 64860 12 ECU reported internal software error 14 Softwarereset CPU Internal software error ECU 23613 64861 0 Rail pressure disrupted 1 Minimum rail pressure exceeded RailMeUn3 2 Setpoint of metering unit in overrun mode not p...

Page 90: ...ay primary side open load 12 SCR mainrelay powerstage over temperature only CV56B SCR mainrelay short circuit to battery only CV56B SCR mainrelay short circuit to ground only CV56B SCR mainrelay open load only CV56B 23719 64967 3 SCR heater urea supplymodule short circuit to battery 4 SCR heater urea supplymodule short circuit to ground 5 SCR heater relay urea supply module open load 23720 64968 2...

Page 91: ...gate 23793 65041 9 Timeout Error of CAN Receive Frame UAA10 AGS sensor service message 23794 65042 9 Timeout Error of CAN Receive Frame UAA11 AGS sensor data 23803 65051 9 Timeout Error of CAN Receive Frame RxEngPres Status burner airpump 23867 65115 12 Timeout Error of CAN Transmit Frame UAA1 on CAN 2 Burner Air Pump Control 23895 65143 13 Check of missing injector adjustment value programming IM...

Page 92: ...check high 4 Sensor error burner dosing valve DV2 downstream pressure sensor signal range check low 23913 65161 3 Sensor error glow plug control diagnostic line voltage signal range check high 4 Sensor error glow plug control diagnostic line voltage signal range check low 23914 65162 3 Glow plug control short circuit to battery 4 Glow plug control short circuit to ground 5 Glow plug control open l...

Page 93: ... for airpump pressure shut off regeneration 1 Physical range check low for airpump pressure shut off regeneration 2 Sensor airpump pressure plausibility error 3 Sensor error airpump pressure signal range check high 4 Sensor error airpump pressure signal range check low 23920 65168 0 Physical range check high for exhaustgas back pressure burner shut off regeneration 1 Physical range check low for e...

Page 94: ...933 65181 0 Fuel Balance Control integrator injector 5 in firing order maximum value exceeded 1 Fuel Balance Control integrator injector 5 in firing order minimum value exceeded 23934 65182 0 Fuel Balance Control integrator injector 6 in firing order maximum value exceeded 1 Fuel Balance Control integrator injector 6 in firing order minimum value exceeded 23935 65183 12 Timeout Error of CAN Transm...

Page 95: ...950 65198 0 Zerofuel calibration injector 5 in firing order maximum value exceeded 1 Zerofuel calibration injector 5 in firing order minimum value exceeded 23951 65199 0 Zerofuel calibration injector 6 in firing order maximum value exceeded 1 Zerofuel calibration injector 6 in firing order minimum value exceeded 23960 65208 0 EGR cooler downstream temperature out of range system reaction initiated...

Page 96: ...Control integrator injector 8 in firing order minimum value exceeded 23992 65240 9 Timeout Error of CAN Receive Frame DM19Vol1 NOX sensor upstream 23993 65241 9 Timeout Error of CAN Receive Frame DM19Vol2 NOX sensor downstream 23995 65243 13 check of missing injector adjustment value programming IMA injector 7 in firing order 23996 65244 13 check of missing injector adjustment value programming IM...

Page 97: ...24019 65267 11 Air Pump air lines blocked 24020 65268 14 Engine power Not enough oxygen for regeneration 24021 65269 11 Burner fuel line pipe leak behind Shut Off Valve 24022 65270 14 DPF wasn t regenerated power reduction phase 2 manuell regeneration request 24023 65271 14 DPF wasn t regenerated warning condition manuell regeneration mode 24024 65272 11 Deviation of the exhaust gas temperature se...

Page 98: ...Slave internal CAN message 24043 65291 9 Timeout error of CAN Receive Frame ComMS_Sys6TO error memory Slave Master Slave internal CAN message 24044 65292 9 CAN message ComMS_Sys7 not received from slave 24045 65293 9 Master Slave CAN Message Counter Error of CAN Receive Frame ComMSMoFOvR 24046 65294 9 Master Slave CAN Checksum Error of CAN Receive Frame ComMSMoFOvR 24047 65295 9 Master Slave CAN M...

Page 99: ...e plausibility error 24068 65316 2 Master ECU and Slave ECU have been identified as the same types 24069 65317 9 Timeout Error of CAN Receive Frame MSMon_FidFCCTO Master Slave CAN communication faulty 24074 9 NOx sensor downstream SCR CAT sensor internally open load 24075 11 NOx sensor downstream SCR CAT sensor internally short circuit 24076 9 NOx sensor downstream SCR CAT sensor internally open l...

Page 100: ...DPFBrnAirPmpCtl 24103 65351 9 Timeout error of CAN Receive Frame ComRxDPFBrnAirPmp 24104 65352 9 Timeout error of CAN Receive Frame ComRxDPFCtl 24105 65353 9 Timeout error of CAN Transmit Frame ComEGRMsFlw 24106 65354 9 Timeout error of CAN Receive Frame ComRxEGRMsFlw1 24107 65355 9 Timeout error of CAN Receive Frame ComRxEGRMsFlw2 24108 65356 9 Timeout error of CAN Transmit Frame ComEGRTVActr 241...

Page 101: ...ve blocked 24147 7 SCR System reverting valve blocked 13 SCR System pressure build up not possible 24152 2 Urea Quality Sensor Timout CAN message 24153 2 Urea tank level urea tank temperature via CAN bus timeout of CAN message 24156 9 Timeout error of CAN Receive Frame ComRxEBC2 24175 0 SCR CAT Nox emissions above minimum threshold 24177 7 SCR System DEF suction line blocked 24178 7 SCR System DEF...

Page 102: ...ld air temperature short to ground 110 3 Engine coolant temperature open short to battery positive 4 Engine coolant temperature short to ground SPN FMI Description 157 3 Fuel rail pressure open short to battery positive 4 Fuel rail pressure short to ground 168 0 System voltage high 1 System voltage low 2 ECM battery power intermittent erratic 172 3 Air inlet temperature voltage high 4 Air inlet te...

Page 103: ...rt 7 Cylinder 4 injector not responding 678 3 8V DC supply short to battery positive 4 8V DC supply shorted to ground 723 8 Secondary engine speed signal abnormal 1188 5 Turbo wastegate drive current low 1196 9 Machine security system module non communication 1347 5 Fuel rail pump output current low 6 Fuel rail pump output current high 7 Fuel rail pressure valve solenoid not responding 2882 2 Mode...

Page 104: ...afety 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 About This Section There are two groups of schematics in this section Electrical Schematics Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watche...

Page 105: ...ervice and Repair Manual Proximity Switch Legend Part No 1287211GT GTH 1056 95 1 Boom Angle Proximity Switch PX2 under boom pivot pin 2 Boom Extend Proximity Switch PX1 under plate at top of boom tube GTH 1056 only ...

Page 106: ...rkins T4i CB1 50A Control System Power CB3 60A Glow Plugs Perkins T4i CB2 50A Engine Power ECM Deutz T3 Perkins T3 CB2 30A Engine Power ECM Deutz T4F CB4 50A EAT Power CB2 50A ECM Power CB1 50A Control System Power CB3 60A Glow Plugs Circuit Breakers located in the Tank Assembly Fuse Board located in the Cab ...

Page 107: ...April 2018 Service and Repair Manual Deutz TCD3 6 T4F Module Part No 1287211GT GTH 1056 97 Deutz TCD3 6 T4F Engine only Located in the Tank Assembly with the circuit breaker panel ...

Page 108: ...Reverse Enable CR11 Parking Brake Latch CR12 Sway Left Right Enable CR13 Tilt Up Down Enable CR14 Boom Angle Monitor CR15 HVAC Blower L CR16 HVAC Blower M CR17 HVAC Blower H Item Description D Diode EMS Engine Management System F Fuse F1 15 Amp Break Shift F2 10 Amp Aux Hydraulics F3 10 Amp Rear Axle Oscillate F4 10 Amp Sway Tilt F5 5 Amp Horn F6 5 Amp Steer Differential Switch F7 5 Amp Gauge Clus...

Page 109: ...ift ON L25 Parking Brake Release OFF L26 Brake Light Power ON L27 Hazard Power ON L28 Not Used M Motor R Resistor Item Description S Switch S1 Key Start Switch S4 Boom Extend Switch S5 Parking Brake Pressure Switch S6 Service Brake Pressure Switch S7 Sway Enable Pressure Switch S8 Sway Enable Switch S9 Tilt Enable Switch S10 Steer Select Switch S11 Left Stabilizer Switch S12 Right Stabilizer Switc...

Page 110: ...B YD D Transmission YE E Transmission YF Transmission Forward YR Transmission Reverse YD1A 4Wheel Steer SVD1A YD1B Crab Steer SVD1B YLD Left Stabilizer Down YLU Left Stabilizer Up YRD Right Stabilizer Down YRU Right Stabilizer Up Wire Color Legend BL Blue BL BK Blue Black BL RD Blue Red BL WH Blue White BK Black BK RD Black Red BK WH Black White BK YL Black Yellow BR Brown GR Green GR BK Green Bla...

Page 111: ...nd 0 VDC Battery Negative Device Ground 3 Digital Output 1 12 VDC Engine Run Hour Meter 12V engine run 0V engine off Monitor Engine Hours 4 Digital Output 2 12 VDC Boom Angle Status 12V boom 55 0V 55 Monitor Machine Utilization 5 Digital Output 3 12 VDC Parking Brake 12V active 0V inactive Monitor Machine Utilization 6 Digital Input 1 12 VDC standard or Ground optional Remote Disable Engine Start ...

Page 112: ...igh Schematic standard wiring Telematics Active Low Schematic optional wiring 1 Ignition Start Input 2 Relay 3 Telematics with Active High input 4 Telematics with Active Low input Wireless Certifications Telematic device s should comply with specific wireless carrier certifications where applicable and comply with the following N America PTCRB FCC IC Europe CE R TTE ...

Page 113: ...inal T circuits connect at terminal Circuits crossing no connection Quick disconnect terminal Circuit breaker with amperage Key switch Toggle Switch DPDT Toggle Switch SPDT Pump or Motor Tilt sensor Horn button normally open Emergency Stop button normally closed Resistor with ohm value Battery separator Gauge sending unit Oil temperature switch normally open Coolant temperature switch normally ope...

Page 114: ...on 3 way Differential sensing valve Filter with bypass relief valve Relief valve with pressure setting Priority flow regulator valve Solenoid operated proportional valve Directional valve mechanically activated Flow divider combiner valve Pilot operated 3 position 3 way shuttle valve Solenoid operated 2 position 3 way directional valve Counterbalance valve with pressure and pilot ratio Solenoid op...

Page 115: ...April 2018 Service and Repair Manual 105 Harness Map Harness Legend ...

Page 116: ...Service and Repair Manual April 2018 106 GTH 1056 Part No 1287211GT Harness Map Harness Legend ...

Page 117: ...April 2018 Service and Repair Manual Part No 1287211GT GTH 1056 107 Harness Map Control System Electronic Joystick ...

Page 118: ...Service and Repair Manual April 2018 108 Harness Map Control System Electronic Joystick ...

Page 119: ...April 2018 Service and Repair Manual 109 Harness Map Deutz T4F Engine ...

Page 120: ...Service and Repair Manual April 2018 110 GTH 1056 Part No 1287211GT Harness Map Deutz T4F Engine ...

Page 121: ...April 2018 Service and Repair Manual Part No 1287211GT GTH 1056 111 Harness Map Deutz T3 Engine ...

Page 122: ...Service and Repair Manual April 2018 112 Harness Map Deutz T3 Engine ...

Page 123: ...April 2018 Service and Repair Manual 113 Harness Map Perkins T4i Engine ...

Page 124: ...Service and Repair Manual April 2018 114 GTH 1056 Part No 1287211GT Harness Map Perkins T4i Engine ...

Page 125: ...April 2018 Service and Repair Manual Part No 1287211GT GTH 1056 115 Harness Map Perkins T3 Engi ne ...

Page 126: ...Service and Repair Manual April 2018 116 Harness Map Perkins T3 Engine ...

Page 127: ...April 2018 Service and Repair Manual 117 Harness Map Road Lights ...

Page 128: ...Service and Repair Manual April 2018 118 GTH 1056 Part No 1287211GT Harness Map Road Lights ...

Page 129: ...April 2018 Service and Repair Manual Part No 1287211GT GTH 1056 119 Harness Map Work Lights ...

Page 130: ...Service and Repair Manual April 2018 120 Harness Map Work Lights ...

Page 131: ...April 2018 Service and Repair Manual 121 Harness Map Deutz HVAC Option ...

Page 132: ...Service and Repair Manual April 2018 122 GTH 1056 Part No 1287211GT Harness Map Deutz HVAC Option ...

Page 133: ...April 2018 Service and Repair Manual Part No 1287211GT GTH 1056 123 Harness Map Perkins HVAC Option ...

Page 134: ...Service and Repair Manual April 2018 124 Harness Map Perkins HVAC Option ...

Page 135: ...April 2018 Service and Repair Manual 125 Harness Map Enclosed Cab Heater ...

Page 136: ...Service and Repair Manual April 2018 126 GTH 1056 Part No 1287211GT Harness Map Enclosed Cab Heater ...

Page 137: ...April 2018 Service and Repair Manual Part No 1287211GT GTH 1056 127 Harness Map Proximity Sensor Beacon Lockout Options ...

Page 138: ...Service and Repair Manual April 2018 128 Harness Map Proximity Sensor Beacon Lockout Options ...

Page 139: ...April 2018 Service and Repair Manual 129 Electrical Schematic View 1 ...

Page 140: ...Service and Repair Manual April 2018 130 GTH 1056 Part No 1287211GT Electrical Schematic View 1 ...

Page 141: ...April 2018 Service and Repair Manual Part No 1287211GT GTH 1056 131 Electrical Schematic View 2 500 ...

Page 142: ...Service and Repair Manual April 2018 132 Electrical Schematic View 2 ...

Page 143: ...April 2018 Service and Repair Manual 133 Electrical Schematic Deutz T4F Eng Harness ...

Page 144: ...Service and Repair Manual April 2018 134 GTH 1056 Part No 1287211GT Electrical Schematic Deutz T4F Eng Harness Page 1 of 3 ...

Page 145: ...April 2018 Service and Repair Manual Part No 1287211GT GTH 1056 135 Electrical Schematic Deutz T4F Eng Harness Page 2 of 3 ...

Page 146: ...Service and Repair Manual April 2018 136 Electrical Schematic Deutz T4F Eng Harness ...

Page 147: ...April 2018 Service and Repair Manual 137 Electrical Schematic Deutz T4F Eng Harness ...

Page 148: ...Service and Repair Manual April 2018 138 GTH 1056 Part No 1287211GT Electrical Schematic Deutz T4F Eng Harness Page 3 of 3 ...

Page 149: ...April 2018 Service and Repair Manual Part No 1287211GT GTH 1056 139 Electrical Schematic Deutz Tier 3 Eng Harness ...

Page 150: ...Service and Repair Manual April 2018 140 Electrical Schematic Deutz T3 Eng Harness ...

Page 151: ...April 2018 Service and Repair Manual 141 Hydraulic Schematic ...

Page 152: ...Service and Repair Manual April 2018 142 GTH 1056 Part No 1287211GT Hydraulic Schematic ...

Page 153: ...April 2018 Service and Repair Manual Part No 1287211GT GTH 1056 143 Hydraulic Schematic ...

Page 154: ...Service and Repair Manual April 2018 144 Hydraulic Schematic GTH 1056 Part No 1287211GT Service and R epair M anual April 2018 ...

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