Genie GTH-2506 Stage A User manual

1.
Service Manual
GTH-2506
(Deutz Stage IIIA - IIIB)
Part No. 57.4400.9220GT
Rev A
August 2018
From GTH250619M-1001
Serial Number Range
GTH-3007
(Deutz Stage IIIA - IIIB)
From GTH300719M-501

ii GTH-2506 GTH-3007 Part No. 57.4400.9220GT
August 2018
Compliance
Machine Classification
Group B/Type 3 as defined by ISO 16368
Machine Design Life
Unrestricted with proper operation, inspection and
scheduled maintenance.
Important
Read, understand and obey the safety rules and
operating instructions in the Genie GTH-2506,
GTH-3007 Operator's Manual before attempting
any maintenance or repair procedure.
This manual provides detailed scheduled
maintenance information for the machine owner
and user. It also provides troubleshooting fault
codes 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 dealer service center.
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.
Serial Number Information
Genie offers the following Service Manuals for
these models:
Title Part No.
Contact Us:
http://www.genielift.com
e-mail: [email protected]
Introduction
Copyright © 2018 by Terex Corporation
57.4400.9220GT Rev A August 2018
First Edition, First Printing
"Genie" and "GTH" are registered trademarks of
Terex South Dakota, Inc. in the USA and many other
countries.
Printed on recycled paper

August 2018
Part No. 57.4400.9220GT GTH-2506 GTH-3007 iii
Revision Date Section Procedure / Schematic Page /
Description
A 08/2018 Initial Release
REFERENCE EXAMPLES:
Deutz Engine_Section 2_Specifications.
A-6,B-3,C-7_Section 3_Maintenance Procedure.
3-2, 6-4, 9-1_Section 4_Repair Procedure.
Fault Codes_Section 5.
6-35, 6-56, 6-104_Section 6_Schematic Page #.
Electronic Version
Click on any procedure or page number
highlighted in blue to view the update.
Revision History

iv GTH-2506 GTH-3007 Part No. 57.4400.9220GT
August 2018
REVISION HISTORY, CONTINUED
Revision Date Section Procedure / Schematic Page /
Description
REFERENCE EXAMPLES:
Deutz Engine_Section 2_Specifications.
A-6,B-3,C-7_Section 3_Maintenance Procedure.
3-2, 6-4, 9-1_Section 4_Repair Procedure.
Fault Codes_Section 5.
6-35, 6-56, 6-104_Section 6_Schematic Page #.
Electronic Version
Click on any procedure or page number
highlighted in blue to view the update.

August 2018
Part No. 57.4400.9220GT GTH-2506 GTH-3007 v
A TEREX BRAND
Model Name: GTH-2506
Model Year: Current Year
Designation: ROUGH TERRAIN VARIABLE REACH TRUCK
Serial Number: GTH250614B-xxxxx
Manufacture Date: DD/MM/YY
Mass: 10,100 lbs 4580 kg
Rated Capacity: 2,500 kg
Nominal Power: 55.4 kW
Max drawbar pull provided for at the coupling hook:
30000 N
Max vertical load provided for on the coupling hook:
10000 N
Country of Manufacture: Italy
Manufacturer:
TEREX Global GmbH
Mühlenstrasse 26
Switzerland
INTRODUCTION
Serial Number legend
GTH -2506 16 MXXXX
Model
Year of
manufacture
Facility code
Sequence
number
Serial label
(located inside chassis)
Serial number
A TEREX BRAND
Model Name: GTH-3007
Model Year: Current Year
Designation: ROUGH TERRAIN VARIABLE REACH TRUCK
Serial Number: GTH300716M-xxxxx
Manufacture Date: DD/MM/YY
Mass: 13,536lbs 6,140 kg
Rated Capacity: 3,000 kg
Nominal Power: 55.4 kW
Max drawbar pull provided for at the coupling hook:
30000 N
Max vertical load provided for on the coupling hook:
10000 N
Country of Manufacture: Italy
Manufacturer:
TEREX Global GmbH
Bleicheplatz 2
Switzerland

vi GTH-2506 GTH-3007 Part No. 57.4400.9220GT
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August 2018
Part No. 57.4400.9220GT GTH-2506 GTH-3007 vii
Section 1 • Safety 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 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.
Safety Rules

viii GTH-2506 GTH-3007 Part No. 57.4400.9220GT
August 2018
Section 1 • Safety Rules
Personal 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.
Read each procedure thoroughly. This
manual and the decals on the machine,
use signal words to identify the following:
Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicates an 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 avoided,
may cause minor or moderate
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may result in property damage.
Be sure to wear protective eye wear and
other protective clothing if the situation
warrants it.
Be aware of potential crushing hazards
such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved
steel-toed shoes.
DANGER
WARNING
CAUTION
NOTICE
Workplace Safety
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 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., 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.
SAFETY RULES

August 2018
Part No. 57.4400.9220GT GTH-2506 GTH-3007 ix
Introduction
Important Information .................................................................................. ii
Revision History...........................................................................................iii
Serial Number Legend................................................................................. v
Section 1 Safety Rules
General Safety Rules .................................................................................vii
Section 2 Specifications
Machine Specifications...........................................................................2 - 1
Performance Specifications....................................................................2 - 2
Hydraulic Specifications .........................................................................2 - 3
Hydraulic Component Specifications......................................................2 - 4
Function Manifold Specifications............................................................2 - 5
Air Conditioner Refrigerant Specifications..............................................2 - 5
Deutz TD 2.9 L4 Engine .........................................................................2 - 6
Dana Axles .............................................................................................2 - 7
Hydraulic Hose and Fitting Torque Specifications..................................2 - 8
Torque Procedure...................................................................................2 - 9
SAE and Metric Fasteners Torque Charts............................................2 - 10
Section 3 Scheduled Maintenance Procedures
Introduction.............................................................................................3 - 1
Pre-delivery Preparation Report.............................................................3 - 3
Maintenance Inspection Report..............................................................3 - 4
Table of Contents

x GTH-2506 GTH-3007 Part No. 57.4400.9220GT
August 2018
TABLE OF CONTENTS
Section 3 Scheduled Maintenance Procedures, continued
Checklist A Procedures
A-1 Inspect the Manuals and Decals ..................................................3 - 5
A-2 Perform Pre-operation Inspection ................................................3 - 6
A-3 Perform Function Tests................................................................3 - 6
A-4 Lubricate the Boom ......................................................................3 - 7
A-5 Perform Engine Maintenance.......................................................3 - 7
A-6 Safety Devices .............................................................................3 - 8
A-7 Perform 30 Day Service ...............................................................3 - 8
A-8 Perform Axle Maintenance...........................................................3 - 9
A-9 Perform Axle Maintenance...........................................................3 - 9
A-10 Perform Axle Maintenance.........................................................3 - 10
Checklist B Procedures
B-1 Inspect the Electrical Wiring.......................................................3 - 11
B-2 Check the Exhaust System ........................................................3 - 12
B-3 Inspect the Tires, Wheels and Lug Nut Torque..........................3 - 12
B-4 Perform Hydraulic Oil Analysis...................................................3 - 13
B-5 Check the Boom Wear Pads......................................................3 - 14
B-6 Perform Axle Maintenance.........................................................3 - 15

August 2018
Part No. 57.4400.9220GT GTH-2506 GTH-3007 xi
Section 3 Scheduled Maintenance Procedures, continued
Checklist C Procedures
C-1 Perform Engine Maintenance.....................................................3 - 16
Checklist D Procedures
D-1 Inspect the Forks........................................................................3 - 17
D-2 Replace the Hydraulic Tank Return Filter Element ....................3 - 18
D-3 Perform Engine Maintenance.....................................................3 - 19
D-4 Perform Axle Maintenance.........................................................3 - 19
D-5 Inspect the Engine Air Filter .......................................................3 - 20
D-6 Perform Engine Maintenance.....................................................3 - 21
Checklist E Procedures
E-1 Test or Replace the Hydraulic Oil...............................................3 - 22
E-2 Perform Engine Maintenance.....................................................3 - 23
E-3 Perform Engine Maintenance.....................................................3 - 23
E-4 Perform Engine Maintenance.....................................................3 - 24
TABLE OF CONTENTS

xii GTH-2506 GTH-3007 Part No. 57.4400.9220GT
August 2018
Section 4 Repair Procedures
Introduction.............................................................................................4 - 1
Boom Components
1-1 Boom............................................................................................4 - 2
1-2 Boom Lift Cylinder........................................................................4 - 6
1-3 Boom Extend Cylinder..................................................................4 - 7
1-4 Fork Level Cylinder ......................................................................4 - 8
1-5 Fork Tilt Cylinder ..........................................................................4 - 9
Operator's compartment
2-1 Operator’s Compartment............................................................4 - 12
2-2 Machine Controls .......................................................................4 - 14
Fuel and Hydraulic Tanks
3-1 Fuel Tank ...................................................................................4 - 18
3-2 Hydraulic Tank ...........................................................................4 - 19
Engines
4-1 Engines ......................................................................................4 - 20
4-2 Engine Fault Codes....................................................................4 - 20
Axle
5-1 Disabled Machine.......................................................................4 - 21
5-2 Axle ............................................................................................4 - 23
Hydraulic pumps
6-1 Boom and Steering Function Pump ...........................................4 - 24
6-2 Hydrostatic Transmission Pump.................................................4 - 28
Manifolds
7-1 Function Manifold.......................................................................4 - 32
7-2 Valve Coils .................................................................................4 - 37
LMI (Overload System)
8-1 LMI .............................................................................................4 - 39
TABLE OF CONTENTS

August 2018
Part No. 57.4400.9220GT GTH-2506 GTH-3007 xiii
Section 4 Repair Procedures, continued
Miscellaneaous
9-1 Parking Brake Reducing Valve...................................................4 - 41
Section 5 Settings
Introduction.............................................................................................5 - 1
How to Calibrate the Load Cell...............................................................5 - 2
Section 6 Fault Codes
Introduction.............................................................................................6 - 1
Diagnostic Display..................................................................................6 - 2
Engine Fault Codes - Models with Deutz TD 2.9 L4...............................6 - 3
Section 7 Schematics
Introduction.............................................................................................7 - 1
Electrical and Hydraulic Symbol Legends ..............................................7 - 2
Electrical Schematic ...............................................................................7 - 3
Hydraulic Schematic.............................................................................7 - 19
TABLE OF CONTENTS

xiv GTH-2506 GTH-3007 Part No. 57.4400.9220GT
August 2018
TABLE OF CONTENTS
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August 2018
Part No. 57.4400.9220GT GTH-2506 GTH-3007 2-1
Section 2 • Specifications
Machine Specifications
Fluid Capacities GTH-2506
Fuel Tank 15.9 gallons
60 liters
Hydraulic tank 17.2 gallons
65 liters
Hydraulic system
(including tank)
25 gallons
95 liters
Fluid Capacities GTH-3007
Fuel Tank 23.7 gallons
90 liters
Hydraulic tank 19.8 gallons
75 liters
Hydraulic system
(including tank)
27.7 gallons
105 liters
For operational specifications, refer to the
Operator's Manual.
Tires and wheels GTH-2506
Tire size 12 x 16.5
Tire ply rating 10
Weight, rough terrain tire wheel
(air filled)
106 lbs
48 kg
Weight, rough terrain tire wheel
(foam filled)
320 lbs
145 kg
Weight, rough terrain solid tire
wheel
278 lbs
126 kg
Tire pressure
(models with air-filled tires)
65 psi
4.5 bar
Lug nut torque 243 ft-lbs
330 Nm
Lug pattern 8 x 10.827
Wheel diameter 32.3 in
820 mm
Wheel width 12.3 in
313 mm
Tires and wheels GTH-3007
Tire size 405/70 20
Tire ply rating 14
Weight, rough terrain tire wheel
(air filled)
214,95 lbs
97.5 kg
Tire pressure
(models with air-filled tires)
80 psi
5.5 bar
Lug nut torque 243 ft-lbs
330 Nm
Lug pattern 8 x 10.827
Wheel diameter 42.3 in
1076 mm
Wheel width 15.9 in
405 mm
Continuous improvement of our products is
a Genie policy. Product specifications are
subject to change without notice.
Specifications

2-2 GTH-2506 GTH-3007 Part No. 57.4400.9220GT
August 2018
Section 2 • Specifications
Performance Specifications
GTH-2506
Drive speed, maximum 14 mph
23 km/h
Draw bar pull 9200 lbs
4173 kg
Lift capacity, maximum 5500 lbs
2500 kg
GTH-3007
Drive speed, maximum 18.6 mph
30 km/h
Draw bar pull 6834 lbs
3100 kg
Lift capacity, maximum 6613 lbs
3000 kg
SPECIFICATIONS
Boom function speeds, maximum GTH-2506
Boom up 8 seconds
Boom down 7 seconds
Boom extend 8 seconds
Boom retract 4 seconds
Fork tilt up 5 seconds
Fork tilt down 4 seconds
Boom function speeds, maximum GTH-3007
Boom up 9 seconds
Boom down 7 seconds
Boom extend 10 seconds
Boom retract 5 seconds
Fork tilt up 6 seconds
Fork tilt down 4 seconds
Continuous improvement of our products is
a Genie policy. Product specifications are
subject to change without notice.

August 2018
Part No. 57.4400.9220GT GTH-2506 GTH-3007 2-3
Section 2 • Specifications
Optional fluids
Biodegradable Petro Canada Environ MV46
Statoil Hydra Way Bio Pa 32
BP Biohyd SE-S
Fire resistant UCON Hydroluble HP-5046
Quintolubric 822
Mineral based Shell Tellus S2 V 32
Shell Tellus S2 V 46
Chevron Aviation A
Eni Arnica 32
Continued use of Chevron Aviation
A hydraulic fluid when ambient
temperatures are consistently
above 32°F / 0°C may result in
component damage.
Note: Use Chevron Aviation A hydraulic fluid when
ambient temperatures are consistently below
0°F / -17°C.
Note: Use Shell Tellus T46 hydraulic oil when oil
temperatures consistently exceed 205°F / 96°C.
Genie specifications require additional equipment
and special installation instructions for the
approved optional fluids. Consult the Genie
Service Department before use.
Continuous improvement of our products
is a Genie policy. Product specifications are
subject to change without notice.
NOTICE
Hydraulic Specifications
Hydraulic Oil Specification
Hydraulic oil type
Viscosity grade
Viscosity index
Chevron Rando HD equivalent
Multi-viscosity
200
Cleanliness level,
minimum 15/13
Water content,
maximum 200 ppm
Chevron Rando HD oil is fully compatible and
mixable with Shell Donax TG (Dexron III) oils.
Genie specifications require hydraulic oils which
are designed to give maximum protection to
hydraulic systems, have the ability to perform over
a wide temperature range, and the viscosity index
should exceed 140. They should provide excellent
antiwear, oxidation, corrosion inhibition, seal
conditioning, and foam and aeration suppression
properties.
SPECIFICATIONS

2-4 GTH-2506 GTH-3007 Part No. 57.4400.9220GT
August 2018
Section 2 • Specifications
Hydraulic Components
Specifications
Boom and Steering Functions Pump
GTH-2506
Type: fixed displacement gear
pump
Displacement 1,65 cu in
27 cc
Flow rate @ 2300 rpm 16,4 gpm
62 L/min
Pump pressure, maximum
(measured at test port TP1)
4,061 psi
280 bar
Boom and Steering Functions Pump
GTH-3007
Type: fixed displacement gear
pump
Displacement 2,07 cu in
34 cc
Flow rate @ 2300 rpm 20,6gpm
78 L/min
Pump pressure, maximum
(measured at test port TP1)
4,061 psi
280 bar
Hydrostatic Transmission Pump
Type: variable displacement
piston pump
Displacement 0 to 2.75 cu in
0 to 56 cc
Flow rate @ 2300 rpm 33.81 gpm
128 L/min
Pump pressure, maximum
(measured at test port TP2)
7180 psi
495 bar
Relief valve pressure,
maximum
(measured at test port TP2)
7540 psi
520 bar
Pump charge relief valve
pressure, maximum
(measured at test port TP3)
360 psi
25 bar
Hydrostatic Transmission Motor
Type: variable displacement
piston motor
Displacement 0 to 5.2 cu in
0 to 85 cc
Flow rate @ 2300 rpm 33.81 gpm
128 L/min
Motor pressure, maximum
(measured at test port TP2)
7180 psi
495 bar
Relief valve pressure,
maximum
(measured at test port TP2)
7540 psi
520 bar
Continuous improvement of our products is
a Genie policy. Product specifications are
subject to change without notice.
SPECIFICATIONS

August 2018
Part No. 57.4400.9220GT GTH-2506 GTH-3007 2-5
Section 2 • Specifications
Function Manifold
Specifications
Function Manifold
System relief valve pressure, maximum
(measured at test port TP1)
4060 psi
280 bar
Fork tilt relief valve pressure, maximum
(measured at test port TP1)
4350 psi
300 bar
Boom telescopic cylinder relief valve
pressure, maximum
(measured at test port TP1)
1450 psi
100 bar
Secondary Function Valves
Steer relief valve pressure, maximum 2537 psi
175 bar
Steer anti-shock relief valve pressure,
maximum
3408 psi
235 bar
Parking brake relief valve pressure,
maximum (measured at test port TP5)
360 psi
25 bar
Service brake pressure, maximum
(measured at test port TP4)
1160 psi
80 bar
SPECIFICATIONS
Air Conditioner Refrigerant
Specifications
System Full Charge
R134a 750 g
1 lbs 10 oz
Continuous improvement of our products is
a Genie policy. Product specifications are
subject to change without notice.

2-6 GTH-2506 GTH-3007 Part No. 57.4400.9220GT
August 2018
Section 2 • Specifications
Fuel requirements
For fuel requirements, refer to the engine Operation
Manual on your machine.
Fuel injection pressure 1595 psi
110 bar
Engine coolant
Capacity 3.3 gallons
12,5 liters
Type Extended Life
Alternator
Output 95 A, 12V DC
Starter Motor
Nominal power 3.2 kW
Nominal current 267 A
Cranking speed 130 - 200 rpm
Glow Plugs
Initial load (0-10 sec) 40 amps
Continuous load (>10 sec) 15 amps
Battery
Type 12V DC
Group G28
Quantity 1
Cold cranking ampere @ 0°F 720 A
Nominal capacity 100 Ah
Continuous improvement of our products is
a Genie policy. Product specifications are
subject to change without notice.
SPECIFICATIONS
Deutz TD 2.9 L4 Engine
Displacement 2925 cm3
Number of cylinders 4
Bore and stroke 3.62 x 4.33 inches
92 x 110 mm
Horsepower 74 HP @ 2300 rpm
55.4 kW @ 2300 rpm
Peak Torque 192 lb-ft @ 1800 rpm
260 Nm @ 1800 rpm
Firing order 1 - 3 - 4 - 2
Compression ratio 17,4:1
Governor Electronic
Low idle
Frequency
1000 rpm
16.6 Hz
High idle
Frequency
2700 rpm
45 Hz
Lubrication system
Minimum oil pressure 17.4 psi
1,2 bar
Maximum oil capacity
(including filter)
2.11 gallons
8 liters
Oil viscosity requirements
Units ship with 15W-40 Shell Rimula R4 L.
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.