Terex Genie GTH -1056 Installation and operating manual

Service and Repair Manual
Serial Number Range
GTH™-1056
From GTH1016E-11305 to
GTH1016E-
11799
includes GTH1016E-
11281
GTH1016E-
11282
GTH1016E-
11286
from GTH10E-11800
to
GTH10E-
12499
f
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
Part No. 1278145
Re
v B2
April 2018

Service and Repair Manual April 2018
Introduction
ii TH-1056 Part No. 1278145
Intr oduct io n Intr oduct io n
Important
Read, understand and obey the safety rules and
operating instructions in the appropriate Operator's
Manual on your machine before attempting any
procedure.
This manual provides troubleshooting and repair
procedures for qualified service professionals.
Basic mechanical, hydraulic and electrical skills are
required to perform most procedures. However,
several procedures require specialized skills, tools,
lifting equipment and a suitable workshop. In these
instances, we strongly recommend that
maintenance and repair be performed at an
authorized Genie dealer service center.
Compliance
Machine Design Life
Unrestricted with proper operation, inspection and
scheduled maintenance.
Technical Publications
Genie has endeavored to deliver the highest
degree of accuracy possible. However, continuous
improvement of our products is a Genie policy.
Therefore, product specifications are subject to
change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.
Contact Us:
Internet: www.genielift.com
E-mail: [e-mail]
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.
Copyright © 2016 by Terex Corporation
1278145 Rev B1, April 2018
Second Edition, First Printing
Genie is a registered trademark of Terex South Dakota, Inc. in
the U.S.A. and many other countries.
"GTH" is a trademark of Terex South Dakota, Inc.

April 2018 Service and Repair Manual
Introduction
Part No. 1278145 TH-1056 iii
Revision History
Revision
Date
Section
Procedure / Page / Description
A 3/2016 Initial Release
A1 4/2016 Repair Revise manifold torque values
B 8/2017 Specifications added T4F specifications
Repair added ZF transmission repair manual
Schematics updated fuse panel layout; updated electrical component
legend; added ES0466B; updated HS0201H and HS0202H
B1
4/2018
Schematics
Added ES0603; added Deutz Engine Harness: added
HS0212
B2
4/2018
Moved ES603 and HS0212 to new SRM; added final serial
number
Reference Examples: Electronic Version
Click on any content or procedure in the Table of Contents to view
the update.
Section – Repair Procedure, 4-2
Section – Fault Codes, All charts
Section – Schematics, Legends and schematics

Service and Repair Manual April 2018
Introduction
iv TH-1056 Part No. 1278145
Serial Number Legend
To August 31, 2016
1 Model
2 Model year
3 Facility code
4 Sequence number
1 Serial label
2 Serial number (stamped on chassis)
3 Serial label (located inside fork frame)
From September 1, 2016
1 Model
2 Facility code
3 Sequence number
1 Serial label
2 Serial number (stamped on chassis)
3 Serial label (located inside fork frame)

April 2018 Service and Repair Manual
Safety Rules
Part No. 1278145 TH-1056 v
Section 1 Safet y Rul es
Danger
Failure to obey the instructions and safety rules in
this manual and the appropriate Operator's Manual
on your machine will result in death or serious
injury.
Many of the hazards identified in the operator's
manual are also safety hazards when maintenance
and repair procedures are performed.
Do Not Perform Maintenance
Unless:
RYou are trained and qualified to perform
maintenance on this machine.
RYou read, understand and obey:
•manufacturer's instructions and safety rules
•employer's safety rules and worksite
regulations
•applicable governmental regulations
RYou have the appropriate tools, lifting
equipment and a suitable workshop.

Service and Repair Manual April 2018
Safety Rules
vi TH-1056 Part No. 1278145
Workplace Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Be sure to keep sparks, flames and lighted
tobacco away from flammable and
combustible materials like battery gases
and engine fuels. Always have an
approved fir
e extinguisher within easy
reach.
Be sure that all tools and working areas
are properly maintained and ready for
use. Keep work surfaces clean and free of
debris that could get into machine
components and cause damage.
Be sure any forklift, overhead
crane or
other lifting or supporting device is fully
capable of supporting and stabilizing the
weight to be lifted. Use only chains or
straps that are in good condition and of
ample capacity.
Be sure that fasteners intended for one
time use (i.e., cotte
r pins and self-locking
nuts) are not reused. These components
may fail if they are used a second time.
Be sure to properly dispose of old oil or
other fluids. Use an approved container.
Please be environmentally safe.
Be sure that your workshop or
work area
is properly ventilated and well lit.

April 2018
Table of Contents
Part No. 1278145 TH-1056 vii
Introduction Introduction ..........................................................................................................ii
Important Information............................................................................................. ii
Find a Manual for this Model.................................................................................. ii
Serial Number Legend .......................................................................................... iv
Section 1 Safety Rules..........................................................................................................v
General Safety Rules.............................................................................................v
Section 2 Specifications.......................................................................................................1
Machine Specifications...........................................................................................1
Performance Specifications ...................................................................................2
Hydraulic Oil Specifications....................................................................................2
Hydraulic Component Specifications .....................................................................5
Manifold Component Specifications.......................................................................6
Air Conditioner Refrigerant Specifications .............................................................6
DEF Storage Specifications ...................................................................................7
Deutz TCD3.6 L4 Engine Specifications................................................................8
Deutz TCD3.6 L4 T4F Engine Specifications ........................................................9
Perkins 1104D-E44TA Engine Specifications......................................................10
Perkins 1204E-E44TA Engine Specifications......................................................11
ZF 4 WG-98 TC Transmission Specifications......................................................12
Dana Planetary Drive Axle Specifications (223_212HY) .....................................12
Hydraulic Hose and Fitting Torque Specifications ...............................................13
Torque Procedure ................................................................................................14
Section 3 Repair Procedures .............................................................................................16
Introduction...........................................................................................................16
Boom Components............................................................................................18
1-1 Boom Proximity Switch ..................................................................................18
How to Test a Proximity Switch ......................................................................18
How to Adjust the Boom Angle Proximity Switch............................................19
How to Adjust the Boom Extend Proximity Switch..........................................19
1-2 Boom..............................................................................................................20
How to Replace the Boom Wear Pads ...........................................................20
How to Remove the Lifting Fork Frame..........................................................20

April 2018
Table of Contents
viii TH-1056 Part No. 1278145
How to Remove the Cable Bridge Assembly..................................................21
How to Replace the Retraction Chain.............................................................22
How to Replace the Extension Chains............................................................24
How to Remove the Boom ..............................................................................26
How to Disassemble the Boom - GTH-1056...................................................28
1-3 Boom Lift Cylinder..........................................................................................31
1-4 Boom Extension Cylinder...............................................................................32
1-5 Fork Level Cylinder ........................................................................................33
1-6 Hydraulic Hoses.............................................................................................34
How to Replace the Fork Level and/or Auxiliary Cylinder Hoses, GTH-1056.34
Operator's Compartment...................................................................................36
2-1 Operator's Compartment................................................................................36
2-2 Machine Controls ...........................................................................................38
How to Remove the Steering Column.............................................................38
How to Remove the Steering Wheel...............................................................38
How to Remove the Steer Orbitral ..................................................................39
How to Remove the Joystick - Models with Single Joystick............................39
How to Remove the Joystick - Models with Dual Joysticks ............................40
How to Remove the Brake Pedal Assembly ...................................................40
How to Remove the Gauge Cluster Assembly................................................41
How to Remove the Diagnostic Display..........................................................41
Fuel and Hydraulic Tanks..................................................................................42
3-1 Fuel and Hydraulic Tanks...............................................................................42
Engines................................................................................................................43
4-1 Engines ..........................................................................................................43
How to Repair the Perkins 1104D-E44TA Engine ..........................................43
How to Repair the Deutz TCD3.6 Engine .......................................................43
How to Remove the Engine.............................................................................43
4-2 Engine Fault Codes........................................................................................44
Transmission ......................................................................................................45
5-1 Transmission..................................................................................................45
How to Repair the Transmission.....................................................................45
How to Remove the Transmission ..................................................................45

April 2018
Table of Contents
Part No. 1278145 TH-1056 ix
Hydraulic Pump..................................................................................................47
6-1 Hydraulic Pump..............................................................................................47
How to Test the Function Pump......................................................................47
How to Remove the Function Pump...............................................................48
How to Install the Function..............................................................................49
How to Prime the Function Pump...................................................................49
How to Adjust the Function Pump Standby Pressure.....................................50
How to Adjust the Function Pump Pressure Compensator ............................51
Manifolds.............................................................................................................54
7-1 Primary Function Manifold Components - Models with Single Joystick ........54
7-2 Primary Function Manifold Components - Models with Dual Joysticks.........58
7-3 Secondary Function Manifold Components...................................................62
7-4 Outrigger Manifold Components....................................................................64
7-5 Auxiliary Manifold Components (option)........................................................66
7-6 Brake Manifold Components..........................................................................67
7-7 AC Hydraulic Manifold Components..............................................................68
7-8 Valve Adjustments - Secondary Function Manifold .......................................69
How to Set the Steer System Pressure ..........................................................69
How to Set the Parking Brake System Pressure............................................70
How to Set the Differential Lock/Joystick System Pressure...........................71
How to Set the Rear Lock-up System Pressure.............................................72
7-9 Valve Coils .....................................................................................................73
Axle......................................................................................................................75
8-1 Axles ..............................................................................................................75
How to Remove the Axle ................................................................................75
How to Repair the Axle ...................................................................................75
Outriggers...........................................................................................................76
9-1 Outriggers ......................................................................................................76
How to Remove an Outrigger .........................................................................76
How to Remove an Outrigger Cylinder...........................................................77
Section 4 Fault Codes.........................................................................................................79
Introduction...........................................................................................................79
Diagnostic Display.............................................................................................80

April 2018
Table of Contents
x TH-1056 Part No. 1278145
Deutz TCD3.6 Engine Fault Codes....................................................................81
Perkins 1104 Engine Fault Codes...................................................................105
Section 5 Schematics........................................................................................................107
Introduction.........................................................................................................107
Proximity Switch Legend....................................................................................108
Fuse Panel Layout..............................................................................................109
Deutz TCD3.6 T4F Module.................................................................................110
Electrical Component & Wire Color Abbreviation Legend..................................111
Telematics Connector Pin Legend .....................................................................114
Electrical Symbol Legend...................................................................................116
Hydraulic Symbols Legend.................................................................................117
Electrical Schematics.......................................................................................119
Electrical Schematic (to GTH10E-11889) ..........................................................120
Electrical Schematic (from GTH10E-11890 to 12499).......................................124
Electrical Schematic (from GTH10E-12500)......... Error! Bookmark not defined.
Electrical Schematic- Deutz T4F Engine Harness .............................................131
Electrical Schematic- Deutz T3 Engine Harness................................................139
Hydraulic Schematics......................................................................................138
Hydraulic Schematic - Models with Single Joystick (to SN GTH10E-12499).....139
Hydraulic Schematic - Models with Dual Joystick (to SN GTH10E-12499) .......140
Hydraulic Schematic - Electronic Joystick (from SN GTH10E-12500)...........Error!
Bookmark not defined.
Hydraulic Schematic - Electronic Joystick (from SN GTH10E-12500)...............142