Terex Genie GTH1056 Installation and operating manual

Service and Repair Manual
Serial Number Range
GTH™-1056
from GTH10E-16000
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics
F
or detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
Part No. 1303145GT
Rev A
May 2021

Service and Repair Manual May 2021
Introduction
ii GTH™-1056 Part No. 1303145GT
Introducti on Introduction
Important Information
Important
Read, understand and obey the safety rules
and operating instructions in the appropriate
Operator's Manual on your machine before
attempting any procedure.
This manual provides troubleshooting and
repair procedures for qualified service
professionals.
Basic mechanical, hydraulic and electrical
skills are required to perform most procedures.
However, several procedures require
specialized skills, tools, lifting equipment and a
suitable workshop. In these instances, we
strongly recommend that maintenance and
repair be performed at an authorized Genie
dealer service center.
Compliance
Machine Design Life
Unrestricted with proper operation, inspection
and scheduled maintenance.
Technical Publications
Genie has endeavored to deliver the highest
degree of accuracy possible. However,
continuous improvement of our products is a
Genie policy. Therefore, product specifications
are subject to change without notice.
Readers are encouraged to notify Genie of
errors and send in suggestions for
improvement. All communications will be
carefully considered for future printings of this
and all other manuals.
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 © 2018 by Terex Corporation
1303145GT Rev A, May 2021
Fifth Edition, First Printing
Genie is a registered trademark of Terex South Dakota,
Inc. in the U.S.A. and many other countries.
"GTH" is a trademark of Terex South Dakota, Inc.

May 2021 Service and Repair Manual
Introduction
Part No. 1303145GT GTH™-1056 iii
Revision History
Revision Date Section Procedure / Page / Description
A 5/2021 Initial Release
Reference Examples:
Electronic Version
Click on any content or procedure in the Table of Contents to view
the update.
Section – Repair Procedure, 4-2
Section – Fault Codes, All charts
Section – Schematics, Legends and schematics

Service and Repair Manual May 2021
Introduction
iv GTH™-1056 Part No. 1303145GT
Serial Number Legend
1 Model
2 Facility code
3 Sequence number
4 Serial label (located inside fork frame)
5 Serial number (stamped on chassis)
6 Serial label (located inside chassis)

May 2021 Service and Repair Manual
Safety Rules
Part No. 1303145GT GTH™-1056 v
Section 1 Safety Rul es GeneralSaf ety Rules
Danger
Failure to obey the instructions and safety rules in
this manual and the appropriate Operator's Manual
on your machine will result in death or serious
injury.
Many of the hazards identified in the operator's
manual are also safety hazards when
maintenance and repair procedures are
performed.
Do not modify or alter a Telehandler without prior
written permission from the manufacture.
Do Not Perform Maintenance
Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
•manufacturer's instructions and safety rules
•employer's safety rules and worksite
regulations
•applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.

Service and Repair Manual May 2021
Safety Rules
vi GTH™-1056 Part No. 1303145GT
Workplace Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Be sure to keep sparks, flames and
lighted tobacco away from flammable and
combustible materials like battery
gases
and engine fuels. Always have an
approved fire extinguisher within easy
reach.
Be sure that all tools and working areas
are properly maintained and ready for
use. Keep work surfaces clean and free
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 goo
d condition and of
ample capacity.
Be sure t
hat fasteners intended for one
time use (i.e., cotter pins and self
-locking
nuts) are not reused. These components
may fail if they are used a second time.
Be sure to properly dispose of old oil or
other fl
uids. Use an approved container.
Please be
environmentally safe.
Be sure that your workshop or work area
is properly ventilated and well lit.

May 2021
Table of Contents
Part No. 1303145GT GTH™-1056 vii
Introduction Introduction...........................................................................................................ii
Important Information ............................................................................................. ii
Find a Manual for this Model .................................................................................. ii
Serial Number Legend .......................................................................................... iv
Section 1 Safety Rules..........................................................................................................v
General Safety Rules ............................................................................................. v
Section 2 Specifications .......................................................................................................1
Machine Specifications...........................................................................................1
Performance Specifications....................................................................................2
Hydraulic Oil Specifications....................................................................................2
Hydraulic Component Specifications .....................................................................6
Manifold Component Specifications.......................................................................7
Air Conditioner Refrigerant Specifications .............................................................7
DEF Storage Specifications ...................................................................................7
Deutz TCD3.6 120HP T4F Engine Specifications..................................................8
Deutz TCD3.6 L4 T4F Engine Specifications.........................................................9
Deutz TCD3.6 ROW Engine Specifications .........................................................10
ZF 4 WG-98 TSC Transmission Specifications....................................................11
ECOMEC CVT 150 Transmission Specifications.................................................11
Dana VDT12000 Transmission Specifications.....................................................12
Dana Planetary Drive Axle Specifications (223_212HY) .....................................12
Hydraulic Hose and Fitting Torque Specifications ...............................................13
Torque Procedure ................................................................................................14

May 2021
Table of Contents
viii GTH™-1056 Part No. 1303145GT
Section 3 Repair Procedures ............................................................................................. 15
Introduction .......................................................................................................... 15
Boom Components............................................................................................ 17
1-1 Boom Proximity Switch .................................................................................. 17
How to Test a Proximity Switch ...................................................................... 17
How to Adjust the Boom Angle Proximity Switch ........................................... 18
How to Adjust the Boom Extend Proximity Switch ......................................... 18
1-2 Boom.............................................................................................................. 19
How to Replace the Boom Wear Pads ........................................................... 19
How to Remove the Lifting Fork Frame.......................................................... 19
How to Remove and Install the Cable Track Assembly.................................. 20
How to Replace the Retract Chains................................................................ 25
How to Replace the Extend Chain.................................................................. 28
How to Remove the Boom.............................................................................. 30
How to Disassemble the Boom....................................................................... 32
1-3 Boom Lift Cylinder ......................................................................................... 35
1-4 Boom Extension Cylinder .............................................................................. 36
1-5 Fork Level Cylinder........................................................................................ 37
1-6 Hydraulic Hoses............................................................................................. 38
How to Replace the Fork Level and/or Auxiliary Cylinder Hoses ................... 38
Operator's Compartment................................................................................... 40
2-1 Operator's Compartment ............................................................................... 40
2-2 Machine Controls........................................................................................... 41
How to Remove the Steering Column ............................................................ 41
How to Remove the Steering Wheel .............................................................. 42
How to Remove the Steer Orbitral.................................................................. 42
How to Remove the Joystick - Models with Electronic Joystick ..................... 43
How to Remove the Brake Pedal Assembly................................................... 43
How to Remove the Gauge Cluster Assembly ............................................... 44

May 2021
Table of Contents
Part No. 1303145GT GTH™-1056 ix
Fuel and Hydraulic Tanks..................................................................................45
3-1 Fuel and HydraulicTanks ...............................................................................45
Engines................................................................................................................47
4-1 Engines ..........................................................................................................47
How to Repair the Deutz TCD3.6 Engine .......................................................47
4-2 Engine Fault Codes........................................................................................47
Transmission ......................................................................................................48
5-1 Transmission..................................................................................................48
How to Repair the Transmission.....................................................................48
Hydraulic Pump ..................................................................................................49
6-1 Hydraulic Pump..............................................................................................49
How to Test the Function Pump......................................................................49
How to Remove the Function Pump ...............................................................50
How to Install the Function Pump ...................................................................51
How to Prime the Function Pump ...................................................................51
How to Adjust the Function Pump Standby Pressure.....................................52
How to Adjust the Function Pump Pressure Compensator ............................53
Manifolds.............................................................................................................55
7-1 PVG Manifold .................................................................................................55
7-2 Secondary Function Manifold Components...................................................56
7-3 Brake Manifold Components..........................................................................58
7-4 Valve Adjustments - Secondary Function Manifold .......................................59
How to Set the Parking Brake System Pressure ............................................59
How to Set the Rear Lock-up System Pressure .............................................60
7-5 Valve Coils .....................................................................................................61
Axle ......................................................................................................................63
8-1 Axles...............................................................................................................63
How to Repair the Axle ...................................................................................63
Outriggers ...........................................................................................................64
9-1 Outriggers.......................................................................................................64
How to Remove an Outrigger..........................................................................64
How to Remove an Outrigger Cylinder ...........................................................65

May 2021
Table of Contents
x GTH™-1056 Part No. 1303145GT
Section 4 Fault Codes......................................................................................................... 67
Introduction .......................................................................................................... 67
Diagnostic Display............................................................................................. 68
Diagnostic Display ............................................................................................... 68
Deutz TCD3.6 Engine Fault Codes ................................................................... 69
ECGenius 150 Transmission Fault Codes....................................................... 93
Section 5 Schematics ......................................................................................................... 94
Introduction .......................................................................................................... 94
Proximity Switch Legend...................................................................................... 95
Fuse Panel Layout (120HP & ROW Engine) ....................................................... 96
Fuse Panel Layout (74HP Engine with CVT Transmission) ................................ 97
Deutz TCD3.6 T4F Module .................................................................................. 98
Electrical Component & Wire Color Abbreviation Legend ................................... 99
Electrical Symbol Legend .................................................................................. 102
Hydraulic Symbols Legend ................................................................................ 103
Electrical Schematics ...................................................................................... 105
Electrical Schematic - Deutz T4F 74HP CVT .................................................... 106
Electrical Schematic - Deutz T4F HP CVT Transmission.................................. 107
Electrical Schematic - Deutz T4F 74HP Engine Harness.................................. 110
Electrical Schematic - Options Deutz T4F 74HP ............................................... 111
Electrical Schematic - Deutz T4F 74HP DANA ................................................. 114
Electrical Schematic - Deutz T4F 74HP DANA Engine Harness....................... 115
Electrical Schematic - Options Deutz T4F 74HP DANA.................................... 118
Electrical Schematic - Deutz T3/T4F 120HP ZF................................................ 119
Base Engine ECM Schematic - Deutz T4F 120HP ZF ...................................... 122
Engine ECM Schematic - Deutz T3 120HP ZF.................................................. 123
EAT ECM Schematic - Deutz T4F 120HP ZF.................................................... 126
EAT ECM VEC Schematic - Deutz T4F 120HP ZF ........................................... 127
Schematic - Options Deutz T3/T4F 120HP ZF .................................................. 130
Hydraulic Schematics...................................................................................... 131
Hydraulic Schematic .......................................................................................... 132