Terex Genie GTH-2506 AU.3 User manual

GTH-2506 AU.3
GTH-4014 AU
GTH-4018 AU
Part No. 57.4400.9218
Rev A
October 2015
From GTH250614-101
Serial Number Range
From GTH401414-101
Load Management System Service Manual
From GTH401814-101

ii LMS Service Manual Part No. 57.4400.9218
October 2015
Important
Read, understand and obey the safety rules and
operating instructions in the Genie GTH-2506 AU.3
Operator's Manual and Genie GTH-4014/4018 AU
Operator's Manual before attempting any procedure
described in this manual.
This manual provides detailed Load Management
System (LMS) setup and conguration information
for the machine owner and user. It also provides
LMS service, repair and calibration procedures for
service technicians.
It is a requirement that the persons carrying out
service on the LMS are familiar with and have
experience in telehandler operation, limitations
and functionality. Therefore, it is recommended that
LMS service, repair and calibration 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 specications 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:
Terex Australia Pty Ltd
33 Kimberley St
Darra QLD 4076
Parts and Service Support
1800 331 660
Introducon
Copyright © 2015 by Terex Corporation
57.4400.9218 Rev A October 2015
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

October 2015
Part No. 57.4400.9218 LMS Service Manual iii
REVISION DATE SECTION PROCEDURE / SCHEMATIC PAGE /
DESCRIPTION
A 10/2015 Initial Release
REFERENCE EXAMPLES:
Electronic Version
`Click on any procedure or page number
highlighted in blue to view the update.
Revision History

iv LMS Service Manual Part No. 57.4400.9218
October 2015
REVISION HISTORY
REVISION DATE SECTION PROCEDURE / SCHEMATIC PAGE /
DESCRIPTION
REFERENCE EXAMPLES:
Electronic Version
Click on any procedure or page number
highlighted in blue to view the update.

October 2015
Part No. 57.4400.9218 LMS Service Manual v
Serial Label
Serial number
(stamped on
chassis)
Serial label
A TEREX BRAND
Model:
GTH-2506
Model Year: 2014
Designation:
ROUGH TERRAIN VARIABLE REACH TRUCK
Serial Number: GTH401414B-Xxxxx
Manufacture Date: DD/MM/YY
Mass: 22542 lbs / 10225 kg
Rated Capacity: 4000 kg
Nominal Power: 75 kW
Max drawbar pull provided for all the coupling hook:
30000 N
Max vertical load provided for all the coupling hook:
10000 N
Country of Manufacture: ITALY
Manufacturer:
TEREX Global GmbH
Mühlenstrasse 26
Switzerland
GTH-4014 14 xxxxx-
Model
Year of
manufacture
Sequence
number
Facility code
B
A TEREX BRAND
Model:
GTH-4014
Model Year: 2014
Designation:
ROUGH TERRAIN VARIABLE REACH TRUCK
Serial Number: GTH401414B-Xxxxx
Manufacture Date: DD/MM/YY
Mass: 22542 lbs / 10225 kg
Rated Capacity: 4000 kg
Nominal Power: 75 kW
Max drawbar pull provided for all the coupling hook:
30000 N
Max vertical load provided for all the coupling hook:
10000 N
Country of Manufacture: ITALY
Manufacturer:
TEREX Global GmbH
Mühlenstrasse 26
Switzerland
Serial Number Legend:
SERIAL NUMBER LEGEND

vi LMS Service Manual Part No. 57.4400.9218
October 2015
A TEREX BRAND
Model:
GTH-2506
Model Year: 2014
Designation:
ROUGH TERRAIN VARIABLE REACH TRUCK
Serial Number: GTH250614B-Xxxxx
Manufacture Date: DD/MM/YY
Mass: TBA lbs / TBA kg
Rated Capacity: 2500 kg
Nominal Power: TBA kW
Max drawbar pull provided for all the coupling hook:
TBA N
Max vertical load provided for all the coupling hook:
TBA N
Country of Manufacture: ITALY
Manufacturer:
TEREX Global GmbH
Mühlenstrasse 26
Switzerland
SERIAL NUMBER LEGEND

October 2015
Part No. 57.4400.9218 LMS Service Manual 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 identied 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qualiedtoperformmaintenanceon
thismachine.
You read, understand and obey:
- Manufacturer’sinstruconsandsafetyrules
- Employer’ssafetyrulesandworksiteregulaons
- Applicablegovernmentalregulaons
 Youhavetheappropriatetools,liingequipmentanda
suitableworkshop.
SafetyRules

viii LMS Service Manual Part No. 57.4400.9218
October 2015Section 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:
DANGER
WARNING
CAUTION
NOTICE
Workplace Safety
Safety alert icon—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this icon
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.
Be sure to keep sparks, ames and
lighted tobacco away from ammable
and combustible materials like battery
gases and engine fuels. Always have an
approved re 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 uids. Use an approved container.
Please be environmentally safe.
Be sure that your workshop or work area
is properly ventilated and well lit.
SAFETY RULES

October 2015
Part No. 57.4400.9218 LMS Service Manual ix
Table of Contents
Introduction
Important Information ........................................................................... ii
Revision History................................................................................... iii
Serial Number Legend..........................................................................v
Section 1 Safety Rules
General Safety Rules ......................................................................... vii
Section 2 LMS Components
Description.........................................................................................2-1
Electronic Control Unit (ECU)............................................................2-2
Display Unit .......................................................................................2-2
Pressure Transducers .......................................................................2-3
Angle/Length Sensor.........................................................................2-3
Chassis Angle Sensor .......................................................................2-4
iButton Reader and Converter...........................................................2-4
Section 3 Functional Description
Introduction........................................................................................3-1
LMS - Machine interaction.................................................................3-1
LMS - Operator Interaction................................................................3-2
Software ............................................................................................3-2
GTH Operator Access Manager .......................................................3-3
User Access Levels ...........................................................................3-3
Access Methods ................................................................................3-6
Section 4 Procedures
System Update ('.WBPKG' file) .........................................................4-1
Configuring Available Options ...........................................................4-3
Enabling Login Access ......................................................................4-4
Enabling iButton Access....................................................................4-5
Enabling Front or Rear Cameras.......................................................4-6
Enabling 3000 kg Limit ......................................................................4-7

x LMS Service Manual Part No. 57.4400.9218
October 2015
TABLE OF CONTENTS
Checking ECU Inputs ........................................................................4-8
Checking/Forcing ECU Outputs ........................................................4-9
Viewing Active Alarms and Warnings ..............................................4-10
Viewing, exporting and deleting Alarm/Warning History..................4-12
Uploading ECU Software to Display Unit ('.MOT' file).....................4-14
Downloading ECU Software from Display Unit to ECU...................4-15
Importing Parameter Set to Display Unit .........................................4-16
Sending Parameter Set from Display Unit to ECU ..........................4-17
Sending Parameter Set from ECU to Display Unit ..........................4-18
Exporting Parameter Set from the Display Unit to USB Flash
Drive ................................................................................................4-19
Minimum access level required: 2 ...................................................4-19
Manually Changing Individual ECU Parameters .............................4-20
Reset Parameter Set to Factory Defaults.......................................4-22
Download Load Charts to ECU .......................................................4-23
To Replace the ECU........................................................................4-24
To Replace the Display Unit ............................................................4-25
To Replace the Boom Length/Angle Sensor ...................................4-26
To Replace the Chassis Angle Sensor. ...........................................4-27
To Replace a Pressure Transducer .................................................4-28
To Install the iButton Reader ...........................................................4-29
To Replace the iButton Reader or iButton Converter ......................4-31
Section 5 Calibration
Chassis Angle Sensor Calibration .....................................................5-1
Boom Length Sensor Calibration.......................................................5-3
Boom Angle Sensor Calibration.........................................................5-4
Weight Calibration .............................................................................5-5
Joystick Calibration - Fork Tilt (X) Axis ..............................................5-7
Joystick Calibration - Boom Raise/Lower (Y) Axis.............................5-8

October 2015
Part No. 57.4400.9218 LMS Service Manual xi
TABLE OF CONTENTS
Joystick Calibration - Boom Telescope (Z) Axis.................................5-9
Section 6 Alarms and Warnings
Getting Started ..................................................................................7-1
Section 7 GTH Operator Access Manager
Creating a Project..............................................................................7-3
Creating Operator Lists .....................................................................7-6
Adding Individual Operators to a Project.........................................7-12
Creating a '.WBPKG' Package File .................................................7-14
Web Users.......................................................................................7-16
Section 8 iButton User Manager
iButton User Manager Application .....................................................8-1
Configuring an iButton.......................................................................8-1
Section 9 Troubleshooting
Troubleshooting Guide ......................................................................9-1

xii LMS Service Manual Part No. 57.4400.9218
October 2015
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TABLE OF CONTENTS

October 2015
Part No. 57.4400.9218 LMS Service Manual 2-1
Section 2 • LMS Components
Description
The Load Management System (LMS) is a safety
system primarily designed to prevent further
aggravating motion of the telehandler during the
lifting cycle. The LMS uses information collected
from various sensors to constantly monitor machine
stability condition against rated capacities specied
in load charts. During and overload event, the LMS
restricts further aggravating motion of the load by
disabling boom raise/lower, boom extend and tilt
attachment forward. Apart from monitoring load
and machine geometry, the LMS also integrates
other aspects of machine operation such as valve
bank control, joystick operation and operator
access management. LMS functionality includes
the following:
■Rated capacity limiter
■Dynamic load chart
■Attachment selection and management
■Boom control
■Outrigger control
■Display Diagnostic/debugging information
■Operator access management
■Human Machine Interface (HMI)
An electronic control unit (ECU) is used to control
and monitor boom, outrigger and chassis tilt
functions. It collects information from sensors
and hydraulic control valves, which is then used
to control and monitor boom movement. This
information is shared between the ECU and display
unit via CAN line. Communication between the ECU
and machine components is two-way, this allows
constant monitoring of all components connected to
the ECU. This section contains a short description
of the main hardware components which make up
the LMS.
LMSComponents

2-2 LMS Service Manual Part No. 57.4400.9218
October 2015Section 2 • LMS Components
ECU LMS Display unit
LMS COMPONENTS
Display Unit
This unit is located inside the cab. There are two
versions of the display units available: standard
and enhanced version. Both models offer the same
functionality, however the enhanced display unit
has extra USB and camera ports. An enhanced
display is required when either an ibutton reader
or front camera are installed
Electronic Control Unit (ECU)
The ECU is located inside the cab behind the seat.

October 2015
Part No. 57.4400.9218 LMS Service Manual 2-3
Section 2 • LMS Components
LMS COMPONENTS
Pressure transducers
Boom angle/length sensor
Pressure Transducers
Two pressure transducers are located in the lift
cylinder.
Two pressure transducers are located in the fork
cylinder.
The Pressure transducers output a 4 - 20 mAsignal.
Angle/Length Sensor
The boom length and angle sensors are integrated
into a single unit installed on the side of the boom.
The boom length and angle sensors output a 4 -
20 mA signal.

2-4 LMS Service Manual Part No. 57.4400.9218
October 2015Section 2 • LMS Components
Chassis Angle Sensor
The chassis angle sensor is located under the
chassis cover, near the cabin.
The chassis angle sensor outputs a 2.5 ± 2 V signal
for each axis (X and Y).
LMS COMPONENTS
Chassis angle sensor iButton and iButton reader
iButton Reader and Converter
The optional iButton reader is located in the interior
panel near the joystick. The iButton reader is
connected to the display unit through an iButton
converter located behind the fuse/relay board.
iButton converter

October 2015
Part No. 57.4400.9218 LMS Service Manual 3-1
Section 3 • Functional Description
FunconalDescripon
Introduction
The LMS measures lift and levelling cylinder
hydraulic pressure, and machine geometry to
provide an estimate of the actual load being lifted.
This estimated load is then compared against
machine rated capacity determined from stored
load charts. De-stabilising boom functions are
disabled if the actual load exceeds the rated
capacity of the machine for the given machine
conguration.
Operation of the LMS is setup and congured by:
■ECU software
■Load charts
■User access permissions
■Parameter set
LMS - Machine interaction
The LMS is an integral part of the machine. Most
machine functions are either monitored or managed
by the ECU, or both. Sensors, buttons, switches
and feedback signals from hydraulic valves are
connected to the ECU to provide information about
the machine status. The ECU utilises this information
to assess the condition of various components and
determine if the machine is functioning as it should
be. The ECU also manages various components
such as boom movements, outriggers, and engine
based on the inputs received.
The following gure shows a basic representation
DISPLAY
UNIT
ECU ENGINE
INPUTS
CAN
CAN
Boom angle/length sensor
4 - 20 mA
Pressure transducers
4 - 20 mA
Chassis tilt sensor
0.5 - 4.5 vdc
Joystick
0.5 - 4.5 vdc
Rear camera
VIDEO
DIGITAL INPUTS:
■Outrigger sensors
■ Operator seat sensor
■ Steering mode selector
■ Boom max. angle limit switch
■ Chassis tilt switch
■ LMS override key switch
■ Outrigger switch RH
■ Otrigger switch LH
■ Parking brake ON sensor
■ Wheels aligned sensor
■ Transmission control lever
position sensor
■ Job/Site/Platform switch
OUTPUTS
Boom functions manifold
(PVG)
Chassis levelling
(PWM)
DIGITAL OUTPUTS:
■Christmas tree lights (optional)
■ LMS Audible alarm
■ Dashboard warning light
■ Transmission enable signal
■ Steering mode output
■ Rear axle lock/unlock
USB
Oturiggers
(PWM)
iButton reader
(Optional)
Front camera
(Optional)
LOAD MANAGEMENT SYSTEM COMPONENT CONNECTION
DIAGRAM

3-2 LMS Service Manual Part No. 57.4400.9218
October 2015Section 3 • Functional Description
FUNCTIONAL DESCRIPTION
of how the LMS interacts with the machine.
The display unit is the interface between the
machine and the operator; it connects to the ECU
via a CAN network. Changes to ECU software,
load charts, operator access permissions and
parameter set are uploaded to the display unit
using an USB ash drive via the USB port. A video
input port is located at the back of the display unit
to connect the rear camera; the enhanced display
has an extra video input to connect an optional front
camera. The ECU uses a dedicated CAN network
to manage the engine. Analogue (voltage, current)
and digital inputs, digital (digital output high side,
digital output low side) and pulse width modulation
(PWM) outputs are used to manage the rest of the
machine components.
Feedback signals from sensors and hydraulic
valves are connected to the ECU to monitor the state
of such components. The ECU then reports faults
via the display unit to assist operators and service
technicians with troubleshooting the machine.
LMS - Operator Interaction
The operator interacts with the LMS via the display
unit. This graphical interface relates information
to the operator such as stability condition of
the machine, faults, attachment selection and
outrigger position (if equipped). It is also used to
perform advanced procedures such calibration,
troubleshooting and configuring user access
permissions.
Primary and secondary home screens provide
information to the operator about machine
operation. The operator is able to monitor machine
status via these screens; a warning/fault alarm is
displayed in the home screen to alert the operator
of a problem with the machine. The display unit is
also tted with an audible alarm used to alert the
operator when the telehandler is approaching its
maximum rated capacity or there is a hardware fault
in the machine. See LMS operating instructions in
telehandler Operator's Manual for details on how
to navigate through the display unit menus.
Advanced operations reserved for maintenance
personnel are also performed via the display
unit. The display unit can be used to calibrate the
machine, perform troubleshooting operations via
accessing faults and warning pages, update ECU
software, upload load charts, modify machine
parameters and update user access permissions.
Software
It is possible to update all LMS software, setup and
conguration data by using an USB ash drive to
upload data via the display unit. ECU software,
load charts and user permissions are contained
in a single package le (extension '.WBPKG').
Uploading software and modifying parameters
can only be performed by users with access level
2 or higher.
ECU software is specic to each machine model.
For example, GTH-2506AU.3 ECU software cannot
be uploaded into a GTH-4014 AU telehandler.
Each machine is hardware coded to prevent
inadvertent upload of ECU software onto incorrect
machine model. During ECU software upload, the
system runs a consistency check between the
machine's ECU and display unit; software cannot
be downloaded into the ECU unless the consistency
check returns a positive result.
The load charts contain geometry and rated
capacity information for all attachments which are
compatible with the particular machine model.
The parameter set is a single le (extension '.DB3')
which contains machine specic data such as
function speeds, calibration data and machine
geometry data. The parameter set is specic to
each machine model and must not be uploaded
to incorrect machine model.

October 2015
Part No. 57.4400.9218 LMS Service Manual 3-3
Section 3 • Functional Description
User access permissions are managed via the
display unit and are used to prevent unauthorised
use of the machine. When combined with the
optional iButton reader, registered users are
permitted to operate the machine after rst placing
the iButton on the iButton reader. If the machine
is not equipped with an iButton reader and Login
Access is enabled, users must log in via the display
unit by entering a 4-digit pin.
GTH Operator Access Manager
The GTH Operator Access Manager (GOAM) is a
web based application used to manage user access
permissions for the LMS. The web application is
accessible from the internet using a web browser.
The application currently supports Mozilla Firefox or
Google chrome. The web application allows dealers
and customers to manage users and attachments
by creating their own '.WBPKG' package les
containing user access and attachment permissions
relevant to their site/usage. See Section 7: GTH
Operator Access Manager for detailed instruction
on how to use the GOAM.
User Access Levels
The LMS is set up with different user access levels
which prevent unauthorised modication of LMS
setup or conguration. There are ve different
access levels depending on user role:
LEVEL USER ROLE
0Operator: Personnel whose task is to
operate the machine.
2Maintenance: Personnel who carry out
regular maintenance.
3Dealer: Customer’s service technicians
able to carry out advanced operations
such as software update.
4Service: Terex service technicians
with the ability to carry out advanced
operations.
5Manufacturer: Terex engineers with
the ability to change both, software
and hardware machine setup.
The following table lists all LMS menu pages and
items with their respective access levels.
Table legend:
MMenu
LLeaf
FUNCTIONAL DESCRIPTION

3-4 LMS Service Manual Part No. 57.4400.9218
October 2015Section 3 • Functional Description
FUNCTIONAL DESCRIPTION
Description Level
M Home Menu 1st Stage menu ◌0
M Work Work menu ◌0
L Attachments Attachment selection 0
L Cameras Camera menu 0
L Front camera Front camera images and present status 0
L Rear camera Rear camera images and present status 0
L Camera settings Camera settings 0
L Rear camera Auto Enables rear camera when transmission lever
is set in the reverse position
0
L Front camera Auto Enabler front camera when transmission lever
is set in the forward position
0
LLoad chart when boom moving Allows load chart to be displayed when the
boom is moving and transmission control lever
is set in reverse position
0
F Mute Mute audible alarm (→) 0
M Alarms Alarms menu ◌0
LActive Alarms View list of active alarms 0
L Active Warnings View list of active warnings 0
M Alarm History Historical alarms menu ◌2
F USB export Export alarms and warnings to USB (→) 2
L View alarms View list of alarm history 2
F Erase alarms Erase alarm history (→) 4
L View warnings View list of warnings history 2
F Erase warnings Erase warnings history (→) 4
M Display Display setting menu ◌0
L Brightness Adjust screen brightness 0
L Language Change display language 0
LDate / Time Change date / time 2
L IP address Change display IP address 2
L Information Display system information 0
L Selected options View currently selected options 0
M Maintenance Maintenance menu ◌2
L Options Select / remove available options 2
M ECU Electronic control unit menu ◌2
L Check input Check ECU input signals 2
L Check output Check, force ECU output signals 2