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