Terex Genie GTH1215M-101 Installation and operating manual

1.
Service and Repair Manual
Serial Number Range
GTH-1256 (Perkins Tier 4i) From GTH1215M-101 to
GTH1216M-249
GTH-1256 (Deutz Tier 4i)
From GTH12M-250 to
GTH12M-280
Part No. 1272856
Rev A1
September 2016
This manual includes:
Repair procedures
Fault Codes
Electrical and Hydraulic
Schematics
For detailed maintenance
procedures, Refer to the
appropriate Maintenance
Manual for your machine.
From GTH1215M-101 to
GTH1216M-249
From GTH12M-250 to
GTH12M-280

ii GTH-1256 Part No. 1272856
September 2016
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
1256 Operator's Manual before attempting any
maintenance or repair 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 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.
Contact Us:
http://www.genielift.com
e-mail: [email protected]
Introduction
Copyright © 2016 by Terex Industries
1272856 Rev A1 September 2016
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
Find a Manual for this Model
Go to http://www.genielift.com
Use the links to locate Operator's, Parts or Service
Manuals.

September 2016
Part No. 1272856 GTH-1256 iii
Revision Date Section Procedure / Page / Description
A 03/2016 Initial Release
A1 09/2016 Introduction Serial Number Legend
REFERENCE EXAMPLES:
Section 2_Specifications, Machine Specifications
Section 3_Repair Procedure, 3-2
Section 4_Fault Codes, 4-3
Section 5_Schematics, 5-3
Electronic Version
Click on any procedure or page number
highlighted in blue to view the update.
Revision History

iv GTH-1256 Part No. 1272856
September 2016
REVISION HISTORY, CONTINUED
Revision Date Section Procedure / Page / Description
REFERENCE EXAMPLES:
Section 2_Specifications, Machine Specifications
Section 3_Repair Procedure, 3-2
Section 4_Fault Codes, 4-3
Section 5_Schematics, 5-3
Electronic Version
Click on any procedure or page number
highlighted in blue to view the update.

September 2016
Part No. 1272856 GTH-1256 v
INTRODUCTION
Serial Number legend
6
5
5

vi GTH-1256 Part No. 1272856
September 2016
This page intentionally left blank.

September 2016
Part No. 1272856 GTH-1256 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-1256 Part No. 1272856
September 2016
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

September 2016
Part No. 1272856 GTH-1256 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
Perkins 1204E-E44TA Engine ................................................................2 - 6
Deutz TCD 4.1 L4 Engine.......................................................................2 - 7
Dana Integral Gear Box Shift on Fly.......................................................2 - 8
Dana Axle ...............................................................................................2 - 8
Hydraulic Hose and Fitting Torque Specifications ..................................2 - 9
Torque Procedure.................................................................................2 - 10
SAE and Metric Fasteners Torque Charts............................................ 2 - 11
Section 3 Repair Procedures
Introduction.............................................................................................3 - 1
Boom Components
1-1 Boom............................................................................................3 - 2
1-2 Boom Lift Cylinder......................................................................3 - 10
Table of Contents

x GTH-1256 Part No. 1272856
September 2016
TABLE OF CONTENTS
Section 3 Repair Procedures, continued
1-3 Boom Extend Cylinder ET.......................................................... 3 - 11
1-4 Fork Level Slave Cylinder FS.....................................................3 - 12
1-5 Fork Tilt Cylinder FF ...................................................................3 - 14
Operator's compartment
2-1 Operator’s Compartment............................................................3 - 15
2-2 Machine Controls .......................................................................3 - 17
Fuel and Hydraulic Tank
3-1 Fuel and hydraulic tank ..............................................................3 - 20
Engines
4-1 Engines ......................................................................................3 - 22
4-2 Engine Fault Codes....................................................................3 - 22
Transmission
5-1 Gearbox......................................................................................3 - 23
5-2 Axle ............................................................................................3 - 23
Hydraulic pumps
6-1 Boom and Steering Function Pump ...........................................3 - 25
6-2 Auxiliary Gear Pump ..................................................................3 - 30
6-3 Hydrostatic Transmission Pump.................................................3 - 33
Manifolds
7-1 Function Manifold.......................................................................3 - 37
7-2 Valve coils ..................................................................................3 - 44
Outriggers
8-1 Outriggers...................................................................................3 - 46