Genie GTH-5519 Service And Repair Manual
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Genie GTH-5519 Service And Repair Manual

Deutz tier 4i
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See also: Maintenance Manual
1.
Service and Repair Manual
GTH-5519
Serial Number Range
(Deutz Tier 4i)
From GTH5514B-101
From GTH5516M-4411
to GTH5516M-5799
From GTH55M-5800
to GTH5516B-4410
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. 1272852
Rev A1
September 2016

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Summary of Contents for Genie GTH-5519

  • Page 1 Service and Repair Manual Serial Number Range This manual includes: GTH-5519 (Deutz Tier 4i) Repair procedures From GTH5514B-101 to GTH5516B-4410 Fault Codes From GTH5516M-4411 Electrical and Hydraulic to GTH5516M-5799 Schematics From GTH55M-5800 For detailed maintenance procedures, Refer to the appropriate Maintenance Manual for your machine.

  • Page 2: Introduction

    Genie has endeavored to deliver the highest operating instructions in the Genie GTH-5519 degree of accuracy possible. However, continuous Operator's Manual before attempting any improvement of our products is a Genie policy. maintenance or repair procedure. Therefore, product specifications are subject to change without notice.

  • Page 3: Revision History

    Serial Number Legend REFERENCE EXAMPLES: Electronic Version Section 2_Specifi cations, Machine Specifi cations Section 3_Repair Procedure, 3-2 Click on any procedure or page number Section 4_Fault Codes, 4-3 highlighted in blue to view the update. Section 5_Schematics, 5-3 Part No. 1272852 GTH-5519...

  • Page 4: Gth-5519

    Procedure / Page / Description REFERENCE EXAMPLES: Electronic Version Section 2_Specifi cations, Machine Specifi cations Section 3_Repair Procedure, 3-2 Click on any procedure or page number Section 4_Fault Codes, 4-3 highlighted in blue to view the update. Section 5_Schematics, 5-3 GTH-5519 Part No. 1272852...

  • Page 5: Serial Number Legend

    September 2016 INTRODUCTION Serial Number legend Part No. 1272852 GTH-5519...

  • Page 6: Gth-5519

    September 2016 This page intentionally left blank. GTH-5519 Part No. 1272852...

  • Page 7: Safety Rules

    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. Part No. 1272852 GTH-5519...

  • Page 8: Gth-5519

    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. viii GTH-5519 Part No. 1272852...

  • Page 9: Table Of Contents

    Section 3 Repair Procedures Introduction .....................3 - 1 Boom Components Boom ....................3 - 2 Boom Lift Cylinder ................3 - 6 Boom Extend Cylinder..............3 - 7 Fork Level Cylinder ..............3 - 8 Fork Tilt Cylinder ................3 - 9 Part No. 1272852 GTH-5519...
  • Page 10 Manifolds Function Manifold ...............3 - 30 Valve Coils .................3 - 34 Section 4 Fault Codes Introduction .....................4 - 1 Diagnostic Display ..................4 - 2 Engine Fault Codes - Models with Deutz TD 2.9 L4.......4 - 3 GTH-5519 Part No. 1272852...

  • Page 11: Gth-5519

    September 2016 TABLE OF CONTENTS Section 5 Schematics Introduction .....................5 - 1 Electrical and Hydraulic Symbol Legends ..........5 - 2 Electrical Schematic ................5 - 3 Hydraulic Schematic ................5 - 27 Part No. 1272852 GTH-5519...

  • Page 12: Part

    September 2016 TABLE OF CONTENTS This page intentionally left blank. GTH-5519 Part No. 1272852...

  • Page 13: Specifi Cations

    400 Nm Lug pattern 8 x 10.827 Wheel diameter 32.3 in 820 mm Wheel width 12.3 in 313 mm Continuous improvement of our products is a Genie policy. Product specifi cations are subject to change without notice. Part No. 1272852 GTH-5519...

  • Page 14: Performance Specifications

    4173 kg Fork tilt up 4 seconds Lift capacity, maximum 5500 lbs 2500 kg Fork tilt down 3 seconds Continuous improvement of our products is a Genie policy. Product specifi cations are subject to change without notice. GTH-5519 Part No. 1272852...

  • Page 15: Hydraulic Specifications

    Genie specifications require additional equipment and special installation instructions for the approved optional fluids. Consult the Genie Service Department before use. Continuous improvement of our products is a Genie policy. Product specifi cations are subject to change without notice. Part No. 1272852 GTH-5519...

  • Page 16: Hydraulic Components Specifications

    3915 psi (measured at test port TP2) (measured at test port TP1) 270 bar Continuous improvement of our products is a Genie policy. Product specifi cations are Hydrostatic Transmission Pump subject to change without notice. Type: variable displacement piston pump Displacement 0 to 2.75 cu in...

  • Page 17: Function Manifold Specifications

    (measured at test port TP3) 270 bar Air Conditioner Refrigerant Specifi cations System Full Charge R134a 750 g 1 lbs 10 oz Continuous improvement of our products is a Genie policy. Product specifi cations are subject to change without notice. Part No. 1272852 GTH-5519...

  • Page 18: Deutz Td 2.9 L4 Engine

    For oil requirements, refer to the Engine Operation and Maintenance Manual on your machine. Continuous improvement of our products is a Genie policy. Product specifi cations are subject to change without notice. GTH-5519 Part No. 1272852...

  • Page 19: Comer Axle

    For additional axle information, refer to the Comer Axle S128 Service Manual Comer Axle Service Manual Genie part number 57.4700.0020 Continuous improvement of our products is a Genie policy. Product specifi cations are subject to change without notice. Part No. 1272852 GTH-5519...

  • Page 20: Hydraulic Hose And Fitting Torque Specifications

    Your machine is equipped with Parker Seal-Lok™ ORFS or 37° JIC fittings and hose ends. 14 ft-lbs / 19 Nm Genie specifications require that fittings and hose 23 ft-lbs / 31.2 Nm ends be torqued to specification when they are 36 ft-lbs / 54.2 Nm...

  • Page 21: Torque Procedure

    3 Working clockwise on the body hex fitting, They are not standard SAE size O-rings. They are make a second mark with a permanent ink available in the O-ring field service kit (Genie part marker to indicate the proper tightening number 49612).
  • Page 22 34. 1 48. 6 64. 9 69. 7 94. 5 92. 2 30. 1 40. 8 54. 3 77. 4 46. 9 63. 6 62. 5 84. 8 64. 5 87. 5 86. 2 1055 1233 2-10 GTH-5519 Part No. 1272852...

  • Page 23: Repair Procedures

    Be sure that all necessary tools and parts are serious injury. available and ready for use. Indicates a potentially hazardous WARNING Use only Genie approved replacement parts. situation which, if not avoided, could result in death or serious Read each procedure completely and adhere injury.

  • Page 24: Boom Components

    7 Using the overhead crane, lift and remove the tighten the retainer plates. Do not over tighten. fork frame from the boom. Crushing hazard. The fork CAUTION frame could fall if not properly supported when the lock pin is removed from the machine. GTH-5519 Part No. 1272852...
  • Page 25 7 Using a soft metal drift, remove the slave cylinder locking pin from the boom support. Crushing hazard. The cylinder DANGER will fall if not properly supported when the pivot pin is removed from the machine. Part No. 1272852 GTH-5519...
  • Page 26 Repair Procedure 1-1, How to Remove the How to Remove the Boom Boom. . 2 Remove the lifting fork frame. Refer to Repair Procedure 1-1, How How to Remove the Lifting Fork Frame. GTH-5519 Part No. 1272852...
  • Page 27 12 Once removed, place the second boom Once removed, place the second boom sections on a stand suitably positioned. sections on a stand suitably positioned. Part No. 1272852 GTH-5519...

  • Page 28: Boom Lift Cylinder

    Attach a lifting strap from an overhead crane to the rod end of the lift cylinder. Support the to the rod end of the lift cylinder. Support the cylinder. Do not apply any lifting pressure. cylinder. Do not apply any lifting pressure. GTH-5519 Part No. 1272852...

  • Page 29: Boom Extend Cylinder

    7 Partially pull the cylinder out. Using a lifting strap and an overhead crane, remove the cylinder. Crushing hazard. The cylinder DANGER could fall if not properly supported when removed from the machine. Part No. 1272852 GTH-5519...

  • Page 30: Fork Level Cylinder

    Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Component damage hazard. NOTICE Hoses can be damaged if they are kinked or pinched. GTH-5519 Part No. 1272852...

  • Page 31: Fork Tilt Cylinder

    5 Using a lifting strap and an overhead crane, support the cylinder. 11 Carefully lift and remove the cylinder from the machine. Crushing hazard. The cylinder DANGER could fall if not properly supported when removed from the machine. Part No. 1272852 GTH-5519...
  • Page 32 5 5 Remove screws " Remove screws "a a " and pull out bracket " " and pull out bracket "b b " " from the rear side of the boom. from the rear side of the boom. 3-10 GTH-5519 Part No. 1272852...
  • Page 33 19 Start the engine, and extend and retract the Start the engine, and extend and retract the squirt or spray. boom. Verify that there are no abnormal boom. Verify that there are no abnormal tensions on the hoses. tensions on the hoses. Part No. 1272852 GTH-5519 3-11...

  • Page 34: Operator's Compartment

    For further information or assistance, consult the gradually. Do not allow oil to Genie Service Department. squirt or spray. Bodily injury hazard. This WARNING 6 Tag, disconnect and plug the heater lines (n.2 procedure requires specific hoses).
  • Page 35 Do not lift the cab using a strap from an overhead crane. Bolt torque specifi cation Operator's cab mounting bolts 155 ft-lbs 210 Nm (plus Locktite compound) Part No. 1272852 GTH-5519 3-13...

  • Page 36: Machine Controls

    3 Remove the lower part of the dashboard. 4 Remove the transmission control lever. 5 Remove the light control lever (if present). 6 Remove the screws which secure the steering column to the frame. 7 Remove the steering column. 3-14 GTH-5519 Part No. 1272852...
  • Page 37 WARNING hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 4 Remove the steer rotation actuator. Part No. 1272852 GTH-5519 3-15...
  • Page 38 7 Tag and disconnect the joystick harness connector from the machine. 8 Tag, disconnect and plug the hoses from ports 1, 2, 3, 4, P and T of the joystick. Cap the fittings. Joystick port orientation 3-16 GTH-5519 Part No. 1272852...
  • Page 39 Do not allow oil to squirt or spray. 6 Remove the pin securing the brake pedal to the brake pump support. Remove the brake pedal. Part No. 1272852 GTH-5519 3-17...

  • Page 40: Fuel And Hydraulic Tanks

    Remove the tank from the machine. The reduced weight of the empty The reduced weight of the empty NOTICE tank makes it possible to handle tank makes it possible to handle it manually. it manually. 3-18 GTH-5519 Part No. 1272852...

  • Page 41: Hydraulic Tank

    Refer to Section 2, Specifications. 6 Remove the drain plug from the hydraulic tank and completely drain the tank. Bodily injury hazard. Beware of CAUTION hot oil. Contact with hot oil may cause severe burns. Part No. 1272852 GTH-5519 3-19...

  • Page 42: Engines

    Deutz TD 2.9 L4 Workshop Manual dashboard in the operator's compartment. Genie part number 57.4700.0022 To learn the specifications of and how to use the fault codes, refer to Section 5, Fault Codes.

  • Page 43: Axle

    Do not allow oil to squirt or spray. 4 Loosen the lug nuts of both wheels on the axle to be removed. Do not remove the lug nuts. Part No. 1272852 GTH-5519 3-21...

  • Page 44: Hydraulic Pumps

    When testing the pump, crank the engine in one second intervals until the correct pressure is confirmed. Do not over-pressurize the pump. 6 Remove the pressure gauge and install plug onto port TP1. 3-22 GTH-5519 Part No. 1272852...
  • Page 45 Contact with electrically charged when the fasteners are removed circuits could result in death or from the machine. serious injury. Remove all rings, watches and other jewelry. 3 Remove the cover that is under engine. Part No. 1272852 GTH-5519 3-23...
  • Page 46 Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 5 Open the hydraulic tank ball valve. 3-24 GTH-5519 Part No. 1272852...
  • Page 47 15 seconds then shut off the engine. 2 Wait 15 seconds, then start the engine again. 3 Allow the engine to run at low idle for 15 seconds and then shut off the engine. Part No. 1272852 GTH-5519 3-25...

  • Page 48: Hydrostatic Transmission Pump

    Result: the pressure gauge connected to test Pressure is not within specification. port TP3 reads 360 psi / 25 bar. Contact Genie Service Department. Pressure is not within specification. Contact Genie Service Department. 4 Increase the engine speed to 1200 rpm.
  • Page 49 2 Remove the cover that is under engine. will fall if not properly supported when the fasteners are removed 3 3 Disconnect the battery negative (-) terminal. Disconnect the battery negative (-) terminal. from the machine. Part No. 1272852 GTH-5519 3-27...
  • Page 50 Place a suitable support for the pump to install it from the bottom. it from the bottom. 4 Install the hydrostatic transmission pump on the engine. 5 Remove the fitting caps from the hydrostatic transmission pump. 6 Remove the hoses caps. 3-28 GTH-5519 Part No. 1272852...
  • Page 51 5 Apply the brake pedal and start the engine. Shift the transmission into forward and disengage the emergency brake. 6 Release the brake pedal and slowly increase the engine rpm until the machine starts to move. Apply the brake. Part No. 1272852 GTH-5519 3-29...

  • Page 52: Manifolds

    5 Adjust the internal hex socket. Turn clockwise to increase the pressure; turn counterclockwise to decrease the pressure. 6 Cap the valve. 7 Repeat this procedure beginning with step 2. 3-30 GTH-5519 Part No. 1272852...
  • Page 53 Do not allow oil to squirt or spray. 5 Support and secure the function manifold to a suitable lifting device. Do not apply lighting pressure. Part No. 1272852 GTH-5519 3-31...
  • Page 54 4 Moving the joystick, retract the boom. Result: the pressure gauge reads 3915 psi / 270 bar. The pump is good. Pressure is not within specification. Adjust the main relief valve placed above the manifold. 3-32 GTH-5519 Part No. 1272852...
  • Page 55 Hydraulic proportional control A2 - B2 Boom in/out Hydraulic proportional control A3 - B3 Auxiliary Circuit Hydraulic proportional control A4 - B4 Load Sensing Relief Valve (4205 psi / 290 bar) Valve (3915 psi / 270 bar) Part No. 1272852 GTH-5519 3-33...

  • Page 56: Valve Coils

    2 Test the coil resistance using a multimeter set to resistance (). Refer to the Valve Coil Resistance Specification table. Result: If the resistance is not within the adjusted specification, plus or minus 10%, replace the coil. 3-34 GTH-5519 Part No. 1272852...
  • Page 57 September 2016 Section 3 • Repair Procedures MANIFOLDS How to Test a Coil Diode COIL Genie incorporates spike suppressing diodes in all MULTI- of its coils. Properly functioning coil diodes protect METER the electrical circuit by suppressing voltage spikes. Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil.
  • Page 58 Section 3 • Repair Procedures September 2016 This page intentionally left blank. 3-36 GTH-5519 Part No. 1272852...

  • Page 59: Fault Codes

    Do not allow oil to squirt or spray. General Repair Process Malfunction Identify Troubleshoot discovered symptoms problem still exists Return to Inspect Perform service and test Repair problem solved Part No. 1272852 GTH-5519...

  • Page 60: Diagnostic Display

    ECM memory. The presence of faults is indicated by the word Note: Additional hardware will be necessary to “SERVICE” (replacing GENIE) on the LCD display access stored codes. which is located on the gauge cluster in the operator's compartment.

  • Page 61: Engine Fault Codes - Models With Deutz Td 2.9 L4

    Sensor error glow plug control diagnostic line voltage; signal range check high 523913 Sensor error glow plug control diagnostic line voltage; signal range check low 523914 Glow plug control; open load 523914 Glow plug control; powerstage over temperature Part No. 1272852 GTH-5519...
  • Page 62 Timeout Error of CAN-Receive-Frame AT1IG1; NOX sensor upstream 3224 DLC Error of CAN-Receive-Frame AT1IG1Vol NOX Sensor (SCR-system upstream cat; DPF-system downstream cat); length of frame incorrect 3224 Timeout Error of CAN-Receive-Frame AT1IG1Vol; NOX sensor (SCR-system upstream cat; DPF-system downstream cat) GTH-5519 Part No. 1272852...
  • Page 63 Passive Timeout Error of CAN-Receive-Frame TSC1TE; Setpoint 523778 Active Timeout Errorof CAN-Receive-Frame TSC1TR 523779 Passive Timeout Error of CAN-Receive-Frame TSC1TR 523788 Timeout Error of CAN-Transmit-Frame TrbCH; Status Wastegate 523605 Timeout Error of CAN-Receive-Frame TSC1AE; Traction Control Part No. 1272852 GTH-5519...
  • Page 64 Digital fan control; powerstage over temperature Digital fan control; short circuit to battery Digital fan control; short circuit to ground Fan actuator (PWM output); open load Fan actuator (PWM output); powerstage over temperature Fan actuator (PWM output); short circuit to battery GTH-5519 Part No. 1272852...
  • Page 65 Physical range check high for DV1 & DV2 upstream temperature; shut off regeneration 523918 Physical range check low for DV1 & DV2 upstream temperature; shut off regeneration 523918 Sensor error DV1 & DV2 upstream temperature; signal range check high Part No. 1272852 GTH-5519...
  • Page 66 High side to low side short circuit in the injector 5 (in firing order) High side to low side short circuit in the injector 6 (in firing order) 523615 Metering unit (Fuel-System); open load 523615 Metering unit (Fuel-System); powerstage over temperature GTH-5519 Part No. 1272852...
  • Page 67 Sensor error oil pressure; signal range check high Sensor error oil pressure sensor; signal range check low High oil pressure; warning threshold exceeded High oil pressure; shut off threshold exceeded Low oil pressure; warning threshold exceeded Part No. 1272852 GTH-5519...
  • Page 68 Sensor differential pressure (DPF); plausibility error regarding signal offset 3251 Physical range check high for differential pressure (DPF); shut off regeneration 3251 Physical range check low for differential pressure (DPF); shut off regeneration 3253 Sensor error differential pressure (DPF); signal range check high 4-10 GTH-5519 Part No. 1272852...
  • Page 69 Sesnor error rail pressure; signal range check high Sensor error rail pressure; signal range check low 523633 Nox conversion rate insufficient (SCR-Cat defect, bad AdBule quality) 523633 Nox conversion rate insufficient (SCR-Cat defect, bad AdBule quality); temperature range 1 Part No. 1272852 GTH-5519 4-11...
  • Page 70 Accelerator pedal duty cycle PWM signal; signal range check high Acceleration pedal cycle duration PWM signal; signal range check high Sensor error accelerator pedal; signal range check high Sesnor error handthrottle; signal range check high Handthrottle idle validation switch; short circuit to ground 4-12 GTH-5519 Part No. 1272852...
  • Page 71 Sensor error intake air; signal range check high Sensor error intake air sensor; signal range check low Intake air sensor; plausibility error 523921 Sensor burner temperature; plausibility error 523921 Physical range check high for burner temperature Part No. 1272852 GTH-5519 4-13...
  • Page 72 Sensor error exhaust gas temperature upstream (DOC); signal range check low 3248 Sensor error particle filter downstream temperature; signal range check low 1180 Sensor exhaust gas temperature upstream turbine; plausibility error 1180 Sensor error exhaust gas temperature upstream turbine; signal range check high 4-14 GTH-5519 Part No. 1272852...
  • Page 73 SCR-heater urea supplyline; short circuit to ground 523719 SCR heater relay urea supplymodule primary side; open load 523719 SCR heater urea supplymodule; short circuit to battery 523719 SCR heater urea supplymodule; short circuit to ground Part No. 1272852 GTH-5519 4-15...
  • Page 74 Zerofuel calibration injector 3 (in firing order); minimum value exceeded 523949 Zerofuel calibration injector 4 (in firing order); minimum value exceeded 523950 Zerofuel calibration injector 5 (in firing order); minimum value exceeded 523951 Zerofuel calibration injector 6 (in firing order); minimum value exceeded 4-16 GTH-5519 Part No. 1272852...
  • Page 75 Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); Overload by short-circuit Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); Power stage overtemperature due to high current Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); Voltage below threshold 523988 Charging lamp; open load 523988 Charging lamp; over temperature Part No. 1272852 GTH-5519 4-17...
  • Page 76 Timeout error of CAN-Receive-Frame ComMS_Sys4TO (error memory Slave); Master-Slave internal CAN message 524042 Timeout error of CAN-Receive-Frame ComMS_Sys5TO (error memory Slave); Master-Slave internal CAN message 524043 Timeout error of CAN-Receive-Frame ComMS_Sys6TO (error memory Slave); Master-Slave internal CAN message 4-18 GTH-5519 Part No. 1272852...
  • Page 77 Error memory Slave reports FID MSMonFC3; timeout of engine state messages (ComMS_Sys1 7) from master ECU 523919 Sensor air pump airpressure; plausibility error 523920 Sensor exhaust gas back pressure burner; plausibility error 3253 Sensor differential pressure (DPF); plausibility error Part No. 1272852 GTH-5519 4-19...
  • Page 78 Zerofuel calibration injector 8 (in firing order); minimum value exceeded 524028 CAN message PROEGRActr; plausibility error 524029 Timeout Error of CAN-Receive-Frame ComEGRActr -exhaust gas recirculation positioner 524034 Disc Separator; open load 524034 Disc Separator; powerstage over temperature 4-20 GTH-5519 Part No. 1272852...
  • Page 79 Master ECU and Slave ECU data sets or software are not identical 523718 SCR mainrelay; open load (only CV56B) 523718 SCR mainrelay; powerstage over temperature (only CV56B) 523718 SCR mainrelay; short circuit to battery (only CV56B) Part No. 1272852 GTH-5519 4-21...
  • Page 80 Timeout error of CAN-Receive-Frame ComRxDPFBrnAirPmp Handthrottle idle validation switch; short circuit to battery Sesnor error handthrottle; signal range check high Handthrottle idle validation switch; short circuit to ground Sensor error handthrottle sensor; signal range check low 4-22 GTH-5519 Part No. 1272852...
  • Page 81 Plausibility error between APP1 and APP2 or APP1 and idle switch Low fuel pressure; warning threshold exceeded Low fuel pressure; shut off threshold exceeded Sensor error low fuel pressure; signal range check high Sensor error low fuel pressure; signal range check low Part No. 1272852 GTH-5519 4-23...
  • Page 82 Air flow sensor load correction factor exceeding the maximum drift limit Sesnor error rail pressure; signal range check high Sensor error rail pressure; signal range check low Rail pressure safety function is not executed correctly 4-24 GTH-5519 Part No. 1272852...
  • Page 83 Offset angle between crank-and camshaft sensor is too large Sensor camshaft speed; disturbed signal Sensor crankshaft speed; disturbed signal Engine speed above warning threshold (FOC-Level 2) Sensor camshaft speed; no signal Sensor crankshaft speed; no signal Part No. 1272852 GTH-5519 4-25...
  • Page 84 Injector 4 (in firing order); interruption of electric connection Injector 5 (in firing order); short circuit High side to low side short circuit in the injector 5 (in firing order) Injector 5 (in firing order); interruption of electric connection 4-26 GTH-5519 Part No. 1272852...
  • Page 85 Physikal range check low for ECU temperature 1136 Sensor error ECU temperature; signal range check high 1136 Sensor error ECU temperature; signal range check low 1176 Sensor error pressure sensor upstream turbine; signal range check high Part No. 1272852 GTH-5519 4-27...
  • Page 86 1761 Urea tank level; warning threshold exceeded 2621 Flush valve burner (EPV DPF-System); short circuit to battery 2621 Flush valve burner (EPV DPF-System); short circuit to ground 2621 Flush valve burner (EPV DPF-System); open load 4-28 GTH-5519 Part No. 1272852...
  • Page 87 Physical range check low for exhaust gas temperature particulate filter downstream 3248 Physikal range check low for exhaust gas temperature particulate filter downstream; shut off regeneration 3248 Physical range check low for exhaust gas temperature particulate filter downstream; warning Part No. 1272852 GTH-5519 4-29...
  • Page 88 SCR heater urea pressureline; short circuit to battery 4343 SCR heater urea pressureline; short circuit to ground 4343 SCR heater relay urea pressureline secondary side; open load 4343 SCR heater relay urea pressureline primary side; open load 4-30 GTH-5519 Part No. 1272852...
  • Page 89 Physical range check high for exhaust gas temperature upstream (DOC) 4765 Physical range check low for exhaust gas temperature upstream (DOC) 4766 Physical range check high for exhaust gas temperature downstream (DOC) 4766 Physical range check low for exhaust gas temperature downstream (DOC) Part No. 1272852 GTH-5519 4-31...
  • Page 90 Pressure Relief Valve (PRV) forced to open; performed by pressure shock 523470 Maximum rail pressure in limp home mode exceeded (PRV) 523470 The PRV can not be opened at this operating point with a pressure shock 4-32 GTH-5519 Part No. 1272852...
  • Page 91 Internal software error ECU 523612 Softwarereset CPU SWReset_0 523612 Softwarereset CPU SWReset_1 523612 Softwarereset CPU SWReset_2 523613 Maximum positive deviation of rail pressure exceeded (RailMeUn0) 523613 Maximum positive deviation of rail pressure in metering unit exceeded (RailMeUn1) Part No. 1272852 GTH-5519 4-33...
  • Page 92 SCR heater urea supplymodule; short circuit to battery 523719 SCR heater urea supplymodule; short circuit to ground 523719 SCR heater relay urea supply modul secondary side; open load 523719 SCR heater relay urea supplymodule primary side; open load 4-34 GTH-5519 Part No. 1272852...
  • Page 93 (IMA) injector 2 (in firing order) 523897 check of missing injector adjustment value programming (IMA) injector 3 (in firing order) 523898 check of missing injector adjustment value programming (IMA) injector 4 (in firing order) Part No. 1272852 GTH-5519 4-35...
  • Page 94 HCI dosing valve (DV1); overcurrent at the end of the injection phase 523915 HCI dosing valve (DV1); short circuit to battery 523915 HCI dosing valve (DV1); short circuit to battery high side 523915 HCI dosing valve (DV1); short circuit to ground 4-36 GTH-5519 Part No. 1272852...
  • Page 95 Sensor error exhaustgas back pressure burner; signal range check high 523920 Sensor error exhaustgas back pressure burner; signal range check low 523921 Physical range check high for burner temperature 523921 Physical range check low for burner temperature 523921 Sensor burner temperature; plausibility error Part No. 1272852 GTH-5519 4-37...
  • Page 96 Timeout Error (PCK2PCK) for CAN-Receive-Frame AT1IGCVol1 information; factors & Sensorcalibration for NOX Sensor (SCR-system upstream cat; DPF-system downstream cat) 523941 Timeout Error (BAM to packet) for CAN-Receive-Frame AT1OGCVol2 information; factors & Sensorcalibration for NOX Sensor (SCR-system downstream cat; DPF-system downstream cat) 4-38 GTH-5519 Part No. 1272852...
  • Page 97 Charging lamp; short circuit to battery 523988 Charging lamp; short circuit to ground 523988 Charging lamp; open load 523988 Charging lamp; over temperature 523989 Fuel Balance Control integrator injector 7 (in firing order); maximum value exceeded Part No. 1272852 GTH-5519 4-39...
  • Page 98 524019 Air Pump; air lines blocked 524020 Engine power; Not enough oxygen for regeneration 524021 Burner fuel line pipe leak behind Shut Off Valve 524022 DPF wasn´t regenerated, power reduction phase 2 (manuell regeneration request) 4-40 GTH-5519 Part No. 1272852...
  • Page 99 Error memory Slave reports FID MSMonFC2; Shut-Off Path test error of fuel injection system 524052 Error memory Slave reports FID MSMonFC3; timeout of engine state messages (ComMS_Sys1 7) from master ECU 524052 Master ECU and Slave ECU data sets or software are not identical Part No. 1272852 GTH-5519 4-41...
  • Page 100 Timeout error of CAN-Receive-Frame ComRxSCRHtDiag 524121 Timeout error of CAN-Receive-Frame ComRxTrbChActr 524122 Timeout error of CAN-Receive-Frame ComRxUQSens 524123 Timeout error of CAN-Receive-Frame ComSCRHtCtl 524124 Timeout error of CAN-Receive-Frame ComTxAT1IMG 524125 Timeout error of CAN-Receive-Frame ComTxTrbChActr 4-42 GTH-5519 Part No. 1272852...
  • Page 101 Malfunction Identify Troubleshoot discovered symptoms Be sure that all necessary tools and test equipment are available and ready for use. problem still exists Return to Inspect Perform service and test Repair problem solved Part No. 1272852 GTH-5519...

  • Page 102: Electrical And Hydraulic Symbol Legends

    Valve coil Valve coil 2 position 4 way 2 position 2 way with diode solenoid valve solenoid valve Diode Switch Joystick Proximity switch Limit switch Counterbalance valve Temperature switch Fuel level sender Pressure switch Battery GTH-5519 Part No. 1272852...

  • Page 103: Electrical Schematic

    September 2016 Section 5 • Schematics Electrical Schematic Sheet 1 of 8 Up to SN GTH5515B-2364 GENIE a Terex brand GENIE °C ENGINE RPM hour °C Part No. 1272852 GTH-5519...
  • Page 104 Section 5 • Schematics September 2016 ELECTRICAL SCHEMATIC Sheet 2 of 8 Up to SN GTH5515B-2364 GTH-5519 Part No. 1272852...
  • Page 105 September 2016 Section 5 • Schematics ELECTRICAL SCHEMATIC Sheet 3 of 8 Up to SN GTH5515B-2364 Part No. 1272852 GTH-5519...
  • Page 106 Section 5 • Schematics September 2016 ELECTRICAL SCHEMATIC Sheet 4 of 8 Up to SN GTH5515B-2364 GTH-5519 Part No. 1272852...
  • Page 107 September 2016 Section 5 • Schematics ELECTRICAL SCHEMATIC Sheet 5 of 8 Up to SN GTH5515B-2364 Part No. 1272852 GTH-5519...
  • Page 108 Section 5 • Schematics September 2016 ELECTRICAL SCHEMATIC Sheet 6 of 8 Up to SN GTH5515B-2364 GTH-5519 Part No. 1272852...
  • Page 109 September 2016 Section 5 • Schematics ELECTRICAL SCHEMATIC Sheet 7 of 8 Up to SN GTH5515B-2364 Part No. 1272852 GTH-5519...
  • Page 110 F 12 F 02 F 03 F 13 F 14 F 04 F 15 F 05 F 16 F 06 F 17 F 07 F 08 F 18 F 19 F 09 F 20 F 10 5-10 GTH-5519 Part No. 1272852...
  • Page 111 September 2016 Section 5 • Schematics ELECTRICAL SCHEMATIC Sheet 1 of 8 From SN GTH5515B-2365 to SN GTH5516M-4630 Part No. 1272852 GTH-5519 5-11...
  • Page 112 Section 5 • Schematics September 2016 ELECTRICAL SCHEMATIC Sheet 2 of 8 From SN GTH5515B-2365 to SN GTH5516M-4630 5-12 GTH-5519 Part No. 1272852...
  • Page 113 September 2016 Section 5 • Schematics ELECTRICAL SCHEMATIC Sheet 3 of 8 From SN GTH5515B-2365 to SN GTH5516M-4630 Part No. 1272852 GTH-5519 5-13...
  • Page 114 Section 5 • Schematics September 2016 ELECTRICAL SCHEMATIC Sheet 4 of 8 From SN GTH5515B-2365 to SN GTH5516M-4630 5-14 GTH-5519 Part No. 1272852...
  • Page 115 September 2016 Section 5 • Schematics ELECTRICAL SCHEMATIC Sheet 5 of 8 From SN GTH5515B-2365 to SN GTH5516M-4630 Part No. 1272852 GTH-5519 5-15...
  • Page 116 Section 5 • Schematics September 2016 ELECTRICAL SCHEMATIC Sheet 8 of 8 Sheet 6 of 8 From SN GTH5515B-2365 to SN GTH5516M-4630 5-16 GTH-5519 Part No. 1272852...
  • Page 117 September 2016 Section 5 • Schematics ELECTRICAL SCHEMATIC Sheet 7 of 8 From SN GTH5515B-2365 to SN GTH5516M-4630 Part No. 1272852 GTH-5519 5-17...
  • Page 118 Section 5 • Schematics September 2016 ELECTRICAL SCHEMATIC Sheet 8 of 8 From SN GTH5515B-2365 to SN GTH5516M-4630 5-18 GTH-5519 Part No. 1272852...
  • Page 119 September 2016 Section 5 • Schematics ELECTRICAL SCHEMATIC Sheet 1 of 8 From SN GTH5516M-4631 GENIE a Terex brand GENIE °C ENGINE RPM hour °C Part No. 1272852 GTH-5519 5-19...
  • Page 120 Section 5 • Schematics September 2016 ELECTRICAL SCHEMATIC Sheet 2 of 8 From SN GTH5516M-4631 5-20 GTH-5519 Part No. 1272852...
  • Page 121 September 2016 Section 5 • Schematics ELECTRICAL SCHEMATIC Sheet 3 of 8 From SN GTH5516M-4631 Part No. 1272852 GTH-5519 5-21...
  • Page 122 Section 5 • Schematics September 2016 ELECTRICAL SCHEMATIC Sheet 4 of 8 From SN GTH5516M-4631 Optional Part 5-22 GTH-5519 Part No. 1272852...
  • Page 123 September 2016 Section 5 • Schematics ELECTRICAL SCHEMATIC Sheet 5 of 8 From SN GTH5516M-4631 Optional Part Part No. 1272852 GTH-5519 5-23...
  • Page 124 Section 5 • Schematics September 2016 ELECTRICAL SCHEMATIC Sheet 6 of 8 From SN GTH5516M-4631 Optional Part 5-24 GTH-5519 Part No. 1272852...
  • Page 125 September 2016 Section 5 • Schematics ELECTRICAL SCHEMATIC Sheet 7 of 8 From SN GTH5516M-4631 Optional Part Part No. 1272852 GTH-5519 5-25...
  • Page 126 F 02 F 12 F 13 F 03 F 14 F 04 F 15 F 05 F 16 F 06 F 17 F 07 F 08 F 18 F 19 F 09 F 20 F 10 5-26 GTH-5519 Part No. 1272852...

  • Page 127: Hydraulic Schematic

    Section 5 • Schematics September 2016 Hydraulic Schematic 5-27 5-28...
  • Page 128 Tank lines Hydrostatic transmission pump max displacement: cc / rev Check valve Shutoff valve Hydrostatic transmission cracking pressure Suction screen boost pressure test port 8 bar (116 psi) Oil tank capacity 75 liters (20 gallons) 5-29 GTH-5519 Part No. 1272852...
  • Page 129 California Proposition 65 WARNING Operating, servicing and maintaining this equipment, passenger vehicle or off-highway motor vehicle can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm.

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Gth5514b-101Gth5516b-4410Gth5516m-5799Gth5516m-4411Gth55m-5800

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