Genie GTH-2506 Service Manual
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Genie GTH-2506 Service Manual

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See also: Operator's Manual
1.
Service Manual
GTH-2506
(Deutz Stage IIIA - IIIB)
GTH-3007
(Deutz Stage IIIA - IIIB)
Serial Number Range
From
GTH250619M-1001
From GTH300719M-501
Part No.
57.4400.9220GT
Rev
A
August 2018

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Summary of Contents for Genie GTH-2506

  • Page 1 Service Manual Serial Number Range GTH-2506 From GTH250619M-1001 (Deutz Stage IIIA - IIIB) GTH-3007 From GTH300719M-501 (Deutz Stage IIIA - IIIB) Part No. 57.4400.9220GT August 2018...

  • Page 2: Introduction

    Genie has endeavored to deliver the highest Copyright © 2018 by Terex Corporation degree of accuracy possible. However, continuous 57.4400.9220GT Rev A August 2018 improvement of our products is a Genie policy. First Edition, First Printing Therefore, product specifications are subject to change without notice.

  • Page 3: Revision History

    Electronic Version Deutz Engine_Section 2_Specifications. A-6,B-3,C-7_Section 3_Maintenance Procedure. Click on any procedure or page number 3-2, 6-4, 9-1_Section 4_Repair Procedure. highlighted in blue to view the update. Fault Codes_Section 5. 6-35, 6-56, 6-104_Section 6_Schematic Page #. Part No. 57.4400.9220GT GTH-2506 GTH-3007...
  • Page 4 Electronic Version Deutz Engine_Section 2_Specifications. A-6,B-3,C-7_Section 3_Maintenance Procedure. Click on any procedure or page number 3-2, 6-4, 9-1_Section 4_Repair Procedure. highlighted in blue to view the update. Fault Codes_Section 5. 6-35, 6-56, 6-104_Section 6_Schematic Page #. GTH-2506 GTH-3007 Part No. 57.4400.9220GT...

  • Page 5: Serial Number Legend

    Country of Manufacture: Italy Manufacturer: Manufacturer: TEREX Global GmbH TEREX Global GmbH Mühlenstrasse 26 Bleicheplatz 2 Switzerland Switzerland XXXX GTH -2506 Serial number Sequence Model number Year of manufacture Serial label (located inside chassis) Facility code Part No. 57.4400.9220GT GTH-2506 GTH-3007...
  • Page 6 August 2018 This page intentionally left blank. GTH-2506 GTH-3007 Part No. 57.4400.9220GT...

  • 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. 57.4400.9220GT GTH-2506 GTH-3007...
  • Page 8 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-2506 GTH-3007 Part No. 57.4400.9220GT...

  • Page 9: Table Of Contents

    Hydraulic Hose and Fitting Torque Specifications ........2 - 8 Torque Procedure...................2 - 9 SAE and Metric Fasteners Torque Charts..........2 - 10 Section 3 Scheduled Maintenance Procedures Introduction .....................3 - 1 Pre-delivery Preparation Report .............3 - 3 Maintenance Inspection Report ..............3 - 4 Part No. 57.4400.9220GT GTH-2506 GTH-3007...
  • Page 10 Check the Exhaust System ............3 - 12 Inspect the Tires, Wheels and Lug Nut Torque ......3 - 12 Perform Hydraulic Oil Analysis ...........3 - 13 Check the Boom Wear Pads ............3 - 14 Perform Axle Maintenance ............3 - 15 GTH-2506 GTH-3007 Part No. 57.4400.9220GT...
  • Page 11 Perform Engine Maintenance .............3 - 21 Checklist E Procedures Test or Replace the Hydraulic Oil..........3 - 22 Perform Engine Maintenance .............3 - 23 Perform Engine Maintenance .............3 - 23 Perform Engine Maintenance .............3 - 24 Part No. 57.4400.9220GT GTH-2506 GTH-3007...
  • Page 12 Axle ....................4 - 23 Hydraulic pumps Boom and Steering Function Pump ...........4 - 24 Hydrostatic Transmission Pump..........4 - 28 Manifolds Function Manifold ...............4 - 32 Valve Coils .................4 - 37 LMI (Overload System) LMI .....................4 - 39 GTH-2506 GTH-3007 Part No. 57.4400.9220GT...
  • Page 13 Engine Fault Codes - Models with Deutz TD 2.9 L4.......6 - 3 Section 7 Schematics Introduction .....................7 - 1 Electrical and Hydraulic Symbol Legends ..........7 - 2 Electrical Schematic ................7 - 3 Hydraulic Schematic ................7 - 19 Part No. 57.4400.9220GT GTH-2506 GTH-3007 xiii...
  • Page 14 August 2018 TABLE OF CONTENTS This page intentionally left blank. GTH-2506 GTH-3007 Part No. 57.4400.9220GT...

  • Page 15: Specifications

    330 Nm Lug pattern 8 x 10.827 Wheel diameter 42.3 in 1076 mm Wheel width 15.9 in 405 mm Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. Part No. 57.4400.9220GT GTH-2506 GTH-3007...

  • Page 16: Performance Specifications

    Section 2 • Specifications August 2018 SPECIFICATIONS Performance Specifications Boom function speeds, maximum GTH-2506 Boom up 8 seconds Boom down 7 seconds GTH-2506 Boom extend 8 seconds Drive speed, maximum 14 mph Boom retract 4 seconds 23 km/h Fork tilt up...

  • Page 17: 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 specifications are subject to change without notice. Part No. 57.4400.9220GT GTH-2506 GTH-3007...

  • Page 18: Hydraulic Component Specifications

    (measured at test port TP1) 280 bar Relief valve pressure, 7540 psi maximum 520 bar (measured at test port TP2) Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. GTH-2506 GTH-3007 Part No. 57.4400.9220GT...

  • Page 19: Function Manifold Specifications

    (measured at test port TP1) 300 bar Continuous improvement of our products is Boom telescopic cylinder relief valve 1450 psi a Genie policy. Product specifications are pressure, maximum 100 bar subject to change without notice. (measured at test port TP1)

  • Page 20: 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 specifications are subject to change without notice. GTH-2506 GTH-3007 Part No. 57.4400.9220GT...

  • Page 21: Dana Axles

    For additional axle information, refer to the Dana Axle Service Manual Dana Axle Service Manual Genie part number 57.4700.0026 Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. Part No. 57.4400.9220GT GTH-2506 GTH-3007...

  • Page 22: 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 23: Torque Procedure

    O-rings. They are not standard SAE size O-rings. They are 3 Working clockwise on the body hex fitting, available in the O-ring field service kit (Genie part make a second mark with a permanent ink number 49612).
  • Page 24 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-2506 GTH-3007 Part No. 57.4400.9220GT...

  • Page 25: Scheduled Maintenance Procedures

    Indicates a potentially hazardous NOTICE Use only Genie approved replacement parts. situation which, if not avoided, Machines that have been out of service for a may result in property damage. period longer than 3 months must complete the quarterly inspection.

  • Page 26: Pre-Delivery Preparation Report

    Make copies of the Maintenance Inspection Report to use for each inspection. Maintain completed forms for a minimum of 4 years or in compliance with your employer, job site and governmental regulations and requirements. GTH-2506 GTH-3007 Part No. 57.4400.9220GT...
  • Page 27 500 Oak Wood Road The Maltings, Wharf Road Inspector company PO Box 1150 Grantham, Lincolnshire Watertown, SD 57201-6150 NG31- 6BH England (605) 882-4000 (44) 1476-584333 Copyright © 2011 Terex Corporation. Genie® is a registered trademark of Terex South Dakota, Inc. 133192 Rev D...

  • Page 28: Maintenance Inspection Report

    If any inspection receives an “N”, tag and remove the machine from service, repair and re-inspect it. After repair, place a check in the “R” box. Comments Legend Y = yes, acceptable N = no, remove from service R = repaired GTH-2506 GTH-3007 Part No. 57.4400.9220GT...

  • Page 29: Checklist A Procedures

    They also provide users with operation and maintenance Contact your authorized Genie distributor or Genie information. An illegible decal will fail to alert Industries if replacement manuals or decals are personnel of a procedure or hazard and could needed.

  • Page 30: Perform Pre-Operation Inspection

    August 2018 CHECKLIST A PROCEDURES Perform Pre-operation Perform Function Tests Inspection Genie specifications require that this procedure be performed every 8 hours or daily, whichever Genie specifications require that this procedure comes first. be performed every 8 hours or daily, whichever comes first.

  • Page 31: Lubricate The Boom

    Section 3 • Scheduled Maintenance Procedures CHECKLIST A PROCEDURES Lubricate the Boom Perform Engine Maintenance Genie specifications require that this procedure Engine specifications require that this procedure be performed every 8 hours or daily, whichever be performed every 8 hours or daily, whichever comes first.

  • Page 32: Safety Devices

    5 Pressure Switch On The Parking Brake Engage the parking brake and start the engine. The parking brake warning light should come Attempt to move with the machine. The machine must not move. GTH-2506 GTH-3007 Part No. 57.4400.9220GT...

  • Page 33: Perform Axle Maintenance

    Required maintenance procedures and additional Dana Axle S211 Service Manual axle information is available in the Dana Axle S211 Service Manual Dana Axle Service Manual Dana Axle Service Manual Genie part number 57.4700.0026 Genie part number 57.4700.0026 Part No. 57.4400.9220GT GTH-2506 GTH-3007...

  • Page 34: Perform Axle Maintenance

    10 working hours, then weekly. Axle - grease Required maintenance procedures and additional axle information is available in the Dana Axle S211 Service Manual. Dana Axle Service Manual Genie part number 57.4700.0026 3-10 GTH-2506 GTH-3007 Part No. 57.4400.9220GT...

  • Page 35: Checklist B Procedures

    5 Remove all engine covers and chassis covers. Crushing hazard. Death or DANGER serious injury could result if the Genie requires that this procedure be performed boom should unexpectedly fall every 250 hours or quarterly, whichever comes while working underneath the first.

  • Page 36: Check The Exhaust System

    CHECKLIST B PROCEDURES Check the Exhaust System Inspect the Tires, Wheels and Lug Nut Torque Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes Genie requires that the first inspection be first. performed after the first 50 hours of operation.

  • Page 37: Perform Hydraulic Oil Analysis

    August 2018 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES Perform Hydraulic Oil Analysis Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first. Replacement or testing of the hydraulic oil is essential for good machine performance and service life.

  • Page 38: Check The Boom Wear Pads

    August 2018 CHECKLIST B PROCEDURES Check the Boom Wear Pads Genie specifications require that this procedure be performed every 250 hours of operation. Any boom section is fitted with adjustable pads located on the four sides of the profile. These pads are secured to both fixed and mobile part of every section.

  • Page 39: Perform Axle Maintenance

    August 2018 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES Perform Axle Maintenance Genie specifications require that this procedure be performed every 100/250 hours. Differential lubricating oil - check/add Planetary reduction lubricating oil - check/add Oil breather - clean...

  • Page 40: C-1 Perform Engine Maintenance

    Required maintenance procedures and additional engine information is available in the Deutz TD 2.9 L4 Operation and Maintenance Manual (Deutz part number 0312 3893). Deutz TD 2.9 L4 Operation and Maintenance Manual Genie part number 57.4700.0006 3-16 GTH-2506 GTH-3007 Part No. 57.4400.9220GT...

  • Page 41: D-1 Inspect The Forks

    August 2018 Section 3 • Scheduled Maintenance Procedures Checklist D Procedures Inspect the Forks Genie specifications require that this procedure be performed every 1000 hours or annually, whichever comes first OR whenever permanent deformation of the forks is suspected. Maintaining the lifting forks in good condition is essential to safe operation and good machine performance.
  • Page 42 Filter Element are no leaks. 11 Clean up any oil that may have spilled during the installation procedure. Genie specifications require that this procedure be performed every 1000 hours or annually, whichever comes first. Replacing the hydraulic return filter element is essential to good machine performance and service life.

  • Page 43: D-3 Perform Engine Maintenance

    Fuel filter cartridge - replace Fuel pre-filter - replace Dana Axle Service Manual Dry air filter - replace V-belts - replace Genie part number 57.4700.0026 Required maintenance procedures and additional engine information is available in the Deutz TD 2.9 L4 Operation and Maintenance Manual (Deutz part number 0312 3893).

  • Page 44: D-5 Inspect The Engine Air Filter

    6 Renew the filter element if heavily soiled. 7 Unscrew hexagon nut then pull out safety Genie requires that this procedure be performed cartridge. every 1000 hours. Perform this procedure more often if dusty conditions exist.

  • Page 45: D-6 Perform Engine Maintenance

    Required maintenance procedures and additional engine information is available in the Deutz TD 2.9 L4 Operation and Maintenance Manual (Deutz part number 0312 3893). Deutz TD 2.9 L4 Operation and Maintenance Manual Genie part number 57.4700.0006 Part No. 57.4400.9220GT GTH-2506 GTH-3007 3-21...

  • Page 46: E-1 Test Or Replace The Hydraulic Oil

    Bodily injury hazard. Beware of CAUTION hot oil. Contact with hot oil may cause severe burns. Genie specifications require that this procedure 6 Remove the drain plug. be performed every 2000 hours or two years, whichever comes first 7 Rinse out the inside of the tank using a mild Replacement or testing of the hydraulic oil is solvent.

  • Page 47: E-2 Perform Engine Maintenance

    Manual (Deutz part number 0312 3893). Manual (Deutz part number 0312 3893). Deutz TD 2.9 L4 Operation and Maintenance Deutz TD 2.9 L4 Operation and Maintenance Manual Manual Genie part number 57.4700.0006 Genie part number 57.4700.0006 Part No. 57.4400.9220GT GTH-2506 GTH-3007...

  • Page 48: E-4 Perform Engine Maintenance

    Required maintenance procedures and additional engine information is available in the Deutz TD 2.9 L4 Operation and Maintenance Manual (Deutz part number 0312 3893). Deutz TD 2.9 L4 Operation and Maintenance Manual Genie part number 57.4700.0006 3-24 GTH-2506 GTH-3007 Part No. 57.4400.9220GT...

  • Page 49: Repair Procedures, Continued

    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 50: Boom

    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-2506 GTH-3007 Part No. 57.4400.9220GT...
  • Page 51 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. 57.4400.9220GT GTH-2506 GTH-3007...
  • Page 52 Refer strongly recommended. to Repair Procedure 1-1, How to Remove the Boom. 2 Remove the lifting fork frame. Refer to Repair Procedure 1-1, How to Remove the Lifting Fork Frame. GTH-2506 GTH-3007 Part No. 57.4400.9220GT...
  • Page 53 Pull the section out and handle very slowly, paying attention to the position of the straps to make sure the section is always horizontal. 12 Once removed, place the second boom sections on a stand suitably positioned. Part No. 57.4400.9220GT GTH-2506 GTH-3007...

  • Page 54: Boom Lift Cylinder

    Hoses can be damaged if they are kinked or pinched. 4 Attach a lifting strap from an overhead crane to the rod end of the lift cylinder. Support the cylinder. Do not apply any lifting pressure. GTH-2506 GTH-3007 Part No. 57.4400.9220GT...

  • Page 55: 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. 57.4400.9220GT GTH-2506 GTH-3007...

  • Page 56: 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-2506 GTH-3007 Part No. 57.4400.9220GT...

  • Page 57: 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. 57.4400.9220GT GTH-2506 GTH-3007...
  • Page 58 2 Raise the boom to a horizontal position. 3 Retract the boom. 4 Turn the machine off and remove the key from the key switch. 5 Before replacing a hydraulic hose, thoroughly clean the machine. 4-10 GTH-2506 GTH-3007 Part No. 57.4400.9220GT...
  • Page 59 Do not allow oil to squirt or spray. 17 Start the engine, and extend and retract the boom. Verify that there are no abnormal tensions on the hoses. Part No. 57.4400.9220GT GTH-2506 GTH-3007 4-11...

  • Page 60: Operator's Compartment

    All of these components are replaceable. the oil pressure to dissipate gradually. Do not allow oil to For further information or assistance, consult the squirt or spray. Genie Service Department. 6 Tag, disconnect and plug the heater lines (n.2 Bodily injury hazard. This WARNING hoses).
  • Page 61 Do not lift the cab using a strap from an overhead crane. Bolt torque specification Operator's cab mounting bolts 155 ft-lbs 210 Nm (plus Locktite compound) Part No. 57.4400.9220GT GTH-2506 GTH-3007 4-13...

  • Page 62: Machine Controls

    3 Remove the lower part of the dashboard. 4 Remove the transmission control lever. 5 Remove the light control lever. 6 Remove the screws which secure the steering column to the frame. 7 Remove the steering column. 4-14 GTH-2506 GTH-3007 Part No. 57.4400.9220GT...
  • Page 63 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. 57.4400.9220GT GTH-2506 GTH-3007 4-15...
  • Page 64 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. 4-16 GTH-2506 GTH-3007 Part No. 57.4400.9220GT...
  • Page 65 2 Act on the lock device to remove the gauge cluster from the panel. 3 Tag and disconnect the wire harness from the gauge cluster. Remove the gauge cluster from the machine. Part No. 57.4400.9220GT GTH-2506 GTH-3007 4-17...

  • Page 66: Fuel Tank

    Engine fuels are combustible. 2 Reach the rear side of the machine and remove Remove the fuel tank in an the counterweight (only for GTH-2506) and the open, wellventilated area away rear cover (GTH-2506, GTH-3007) from heaters, sparks, flames and lighted tobacco.

  • Page 67: 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. 57.4400.9220GT GTH-2506 GTH-3007 4-19...

  • Page 68: 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 6, Fault Codes.

  • Page 69: Disabled Machine

    (less than 3 mph). Tow the machine at a low WARNING speed only (less than 1.85 mph / 3 km/h). The motor can be damaged if it runs without oil for a greater distance. Part No. 57.4400.9220GT GTH-2506 GTH-3007 4-21...
  • Page 70 (the wheels are free). Clear the area of any personnel NOTICE before remove the locking from each of the four tires and tow the vehicle to a safe location. 4-22 GTH-2506 GTH-3007 Part No. 57.4400.9220GT...

  • Page 71: 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. 57.4400.9220GT GTH-2506 GTH-3007 4-23...

  • Page 72: Boom And Steering Function Pump

    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. 4-24 GTH-2506 GTH-3007 Part No. 57.4400.9220GT...
  • Page 73 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. 57.4400.9220GT GTH-2506 GTH-3007 4-25...
  • Page 74 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. 4-26 GTH-2506 GTH-3007 Part No. 57.4400.9220GT...
  • Page 75 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. 57.4400.9220GT GTH-2506 GTH-3007 4-27...

  • Page 76: Hydrostatic Transmission Pump

    Pressure is not within specification. 1 Connect a 0 to 8700 psi / 0 to 600 bar pressure Contact Genie Service Department. gauge to port TP2 (hydrostatic transmission high pressure test port). 2 Connect a 0 to 870 psi / 0 to 60 bar pressure gauge to port TP3 (hydrostatic transmission boost pressure test port).
  • Page 77 Electrocution/burn hazard. WARNING from the machine. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Part No. 57.4400.9220GT GTH-2506 GTH-3007 4-29...
  • Page 78 3 Place a suitable support for the pump to install 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. 4-30 GTH-2506 GTH-3007 Part No. 57.4400.9220GT...
  • Page 79 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. 57.4400.9220GT GTH-2506 GTH-3007 4-31...

  • Page 80: Function Manifold

    4 Fully extend the boom without releasing the joystick. Result: the pressure gauge reads 1450 psi / 100 bar for GTH-2506 or 2030 psi / 140 bar for GTH-3007. The pressure setting is correct. Pressure is not within specification. Adjust the high pressure relief valve "a" located on the Function Manifold.
  • Page 81 7 Tilt the forks in the opposite direction as before. Result: the pressure gauge reads 4350 psi / 300 bar. The pressure setting is correct. Pressure is not within specification. Adjust the fork tilt relief valve "c" located on the Function Manifold. Part No. 57.4400.9220GT GTH-2506 GTH-3007 4-33...
  • Page 82 Do not allow oil to squirt or spray. 4 Support and secure the function manifold to a suitable lifting device. Do not apply lighting pressure. 4-34 GTH-2506 GTH-3007 Part No. 57.4400.9220GT...
  • Page 83 4 Moving the joystick, retract the boom. Result: the pressure gauge reads 4060 psi / 280 bar. The pump is good. Pressure is not within specification. Adjust the main relief valve placed above the manifold. Part No. 57.4400.9220GT GTH-2506 GTH-3007 4-35...
  • Page 84 Hydraulic proportional control A1 - B1 Load Sensing Fork Tilt Relief Valve (4350 psi / 300 bar) Valve (1450 psi / 100 bar for GTH-2506, 2030 psi / 140 bar for GTH-3007) Max pressure valve (4060 psi / 280 bar) 4-36 GTH-2506 GTH-3007 Part No.

  • Page 85: Valve Coils

    2 Test the coil resistance using a multimeter set to resistance (Ω). 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. Part No. 57.4400.9220GT GTH-2506 GTH-3007 4-37...
  • Page 86 Section 4 • Repair Procedures August 2018 MANIFOLD 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 87 2 This mechanical running in consists in making the axle work to a level of strain equivalent to 3 times the nominal level of strain in the axle for the full range in static. Part No. 57.4400.9220GT GTH-2506 GTH-3007 4-39...
  • Page 88 4 We suggest driving fast 10 times on a beam fixed to the ground. 5 After this operation, it is recommended to let the machine set unused for 12 hours before calibration. 4-40 GTH-2506 GTH-3007 Part No. 57.4400.9220GT...

  • Page 89: Miscellaneaous

    2 Start the engine and let it run at low idle. 3 Engage the parking brake. Result: the pressure gauge on test port TP5 reads 360 psi / 25 bar. Pressure is not within specification. Contact Genie Service Department. Part No. 57.4400.9220GT GTH-2506 GTH-3007 4-41...
  • Page 90 Section 4 • Repair Procedures August 2018 This page intentionally left blank. 4-42 GTH-2506 GTH-3007 Part No. 57.4400.9220GT...

  • Page 91: Settings

    Be sure that all necessary tools and parts are Observe and Obey: available and ready for use. Use only Genie approved replacement parts. Troubleshooting and repair procedures shall be Read each procedure completely and adhere completed by a person trained and qualified on to the instructions.

  • Page 92: How To Calibrate The Load Cell

    5 Press the function key "a" to acquire the first datum (ensure that the red LEDs blink). After the first calibration, the NOTICE machine must be turned off. This procedure is not needed for any subsequent calibrations. GTH-2506 GTH-3007 Part No. 57.4400.9220GT...

  • Page 93: 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. 57.4400.9220GT GTH-2506 GTH-3007...

  • Page 94: Diagnostic Display

    Active fault codes, indicating an engine condition or conditions which have not been corrected, are signaled on the LCD display by the word "SERVICE" replacing “GENIE”. Gauge Cluster LCD screen amber warning light stop engine light diagnostic button GTH-2506 GTH-3007 Part No. 57.4400.9220GT...

  • Page 95: 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. 57.4400.9220GT GTH-2506 GTH-3007...
  • Page 96 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-2506 GTH-3007 Part No. 57.4400.9220GT...
  • Page 97 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. 57.4400.9220GT GTH-2506 GTH-3007...
  • Page 98 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-2506 GTH-3007 Part No. 57.4400.9220GT...
  • Page 99 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. 57.4400.9220GT GTH-2506 GTH-3007...
  • Page 100 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-2506 GTH-3007 Part No. 57.4400.9220GT...
  • Page 101 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. 57.4400.9220GT GTH-2506 GTH-3007...
  • Page 102 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 6-10 GTH-2506 GTH-3007 Part No. 57.4400.9220GT...
  • Page 103 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. 57.4400.9220GT GTH-2506 GTH-3007 6-11...
  • Page 104 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 6-12 GTH-2506 GTH-3007 Part No. 57.4400.9220GT...
  • Page 105 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. 57.4400.9220GT GTH-2506 GTH-3007 6-13...
  • Page 106 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 6-14 GTH-2506 GTH-3007 Part No. 57.4400.9220GT...
  • Page 107 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. 57.4400.9220GT GTH-2506 GTH-3007 6-15...
  • Page 108 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 6-16 GTH-2506 GTH-3007 Part No. 57.4400.9220GT...
  • Page 109 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. 57.4400.9220GT GTH-2506 GTH-3007 6-17...
  • Page 110 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 6-18 GTH-2506 GTH-3007 Part No. 57.4400.9220GT...
  • Page 111 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. 57.4400.9220GT GTH-2506 GTH-3007 6-19...
  • Page 112 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 6-20 GTH-2506 GTH-3007 Part No. 57.4400.9220GT...
  • Page 113 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. 57.4400.9220GT GTH-2506 GTH-3007 6-21...
  • Page 114 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 6-22 GTH-2506 GTH-3007 Part No. 57.4400.9220GT...
  • Page 115 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. 57.4400.9220GT GTH-2506 GTH-3007 6-23...
  • Page 116 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 6-24 GTH-2506 GTH-3007 Part No. 57.4400.9220GT...
  • Page 117 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. 57.4400.9220GT GTH-2506 GTH-3007 6-25...
  • Page 118 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 6-26 GTH-2506 GTH-3007 Part No. 57.4400.9220GT...
  • Page 119 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. 57.4400.9220GT GTH-2506 GTH-3007 6-27...
  • Page 120 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 6-28 GTH-2506 GTH-3007 Part No. 57.4400.9220GT...
  • Page 121 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. 57.4400.9220GT GTH-2506 GTH-3007 6-29...
  • Page 122 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 6-30 GTH-2506 GTH-3007 Part No. 57.4400.9220GT...
  • Page 123 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. 57.4400.9220GT GTH-2506 GTH-3007 6-31...
  • Page 124 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 6-32 GTH-2506 GTH-3007 Part No. 57.4400.9220GT...
  • Page 125 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. 57.4400.9220GT GTH-2506 GTH-3007 6-33...
  • Page 126 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 6-34 GTH-2506 GTH-3007 Part No. 57.4400.9220GT...
  • Page 127 (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. 57.4400.9220GT GTH-2506 GTH-3007 6-35...
  • Page 128 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 6-36 GTH-2506 GTH-3007 Part No. 57.4400.9220GT...
  • Page 129 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. 57.4400.9220GT GTH-2506 GTH-3007 6-37...
  • Page 130 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) 6-38 GTH-2506 GTH-3007 Part No. 57.4400.9220GT...
  • Page 131 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. 57.4400.9220GT GTH-2506 GTH-3007 6-39...
  • Page 132 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) 6-40 GTH-2506 GTH-3007 Part No. 57.4400.9220GT...
  • Page 133 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. 57.4400.9220GT GTH-2506 GTH-3007 6-41...
  • Page 134 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 6-42 GTH-2506 GTH-3007 Part No. 57.4400.9220GT...

  • Page 135: Schematics

    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. 57.4400.9220GT GTH-2506 GTH-3007...

  • Page 136: 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-2506 GTH-3007 Part No. 57.4400.9220GT...

  • Page 137: Electrical Schematic

    August 2018 Section 7 • Schematics Electrical Schematic GTH-2506 From GTH250619M-1001 & GTH300719M-501 Sheet 1 of 16 Part No. 57.4400.9220GT GTH-2506 GTH-3007...
  • Page 138 Section 7 • Schematics August 2018 ELECTRICAL SCHEMATIC GTH-2506 From GTH250619M-1001 & GTH300719M-501 Sheet 2 of 16 GTH-2506 GTH-3007 Part No. 57.4400.9220GT...
  • Page 139 August 2018 Section 7 • Schematics ELECTRICAL SCHEMATIC GTH-2506 From GTH250619M-1001 & GTH300719M-501 Sheet 3 of 16 Part No. 57.4400.9220GT GTH-2506 GTH-3007...
  • Page 140 Section 7 • Schematics August 2018 ELECTRICAL SCHEMATIC GTH-2506 From GTH250619M-1001 & GTH300719M-501 Sheet 4 of 16 GTH-2506 GTH-3007 Part No. 57.4400.9220GT...
  • Page 141 August 2018 Section 7 • Schematics ELECTRICAL SCHEMATIC GTH-2506 From GTH250619M-1001 & GTH300719M-501 Sheet 5 of 16 Part No. 57.4400.9220GT GTH-2506 GTH-3007...
  • Page 142 Section 7 • Schematics August 2018 ELECTRICAL SCHEMATIC GTH-2506 From GTH250619M-1001 & GTH300719M-501 Sheet 6 of 16 GTH-2506 GTH-3007 Part No. 57.4400.9220GT...
  • Page 143 August 2018 Section 7 • Schematics ELECTRICAL SCHEMATIC GTH-2506 From GTH250619M-1001 & GTH300719M-501 Sheet 7 of 16 Part No. 57.4400.9220GT GTH-2506 GTH-3007...
  • Page 144 Section 7 • Schematics August 2018 ELECTRICAL SCHEMATIC GTH-2506 From GTH250619M-1001 & GTH300719M-501 Sheet 8 of 16 7-10 GTH-2506 GTH-3007 Part No. 57.4400.9220GT...
  • Page 145 August 2018 Section 7 • Schematics ELECTRICAL SCHEMATIC GTH-2506 From GTH250619M-1001 & GTH300719M-501 Sheet 9 of 16 Part No. 57.4400.9220GT GTH-2506 GTH-3007 7-11...
  • Page 146 Section 7 • Schematics August 2018 ELECTRICAL SCHEMATIC GTH-2506 From GTH250619M-1001 & GTH300719M-501 Sheet 10 of 16 7-12 GTH-2506 GTH-3007 Part No. 57.4400.9220GT...
  • Page 147 August 2018 Section 7 • Schematics ELECTRICAL SCHEMATIC GTH-2506 From GTH250619M-1001 & GTH300719M-501 Sheet 11 of 16 Part No. 57.4400.9220GT GTH-2506 GTH-3007 7-13...
  • Page 148 Section 7 • Schematics August 2018 ELECTRICAL SCHEMATIC GTH-2506 From GTH250619M-1001 & GTH300719M-501 Sheet 12 of 16 7-14 GTH-2506 GTH-3007 Part No. 57.4400.9220GT...
  • Page 149 August 2018 Section 7 • Schematics ELECTRICAL SCHEMATIC GTH-2506 From GTH250619M-1001 & GTH300719M-501 Sheet 13 of 16 Part No. 57.4400.9220GT GTH-2506 GTH-3007 7-15...
  • Page 150 Section 7 • Schematics August 2018 ELECTRICAL SCHEMATIC GTH-2506 From GTH250619M-1001 & GTH300719M-501 Sheet 14 of 16 7-16 GTH-2506 GTH-3007 Part No. 57.4400.9220GT...
  • Page 151 August 2018 Section 7 • Schematics ELECTRICAL SCHEMATIC GTH-2506 From GTH250619M-1001 & GTH300719M-501 Sheet 15 of 16 Part No. 57.4400.9220GT GTH-2506 GTH-3007 7-17...
  • Page 152 Section 7 • Schematics August 2018 ELECTRICAL SCHEMATIC GTH-2506 From GTH250619M-1001 & GTH300719M-501 Sheet 16 of 16 7-18 GTH-2506 GTH-3007 Part No. 57.4400.9220GT...
  • Page 153 Section 7 • Schematics August 2018 Hydraulic Schematic 7-19 7-20...
  • Page 154 Section 7 • Schematics August 2018 Hydraulic Schematic - GTH-2506 From GTH250619M-1001 Service brake pressure switch Service brake Inching valve (optional) activating pressure: circuit reservoir 2,8-6,3 bar 100 bar Service brake Service brake circuit test port pedal pump Pp Tp...
  • Page 155 0 bar Load sensing and piloting lines Suction lines Cracking press. Tank lines Hydrostatic transmission pump max displacement: cc / rev Shutoff valve Suction screen Oil tank capacity at gauge level 65 liters 7-22 GTH-2506 GTH-3007 Part No. 57.4400.9220GT...

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