Terex Genie GTH-1544 Service And Repair Manual
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Terex Genie GTH-1544 Service And Repair Manual

Terex Genie GTH-1544 Service And Repair Manual

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1.
Service and Repair Manual
GTH-1544
Serial Number Range
(Deutz Tier 4 Final)
From GTH15M-601
This manual includes:
Electrical and Hydraulic
Schematics
For detailed maintenance
procedures, Refer to the
appropriate Maintenance
Manual for your machine.
Part No. 1282264
Rev A
May 2017

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Summary of Contents for Terex Genie GTH-1544

  • Page 1 Service and Repair Manual Serial Number Range GTH-1544 This manual includes: From GTH15M-601 (Deutz Tier 4 Final) Repair procedures Fault Codes Electrical and Hydraulic Schematics For detailed maintenance procedures, Refer to the appropriate Maintenance Manual for your machine. Part No. 1282264 Rev A May 2017...
  • Page 2 Copyright © 2017 by Terex Industries 1282264 Rev A May 2017 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 GTH-1544 Part No. 1282264...
  • Page 3 May 2017 Revision History Revision Date Section Procedure / Page / Description 05/2017 Initial Release REFERENCE EXAMPLES: Section 2_Specifi cations, Machine Specifi cations Electronic Version Section 3_Repair Procedure, 3-2 Section 4_Fault Codes, 4-3 Click on any procedure or page number Section 5_Schematics, 5-3 highlighted in blue to view the update.
  • Page 4 May 2017 REVISION HISTORY, CONTINUED Revision Date Section 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-1544 Part No.
  • Page 5 May 2017 INTRODUCTION Serial Number legend Part No. 1282264 GTH-1544...
  • Page 6 May 2017 This page intentionally left blank. GTH-1544 Part No. 1282264...
  • Page 7 May 2017 Section 1 • Safety Rules 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 identifi ed in the Operator’s Manual are also safety hazards when maintenance and repair procedures are performed.
  • Page 8 Section 1 • Safety Rules May 2017 SAFETY RULES Personal Safety Workplace Safety Any person working on or around a machine must Be sure to keep sparks, fl ames and be aware of all known safety hazards. Personal lighted tobacco away from fl ammable and safety and the continued safe operation of the combustible materials like battery gases machine should be your top priority.
  • Page 9 May 2017 Table of Contents Introduction Important Information .................. ii Revision History...................iii Serial Number Legend................. v Section 1 Safety Rules General Safety Rules .................vii Section 2 Specifi cations Machine Specifi cations ................2 - 1 Performance Specifi cations ..............2 - 2 Hydraulic Specifi...
  • Page 10 May 2017 TABLE OF CONTENTS Section 3 Repair Procedures, continued Boom Extend Cylinder..............3 - 12 Fork Level Slave Cylinder ............3 - 14 Fork Tilt Cylinder ................3 - 16 Operator's compartment Operator’s Compartment ............3 - 17 Machine Controls ...............3 - 19 Fuel and Hydraulic Tank Fuel tank..................3 - 22 Hydraulic tank................3 - 23...
  • Page 11 May 2017 TABLE OF CONTENTS Section 5 Schematics Introduction .....................5 - 1 Electrical and Hydraulic Symbol Legends ..........5 - 2 Electrical Schematic ................5 - 3 Hydraulic Schematic - Deutz Engine ............5 - 20 Part No. 1282264 GTH-1544...
  • Page 12 May 2017 This page intentionally left blank. GTH-1544 Part No. 1282264...
  • Page 13 May 2017 Section 2 • Specifications Specifications Machine Specifi cations Tires and wheels Tire size 17.5 x 25 Fluid capacities Tire ply rating Fuel tank 47.6 gallons Weight, rough terrain tire 427 lbs 180 liters (air fi lled) 194 kg Hydraulic tank 48.1 gallons Weight, rough terrain tire...
  • Page 14 Section 2 • Specifications May 2017 SPECIFICATIONS Performance Specifi cations Boom function speeds, maximum Boom up 19 seconds Drive speed, maximum 18 mph Boom down 15 seconds 29 km/h Boom extend 16 seconds Draw bar pull 23780 lbs Boom retract 14 seconds 10786 kg Fork tilt up...
  • Page 15 May 2017 Section 2 • Specifications SPECIFICATIONS Hydraulic Specifi cations Optional fl uids Biodegradable Petro Canada Environ MV46 Statoil Hydra Way Bio Pa 32 Hydraulic Oil Specifi cation BP Biohyd SE-S Hydraulic oil type Chevron Rando HD equivalent Fire resistant UCON Hydroluble HP-5046 Viscosity grade Multi-viscosity...
  • Page 16 Section 2 • Specifications May 2017 SPECIFICATIONS Hydraulic Components Hydrostatic Transmission Motor Specifi cations Type: variable displacement piston motor Displacement 0 to 6.5 cu in Boom and Steering Functions Pump 0 to 107 cc Type: variable displacement Flow rate @ 2200 rpm 52 gpm piston pump 198 l/min...
  • Page 17 May 2017 Section 2 • Specifications SPECIFICATIONS Function Manifold Specifi cations Function Manifold System relief valve pressure, maximum 4060 psi (measured at test port TP1) 280 bar Fork tilt relief valve pressure, maximum 4350 psi 300 bar Secondary Function Valves Steer relief valve pressure, maximum 2610 psi 180 bar...
  • Page 18 9 gallons 98 x 120 mm 33 liters Horsepower 134 hp @ 2200 rpm Type TEREX PRO COOL 100 kW @ 2200 rpm Ethylene Glycol Peak Torque 320 lb-ft @ 1600 rpm (ASTM D3306, ASTM 434 Nm @ 1600 rpm D1384, FORD, G.M, FIAT)
  • Page 19 May 2017 Section 2 • Specifications SPECIFICATIONS Dana Gear Box 367 Transmission Type Hydrostatic with Mechanical Gear, 2 speed Transmission ratio - 1 speed 4.53 Transmission ratio - 2 speed 1.62 Lubrication Oil capacity, gear box 1.9 quarts 1.8 liters Oil viscosity requirements Units ship with SAE 85W90 API GL4.
  • Page 20 Section 2 • Specifications May 2017 SPECIFICATIONS Dana 223 Front Axle Dana 212 Rear Axle Steering Integrated steer cylinder Steering Integrated steer cylinder Joints Joints Heavy duty double Heavy duty double U-joints U-joints Steering angle, 35 ° Steering angle, 35 ° maximum maximum Axle Lubrication...
  • Page 21 May 2017 Section 2 • Specifications SPECIFICATIONS Hydraulic Hose and Fitting SAE O-ring Boss Port (tube fi tting - installed into Aluminum) Torque Specifi cations (all types) SAE Dash size Torque Your machine is equipped with Parker Seal-Lok™ ORFS or 37° JIC fi ttings and hose ends. 14 ft-lbs / 19 Nm Genie specifi...
  • Page 22 Section 2 • Specifications May 2017 SPECIFICATIONS Torque Procedure Seal-Lok fi ttings 1 Replace the O-ring. The O-ring must be replaced anytime the seal has been broken. The O-ring cannot be re-used if the fi tting or hose end has been tightened beyond fi nger Figure 1 tight.
  • Page 23 May 2017 Section 2 • Specifications SPECIFICATIONS SAE FASTENER TO RQ UE C HART • Thi s chart i s t o be used as a gui de onl y unl ess not ed el sew here i n t hi s m anual • A 574 Hi gh St rengt h G r ade 5 G r ade 8...
  • Page 24 Section 2 • Specifications May 2017 This page intentionally left blank. 2-12 GTH-1544 Part No. 1282264...
  • Page 25 May 2017 Section 3 • Repair Procedures Repair Procedures About This Section Most of the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop. Select the appropriate repair procedure after troubleshooting the problem.
  • Page 26 Section 3 • Repair Procedures May 2017 Boom Components How to Test The Boom Boom Proximity Switch Proximity Switch 1 Remove the switch from the machine. Do not The boom angle switch is a proximity switch. disconnect the switch wire harness from the This switch functions by sensing a change in its machine.
  • Page 27 May 2017 Section 3 • Repair Procedures BOOM COMPONENTS How to Adjust The Boom Angle Proximity Switch Boom The boom angle proximity switch is attached to a How to Replace the mounting bracket, located between the boom and Boom Wear Pads the chassis directly beneath the boom pivot pin.
  • Page 28 Section 3 • Repair Procedures May 2017 BOOM COMPONENTS How to Remove the Lifting How to Replace the Boom Fork Frame Retract Chains 1 With the boom in the stowed position, attach a Note: Perform this procedure on a fi rm, level lifting strap from an overhead crane to the top surface with the wheels chocked.
  • Page 29 May 2017 Section 3 • Repair Procedures BOOM COMPONENTS 9 Use an overhead crane to pull the boom telescope cylinder out of the second boom 15 Remove the guide rope. section by approximately 80 in / 2 m. 16 Install the screws "a" securing the chains. 10 Remove the screws "f"...
  • Page 30 Section 3 • Repair Procedures May 2017 BOOM COMPONENTS How to Replace the Boom 8 Remove the screws "g" securing the chain anchor plates "h" of the retract chains,. Extend Chains 9 At the pivot end of the boom, remove the chain by pulling it out of the boom assembly.
  • Page 31 May 2017 Section 3 • Repair Procedures BOOM COMPONENTS How to Remove the Boom 17 Extend and retract the boom to insure it operates smoothly. Component damage hazard. NOTICE Bodily injury hazard. This WARNING Chains can be damaged if the procedure requires specifi...
  • Page 32 Section 3 • Repair Procedures May 2017 BOOM COMPONENTS How to Disassemble the Boom 8 Using a soft metal drift, remove the lift cylinder locking pin, boom side. Bodily injury hazard. This WARNING 9 Operate the 2 overhead cranes at the same procedure requires specifi...
  • Page 33 May 2017 Section 3 • Repair Procedures BOOM COMPONENTS 8 Cover the ends of the fl exible hoses to prevent 15 Reach the upper area of the boom fork end and dirt from entering inside. remove the 4 screws “h” securing the boom retract chains, then pull out the end of the chain 9 At the pivot end of the boom, remove the retaining the fi...
  • Page 34 Section 3 • Repair Procedures May 2017 BOOM COMPONENTS 26 Once removed, place the third section on two Ensure that the third section DANGER stands suitably positioned. remains inside the second one and does not come out. 27 Remove the fork level cylinder by following the procedure described under “How to remove the 20 Once removed, place the second and fork level cylinder”.
  • Page 35 May 2017 Section 3 • Repair Procedures BOOM COMPONENTS 6 Remove the fasteners securing the lift cylinder rod-end pivot pin to the boom. Boom Lift Cylinder 7 Use a soft metal drift to remove the pivot pin. Crushing hazard. The boom How to Remove the Lift DANGER will fall if not properly supported...
  • Page 36 Section 3 • Repair Procedures May 2017 BOOM COMPONENTS 3 Tag, disconnect and plug the hydraulic hoses from the extend cylinder. Cap the cylinder Boom Extend Cylinder fi ttings. Bodily injury hazard. Spraying WARNING hydraulic oil can penetrate and How to Remove the Extend burn skin.
  • Page 37 May 2017 Section 3 • Repair Procedures BOOM COMPONENTS 8 Using a soft metal drift and a hammer, remove the pivot pin "d". 9 Remove the rear bracket the chain tensioners are secured to. 10 Partially pull the cylinder out. Using a lifting strap and an overhead crane, remove the cylinder.
  • Page 38 Section 3 • Repair Procedures May 2017 BOOM COMPONENTS 6 Remove the retaining fasteners securing the level cylinder barrel end pivot pin. Fork Level Cylinder 7 Using a soft metal drift and a hammer, remove the pivot pin. How to Remove the Fork Level Cylinder 8 Carefully lift and remove the cylinder from the machine.
  • Page 39 May 2017 Section 3 • Repair Procedures BOOM COMPONENTS How to Replace the Fork Level 9 Get underneath the boom, disconnect the hoses from fi ttings “c”, then pull out the hoses Cylinder Hoses from underneath the boom. Note: When removing a hose assembly or fi tting, 10 Remove the rope from the old hydraulic hoses the O-ring on the fi...
  • Page 40 Section 3 • Repair Procedures May 2017 BOOM COMPONENTS Component damage hazard. NOTICE Hoses can be damaged if they Fork Tilt Cylinder are kinked or pinched. 7 Remove the retaining fasteners securing the How to Remove the Fork Tilt fork tilt cylinder barrel end pivot pin. Cylinder 8 Using a soft metal drift and a hammer, remove the pivot pin.
  • Page 41 May 2017 Section 3 • Repair Procedures Operator's Compartment 3 Remove the protective cover next to the cab - inner side of the machine. Operator's Compartment 4 Cut the plastic fasteners fi xing the electrical cables, then disconnect all of the electrical How to Remove the Operator's wires.
  • Page 42 Section 3 • Repair Procedures May 2017 OPERATOR'S COMPARTMENT 10 Remove the 4 retaining fasteners of the cabin. 11 Install and secure two eyebolts to the top the cabin in the special seats. 12 Using a sling chain and an overhead crane, slowly raise the cabin away from the machine and set it on a supporting device.
  • Page 43 May 2017 Section 3 • Repair Procedures OPERATOR'S COMPARTMENT How to Remove the Steering Machine Controls Wheel 1 Get behind the front right wheel and disconnect How to Remove the Steering the battery from the machine. Column Electrocution/burn hazard. WARNING Contact with electrically charged circuits could result in death or 1 Get behind the front right wheel and disconnect...
  • Page 44 Section 3 • Repair Procedures May 2017 OPERATOR'S COMPARTMENT How to Remove the Steer How to Remove the Joystick Rotation Actuator 1 Get behind the front right wheel and disconnect the battery from the machine. 1 Remove the steering column. See 2-2, How to Electrocution/burn hazard.
  • Page 45 May 2017 Section 3 • Repair Procedures OPERATOR'S COMPARTMENT How to Remove the Brake How to Remove the Gauge Pedal Assembly Cluster Assembly 1 Set the ignition switch to position "1". 1 Get behind the front right wheel and disconnect the battery from the machine.
  • Page 46 Section 3 • Repair Procedures May 2017 Fuel and Hydraulic Tanks 1 Get behind the front right wheel and disconnect the battery from the machine. Fuel Tank Electrocution/burn hazard. WARNING Contact with electrically charged How to Remove the Fuel Tank circuits could result in death or serious injury.
  • Page 47 May 2017 Section 3 • Repair Procedures FUEL AND HYDRAULIC TANKS 8 Remove the wire harness from the bulb on the hydraulic fi lter and from the low oil level Hydraulic Tank indicator. 9 Place a container of suitable size under the How to Remove the Hydraulic hydraulic hoses before disconnecting.
  • Page 48 Section 3 • Repair Procedures May 2017 Engine Engine Engine Fault Codes How to Retrieve Engine Fault How to Repair the Codes Deutz TCD 3.6 L4 Engine When the engine Electronic Control Module Repair procedures and additional engine (ECM) detects an abnormal operating condition, information is available in the a fault code is immediately stored in the ECM Deutz TCD 3.6 L4 Workshop Manual...
  • Page 49 May 2017 Section 3 • Repair Procedures Transmission Gear Box Axle How to Repair the Gear Box How to Remove the Axle Bodily injury hazard. This WARNING Repair procedures and additional gear box procedure requires specifi c information are available in the repair skills, lifting equipment Dana 367 Gear Box Service Manual and a suitable workshop.
  • Page 50 Section 3 • Repair Procedures May 2017 TRANSMISSION How to Repair the 212 Axle 6 Raise the end of the machine until the tires are off the ground. Place blocks under the chassis for support. Repair procedures and additional axle information Crushing hazard.
  • Page 51 May 2017 Section 3 • Repair Procedures Hydraulic Pumps 9 Without releasing the joystick, keep pushing the throttle pedal. Boom and Steering Function Pump 10. Untighten the manifold relief valve pressure Result: the pressure gauge reads 4060 psi / How to Test the Boom and 280 bar.
  • Page 52 Section 3 • Repair Procedures May 2017 HYDRAULIC PUMPS How to Remove the Boom and 4 Tag, disconnect and plug the case drain hose located at the top of the pump. Cap the fi tting Steering Function Pump on the pump. Bodily injury hazard.
  • Page 53 May 2017 Section 3 • Repair Procedures HYDRAULIC PUMPS How to Install the Boom and 5 Install the case drain hose onto the pump. Steering Function Pump 6 Securely install the wire harness onto the pump. Bodily injury hazard. This WARNING procedure requires specifi...
  • Page 54 Section 3 • Repair Procedures May 2017 HYDRAULIC PUMPS How to Prime the Boom and How to Adjust the Boom Steering Function Pump and Steering Function Pump Standby Pressure 1 Connect a 0 to 870 psi / 0 to 60 bar pressure gauge to port TP1.
  • Page 55 May 2017 Section 3 • Repair Procedures HYDRAULIC PUMPS How to Adjust the Boom 8 Adjust the pressure compensator pressure. Turn the adjustment screw clockwise to and Steering Function Pump increase the pressure; turn the adjustment Pressure Compensator screw counterclockwise to decrease the pressure.
  • Page 56 Section 3 • Repair Procedures May 2017 HYDRAULIC PUMPS How to Remove the Auxiliary Auxiliary Gear Pump Gear Pump Bodily injury hazard. This WARNING procedure requires specifi c How to Test the Auxiliary Gear repair skills, lifting equipment Pump and a suitable workshop. Attempting this procedure without these skills and tools 1 Locate the shutoff valve positioned underneath...
  • Page 57 May 2017 Section 3 • Repair Procedures HYDRAULIC PUMPS How to Install the Auxiliary 4 Start the engine and prime the pump. See 6-2, How to Prime the Auxiliary Gear Pump. Gear Pump 5 Inspect for leaks. Bodily injury hazard. This WARNING 6 Adjust the pump pressure.
  • Page 58 Section 3 • Repair Procedures May 2017 HYDRAULIC PUMPS How to Prime the Auxiliary Gear Pump 1 Start the engine, allow the engine to run at low idle for 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.
  • Page 59 May 2017 Section 3 • Repair Procedures HYDRAULIC PUMPS 6 Release parking brake. Hydrostatic Transmission 7 Engage forward gear. Pump Result: the pressure gauge connected to test port TP4 reads 725 psi / 50 bar. How to Test the Hydrostatic Pressure is not within specifi...
  • Page 60 Section 3 • Repair Procedures May 2017 HYDRAULIC PUMPS How to Remove the Hydrostatic 6 Tag, disconnect and plug the hoses that are connected to the hydrostatic transmission Transmission Pump pump. Cap the fi ttings. Bodily injury hazard. This WARNING Bodily injury hazard.
  • Page 61 May 2017 Section 3 • Repair Procedures HYDRAULIC PUMPS How to Install the Hydrostatic 8 Connect the hoses to the pump. Bodily injury hazard. Spraying WARNING Transmission Pump hydraulic oil can penetrate and Bodily injury hazard. This WARNING burn skin. Loosen hydraulic procedure requires specifi...
  • Page 62 Section 3 • Repair Procedures May 2017 HYDRAULIC PUMPS How to Prime the Hydrostatic 7 Shift the transmission into reverse. Release the brake pedal and slowly increase the engine Transmission Pump rpm until the machine starts to move. Apply the brake.
  • Page 63 May 2017 Section 3 • Repair Procedures Manifolds 4 Support and secure the function manifold to a suitable lifting device. Do not apply lighting Function Manifold pressure. 5 Remove the retaining fasteners securing the How to Remove the Function function manifold. Manifold 6 Remove the function manifold.
  • Page 64 Section 3 • Repair Procedures May 2017 MANIFOLDS How to Test the Function Manifold 1 Remove the cover above the oil tank. 2 Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to port TP1 (main valve hydraulic circuit test port).
  • Page 65 May 2017 Section 3 • Repair Procedures MANIFOLDS Function Manifold Components Pos. Function Description Schematic ITEM Boom down/up Hydraulic proportional control A1 - B1 Boom in/out Hydraulic proportional control A2 - B2 Chassis sway functions left/right Hydraulic proportional control A3 - B3 Fork tilt down/up Hydraulic proportional control A4 - B4...
  • Page 66 Section 3 • Repair Procedures May 2017 MANIFOLDS Valve Coil Resistance Valve Coils Specifi cation Note: The following coil resistance specifi cations How to Test a Coil are at an ambient temperature of 68°F / 20°C. As valve coil resistance is sensitive to changes in air temperature, the coil resistance will typically A properly functioning coil provides an increase or decrease by 4% for each 18°F / 20°C...
  • Page 67 May 2017 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 68 Section 3 • Repair Procedures May 2017 This page intentionally left blank. 3-44 GTH-1544 Part No. 1282264...
  • Page 69 May 2017 Section 4 • Fault Codes Fault Codes Before Troubleshooting: Read, understand and obey the safety rules and operating instructions in the appropriate operator's manual on your machine. Be sure that all necessary tools and test Observe and Obey: equipment are available and ready for use.
  • Page 70 Section 4 • Fault Codes May 2017 FAULT CODES Diagnostic Display Stored fault codes are the cumulative history of fault codes which the ECM has detected. These fault codes may be recalled by service personnel When the engine Electronic Control Module (ECM) at a later time even if the condition which caused detects an abnormal operating condition, a fault the engine fault has ceased to exist.
  • Page 71 May 2017 Section 4 • Fault Codes FAULT CODES Engine Fault Codes - Models with Deutz TCD 3.6 L4 Short Text Detail Air fl ow sensor load correction factor exceeding the maximum drift limit; plausibility error The air mass fl ow AFS_dm is greater than or equal to AFS_PhysRng.Min_C Physical Range Check low for air mass fl...
  • Page 72 Section 4 • Fault Codes May 2017 FAULT CODES 523911 Burner dosing valve (DV2); overcurrent at the end of the injection phase 523911 Burner dosing valve (DV2); powerstage over temperature 523911 Burner dosing valve (DV2); short circuit to battery 523911 Burner dosing valve (DV2);...
  • Page 73 May 2017 Section 4 • Fault Codes FAULT CODES Sensor error coolant temperature; signal range check high Sensor error coolant temperature; signal range check low High coolant temperature; warning threshold exceeded Coolant temperature; system reaction initiated Coolant level too low Plausibility check for Clutch No detail informationen! 1109...
  • Page 74 Section 4 • Fault Codes May 2017 FAULT CODES 523741 Engine shut off request through CAN No detail informationen! 523213 Timeout Error of CAN-Transmit-Frame ERC1 No detail informationen! 523706 Timeout Error of CAN-Transmit-Frame FlEco No detail informationen! 523240 Timeout CAN-message FunModCtl; Function Mode Control 523937 Timeout DFC for NOxSensGlbReqTx.
  • Page 75 May 2017 Section 4 • Fault Codes FAULT CODES Access error EEPROM memory (write) Physical range check low for EGR differential pressure 2791 Actuator EGR Valve; powerstage over temperature 523612 Internal software error ECU; injection cut off Engine speed above warning threshold Overspeed detection in component engine protection Engine speed above warning threshold (FOC-Level 1) Engine speed above warning threshold (FOC-Level 2)
  • Page 76 Section 4 • Fault Codes May 2017 FAULT CODES Low fuel pressure; shut off threshold exceeded DFC for fuel temperature plausibility check function No detail informationen! 523618 Gearbox oil temperature; Short circuit to battery or broken harness 523618 Gearbox oil temperature; Short circuit to ground 523619 Physical range check high for exhaust gas temperature upstrem (SCR-CAT) 523915...
  • Page 77 May 2017 Section 4 • Fault Codes FAULT CODES 523350 Injector cylinder-bank 1; short circuit 523352 Injector cylinder-bank 2; short circuit 523354 Injector powerstage output defect Injector 1 (in fi ring order); interruption of electric connection Injector 2 (in fi ring order); interruption of electric connection Injector 3 (in fi...
  • Page 78 Section 4 • Fault Codes May 2017 FAULT CODES 1346 Misfi re detection monitoring No detail informationen! 523612 Internal ECU monitoring detection reported error 523612 ECU reported internal software error Internal ECU monitoring detection reported error 523612 ECU reported internal software error 523612 ECU reported internal software error 523612...
  • Page 79 May 2017 Section 4 • Fault Codes FAULT CODES 523612 Reported UnderVoltage of Supply 523008 Manipulation control was triggered 523008 Timeout error in Manipulation control 2634 Early opening defect of main relay No detail informationen! 2634 DFC for stuck main relay error No detail informationen! 3226 Nox feed back fault detection...
  • Page 80 Section 4 • Fault Codes May 2017 FAULT CODES 523920 Exhaustgaspressure upstream burner, plausibility error 523920 Exhaustgaspressure upstream burner, pressure above upper shutoff threshold 523920 Exhaustgaspressure upstream burner, short circuit to battery or open load 523920 Exhaustgaspressure upstream burner, short circuit to ground Pressure downstream charge air cooler, plausibility error Pressure downstream charge air cooler, pressure below lower physical threshold Pressure downstream charge air cooler, short circuit to battery or open load...
  • Page 81 May 2017 Section 4 • Fault Codes FAULT CODES 523470 Pressure Relief Valve (PRV) error; Rail pressure out of tolerance range 523470 Rail pressure out of tolerance range. The PRV can not be opened at this operating point with a pressure shock 523009 Open time of Pressure Relief Valve (PRV) for wear out monitoring had exceeded 523906...
  • Page 82 Section 4 • Fault Codes May 2017 FAULT CODES 4345 Sensor backfl ow line pressure (SCR); plausibility error 4343 SCR Monitoring; Pressure stabilisation error, general pressure check error (SCR) 4374 Pressure stabilisation error dosing valve (SCR) 523632 Pump pressure SCR metering unit too high 523632 Pump pressure SCR metering unit too low 523632...
  • Page 83 May 2017 Section 4 • Fault Codes FAULT CODES 3532 Sensor error DEF tank level; signal range check high 523921 Sensor error burner temperature; signal range check low 3532 Sensor error DEF tank level; signal range check low 1079 Failure of sensor supply voltage 1 1080 Failure of sensor supply voltage 2 523601...
  • Page 84 Section 4 • Fault Codes May 2017 FAULT CODES 523921 Burner temperature, temperature below lower shutoff threshold Charged air cooler down stream temperature. Temperature below lower physical threshold Electrical error charged air temperature. Signal range check high.(SRC) Electrical error charged air temperature. Signal range check low Charged air cooler temperature.
  • Page 85 May 2017 Section 4 • Fault Codes FAULT CODES 1180 Sensor error exhaust gas temperature upstream turbine; signal range check high 1180 Sensor error exhaust gas temperature upstream turbine; signal range check low 4360 Exhaust temperature upstream SCR-Cat, temperature above upper physical threshold 4360 Sensed exhaust temperature before SCR-Cat is <...
  • Page 86 Section 4 • Fault Codes May 2017 FAULT CODES 523718 SCR main relay (primary side); powerstage over temperature 523718 SCR main relay (primary side); short circuit to battery 523718 SCR main relay (primary side); short circuit to ground 4341 SCR heater relay DEF supply line primary side; open load 4341 SCR-heater DEF supplyline;...
  • Page 87 May 2017 Section 4 • Fault Codes FAULT CODES Water in fuel level prefi lter; maximum value exceeded 523946 Zerofuel calibration injector 1 (in fi ring order); maximum value exceeded 523947 Zerofuel calibration injector 2 (in fi ring order); maximum value exceeded 523948 Zerofuel calibration injector 3 (in fi...
  • Page 88 Section 4 • Fault Codes May 2017 FAULT CODES 5763 Power stage overtemperature due to high current 5763 Actuator AGR valve (2.9;3.6) throttle valve (4.1;6.1;7.8); Voltage below threshold 523984 UB7; Short circuit to battery error of actuator relay 6 523986 Relais SCR-Heater, Short Circuit to Ground (Highside Control side) 523987 UB6;...
  • Page 89 May 2017 Section 4 • Fault Codes FAULT CODES 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 524045 Master Slave, Error of message counter CAN receive message ComMSMoFOvR; ComMSMoFOvR1CNT 524046 Master-Slave CAN;...
  • Page 90 Section 4 • Fault Codes May 2017 FAULT CODES 523922 Burner Shut Off Valve; powerstage over temperature 523922 Burner Shut Off Valve; short circuit to ground 523921 Burner temperature sensor; Plausibility Check for burner temperature sensor Sensor burner temperature; plausibility error 1136 Physical range check high for ECU temperature 4769...
  • Page 91 May 2017 Section 4 • Fault Codes FAULT CODES 523718 SCR mainrelay; short circuit to battery (only CV56B) 523718 SCR mainrelay; short circuit to ground (only CV56B) 4376 SCR reverting valve; open load 4376 SCR reversing valve; over temperature 4376 SCR reversing valve;...
  • Page 92 Section 4 • Fault Codes May 2017 FAULT CODES 524063 SCR heater return line; open load 524063 SCR main relay not connected 524063 SCR heater pressureline; open load 524063 SCR heater mainrelay; short circuit to battery 524063 SCR heater main relay load side (K31) on heating valve (Y31), Short cut to ground 524063 SCR relay for suction line not connected 524063...
  • Page 93 May 2017 Section 4 • Fault Codes FAULT CODES 524147 SCR System,pressure build up not possible 524063 DEF supply modul, time for defrosting too long 524063 DEF tank, time for defrosting too long 1716 Urea Tank Signal to HMI for indicating the Urea Tank-Level (Urea tank volume ratio low threshold 1716 DEF tank, DEF level below fi...
  • Page 94 Section 4 • Fault Codes May 2017 FAULT CODES 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 524133 HMI system; set if restore button blocked 524134 DPF, ash load exceeds the shutoff threshold 524134...
  • Page 95 May 2017 Section 4 • Fault Codes FAULT CODES 524147 SCR-System, reverting valve blocked 524175 SCR-CAT, Nox emissions above maximum threshold 524074 NOx-Sensor after SCR-Cat: Nox-Sensor dew point problem or plausibility problem 524076 NOx-Sensor before SCR-Cat: Nox-Sensor dew point problem or plausibility problem 524177 SCR System, DEF suction line blocked 524178...
  • Page 96 Section 4 • Fault Codes May 2017 FAULT CODES 524196 Variant handling, Synchronisation error 3520 DEF quality seonsor, bad DEF quality detected or no DEF measuring possible 3520 Urea quality at UQS invalid 3519 Temperature at UQS invalid 3532 The DEF Level at UQS out of max. physical range 3532 Quality at UQS out of min.
  • Page 97 May 2017 Section 4 • Fault Codes FAULT CODES 524256 DEF supply module heater error on slave ECU 524257 Error Exhaust pressure upstream SCR on Slave ECU 524258 Error Exhaust temperature upstream SCR on Slave ECU 524259 DEF pressure line heater error on slave ECU 524260 Error Urea pump temperature on Slave ECU 524261...
  • Page 98 Section 4 • Fault Codes May 2017 This page intentionally left blank. 4-30 GTH-1544 Part No. 1282264...
  • Page 99 May 2017 Section 5 • Schematics Schematics About This Section There are two groups of schematics in this section. An illustration legend precedes each group of drawings. Electrical Schematics Observe and Obey: Electrocution/burn hazard. WARNING Contact with electrically charged Troubleshooting and repair procedures shall be circuits could result in death or completed by a person trained and qualifi...
  • Page 100 Section 5 • Schematics May 2017 Electrical and Hydraulic Symbols Legend Electrical Schematic Symbols Hydraulic Schematic Symbols Pressure switch Hydraulic cylinder Axle START STARTER SWITCH Key switch Engine start Orifi ce Adjustable orifi ce Filter Control relay Alternator Check valve Flow regulator Relief valve Fuse...
  • Page 101 May 2017 Section 5 • Schematics Electrical Schematic - Deutz From SN GTH15M-601 Sheet 1 of 15 GENIE a Terex brand °C GENIE ENGINE RPM hour Part No. 1282264 GTH-1544...
  • Page 102 Section 5 • Schematics May 2017 ELECTRICAL SCHEMATIC - DEUTZ From SN GTH15M-601 Sheet 2 of 15 GTH-1544 Part No. 1282264...
  • Page 103 May 2017 Section 5 • Schematics ELECTRICAL SCHEMATIC - DEUTZ From SN GTH15M-601 Sheet 3 of 15 Part No. 1282264 GTH-1544...
  • Page 104 Section 5 • Schematics May 2017 ELECTRICAL SCHEMATIC - DEUTZ From SN GTH15M-601 Sheet 4 of 15 GTH-1544 Part No. 1282264...
  • Page 105 May 2017 Section 5 • Schematics ELECTRICAL SCHEMATIC - DEUTZ From SN GTH15M-601 Sheet 5 of 15 Part No. 1282264 GTH-1544...
  • Page 106 Section 5 • Schematics May 2017 ELECTRICAL SCHEMATIC - DEUTZ From SN GTH15M-601 Sheet 6 of 15 GTH-1544 Part No. 1282264...
  • Page 107 May 2017 Section 5 • Schematics ELECTRICAL SCHEMATIC - DEUTZ From SN GTH15M-601 Sheet 7 of 15 Part No. 1282264 GTH-1544...
  • Page 108 Section 5 • Schematics May 2017 ELECTRICAL SCHEMATIC - DEUTZ From SN GTH15M-601 Sheet 8 of 15 5-10 GTH-1544 Part No. 1282264...
  • Page 109 May 2017 Section 5 • Schematics ELECTRICAL SCHEMATIC - DEUTZ From SN GTH15M-601 Sheet 9 of 15 Part No. 1282264 GTH-1544 5-11...
  • Page 110 Section 5 • Schematics May 2017 ELECTRICAL SCHEMATIC - DEUTZ From SN GTH15M-601 Sheet 10 of 15 5-12 GTH-1544 Part No. 1282264...
  • Page 111 May 2017 Section 5 • Schematics ELECTRICAL SCHEMATIC - DEUTZ From SN GTH15M-601 Sheet 11 of 15 Part No. 1282264 GTH-1544 5-13...
  • Page 112 Section 5 • Schematics May 2017 ELECTRICAL SCHEMATIC - DEUTZ From SN GTH15M-601 Sheet 12 of 15 5-14 GTH-1544 Part No. 1282264...
  • Page 113 May 2017 Section 5 • Schematics ELECTRICAL SCHEMATIC - DEUTZ From SN GTH15M-601 Sheet 13 of 15 GENIE a Terex brand °C GENIE ENGINE RPM hour D4/D6 Part No. 1282264 GTH-1544 5-15...
  • Page 114 Section 5 • Schematics May 2017 ELECTRICAL SCHEMATIC - DEUTZ From SN GTH15M-601 Sheet 14 of 15 5-16 GTH-1544 Part No. 1282264...
  • Page 115 May 2017 Section 5 • Schematics ELECTRICAL SCHEMATIC - DEUTZ From SN GTH15M-601 Sheet 15 of 15 Part No. 1282264 GTH-1544 5-17...
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  • Page 117 Section 5 • Schematics May 2017 Hydraulic Schematic - Deutz Engine Deutz engine - Sheet 1 of 2 5-19 5-20...
  • Page 118 Section 5 • Schematics May 2017 Hydraulic Schematic - Deutz Engine Deutz engine - Sheet 2 of 2 Double displacement steering actuator max displacement 13.43 ci/rev Double overcenter safety valve min displacement 3.66 ci/rev Double overcenter safety valve Double overcenter safety valve piloting ratio: 7.6/1 piloting ratio: /1 Boom functions control...

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