Terex Genie GTH1215M-101 Service And Repair Manual
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Terex Genie GTH1215M-101 Service And Repair Manual

Terex Genie GTH1215M-101 Service And Repair Manual

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

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Summary of Contents for Terex Genie GTH1215M-101

  • Page 1 Service and Repair Manual Serial Number Range GTH-1256 This manual includes: From GTH1215M-101 to (Perkins Tier 4i) Repair procedures GTH1216M-249 Fault Codes From GTH12M-250 to GTH12M-280 Electrical and Hydraulic Schematics GTH-1256 From GTH1215M-101 to (Deutz Tier 4i) GTH1216M-249 For detailed maintenance From GTH12M-250 to procedures, Refer to the GTH12M-280...
  • Page 2 Copyright © 2016 by Terex Industries 1272856 Rev A1 September 2016 First Edition, First Printing "Genie" and "GTH" are registered trademarks of Terex South Dakota, Inc. in the USA and many other countries. Printed on recycled paper GTH-1256 Part No. 1272856...

  • Page 3: Introduction

    September 2016 Revision History Revision Date Section Procedure / Page / Description 03/2016 Initial Release 09/2016 Introduction 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.
  • Page 4 September 2016 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-1256 Part No.

  • Page 5: Serial Number Legend

    September 2016 INTRODUCTION Serial Number legend Part No. 1272856 GTH-1256...
  • Page 6 September 2016 This page intentionally left blank. GTH-1256 Part No. 1272856...

  • Page 7: Safety Rules

    September 2016 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 September 2016 Section 1 • Safety Rules 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: Table Of Contents

    September 2016 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 September 2016 TABLE OF CONTENTS Section 3 Repair Procedures, continued Boom Extend Cylinder ET ............3 - 11 Fork Level Slave Cylinder FS .............3 - 12 Fork Tilt Cylinder FF ..............3 - 14 Operator's compartment Operator’s Compartment ............3 - 15 Machine Controls ...............3 - 17 Fuel and Hydraulic Tank Fuel and hydraulic tank ..............3 - 20...
  • Page 11 September 2016 TABLE OF CONTENTS Section 4 Fault Codes Introduction .....................4 - 1 Diagnostic Display ..................4 - 2 Engine Fault Codes - Models with Deutz TCD 4.1 L4 ......4 - 3 How to Troubleshoot the Perkins 1204E-E44TA Engine ......4 - 42 Section 5 Schematics Introduction .....................5 - 1...
  • Page 12 September 2016 This page intentionally left blank. GTH-1256 Part No. 1272856...

  • Page 13: Specifications

    September 2016 Section 2 • Specifications Specifications Machine Specifi cations Tires and wheels Tire size 17.5 x 25 Fluid capacities Tire ply rating Fuel tank 47 gallons Weight, rough terrain tire 427 lbs 180 liters (air fi lled) 194 kg Hydraulic tank 48 gallons Weight, rough terrain tire...

  • Page 14: Performance Specifi Cations

    September 2016 Section 2 • Specifications SPECIFICATIONS Performance Specifi cations Boom function speeds, maximum Boom up 16 seconds Drive speed, maximum 18 mph Boom down 13 seconds 29 km/h Boom extend 22 seconds Draw bar pull 22500 lbs Boom retract 15 seconds 10206 kg Fork tilt up...

  • Page 15: Hydraulic Specifi Cations

    September 2016 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: Hydraulic Component Specifi Cations

    September 2016 Section 2 • Specifications SPECIFICATIONS Hydraulic Components Hydraulic Oil Radiator Fan Pump Specifi cations Pump pressure, maximum 1740 psi 120 bar Relief valve pressure, maximum 1740 psi Boom and Steering Functions Pump 120 bar Type: variable displacement piston pump Hydrostatic Transmission Pump Displacement 0 to 3.7 cu in...

  • Page 17: Function Manifold Specifi Cations

    September 2016 Section 2 • Specifications SPECIFICATIONS Function Manifold Specifi cations Function Manifold System relief valve pressure, maximum 3770 psi (measured at test port TP1) 260 bar Fork tilt relief valve pressure, maximum 4060 psi 280 bar Auxiliary function manifold- Outriggers / chassis leveling Steer relief valve pressure, maximum 2610 psi...

  • Page 18: Perkins 1204E-E44Ta Engine

    Engine coolant Bore and stroke 4.13 x 5 inches Capacity 105 x 127 mm Horsepower Type TEREX PRO COOL Ethylene Glycol Peak Torque (ASTM D3306, ASTM Firing order 1 - 3 - 4 - 2 D1384, FORD, G.M, Compression ratio 16.5:1...

  • Page 19: Deutz Tcd 4.1 L4 Engine

    101 x 126 mm Capacity Horsepower 154 hp @ 2200 rpm 115 kW @ 2200 rpm Type TEREX PRO COOL Ethylene Glycol Peak Torque 826 lb-ft @ 1600 rpm (ASTM D3306, ASTM 609 Nm @ 1600 rpm D1384, FORD, G.M, FIAT)

  • Page 20: Dana Integral Gear Box Shift On Fly

    September 2016 Section 2 • Specifications SPECIFICATIONS Dana Integral Gear Box Shift Dana Axle on Fly Steering Integrated steer cylinder Joints Heavy duty double Transmission Type Hydrostatic with U-joints Mechanical Gear, 2 speed Steering angle, 35 ° maximum Transmission ratio - 1 speed 4.53 Front Axle Lubrication...

  • Page 21: Hydraulic Hose And Fitting Torque Specifi Cations

    September 2016 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: Torque Procedure

    September 2016 Section 2 • Specifications 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 September 2016 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 September 2016 Section 2 • Specifications This page intentionally left blank. 2-12 GTH-1256 Part No. 1272856...

  • Page 25: Repair Procedures

    September 2016 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: Boom Components

    Section 3 • Repair Procedures September 2016 Boom Components How to Remove the Lifting Boom Fork Frame 1 With the boom in the stowed position, attach a lifting strap from an overhead crane to the top How to Replace the of the lifting fork frame at the front of the boom.
  • Page 27 September 2016 Section 3 • Repair Procedures BOOM COMPONENTS How to Replace the Boom Retract Chains Note: Perform this procedure on a fi rm, level surface with the wheels chocked. 1 Start the engine and allow the engine to idle. 2 Raise the boom to a horizontal position.
  • Page 28 Section 3 • Repair Procedures September 2016 BOOM COMPONENTS 7 At the fork end of the boom, remove the 19 Install the pulleys and pins previously removed tensioning screw "n" and relevant nuts and from the pivot end of the boom. counternuts.
  • Page 29 September 2016 Section 3 • Repair Procedures BOOM COMPONENTS How to Replace the Boom Extend Chains Note: Perform this procedure on a fi rm, level surface with the wheels chocked. 1 Start the engine and allow the engine to idle. 2 Raise the boom to a horizontal position.
  • Page 30 Section 3 • Repair Procedures September 2016 BOOM COMPONENTS 7 At the fork end of the boom, remove nuts and 11 At the pivot end of the boom, remove the chain counternuts to free the tensioners "n" placed by pulling it out of the boom assembly. under the boom.
  • Page 31 September 2016 Section 3 • Repair Procedures BOOM COMPONENTS How to Remove the Boom Crushing hazard. The cylinder DANGER will fall if not properly supported when the pivot pin is removed Bodily injury hazard. This WARNING from the machine. procedure requires specifi c repair skills, lifting equipment 8 Using a soft metal drift, remove the lift cylinder and a suitable workshop.
  • Page 32 Section 3 • Repair Procedures September 2016 BOOM COMPONENTS How to Disassemble the Boom 7 Completely retract the boom. 8 Pull out the internal steel hoses assembly. Bodily injury hazard. This WARNING procedure requires specifi c 9 Using a soft metal drift and a hammer, remove repair skills, lifting equipment the rod end pivot pin from the extend cylinder.
  • Page 33 September 2016 Section 3 • Repair Procedures BOOM COMPONENTS 12 Tag and disconnect the chains placed in the pivot end of the boom. 13 Remove all the pads inside the boom but the ones in the lower side. 14 With a lifting strap connected to the overhead crane, sling the fi...
  • Page 34 Section 3 • Repair Procedures September 2016 BOOM COMPONENTS 6 Remove the fasteners securing the lift cylinder rod-end pivot pin to the boom. Boom Lift Cylinder LL 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 35: Boom Extend Cylinder Et

    September 2016 Section 3 • Repair Procedures BOOM COMPONENTS 15 Remove the retaining fasteners securing the extend cylinder barrel end pivot pin. Boom Extend Cylinder ET 16 Using a soft metal drift and a hammer, remove the pivot pin. How to Remove the Extend 17 Partially pull the cylinder out.

  • Page 36: Fork Level Slave Cylinder Fs

    Section 3 • Repair Procedures September 2016 BOOM COMPONENTS 6 Remove the retaining fasteners securing the level cylinder barrel end pivot pin. Fork Level Slave Cylinder FS 7 Using a soft metal drift and a hammer, remove the pivot pin. How to Remove the Fork Level Slave Cylinder 8 Carefully lift and remove the cylinder from the...
  • Page 37 September 2016 Section 3 • Repair Procedures BOOM COMPONENTS How to Replace the Fork Level 5 Connect both ends of the hydraulic hose. Clean up any oil that may have spilled. Slave Cylinder Hoses Component damage hazard. NOTICE Hoses can be damaged if they Note: When removing a hose assembly or fi...

  • Page 38: Fork Tilt Cylinder Ff

    Section 3 • Repair Procedures September 2016 BOOM COMPONENTS 7 Remove the retaining fasteners securing the fork tilt cylinder barrel end pivot pin. Fork Tilt Cylinder FF 8 Using a soft metal drift and a hammer, remove the pivot pin. How to Remove the Fork Tilt 9 Carefully lift and remove the cylinder from the Cylinder...

  • Page 39: Operator's Compartment

    September 2016 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 40 Section 3 • Repair Procedures September 2016 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 41: Machine Controls

    September 2016 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 42 Section 3 • Repair Procedures September 2016 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 43 September 2016 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 44: Fuel And Hydraulic Tank

    Section 3 • Repair Procedures September 2016 Fuel and Hydraulic Tank 1 Get behind the front right wheel and disconnect the battery from the machine. Fuel and Hydraulic Tank Electrocution/burn hazard. WARNING Contact with electrically charged circuits could result in death or How to Remove the Fuel and serious injury.
  • Page 45 September 2016 Section 3 • Repair Procedures FUEL AND HYDRAULIC TANK 11 Using an approved hand-operated pump, drain the fuel tank into a container of suitable capacity. Refer to Section 2, Specifi cations. Explosion and fi re hazard. When WARNING transferring fuel, connect a grounding wire between the machine and pump or container.

  • Page 46: Engines

    Section 3 • Repair Procedures September 2016 Engines Engines Engine Fault Codes How to Retrieve Engine Fault How to Repair the Codes Perkins 1204E-E44TA 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 Perkins 1204E-E44TA Operation and Maintenance...

  • Page 47: Transmission

    September 2016 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 is available in the repair skills, lifting equipment Dana Integral Gear Box Shift in Fly Maintenance and a suitable workshop.
  • Page 48 Section 3 • Repair Procedures September 2016 TRANSMISSION 6 Raise the end of the machine until the tires are off the ground. Place blocks under the chassis for support. Crushing hazard. The chassis WARNING will fall if not properly supported. 7 Remove the lug nuts.

  • Page 49: Hydraulic Pumps

    September 2016 Section 3 • Repair Procedures Hydraulic Pumps Boom and Steering Function Pump How to Test the Boom and Steering Function Pump 1 Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to port TP1. 2 Start the engine.
  • Page 50 Section 3 • Repair Procedures September 2016 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 51 September 2016 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 52 Section 3 • Repair Procedures September 2016 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 TP5.
  • Page 53 September 2016 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 54: Auxiliary Gear Pump

    Section 3 • Repair Procedures September 2016 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 Connect a 0 to 5000 psi / 0 to 350 bar pressure...
  • Page 55 September 2016 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 56 Section 3 • Repair Procedures September 2016 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 57: Hydrostatic Transmission Pump

    September 2016 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 58 Section 3 • Repair Procedures September 2016 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 59 September 2016 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 60 Section 3 • Repair Procedures September 2016 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 61: Manifolds

    September 2016 Section 3 • Repair Procedures Manifolds 8 Turn the machine off. Remove the pressure gauge from the test port. Function Manifold How to Set the Steer Pressure 1 Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to port TP1 on the function manifold (boom and steering functions hydraulic test port).
  • Page 62 Section 3 • Repair Procedures September 2016 MANIFOLDS How to Remove the Function 5 Remove the retaining fasteners securing the function manifold. Manifold 6 Remove the function manifold. Bodily injury hazard. This WARNING procedure requires specifi c Crushing hazard. The function WARNING repair skills, lifting equipment manifold will fall if not properly...
  • Page 63 September 2016 Section 3 • Repair Procedures MANIFOLDS How to Test the Function Manifold 1 Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to port TP1 (boom and steering functions hydraulic circuit test port). 2 Start the engine. 3 Increase the engine speed to maximum rpm.
  • Page 64 Section 3 • Repair Procedures September 2016 MANIFOLDS How to Remove the Auxiliary 6 Remove the retaining fasteners securing the auxiliary function manifold. Function Manifold 7 Remove the function manifold. Bodily injury hazard. This WARNING procedure requires specifi c Crushing hazard. The function WARNING repair skills, lifting equipment manifold will fall if not properly...
  • Page 65 September 2016 Section 3 • Repair Procedures MANIFOLDS How to Test the Auxiliary Function Manifold 1 Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to port TP2. 2 Start the engine. 3 Increase the engine speed to maximum rpm. 4 Move the joystick to lock/unlock the attachment.
  • Page 66 Section 3 • Repair Procedures September 2016 MANIFOLDS Function Manifold Components Pos. Function Description Schematic ITEM Boom up/down Hydraulic proportional control A1 -B1 Boom in/out Hydraulic proportional control A2 -B2 Fork tilt Hydraulic proportional control A3 -B3 Load Sensing Relief Valve (3770 psi) 3-42 GTH-1256 Part No.
  • Page 67 September 2016 Section 3 • Repair Procedures MANIFOLDS Auxiliary Function Manifold Components Pos. Function Description Schematic ITEM Chassis sway function Boom auxiliary line ON/OFF solenoid valve X210 - X211 Relief Valve (3335 psi) Part No. 1272856 GTH-1256 3-43...

  • Page 68: Valve Coils

    Section 3 • Repair Procedures September 2016 MANIFOLDS 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 69 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 70 Section 3 • Repair Procedures September 2016 Outriggers 7. Remove the retaining fasteners securing the level cylinder barrel end pivot pin. Outriggers 8. Using a soft metal drift and a hammer, remove How to Remove the Outriggers the pivot pin. Cylinders 9.

  • Page 71: Fault Codes

    September 2016 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 72: Diagnostic Display

    Section 4 • Fault Codes September 2016 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 73: Engine Fault Codes - Models With Deutz Tcd 4.1 L4

    September 2016 Section 4 • Fault Codes FAULT CODES Engine Fault Codes - Models with Deutz TCD 4.1 L4 Short Text Detail Air fl ow sensor load correction factor exceeding the maximum drift limit; plausibility error Air fl ow sensor load correction factor exceeding drift limit; plausibility error Air fl...
  • Page 74 Section 4 • Fault Codes September 2016 FAULT CODES 523914 Glow plug control; powerstage over temperature 523914 Glow plug control; short circuit to battery 523914 Glow plug control; short circuit to ground CAN-Bus 0 "BusOff-Status" 1231 CAN-Bus 1 "BusOff-Status" 1235 CAN-Bus 2 "BusOff-Status"...
  • Page 75 September 2016 Section 4 • Fault Codes FAULT CODES 523938 Timeout Error (BAM to packet) for CAN-Receive-Frame AT1IGCVol1 information; factors & Sensorcalibration for NOX Sensor (SCR-system upstream cat; DPF-system downstream cat) 523939 Timeout Error (BAM to BAM) for CAN-Receive-Frame AT1IGCVol1 information; factors & Sensorcalibration for NOX Sensor (SCR-system upstream cat;...
  • Page 76 Section 4 • Fault Codes September 2016 FAULT CODES Timeout Error of CAN-Receive-Frame TSC1TE; Setpoint Timeout Error of CAN-Receive-Frame TSC1TR; Setpoint 523867 Timeout Error of CAN-Transmit-Frame UAA1 on CAN 2; Burner Air Pump Control 523982 Powerstage diagnosis disabled; high battery voltage 523982 Powerstage diagnosis disabled;...
  • Page 77 September 2016 Section 4 • Fault Codes FAULT CODES 523602 High fan speed; warning threshold exceeded 523602 High fan speed; shut off threshold exceeded Sensor error water in fuel; signal range check high Sensor error water in fuel; signal range check low Sensor error low fuel pressure;...
  • Page 78 Section 4 • Fault Codes September 2016 FAULT CODES Cold start aid relay; over temperature error 523895 Check of missing injector adjustment value programming (IMA) injector 1 (in fi ring order) 523896 check of missing injector adjustment value programming (IMA) injector 2 (in fi ring order) 523897 check of missing injector adjustment value programming (IMA) injector 3 (in fi...
  • Page 79 September 2016 Section 4 • Fault Codes FAULT CODES 1325 Too many recognized misfi res in cylinder 3 (in fi ring order) 1326 Too many recognized misfi res in cylinder 4 (in fi ring order) 1327 Too many recognized misfi res in cylinder 5 (in fi ring order) 1328 Too many recognized misfi...
  • Page 80 Section 4 • Fault Codes September 2016 FAULT CODES High oil temperature; shut off threshold exceeded 1237 Override switch; plausibility error Sensor error airfi lter differential pressure; short circuit to battery Sensor error airfi lter differential pressure; short circuit to ground High air fi...
  • Page 81 September 2016 Section 4 • Fault Codes FAULT CODES 523450 Multiple Stage Switch constant speed; short circuit to battery 523450 Multiple Stage Switch constant speed; short circuit to ground 523450 Multiple Stage Switch constant speed; plausibility error 523451 Multiple Stage Switch engine speed control parameter; short circuit to battery 523451 Multiple Stage Switch engine speed control parameter;...
  • Page 82 Section 4 • Fault Codes September 2016 FAULT CODES 3241 Sensor SCR catalyst upstream temperature too high; plausibility error 3241 Sensor SCR catalyst upstream temperature too low; plausibility error 3361 AdBlue dosing valve blocked (SCR) 523720 Sensor urea supply module heater temperature; plausibility error (normal condition) 523720 Sensor urea supply module heater temperature;...
  • Page 83 September 2016 Section 4 • Fault Codes FAULT CODES Starter relay; powerstage over temperature Starter relay low side; short circuit to battery Starter relay low side; short circuit to ground 523922 Burner shut off valve; open load 523922 Burner shut of valve; short circuit to battery 523922 Burner shut of valve;...
  • Page 84 Section 4 • Fault Codes September 2016 FAULT CODES Mechanical actuator defect EGR-Valve (2.9,3.6) or Throttle-Valve (6.1,7.8) Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); signal range check high Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); signal range check low Position sensor error of actuator EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); signal range check high Position sensor error actuator EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8);...
  • Page 85 September 2016 Section 4 • Fault Codes FAULT CODES 523719 SCR heater relay urea supply modul secondary side; open load 4366 SCR Tank heating valve secundary side: open load 4243 SCR system heater diagnostic reports error; shut off SCR-system 4345 SCR heater relay urea returnline primary side;...
  • Page 86 Section 4 • Fault Codes September 2016 FAULT CODES 3031 DEF-Tank temperature: below minimum 3031 Sensor error urea tank temperature; short circuit to battery 3031 Sensor error urea tank temperature; short circuit to ground Water in fuel level prefi lter; maximum value exceeded 523946 Zerofuel calibration injector 1 (in fi...
  • Page 87 September 2016 Section 4 • Fault Codes FAULT CODES 524023 DPF wasn´t regenerated, warning condition (manuell regeneration mode) Camshaft-and Crankshaft speed sensor signal not available on CAN Actuator EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); open load Actuator EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); over current Actuator EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8);...
  • Page 88 Section 4 • Fault Codes September 2016 FAULT CODES 524017 Spark plug control unit (SPCU); internal error 523989 Fuel Balance Control integrator injector 7 (in fi ring order); maximum value exceeded 523990 Fuel Balance Control integrator injector 8 (in fi ring order); maximum value exceeded 523989 Fuel Balance Control integrator injector 7 (in fi...
  • Page 89 September 2016 Section 4 • Fault Codes FAULT CODES 524000 High side to low side short circuit in the injector 7 (in fi ring order) 524001 High side to low side short circuit in the injector 8 (in fi ring order) 2797 Injector diagnostics;...
  • Page 90 Section 4 • Fault Codes September 2016 FAULT CODES 3248 Physical range check low for exhaust gas temperature particulate fi lter downstream; warning 1188 Wastegate actuator; internal error 1188 Wastegate actuator; EOL calibration not performed correctly 1188 Wastegate actuator calibration deviation too large, recalibration required 1188 Wastegate;...
  • Page 91 September 2016 Section 4 • Fault Codes FAULT CODES 1180 Exhaust gas temperature upstream turbine; shut off threshold exceeded 524037 Ashlamp; open load Sensor vehicle speed; plausibility error 524037 Ashlamp; short circuit to battery 524037 Ashlamp; short circuit to ground 524062 Regeneration inhibit switch not available;...
  • Page 92 Section 4 • Fault Codes September 2016 FAULT CODES 524101 Timeout error of CAN-Transmit-Frame ComDPFTstMon 524105 Timeout error of CAN-Transmit-Frame ComEGRMsFlw 524108 Timeout error of CAN-Transmit-Frame ComEGRTVActr 524110 Timeout error of CAN-Transmit-Frame ComETVActr 524112 Timeout ComITVActr 524118 Timeout error of CAN-Receive-Frame ComRxCM1 524119 Timeout error of CAN-Receive-Frame ComRxCustSCR3 524102...
  • Page 93 September 2016 Section 4 • Fault Codes FAULT CODES Mechanical actuator defect EGR-Valve (2.9,3.6) or Throttle-Valve (6.1,7.8) Actuator EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); over temperature Sensor vehicle speed; plausibility error Sensor error accelerator pedal; signal range check high Sensor error accelerator pedal; signal range check low Accelerator pedal duty cycle PWM signal;...
  • Page 94 Section 4 • Fault Codes September 2016 FAULT CODES High coolant temperature; warning threshold exceeded High coolant temperature; shut off threshold exceeded Sensor error coolant temperature; signal range check high Sensor error coolant temperature; signal range check low Coolant level too low Air fl...
  • Page 95 September 2016 Section 4 • Fault Codes FAULT CODES Customer oiltemperature: signal unplausible Sensor error oil temperature; signal range check high Sensor error oil temperature; signal range check low Engine speed above warning threshold (FOC-Level 1) Offset angle between crank-and camshaft sensor is too large Sensor camshaft speed;...
  • Page 96 Section 4 • Fault Codes September 2016 FAULT CODES High side to low side short circuit in the injector 3 (in fi ring order) Injector 3 (in fi ring order); interruption of electric connection Injector 4 (in fi ring order); short circuit High side to low side short circuit in the injector 4 (in fi...
  • Page 97 September 2016 Section 4 • Fault Codes FAULT CODES 1109 Engine shut off demand ignored 1136 Physikal range check high for ECU temperature 1136 Physikal range check low for ECU temperature 1136 Sensor error ECU temperature; signal range check high 1136 Sensor error ECU temperature;...
  • Page 98 Section 4 • Fault Codes September 2016 FAULT CODES 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 2621 Flush valve burner (EPV DPF-System);...
  • Page 99 September 2016 Section 4 • Fault Codes FAULT CODES 3248 Physical range check high for exhaust gas temperature particulate fi lter downstream; shut off regeneration 3248 Physical range check high for exhaust gas temperature particulate fi lter downstream; warning 3248 Physical range check low for exhaust gas temperature particulate fi...
  • Page 100 Section 4 • Fault Codes September 2016 FAULT CODES 4341 SCR heater relay urea supplyline primary side; open load 4343 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;...
  • Page 101 September 2016 Section 4 • Fault Codes FAULT CODES 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) 4768 Sensor exhaust gas temperature upstream (DOC);...
  • Page 102 Section 4 • Fault Codes September 2016 FAULT CODES FAULT CODES 523470 The PRV can not be opened at this operating point with a pressure shock 523470 Rail pressure out of tolerance range 523470 Open Pressure Relief Valve (PRV); shut off condition 523470 Open Pressure Relief Valve (PRV);...
  • Page 103 September 2016 Section 4 • Fault Codes FAULT CODES 523613 Maximum negative deviation of rail pressure in metering unit exceeded (RailMeUn2) 523613 Negative deviation of rail pressure second stage (RailMeUn22) 523613 Maximum rail pressure exceeded (RailMeUn4) 523613 Minimum rail pressure exceeded (RailMeUn3) 523613 Setpoint of metering unit in overrun mode not plausible 523615...
  • Page 104 Section 4 • Fault Codes September 2016 FAULT CODES 523720 Urea supply module heater temperature; duty cycle in invalid range 523721 Sesnor urea supply module temperature; plausibility error (normal condition) 523721 Sensor urea supply module temperature; plausibility error (cold start condition) 523721 Urea supply module temperature;...
  • Page 105 September 2016 Section 4 • Fault Codes FAULT CODES 523910 Air pump; CAN communication interrupted no purge function available 523910 Air Pump; CAN communication lost 523910 Air Pump; internal error 523910 Air pump doesn´t achieve air mass fl ow setpoint 523911 Burner dosing valve (DV2);...
  • Page 106 Section 4 • Fault Codes September 2016 FAULT CODES 523916 Physical range check low for HCI dosing valve (DV1) downstream pressure; shut off regeneration 523916 Sensor HCI dosing valve (DV1) downstream pressure; plausibility error 523916 Sensor error HCI dosing valve (DV1) downstream pressure; signal range check high 523916 Sensor error HCI dosing valve (DV1) downstream pressure;...
  • Page 107 September 2016 Section 4 • Fault Codes FAULT CODES 523922 Burner Shut Off Valve; open load 523922 Burner Shut Off Valve; blocked closed 523922 Burner Shut Off Valve; blocked open 523922 Over temperature error on burner shut of valve 523922 Burner Shut Off Valve;...
  • Page 108 Section 4 • Fault Codes September 2016 FAULT CODES 523949 Zerofuel calibration injector 4 (in fi ring order); maximum value exceeded 523949 Zerofuel calibration injector 4 (in fi ring order); minimum value exceeded 523950 Zerofuel calibration injector 5 (in fi ring order); maximum value exceeded 523950 Zerofuel calibration injector 5 (in fi...
  • Page 109 September 2016 Section 4 • Fault Codes FAULT CODES 524000 Injector 7 (in fi ring order); interruption of electric connection 524001 Injector 8 (in fi ring order); short circuit 524001 High side to low side short circuit in the injector 8 (in fi ring order) 524001 Injector 8 (in fi...
  • Page 110 Section 4 • Fault Codes September 2016 FAULT CODES 524034 Disc Separator; powerstage over temperature 524035 Injector diagnostics; time out error in the SPI communication 524036 Injector diagnostics Slave; time out error in the SPI communication 524037 Ashlamp; short circuit to battery 524037 Ashlamp;...
  • Page 111 September 2016 Section 4 • Fault Codes FAULT CODES 524099 Timeout error of CAN-Transmit-Frame ComDPFC1 524100 Timeout error of CAN-Transmit-Frame ComDPFHisDat 524101 Timeout error of CAN-Transmit-Frame ComDPFTstMon 524102 Timeout error of CAN-Receive-Frame ComRxDPFBrnAirPmpCtl 524103 Timeout error of CAN-Receive-Frame ComRxDPFBrnAirPmp 524104 Timeout error of CAN-Receive-Frame ComRxDPFCtl 524105 Timeout error of CAN-Transmit-Frame ComEGRMsFlw...

  • Page 112: How To Troubleshoot The Perkins 1204E-E44Ta Engine

    Section 4 • Fault Codes September 2016 FAULT CODES How to Troubleshoot the Perkins 1204E-E44TA Engine Troubleshooting procedures and additional engine information is available in the Perkins 1204E-E44TA Troubleshooting Manual (Perkins part number KENR9116-01). Perkins 1204E-E44TA Troubleshooting Manual Genie part number 57.4700.1400 4-42 GTH-1256...
  • Page 113 September 2016 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 114 Section 5 • Schematics September 2016 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 115: Electrical Schematic

    September 2016 Section 5 • Schematics Electrical Schematic - Deutz From SN GTH1215 M-001 Sheet 1 of 9 Part No. 1272856 GTH-1256...
  • Page 116 Section 5 • Schematics September 2016 ELECTRICAL SCHEMATIC - DEUTZ From SN GTH1215 M-001 Sheet 2 of 9 GTH-1256 Part No. 1272856...
  • Page 117 September 2016 Section 5 • Schematics ELECTRICAL SCHEMATIC - DEUTZ From SN GTH1215 M-001 Sheet 3 of 9 Part No. 1272856 GTH-1256...
  • Page 118 Section 5 • Schematics September 2016 ELECTRICAL SCHEMATIC - DEUTZ From SN GTH1215 M-001 Sheet 4 of 9 GTH-1256 Part No. 1272856...
  • Page 119 September 2016 Section 5 • Schematics ELECTRICAL SCHEMATIC - DEUTZ From SN GTH1215 M-001 Sheet 5 of 9 Part No. 1272856 GTH-1256...
  • Page 120 Section 5 • Schematics September 2016 ELECTRICAL SCHEMATIC - DEUTZ From SN GTH1215 M-001 Sheet 6 of 9 GTH-1256 Part No. 1272856...
  • Page 121 September 2016 Section 5 • Schematics ELECTRICAL SCHEMATIC - DEUTZ From SN GTH1215 M-001 Sheet 7 of 9 Part No. 1272856 GTH-1256...
  • Page 122 Section 5 • Schematics September 2016 ELECTRICAL SCHEMATIC - DEUTZ From SN GTH1215 M-001 Sheet 8 of 9 5-10 GTH-1256 Part No. 1272856...
  • Page 123 September 2016 Section 5 • Schematics ELECTRICAL SCHEMATIC - DEUTZ From SN GTH1215 M-001 Sheet 9 of 9 Part No. 1272856 GTH-1256 5-11...
  • Page 124 Section 5 • Schematics September 2016 ELECTRICAL SCHEMATIC - PERKINS From SN GTH1215 M-001 Sheet 1 of 8 5-12 GTH-1256 Part No. 1272856...
  • Page 125 September 2016 Section 5 • Schematics ELECTRICAL SCHEMATIC - PERKINS From SN GTH1215 M-001 Sheet 2 of 8 Part No. 1272856 GTH-1256 5-13...
  • Page 126 Section 5 • Schematics September 2016 ELECTRICAL SCHEMATIC - PERKINS From SN GTH1215 M-001 Sheet 3 of 8 5-14 GTH-1256 Part No. 1272856...
  • Page 127 September 2016 Section 5 • Schematics ELECTRICAL SCHEMATIC - PERKINS From SN GTH1215 M-001 Sheet 4 of 8 Part No. 1272856 GTH-1256 5-15...
  • Page 128 Section 5 • Schematics September 2016 ELECTRICAL SCHEMATIC - PERKINS From SN GTH1215 M-001 Sheet 5 of 8 5-16 GTH-1256 Part No. 1272856...
  • Page 129 September 2016 Section 5 • Schematics ELECTRICAL SCHEMATIC - PERKINS From SN GTH1215 M-001 Sheet 6 of 8 Part No. 1272856 GTH-1256 5-17...
  • Page 130 Section 5 • Schematics September 2016 ELECTRICAL SCHEMATIC - PERKINS From SN GTH1215 M-001 Sheet 7 of 8 5-18 GTH-1256 Part No. 1272856...
  • Page 131 September 2016 Section 5 • Schematics ELECTRICAL SCHEMATIC - PERKINS From SN GTH1215 M-001 Sheet 8 of 8 Part No. 1272856 GTH-1256 5-19...
  • Page 132 Section 5 • Schematics September 2016 This page intentionally left blank. 5-20 GTH-1256 Part No. 1272856...

  • Page 133: Hydraulic Schematic - Deutz Engine

    Section 5 • Schematics September 2016 Hydraulic Schematic - Deutz Engine Deutz engine - Sheet 1 of 2 5-21 5-22...
  • Page 134 Section 5 • Schematics September 2016 Hydraulic Schematic - Deutz Engine Deutz engine - Sheet 2 of 2 RH outrigger cylinder LH outrigger cylinder Pressure sensitive regenerative Pressure sensitive regenerative dual counterbalance safety valve dual counterbalance safety valve piloting ratio: 4.1/1 Double overcenter safety valve 3,190 3,190...

  • Page 135: Hydraulic Schematic - Perkins Engine

    Section 5 • Schematics September 2016 Hydraulic Schematic - Perkins Engine Perkins engine - Sheet 2 of 2 RH outrigger cylinder LH outrigger cylinder Pressure sensitive regenerative Pressure sensitive regenerative dual counterbalance safety valve dual counterbalance safety valve piloting ratio: 4.1/1 Double overcenter safety valve 3,190 3,190...

This manual is also suitable for:

Genie gth-1256Genie gth12m-250

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