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Service Manual - Genie Industries

1. zx Heat exchanger Return filter ics with suction line a Dri at 0 5 bar 8 ps IE x26 Genie 6 21 GTH 5519 Part No 57 4400 9210 n cracking TP O iia pressure I Single overcenter safety valve 17 Boom functions hydraulic 270bar 140 piloting ratio 4 2 1 circuit test port T 3 915 psi 1 2 030 psi Meo dou l cracking pressure 350 bar 4 1 5 075 psi P i 9 Boom functions L main valve iy 4 sections i Check valve fonctions purap cracking pressure wil pron ty valve displacement 27 2 5 bar 36 psi max flow rate 18 5 GPM Flush i tatic tr issii ishing Hah pressure fast part Hydrostatic transmission motor Lm max displacement 85cc rev HYDRAULIC CIR
2. E 7 m Ll dab s 3 E Dez amp 2 2 SEP 95 1 lrer EL 15 25 iSo 8 2 T meno 97 565 5 af mat SS 81 8 88 5 3 gt lt 9 Fl 5 5 g 8 6 00 5180 6300 5140 TET may So 5 E E v 4 1 ait INS 8155 INS 2 Tfexosuo E a 85 u 9 9810 IND 9810 IND 1281 E icc C23 N za 2 1 6300 S180 m a 5 1 m 2 Dus E 5 5 10502 Fx 2 om g 1 1221 ok Gu 227 4 2 5 1 g 5 5 x 8 7 0130 180 gt 0150 180 ins E 55 3 E 55 5 Scc SIND gt 1966 SIND X E 8 os E E S T Ss z8 22 is gs pam ae 5 ax Za go t 79110 180 2 09120 180 t amp 11014 9102 9104 1 2 Ez E za ZI 1169001180 1 Sx 2E 151 uo 3 5 E508 iH STORY Y 42509 iu L 1 2509 IHM SEONG 2 c 1 6400 iuo 7 6 00 100 E 209 STAM Ty E208 STHM sz 0209 gt 2209 o e pun
3. Part No 57 4400 9210 ATEREX BRAND enie 1 2 3 4 5 MAIN GAUGE CLUSTER T20ohm DEUTZ mm ENGINE IGNITION KEY ke aoe o no xm hone TENTE 2 4 x157 A E A 5 E FR 1 M 1 r GNOS ase Yos T20ohm 1 GNOS ota FDA E20 ce t oe 2k 150 ptits 168070 bb deb de diode de bed 1 SS HIS 6847 15 sag ol ph ps qu al 750 ES Jeu V 5 fr Ss 5 2 9 5 3 S 3 3 S 2 2 5315 5 3 gt 2 55 S s s 3 s sg sg 9 s s S s s S s s 5 5555 5 lt 5 e dis gt 218 105 218 B WHO 75 6099 WHO 75 6021 110 GNO 75 3028 YLO T5 2065 ENO T5 3065 31 gt Or WHOTS 6565 GY0 75 1007 gt 15E 4 1 ORIS FE So LBB E E 2 g 8 n C E F20 Fa a 15 0A B 7 15 15 z m Yn _ 03 05 05 6 m AL x E in s s K LLL ee utc i gt 130 L 2 o gt 430 Relay 21A pe 5 41001 ae MEOS 7048 WHO 75 7087 Dir 2 025 F20 oy WHO 75 1046 21A El s 5 4 S E amp di amp Kl
4. 3 6 A 3 Perform Function 3 6 4 Lubricate the 4 4 0042 nnne 3 7 5 Perform Engine 2 3 7 6 Safety Devices nennen nennt nnns 3 8 A 7 Perform 30 Day Service sssini iriri 3 8 8 Perform Axle 3 9 9 Perform Axle 3 9 A 10 Perform Axle Maintenance essem 3 10 Checklist B Procedures B 1 Inspect the Electrical 3 11 B 2 Check the Exhaust 3 12 B 3 Inspect the Tires Wheels and Lug Nut 3 12 B 4 Perform Hydraulic Oil 515 3 13 B 5 Check the Boom Wear 3 14 B 6 Perform Axle 3 15 B 7 Perform Axle 3 15 Genie X GTH 5519 Part No 57 4400 9210 July 2015 TABLE CONTENTS Section 3 Scheduled Maintenance Procedures continued Checklist C Procedures C 1 Perform Engine 2 3 16 Checklist D Procedures D 1 D 2 D 3 D 4 D 5 D 6 Inspect the T OrKS eite RE xg 3 17 Replace the Hydraulic Tank Return Filter Element
5. Im 100 9V RESISTOR BATTERY a multimeter b 9V DC battery 100 resistor Note Dotted lines in illustration indicate reversed connection as specified in step 6 5 Momentarily connect the positive lead from the multimeter to the positive terminal on the 9V battery Note and record the current reading 6 At the battery coil terminals reverse the connections Note and record the current reading Result Both current readings are greater than 0 mA and are different by a minimum of 20 The coil is good Result If one or both of the current readings are 0 mA or if the two current readings do not differ by a minimum of 20 the coil and or its internal diode are faulty and the coil should be replaced Section 4 Repair Procedures July 2015 ae This page intentionally left blank Genie 4 36 GTH 5519 Part No 57 4400 9210 July 2015 Section 5 Fault Codes Observe and Obey Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine M Immediately tag and remove from service a damaged or malfunctioning machine M Repair any machine damage or malfunction before operating the machine Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a firm level surface Boom in the stowed position Key s
6. Section 5 Fault Codes July 2015 FAULT CODES sm 164 Rail pressure safety function is not executed correctly 523922 Burner Shut Off Valve open load 523922 Burner Shut Off Valve powerstage over temperature 523922 Burner Shut Off Valve short circuit to ground 523921 Sensor burner temperature plausibility error 1136 E 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 signal range check low 4769 Sensor exhaust gas temperature OxiCat downstream normal operation plausibility error 4769 Sensor exhaust gas temperature OxiCat downstream regeneration plausibility error 3248 Sensor exhaust gas temperature downstream DPF plausibility error 3248 EM Physical range check high for exhaust gas temperature particulate filter downstream 3248 Physical range check high for exhaust gas temperature particulate filter downstream shut off regeneration 3248 Physical range check high for exhaust gas temperature particulate filter downstream warning 3248 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 1188 Wastegate actuator internal error 1188 Waste
7. 1 Optional Part 1 ALD E Genie ATEREX BRAND 6 16 GTH 5519 Part No 57 4400 9210 Sheet 7 of 8 Section 6 Schematics ELECTRICAL SCHEMATIC Be zzz 1 144 4 E Es zE PE k d sels SF 5 22 4 sni 3 I ar ae I amp I m 1 8 8 E x s ok amp EJ TX ISI US es 151 5 1 E 8 Le tod 18 122 ze M 1 5 d 8 58 lg ks 2 1 a2 81 ae i sos Teo 1 170 ST Y Y 1 IE 5 1 8 Se 3e sme je ET 5 tw TT 1 2 D 1 1 i 1 WENT SIX TEOSTA R Se g Y 9 in 1992 gue OREMUS c ENDS EN RR 3i AVT3N SOLYATAL ST 1992
8. 57 4400 9210 6 19 Section 6 Schematics 2015 E Hydraulical Schematic 6 20 Section 6 Schematics July 2015 Hydraulical Schematic Service brake X45 pressure switch 1gc activating pressure 2863ba Service brake 40 90 psi circuit test port cu IB Front axle Li m 7 steering cylinder X51 Steering mode selector valve 4 ways 3 positions Forks levelling slave cylinder Front axle steering cylinder Steering rotating actuator displacement 1 60 zu Anti shock valves cracking pressure 200 bar 2 900 psi Max relief valve Service brake circuit reservoir Service brake pedal pump max operating pressure 80 bar 1 160 psi control lever Boom functions Forks tilt cylinder Double overcenter afety valve piloting ratio 4 2 1 cracking pressure 5 075 psi M Forks attachment quick coupling cylinder 350 bar Auxiliary continous flow metering valve Auxiliary continous flow selector valve Quick connect dis
9. J 2 Ep e 13 9 23 Relay Card J 2 A 5 e s g E 2 8 8 8 E E 5 n al z 1 I J a d Ba B X16 19 E xt pa Ee pe E rua F INS Fl gor n ag 4 5 5 Pume _ amp M S 55 WES GNU7S 1001 2 5 8 EE B amp s 2 WHO 75 7048 amp E s WHIO 1006 1 5 E 8 WHOIS 70671 y 1 GY0 75 1136 n 67015 187 e 6 61 als Tz pepe ES x enie ATEREX BRAND Part No 57 4400 9210 GTH 5519 6 3 Section 6 Schematics July 2015 Ee ELECTRICAL SCHEMATIC Sheet 2 of 8 Up to SN GTH5515B 2364 1 2 3 4 5 Emergency Light Forward Reverse Lever Y1 2002 n Ad 3 f V le L 58 d 3 181 1328 i vi 65 i Y 1 6 IB 1 1 Xm xm din am zs zl gt 53 8 5 WHI 6973 ORT UIT EM ROIS UNE ur 1 ORIS 0012 T za ORI OFIO 34 8 E 3 g 2 E 5 E u ate Te
10. K x a FUSES AND RE LAY ENGINE BOX Ref F01 F02 F03 F04 F05 F06 F07 F08 F09 F10 F11 F12 F13 F14 F15 F16 F17 F18 F19 F20 K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 Le Em Description WARNING HIGH BEAM LOW BEAM HORN ROAD JOBSITE R FRONT amp L REAR POSITION LIGHTS L FRONT amp R REAR POSITION LIGHTS POWER SUPPLY OPT 2 HYDRAULIC CIRCUIT ARB INSTRUMENT HEATING FORWARD REVERSE SELECTOR WORK LIGHT REAR AXLE SENSOR FLASHING BEACON STOP LIGHT HAZARD WARNING LIGHT EMERGENCY STOP WIPER INSTRUMENT PANEL HIGH BEAM LOW BEAM HORN LOW PRESSURE PARKING BRAKE REVERSE MODE FORWARD MODE START ENABLING SWITCH FLASHER Ref Description FG1 MAIN FUSE 50 FG2 GLOW PLUGS FUSE 100A F1 FUEL PUMP FUSE 20A GLOW PLUGS PREHEATING K02 FUEL PUMP LB LIGHT BLUE YL BN BROWN WH WHITE BK BLACK OR ORANGE RD RED PK GY GN PP YELLOW PINK GREY GREEN BLUE PURPLE WIRE COLOR LEGEND REMARK Two colorwires are indicated through combination of the aforesaid initials as follows YL GN YELLOW GREEN crosswise colouring YL GN YELLOW GREEN lengthswise colouring 6 18 Gen ATEREX BRAND 10 15 15 15 10 5 5 10 10 5 25 10 15 10 10 10 10 10 10 10 5519
11. Genie Part No 57 4400 9210 GTH 5519 3 17 Section 3 Scheduled Maintenance Procedures July 2015 CHECKLIST D PROCEDURES D 2 10 Inspect the filter assembly to be sure that there leaks Replace Hydraulic Tank Return Filter Element 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 A dirty or clogged filter element may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filter element be replaced more often A CAUTION Bodily injury hazard Beware of hot oil Contact with hot oil may cause severe burns 1 Startthe engine 2 Raise the boom 3 Stop the engine 4 Release the pressure in the oil reservoir by loosening the filler breather cap 5 Unscrew the return filter 6 Install the new filter element 7 Tighten the filler breather cap 8 Record the hours the filter element was replaced and keep with your maintenance records 9 Start the engine 3 18 GTH 5519 Part No 57 4400 9210 July 2015 Section 3 Scheduled Maintenance Procedures D 3 Perform Engine Maintenance Engine specifications require that this procedure be performed every 1000 ho
12. E boner F brand aunssaud E E Sog 3 9119 SL OHM Y 9 c e 8 Z5 E TEOL THM mi 51 028 CE 019 SL 0HM 533 H21IMS 13A31 1NY 10024 TOES SL OHM 25 SE OHM ae RET E Tove ahead E TELO SL OHM m4 B as s 51029 4 cA E T1813 SCOHR dnd HM es 8 I J 5008 ux 108797 2 SVD 15 we 52049 C ma 3 5 5 lo X X S AWT3Y LV3H 38d MH SUM 55 Ss AS dm C um mm Ine TN 5119 HM T SCOHM E n ae a ee 105017 SL OHM 2 TT 18154 i 167007 SL OHM 5 Ad lt x a July 2015 Part No 57 4400 9210 Section 6 Schematics 2015 Ee ELECTRICAL SCHEMATIC Sheet 4 of 8 From SN GTH5515B 2365 1 2 4 5 ROAD LIGHTS SELECTOR LEVER FORWARD REVERSE LEVER EMERGENCY LIGHT A A 1 5 4 5858 EE
13. Genie part number 57 4700 0006 Genie Part No 57 4400 9210 GTH 5519 3 21 Section 3 Scheduled Maintenance Procedures July 2015 Checklist E Procedures E 1 Test or Replace the Hydraulic Oil Genie specifications require that this procedure be performed every 2000 hours or two years whichever comes first Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more frequently Refer to Section 2 Specifications NOTICE Component damage hazard The work area and surfaces where this procedure will be performed must be clean and Remove oil cap from top of hydraulic tank Using an approved hand operated pump drain the hydraulic tank into a suitable container Refer to Section 2 Specifications ACAUTION Bodily injury hazard Beware of 10 free of debris that could get into the hydraulic system Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary If the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test 1 Start the engine 2 Raise the boom to the upper position 3 Stop the engine Genie 3 22
14. 3 18 Perform Engine 3 19 Perform Axle 3 19 Inspect the Engine Air 114 4 4 441 3 20 Perform Engine 3 21 Checklist E Procedures 1 2 E 3 E 4 Test or Replace the Hydraulic 3 22 Perform Engine 2 3 23 Perform Engine 3 23 Perform Engine 3 24 Genie Part No 57 4400 9210 GTH 5519 xi July 2015 a TABLE OF CONTENTS Section 4 Repair Procedures 4 1 Boom Components Vel BOOM ions eens 4 2 1 2 Lift 4 6 1 3 Extend 4 0 00 4 7 1 4 Fork Level Cylinder 1000 00 4 8 1 5 Fork Tilt Cylinder sese 4 9 Operator s compartment 2 1 Operators 2 420 400 4 12 2 02 Machine Controls ete tato aes kt ev Ld n de 4 14 Fuel and Hydraulic Tanks 3 1 Fuel Tank cm 4 18 3 2 cBydra ulic Tank
15. 4 19 Engines dk aa a 4 20 4 2 Engine Fault 0 04044040040 0 4 20 Axle MEME 4 21 Hydraulic pumps 6 1 and Steering Function Pump 4 22 6 2 Hydrostatic Transmission 4 26 Manifolds TA Funcion 4 30 4 2 Coils idee re eren need 4 34 Genie xii GTH 5519 Part No 57 4400 9210 July 2015 TABLE CONTENTS Section 5 Section 6 Fault Codes 9 EE 5 1 Diagnostic Display 5 2 Engine Fault Codes Models with Deutz TD 2 9 14 5 3 Schematics 0 6 1 Electrical and Hydraulic Symbol Legends 6 2 Electrical Schematic 2 a 6 3 Hydraulic Schetfnatio 6 19 Genie Part No 57 4400 9210 GTH 5519 xiii July 2015 a TABLE CONTENTS This page intentionally left blank Genie xiv GTH 5519 Part No 57 4400 9210 2015 Section 2 Specifications MMM Specifications Machine Specifications Tires and wheels Tire size 12 x 16 5 Fluid capacities Tire ply rating 10 Fue
16. Xt6 1 EZ a 8 Ev 8 E E H H 2 EE Bg E S uo d3 Laa 8 Ls xz elm IM 2 s 805 14 3 T il m 8 des A LEE _ pd amp 5 amp Engine Power 3 GY0 75 137 60 75 1136 1 Sable Denn Sable _ _ BK0 75 E t __ Deutz _ _ 4 1 1 1 Gl 2 8 B6 K gt P r E X amp 69 m d 2 E 3 as 777 STARTER ALTERNATOR FUEL PUMP GLOW PLUG TRASMISSION TRASMISSION OIL FILTER AIR FILTER FORWARD EV REVERSE EV CLOGGED SWITCH CLOGGED SWITCH GTH 5519 6 11 July 2015 From SN GTH5515B 2365 57 4400 9210 5519 m l H MOT 1213 lt Set oR e mmm gt 6019 SL OHM SL 048 tme cro as 25 ELIS SL OHM 2 SH haav Lv3H 3ud Inssad 10 lt 25 NI amp beam 219 SLOHM stone etur gt eran 7 a 58 Ld 2h gt le i as
17. 411 412 412 520 597 624 624 624 624 630 630 630 639 651 651 651 652 652 652 653 654 655 655 655 Engine speed above warning threshold Overrun Mode Camshaft and Crankshaft speed sensor signal not available on CAN Physical range check high for differential pressure Venturiunit EGR Physical range check low for differential pressure Venturiunit EGR Sensor error differential pressure Venturiunit EGR signal range check high Physical range check low for EGR differential pressure Sensor error differential pressure Venturiunit EGR signal range check low Sensor error EGR cooler downstream temperature signal range check high Sensor error EGR cooler downstream temperature signal range check low EX Timeout Error of CAN Receive Frame TSC1TR Setpoint Break lever mainswitch and break lever redundancyswitch status not plausible SVS lamp short circuit to battery SVS lamp short circuit to ground SVS lamp open load SVS lamp powerstage over temperature Access error EEPROM memory delete Access error EEPROM memory read Access error EEPROM memory write CAN Bus 0 BusOff Status njector 1 in firing order short circuit High side to low side short circuit in the injector 1 in firing order njector 1 in firing order interruption of electric connection njector 2 in firing order short circuit High side to low side short circuit in the injector 2 in firing order njector 2 in firing order int
18. Position sensor error actuator EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 signal range check low 4766 0 Physical range check high for exhaust gas temperature downstream 000 000002 Sensor error exhaust gas temperature downstream DOC signal range check high Sensor error exhaust gas temperature downstream DOC signal range check low 4765 0 Physical range check high for exhaust gas temperature upstream DOC oo Genie 5 14 GTH 5519 Part No 57 4400 9210 2015 Section 5 Fault Codes FAULT CODES sm 1180 Sensor error exhaust gas temperature upstream turbine signal range check low 4360 Physical range check high for urea catalyst upstream temperature 4360 Physical range low for urea catalyst upstream temperature 4360 Sensor error urea catalyst exhaust gas temperature upstream signal range check high 4360 Sensor error urea catalyst exhaust gas temperature upstream signal range check low 1761 Urea tank level warning threshold exceeded 3361 Urea dosing valve short circuit to battery on high side 3361 Urea dosing valve short circuit to battery or open load on high side 3361 Urea dosing valve short circuit to ground or open load on low side 3361 Urea dosing valve short circuit on high side 4345 SCR heater relay urea returnline sekondary side open load 4366 SCR main relay secondary side open load 4343 SCR heater relay urea pressureline secondary side open load 4366 SCR main relay s
19. Xin m Tm UM Sond Zen gs E 2 WHS 6112 12066 YL1 2002 YL1 2003 YLT T2065 0815 OFT 8015 0081 ROLS 2 15 YL 2066 WHT 6973 ORT 180 75 1328 e 4 2 ORTOFON er cc E 5 E E C 1 4 5 j u d C A x E E qx 1 4 4 120 ae J 140 i 120 gt H B s vl s si vA 02 3 B o A A KS KT k6 77 30 15 1x 4 Relay Cord D Y D 158 p 080 75 3065 a 21075 3028 saa WHO 15 6021 15B ye WHO 75 6099 E 8 gt n ba t T IT xnl ca ye 8 1 1 2 E btt bus B50 B41 B45 o AT 1 1 X412 45 4 Hur 3 3 sa FUEL LEVEL HYDRAULIC OIL LOW HYDRAULIC PARKING BRAKE LOW GAUGE TEMPERATURE SWITCH OIL LIVEL SWITCH PRESSURE SWITCH 1 Optional Part 1 Genie ATEREX BRAND 6 14 GTH 5519 Part No 57 4400 9210 d Sheet 5 of 8 Section 6 Schematics ELECTRICAL SCHEMATIC 6 15 G GTH 5519
20. hot oil Contact with hot oil may cause severe burns Remove the drain plug Rinse out the inside of the tank using a mild solvent Install the drain plug and securely tighten Do not over tighten Fill the tank with hydraulic oil until the fluid level is in the center of the sight glass at the left side of the tank behind the cab Clean up any oil that may have spilled GTH 5519 Part No 57 4400 9210 July 2015 Section 3 Scheduled Maintenance Procedures E 2 Perform Engine Maintenance Engine specifications require that this procedure be performed every 2 years Deutz TD 2 9 L4 Dry air filter replace Coolant replace Required maintenance procedures and additional engine information is available in the Deutz TD 2 9 L4 Operation and Maintenance Manual Deutz part number 0312 3896 Deutz TD 2 9 L4 Operation and Maintenance Manual Genie part number 57 4700 0006 Part No 57 4400 9210 Genie GTH 5519 3 23 CHECKLIST E PROCEDURES E 3 Perform Engine Maintenance Engine specifications require that this procedure be performed every 3000 hours Deutz TD 2 9 L4 V rib belt and tensioning pulley replace Required maintenance procedures and additional engine information is available in the Deutz TD 2 9 L4 Operation and Maintenance Manual Deutz part number 0312 3896 Deutz TD 2 9 L4 Operation and Maintenance Manual Genie part number 57 4700 0006 Section 3 Scheduled Maint
21. 1 1 Boom How to Replace the Boom Wear Pads 1 Extend the boom until the wear pads accessible Fork end of the boom lower wear pads Using a lifting strap from an overhead crane or a fork lift of sufficient capacity lift the boom tube just enough to remove the weight from the pads Pivot end of the boom lower and upper wear pads Use a prisebar to remove the weight of the boom inner section from the pads Remove the wear pad retainer plates and remove the wear pads from the boom Lubricate the wear surface of the new pads Refer to Maintenance Procedure A 4 Lubricate the Boom Note Do not lubricate the side wear pads Install the wear pads Install and securely tighten the retainer plates Do not over tighten Genie GTH 5519 Part No 57 4400 9210 How to Remove the Lifting Fork Frame 1 With the boom in the stowed position attach a lifting strap from an overhead crane to the top of the lifting fork frame at the front of the boom Support the frame Do not apply any lifting pressure 2 Ifthe machine is equipped with the lifting fork frame locking cylinder disconnect the locking cylinder hoses from the boom AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Remove the screw securing the fork level cylinder pivot pin to the lifti
22. 8 ha 1 s 88 a z 8 215 5 5 1 lt a 7 Ei 4 1 8 5 mo 80 350 1080 1 E 4 T Dal EEE canm amp W 1 5 8 TT TET E z maT E 5 R R 5 gt lt R 9 1 E zB 2 ok 181 T6300 STH ew oe 9719 T E os TTN an 4 m n Das 5300 186 5300 8 8 55 1 TRIE ND TED DE Tore e ut 1502 TH HY 0897 be 5 ra E ete E ab 08100 INS SI 135 r gt 1 9 Tire gt Wo ye T Jd eS j ki Tears 7 esit IND 28 vos 8 5 E gt 5 2 5 E Le 8 t 6200 1 0 6 00 180 1 8 we 5 z E 2009 TAN 2 B 3 Y 5 ______ __ dl TOES S 2 2209 E E 8 E e ea 196 SINT SIND lees LNO 22 J E 6300 180 Dad 5 5 A 2 TET 51300 10 3 a 5 e zi 4 Srt iS E Tate ND DS Tee 2 lise uo 286 My aaa IE Je pune 25 3 k L 5 S L uin iere CE oir 2 nie ape DA d d o E 4 3 25 qeu M VO SIS GET SW 4 3 o i
23. DC with diode Part No 57 4400 9210 July 2015 Section 4 Repair Procedures How to Test a Coil Diode Genie incorporates spike suppressing diodes in all of its coils Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil Faulty diodes can fail to protect the electrical system resulting in a tripped circuit breaker or component damage AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Test the coil for resistance See 7 2 How to Test a Coil 2 Connect a 100 resistor to the negative terminal of a known good 9V DC battery Connect the other end of the resistor to a terminal on the Coil Resistor 100 Genie part number 27287 Note The battery should read 9V DC or more when measured across the terminals 3 Seta multimeter to read DC current Note The multimeter when set to read DC current should be capable of reading up to 800 mA 4 Connect the negative lead to the other terminal on the coil Note If testing a single terminal coil connect the negative lead to the internal metallic ring at either end of the coil Part No 57 4400 9210 Genie GTH 5519 4 35 MANIFOLDS COIL A 9
24. E F B 15 pe E F10 WA SA o2 101 lir E Lal FR ret BA RS 17 ICT 4 Rc 30 is x5 15 L m ix ix Ko K5 Kon 15 Be 13 L s 4 Y zi s 6052 CHANE 3 0 15 3071 T 64 15 3028 WHY 6021 WH1 6099 15 ae WHE 7046 m amp 515 x 4 3 5 E Xn n dn nli amp z id 8 E an 5 8 8 E 5 BEE 6 2 2 5158 BH BPT 8 850 826 x BAS PA TA PH V 1 2 B40 x36 x36 85 Ri 2 amp E upi D EET gt S x E i S Y SUE y E SS S Su 6 oF se es S n gt wa ee 5 SS 9 Genie ATEREX BRAND 6 4 GTH 5519 Part No 57 4400 9210 Section 6 Schematics July 2015 ELECTRICAL SCHEMATIC Sheet 3 of 8 Up to SN GTH5515B 2364 e 323 a 22 2 5 AA 8
25. Fuel and Hydraulic Tanks 3 1 Fuel Tank How to Remove the Fuel Tank Explosion and fire hazard Engine fuels are combustible Remove the fuel tank in an open wellventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Explosion and fire hazard Never drain or store fuel in an open container due to the possibility of fire 71155 Explosion and fire hazard When transferring fuel connect a grounding wire between the machine and pump or container Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Genie 4 18 GTH 5519 1 Open the engine cover and disconnect the battery negative terminal AAWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 2 Reach the rear side of the machine and remove the counterweight and the rear cover 3 Move to the center of the machine 4 Tag and disconnect the wire harness from the fuel level terminals 5 Disconnect the ground wire 6 Remove the filler cap from the fuel tank 7 Using an approved hand operated pump drain
26. Inspection A B C D E Perform after 400 hours B 7 Axle maintenance Checklist Y NR 1 Engine maintenance Place check in the appropriate box after each inspection procedure is completed Use the step by step procedures in this section to learn how to perform these inspections If any inspection receives tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend Comments Y yes acceptable no remove from service Perform every year D 6 Engine maintenance Checklist Y N R E 1 Hydraulic oil 2 5 2 Engine maintenance Perform every 3000 hours E 3 Engine maintenance Perform every 6000 hours E 4 Engine maintenance R repaired Genie 3 4 GTH 5519 Part No 57 4400 9210 July 2015 Section 3 Scheduled Maintenance Procedures A 1 Inspect the Manuals and Decals Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Maintaining the operator s and safety manuals in good condition is essential to safe machine operation Manuals are included with each machine and should be stored in the container provided in the operator s compartment An illegible or missing manual will not provide safety and operational information necessary for a safe ope
27. O mum F20 INSTRUMENT PANEL 10A K7 K8 Gp C K1 HIGH BEAM K2 LOW BEAM Ke x4 K9 K10 K5 LOW PRESSURE PARKING BRAKE REVERSE MODE K7 FORWARD MODE K8 START ENABLING SWITCH K9 OPTIONAL WARNING LIGHT FUSES AND RELAY ENGINE BOX Ref Description K01 GLOW PLUGS PREHEATING K02 FUEL PUMP MAIN FUSE 30A with A C becomes 50A FG2 GLOW PLUGS FUSE 100A E F1 FUEL PUMP FUSE 20A LB LIGHT BLUE YELLOW WIRE COLOR LEGEND BN BROWN PK PINK WH WHITE GY GREY REMARK Two colorwires are indicated through a BK BLACK GN GREEN combination of the aforesaid initials as follows OR GRANGE BL BLUE Y GN YELLOW GREEN crosswise colouring RD RED PP PURPLE Y GNz YELLOW GREEN lengthswise colouring Genie Part No 57 4400 9210 July 2015 Section 6 Schematics From SN GTH5515B 2365 to ELECTRICAL SCHEMATIC Sheet 1 of 8
28. Sheet 3 of 8 Section 6 Schematics ELECTRICAL SCHEMATIC From SN GTH5515B 2365 to 6 13 GTH 5519 G lt x ea ma 1 25 EBIS THM d X aR OOO OOOO BENE 5 619 LHM 5138 mtm 5 um SD 2819 THM H IAS EAE _ YOLWALIV a 0815 THM SUE ems z 5 Ll LT a _ E TESIT THM o 8 sk 7023 STHM 2 gt 38 gt an SUI p ed zy di 53 ag LIS 2o 9 zn mee gt STONE H 13 03345 TAA eum L As a 2 pV sp v V SLOHM gt amp ag zB e 17021 STHM EE E az ul LADANG X 2 a aoe Z 28 ee eee zB 18219 THM STIS c Ly hf 5 11 Dp 2 SH 0334S INONT Z 2 V se m9 V SEONG 55 E i SL One TANINI YILYM 5 al v 25 B 16200 SL OAD SRE 9 OS 99 249 SL OHM gt
29. a 1 J ad 4 al 4 3 E 58 5 5 3588 5 E 208 25 E E 8 2 2 35 ae MIS 10 is a 6044 BKIS 25 015 i un 23 ae MHILE 35 s 6 1 B E apa n n r a 1 F19 r Fil n WA 5 5A A 14 4 zY 7 15 15 15 30 30 p 30 Fh BPR 1 es T Relay Card L 4 4 mn 2 1 4 B 6 al a d B 5 HEE E E 8 E E E 5 E 5 ae 1075 2065 ae ORIS 4 LB1 1314 2 ts ae 15 T FEE 2 853 88 3 8 5 a 5 20 D u D Ei E 3 2000 guion 2000 B S Ej 1 22r 5 8 n in mln im im 4 g qq E 5 8 s 1413 EEE 11 T BS PsP od al 5 click 4 dee e 9 9 L 1 1 1 L 5 A 355 z E53 E42 z 2 3 5 4 31 35 51 Ei S8 S gt e aT 4 49 x S d y 4 4 ATEREX BRAND Genie GTH 5519 Part No 57 4400 9210 2015 Section 6 Schematics SS ELECTRICAL SC
30. blocked SCR Sensor urea supply module heater temperature plausibility error normal condition Sensor urea supply module heater temperature plausibility error cold start condition Sesnor urea supply module temperature plausibility error normal condition Sensor urea supply module temperature plausibility error cold start condition Urea tank without heating function heating phase Immobilizer status fuel blocked 8 Urea supply module heater temperature duty cycle in failure range Urea supply module heater temperature duty cycle invalid range Urea supply module temperature measurement not available 8 Urea supply module PWM signal period outside valid range 8 Detect faulty PWM signal from Supply Modul 8 Urea supply module temperature duty cycle in failure range 8 Urea supply module temperature duty cycle invalid range Handthrottle idle validation switch short circuit to battery 8 Accelerator pedal duty cycle PWM signal signal range check high 8 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 Genie 5 12 GTH 5519 Part No 57 4400 9210 2015 Section 5 Fault Codes FAULT CODES sm 9 8 Accelerator dutycycle PWM signal signal range check low 9 8 Accelera
31. connection 652 njector 2 in firing order interruption of electric connection 653 njector 3 in firing order interruption of electric connection 654 njector 4 in firing order interruption of electric connection 655 njector 5 in firing order interruption of electric connection 656 njector 6 in firing order interruption of electric connection njector 1 in firing order short circuit 652 njector 2 in firing order short circuit njector 3 in firing order short circuit njector 4 in firing order short circuit 655 njector 5 in firing order short circuit 656 njector 6 in firing order short circuit 651 High side to low side short circuit in the injector 1 in firing order 652 High side to low side short circuit in the injector 2 in firing order 653 High side to low side short circuit in the injector 3 in firing order 654 High side to low side short circuit in the injector 4 in firing order 655 High side to low side short circuit in the injector 5 in firing order 656 High side to low side short circuit the injector 6 in firing order 523615 Metering unit Fuel System open load 523615 Metering unit Fuel System powerstage over temperature Genie 5 8 GTH 5519 Part No 57 4400 9210 2015 Section 5 Fault Codes FAULT CODES sm Metering unit Fuel System short circuit to battery highside Metering unit Fuel System short circuit to ground high side Meterin
32. from service until the decals are replaced 4 Always return the manuals to the storage container after use Contact your authorized Genie distributor or Genie Industries if replacement manuals or decals are needed Section 3 Scheduled Maintenance Procedures July 2015 CHECKLIST A PROCEDURES A 2 Perform Pre operation Inspection Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Completing a Pre operation Inspection is essential to safe machine operation The Pre operation Inspection is a visual inspection performed by the operator prior to each work shift The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests The Pre operation Inspection also serves to determine if routine maintenance procedures are required Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine Genie 3 6 GTH 5519 A 3 Perform Function Tests Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Completing the function tests is essential to safe machine operation Function tests are designed to discover any malfunctions before the machine is put into service A malfunctioning machine must never be used If malfunctions are discovered the machine must be
33. integrator injector 6 in fring order maximum value exceeded 52393 523935 12 523936 523938 imeout Error BAM to packet for CAN Receive Frame AT1IGCVol1 information factors amp Sensorcalibration for NOX Sensor SCR system upstream cat DPF system downstream cat 523939 Timeout Error to BAM for CAN Receive Frame AT1IGCVol1 information factors amp Sensorcalibration for NOX Sensor 1 1 SPN 523921 523921 523921 823930 823930 523931 823931 523932 823922 523933 523933 523925 523936 SCR system upstream cat DPF system downstream cat 523940 Timeout Error PCK2PCK for CAN Receive Frame AT1IGCVol1 information factors amp Sensorcalibration for NOX Sensor SCR system upstream cat DPF system downstream cat 523941 Timeout Error to packet for CAN Receive Frame AT1OGCVol information factors amp Sensorcalibration for NOX Sensor SCR system downstream cat DPF system downstream cat Genie 5 38 GTH 5519 Part No 57 4400 9210 2015 Section 5 Fault Codes FAULT CODES sm 523942 Timeout Error BAM to for CAN Receive Frame AT1OGCVol2 information factors amp Sensorcalibration for NOX Sensor SCR system downstream cat DPF system downstream cat 523943 Timeout Error PCK2PCK for CAN Receive Frame AT1OGCVol2 information factors amp Sensorcalibration for NOX Sensor SCR
34. life Failure to perform this procedure can lead to poor engine performance and component damage Perform this procedure with the engine off and the parking brake engaged 1 Open the engine cover 2 Lift up the three clamping yoke 3 Remove the filter hood 4 Pull out the filter element Genie 3 20 GTH 5519 5 Blow out with dry compressed air max pressure 72 5 psi 5 bar from the inside to the outside if soiling is only slight 6 Renew the filter element if heavily soiled 7 Unscrew hexagon nut then pull out safety cartridge 8 Insert new safety cartridge screw on hexagonal nut 9 Fitthe filter element and make sure it is properly positioned 10 Refit the filter hood NOTICE As soon as the warning lamp on the cab dashboard switches on replace the outer element Never wash the cartridge with water or solvents Part No 57 4400 9210 2015 Section 3 Scheduled Maintenance Procedures CHECKLIST D PROCEDURES D 6 Perform Engine Maintenance Engine specifications require that this procedure be performed every year Deutz TD 2 9 L4 Engine monitor warning system Maintenance only to be carried out by authorised service personnel Fuel pre filter replace Required maintenance procedures and additional engine information is available in the Deutz TD 2 9 L4 Operation and Maintenance Manual Deutz part number 0312 3896 Deutz TD 2 9 L4 Operation and Maintenance Manual
35. low 172 ntake air sensor plausibility error 523921 Sensor burner temperature plausibility error 523921 Physical range check high for burner temperature Genie Part No 57 4400 9210 GTH 5519 5 13 Section 5 Fault Codes July 2015 FAULT CODES SPN Short Text Detail 523921 105 0 Hion caged air cooker temperate waring resno exceed 22221 5 0 High charged air cooler temperature shutoffthresholdexceeded o 0 _ Physical ange chek high for EGR coner 1 Physa range or EGR cooler 6 Actuator error EGR Valve es 9 3 6 or Throttle Valve 6 1 7 8 T range check high 5 _ AdutorerorEGRVave 2936 or TrotieVeve 6 78 signal ange creton ost 7 Actuator position for EGR Vale sos or Throttle Vale 7 8 not plausible 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 powerstage over temperature EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 short circuit to battery EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 short circuit to ground 6 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
36. pump on the hydrostatic transmission pump 10 Start the engine and prime the pump See 6 2 How to Prime the Hydrostatic Transmission Pump 11 Inspect for leaks 12 Adjust the pump pressure See 6 2 How to test the Hydrostatic Transmission Pump Part No 57 4400 9210 July 2015 How to Prime the Hydrostatic 7 Transmission Pump AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Connect a 0 to 870 psi to 60 bar pressure gauge to port TP3 hydrostatic transmission boost pressure test port Start the engine Run at low idle for 5 seconds Shut the engine off and wait for 15 seconds Start the engine Run at low idle for 10 seconds Shut the engine off and wait for 15 seconds Note Repeat step 3 until the pressure gauge connected to TP3 reads 360 psi 25 bar or greater Apply the brake pedal and start the engine Shift the transmission into forward and disengage the emergency brake Release the brake pedal and slowly increase the engine rpm until the machine starts to move Apply the brake Section 4 Repair Procedures HYDRAULIC PUMPS Shift the transmission into reverse Release the brake pedal and slowly increase the engine rpm until the machine st
37. reference mark Second mark 4 Tighten the hex nut until the mark on the hex nut is aligned with the second mark on the body hex fitting 5 Operate all machine functions and inspect the hoses and fittings and related components to confirm that there are no leaks Section 2 Specifications July 2015 SPECIFICATIONS SAE FASTENER TORQUE CHART eThis chartis to be used as a guile only unless noted elsew here m this m anuale A574 High Strength Grade 8 65 SZE THREAD Grade 5 lt gt LUBED mus wa xw ia L2 80 9 10 ns no 124 140 158 10 147 __28 90 101 120 135 120 135 160 18 140 158 LUBED LUBED T 282 325 ef 515 ___ 26 352 35 474 37 501 49 664 43 583 7 L4 3 501 49 664 50 678 70 947 _ 61 827 20 41 555 55 745 60 813 80 1084 __68 92 1 1 126 20 64 867 85 115 90 122 120 162 105 142 3 9 149 120 162 150 203 3139 1 18 90 122 120 162 130 176 170 230 140 189 244 271 433 __16 220 298 406 310 420 420 569 350 474 a 691 759 iN 2 52 5 1044 12 530 718 710 962 750 1016 990 1342 840 1139 1 1477 1654 1 2074 2
38. rm Ur eee m LX J 05 ANION LUVLS 6619 SL OHM 57078 00175149 7 2 TOOT SLOAD aa o ee dee on ta a 1 55 84 15008 lt 5 8619 SL OHM 4008 22 51151 SLOHM 2 sque mee t NOILISOd 181038 g3 18261 509717 3 aa 8221 51081 PA 519 SL OHM 1251 2514 e 16130 5280 1 83075240 8101 517080 a Ler 0 gt 9Nn002 1 2 1 2 y 2 0029 SL OHM n 12919 50491 Si 29191 SOAD aN SKINA 18 1 Gea ST FT 6E6LF HIH NYJ a i 2 SN TUNS 54 a z i I 1019 SORT T 0719 5 049 Ss Ing d 28 A ER A 125 25 S 2 SOND qo B 5 2 S u01v831322V oN ran i B S 2 2 5 yu Lx E 2189 SUOHM mae 2785 SOHN 2 i 701 24 06 11445 YIMOd x 8 B m f At ea L 22 Ed EI 2 10693 saa 73 11 H sls E esse SEI ele ala alin sess sis ag xem gt 5 11 14 11 1 aa 55 lt Section 6 Schematics ELECTRICAL SCHEMATIC Sheet 2 of 8 6 12
39. seres 9 Timeout sero 9 Timeout 9 Passve Timeout CAM Receve Fane sers 9 SSCS sers o Pasve Tine orci sume 9 Timeout Eroro aN RereieFrane TS01AE Genie Part No 57 4400 9210 GTH 5519 5 5 Section 5 Fault Codes July 2015 FAULT CODES sm 523606 9 _ Timeout Error of CAN Receive Frame TSC1AR Retarder 898 Timeout Error of CAN Receive Frame TSC1TE Setpoint 520 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 low battery voltage 630 Access error EEPROM memory delete 630 Access error EEPROM memory read 630 Access error EEPROM memory write 411 Physical range check low for EGR differential pressure 523612 Internal software error ECU injection cut off 190 Engine speed above warning threshold FOC Level 1 190 Engine speed above warning threshold FOC Level 2 190 Engine speed above warning threshold Overrun Mode 108 Sensor error ambient air pressure signal range check high 108 Sensor error ambient air pressure signal range check low 171 Sensor error environment temperature signal range check
40. shall be completed daily quarterly semi annually annually and every 2 years as specified on the Maintenance Inspection Report The frequency and extent of periodical examinations and tests may also depend on national regulations AWARNING Failure to perform each procedure as presented and scheduled could result in death serious injury or substantial damage Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Use only Genie approved replacement parts Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection Unless otherwise specified perform each maintenance procedure with the machine in the following configuration o Machine parked on firm level surface n the stowed position o Key switch in the off position with the key removed o Wheels chocked Part No 57 4400 9210 Genie GTH 5519 3 1 About This Section This section contains detailed procedures for each scheduled maintenance inspection Each procedure includes a description safety warnings and step by step instructions Symbols Legend Safety alert symbol used to A alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates an imminently hazardous situation which if not
41. spaa 2 INO DN 5 22 spyus to P 97 amea plovayos 100 C 4 wate WS 14 74 1 m p zl 42 5 EIE 5 5 555 D 1 A 1 114 1 6 5 enie G GTH 5519 Part No 57 4400 9210 Section 6 Schematics July 2015 OO Se ELECTRICAL SCHEMATIC Sheet 4 of 8 Up to SN GTH5515B 2364 1 2 3 4 5 Road Ligths Selector Lever Windscreen Windscreen Roof Rear Road Ligths Switch Stop Ligth Motor Washer Pump Famire 15 pe 100021 BKI sy E 5 ILE 1 i 21 PN z fds 2 1 1 eo b 11 518 M He EN 3 y y UAI a os E xul 21 M22 Mi MLA ae 2 2 E in zg 25 e 1100081 l E al s E E z E 35 Ei E s 18 ls 5 S zl s al al a a
42. strap from the overhead crane to the lifting cylinder rod side and put some tension on it 7 Using a soft metal drift remove the slave cylinder locking pin from the boom support Crushing hazard The cylinder Will fall if not properly supported when the pivot pin is removed from the machine Part No 57 4400 9210 Genie GTH 5519 4 3 BOOM COMPONENTS 8 Flip the slave cylinder towards the cab 9 Using a soft metal drift remove the lift cylinder locking pin boom side 10 Operate the 2 overhead cranes at the same time to lower the boom being careful to rest the lift cylinder onto the support previously placed underneath and the boom tip onto another stand positioned to support the front part of the boom 11 Hook the 3 lifting points and then slowly lift the boom 12 Tag disconnect and plug the hydraulic hoses that go to the extend retract fork tilt and fork leveling cylinders and the quick coupling cylinder if equipped AAWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 13 Using a soft metal drift remove the pin securing the boom to the machine Crushing hazard The boom will fall if not properly supported when the pivot pin is removed from the machine 14 Carefully remove the boom assembly from the machine and p
43. tagged and removed from service Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine Part No 57 4400 9210 July 2015 Section 3 Scheduled Maintenance Procedures A 4 Lubricate the Boom Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Greasing the specified locations is essential for good machine performance and service life Operating the machine with little or no grease may cause the machine to perform poorly and continued use may cause component damage 1 Fully extend and raise the boom then retract the boom checking to insure it operates smoothly There should be a light film of lubricant on wear pad contact surfaces Result Boom operates smoothly and a thin film of lubricant is visible Proceed to step 4 Result Boom does not extend or retract smoothly and no lubricant is visible on wear pad contact surfaces Proceed to step 2 2 Apply athin layer of grease to the underside of the number 2 boom tube where it makes contact with the number 1 boom tube lower wear pads 3 Lubricate the top and side boom tube wear pads 4 Return the boom to the stowed position 5 Reach the pivot end of the boom and lubricate the chain return pulley using a grease gun Grease Specification PTFE INTERFLON FIN GREASE LS 2 CHECKLIST A PROCEDURES A 5 Perfo
44. the drain plug from the hydraulic tank and completely drain the tank A CAUTION Bodily injury hazard Beware of hot oil Contact with hot oil may cause severe burns Part No 57 4400 9210 Genie GTH 5519 4 19 FUEL AND HYDRAULIC TANKS 7 Go under the machine and remove the drive shaft 8 Loosen all the clamps and pull out the hoses 9 Disconnect the electrical harnesses 10 Remove the wire harness from bulb on the hydraulic filter 11 Place a container of suitable size under the hydraulic hoses before disconnecting NOTICE Used oils must be handled and disposed of according to local regulations 12 Disconnect all hydraulic hoses 13 Loosen the bottom clamp and disconnect the oil fill hose 14 Attach a lifting strap from an overhead crane to the lifting points of the tank Crushing hazard The tank could become unbalanced and fall if not properly supported when removed from the machine 15 Remove the retaining fasteners securing the tanks to the machine 16 Lift the tank slightly and push it forward manually until you can lower it on the ground Section 4 Repair Procedures July 2015 Engines 4 1 Engines How to Repair the Deutz TD 2 9 L4 Engine Repair procedures and additional engine information is available in the Deutz TD 2 9 L4 Workshop Manual Deutz part number 03123982 Deutz TD 2 9 L4 Workshop Manual Genie part number 57 4700 0022 Genie 4 20 GTH 5519
45. the fuel tank into a container of suitable capacity Refer to Section 2 Specifications A WARNING Explosion and fire hazard When transferring fuel connect a grounding wire between the machine and pump or container Be sure to only use a hand operated pump suitable for use with gasoline and or diesel fuel 8 Loosen all the clamps and pull out the hoses 9 Remove the retaining fasteners securing the tanks to the machine 10 Remove the tank from the machine NOTICE The reduced weight of the empty tank makes it possible to handle it manually Part No 57 4400 9210 July 2015 Section 4 Repair Procedures 3 2 Hydraulic Tank How to Remove the Hydraulic Tank AAWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended 1 Lift the boom 2 Open the engine cover and disconnect the battery negative terminal AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 3 Close the oil intake valve 4 Remove the filler cap from the hydraulic tank 5 Place a drain pan or other suitable container under the hydraulic tank Refer to Section 2 Specifications 6 Remove
46. the tires off the ground Place blocks under the chassis for support AAWARNING Crushing hazard The chassis will fall if not properly supported 6 Remove the lug nuts Remove the tire and wheel assembly from both ends of the axle 7 Support and secure the axle to an appropriate lifting device 8 Use a soft metal drift to remove the pivot pin 9 Remove the fasteners securing the axle to the chassis Remove the axle from the machine Crushing hazard The axle will fall if not properly supported when the fasteners are removed from the machine Bolt torque specification Axle mounting bolts 515 ft lbs 700 Nm Section 4 Repair Procedures I Hydraulic Pumps 6 1 Boom and Steering Function Pump How to Test the Boom and Steering Function Pump 1 Connect to 5000 psi 0 to 350 bar pressure gauge to port TP1 Start the engine Increase the engine speed to maximum rpm Activate and hold boom retract Without releasing the joystick keep pushing the throttle pedal Result the pressure gauge reads 3915 psi 270 bar The pump is good Pressure is not within specification The pump needs to be adjusted OR the pump or pump coupling is faulty and needs to be serviced or replaced NOTICE Component damage hazard There is no relief valve in the hydraulic pump and the pump can be damaged if the pressure is allowed to exceed specification When testing the pump crank the engine in on
47. 100 100 100 100 100 100 102 102 102 102 105 105 105 105 107 107 107 108 108 110 110 110 110 111 132 132 132 132 157 157 164 Sensor error water fuel signal range check high Sensor error water in fuel signal range check low Water in fuel level prefilter maximum value exceeded High oil pressure warning threshold exceeded High oil pressure shut off threshold exceeded Low oil pressure warning threshold exceeded Low oil pressure shut off threshold exceeded Sensor error oil pressure signal range check high Sensor error oil pressure sensor signal range check low Charged air pressure above warning threshold Charged air pressure above shut off threshold Sensor error charged air pressure signal range check high Sensor error charged air pressure signal range check low High charged air cooler temperature warning threshold exceeded High charged air cooler temperature shut off threshold exceeded Sensor error charged air temperature signal range check high Sensor error charged air temperature signal range check low EN High air filter differential pressure warning threshold exceeded Sensor error airfilter differential pressure short circuit to battery Sensor error airfilter differential pressure short circuit to ground Sensor error ambient air pressure signal range check high Sensor error ambient air pressure signal range check low EN High coolant temperature warning threshol
48. 3 6 or Throttle Valve 6 1 7 8 short circuit to ground 67 5 Actuator error EGR Valve 2 9 3 6 Throttle Valve 6 1 7 8 Voltage below threshold 51 5 Actuator error EGR Valve 2 9 3 6 Throttle Valve 6 1 7 8 signal range check low Actuator EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 open load 5 Actuator error EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 signal range check low 51 5 Actuator EGR Valve 2 93 6 or Throttle Valve 6 1 7 8 open load 6 Actuator error EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 signal range check high 6 Actuator error EGR Valve T 9 3 6 or Throttle Valve 1 7 8 signal range check high 5 2938 51 Actuator error EGR Valve ve 2 5 3 6 Throttle Valve ve 7 8 Overload short circuit __ _ houam postion or EGR Vave 2928 6 7 711 5r Actuator EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 powerstage over temperature Actuator EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 over temperature je duraton PWN sa sal PUM sia ar o8 Acaeraton ucla aon Genie Part No 57 4400 9210 GTH 5519 5 23 Section 5 Fault Codes July 2015 FAULT CODES sm 97 97
49. 304 11 6 1460 199 1950 2643 2370 3213 3160 4284 2600 3620 2 4067 METRI FASTENER TORQUE CHART This chartis to be used as a guide only unless noted elsew here m this m anuale S ize Class 4 6 Class 8 8 Class 12 9 DRY RY us ory LUBED 5 wm i bs mba Nm 5 16 18 21 24 41 463 54 618 58 663 78 884 68 7 75 91 103 6 19 305 36 407 69 787 93 105 100 113 132 15 116 132 155 175 512 eo 683 116 132 294 ft bs ft lbs ft lbs ft lbs Nm ft lbs um ft lbs ft lbs Nm s 54 741 72 988 14 191 188 255 201 273 265 365 235 32 314 426 147 378 372 505 399 541 4627 633 844 12 189 256 251 341 486 66 649 88 697 945 922 125 81 110 108 147 301 108 40 543 774 105 103 140 110 150 147 200 129 175 172 234 16 469 636 625 125 166 365 503 20 124 121 165 441 458 610 713 22 124 169 166 225 331 450 442 600 458 622 612 830 536 727 715 970 214 570 791 1055 682 925 909 1233 Genie 15 5519 Part No 57 4400 9210 1 July 2015 Section 3 Scheduled Maintenance Procedures Scheduled Maintenance Procedures Observe and Obey Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine Scheduled maintenance inspections
50. 4 2 Engine Fault Codes How to Retrieve Engine Fault Codes When the engine Electronic Control Module ECM detects an abnormal operating condition a fault code is immediately stored in the ECM memory At the same time a colored warning lamp is illuminated and the fault code is shown on the engine diagnostic display located on the dashboard in the operator s compartment To learn the specifications of and how to use the fault codes refer to Section 5 Fault Codes Part No 57 4400 9210 July 2015 Section 4 Repair Procedures 5 1 Axle How to Remove the Axle AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is required 1 Chock the wheels 2 Remove the fasteners securing the driveshaft to the axle Remove the driveshaft from the machine 3 Tag and remove the hydraulic hoses from the axle AAWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 4 Loosen the lug nuts of both wheels on the axle to be removed Do not remove the lug nuts Part No 57 4400 9210 Genie GTH 5519 4 21 5 Raise the end of the machine until
51. 4345 4345 4345 4345 4345 4360 4360 4360 4360 4365 4366 4366 4366 4366 4366 4366 4366 4366 4374 4375 4375 4375 4376 4376 4376 4376 4376 4376 4376 4765 4765 4766 4766 General pressure check error SCR SCR heater urea returnline short circuit to battery SCR heater urea returnline short circuit to ground SCR heater relay urea returnline sekondary side open load SCR heater relay urea returnline primary side open load Sensor backflow line pressure SCR plausibility error Physical range check high for urea catalyst upstream temperature Physical range low for urea catalyst upstream temperature Sensor error urea catalyst exhaust gas temperature upstream signal range check high Sensor error urea catalyst exhaust gas temperature upstream signal range check low Urea tank temperature too high SCR Tank heating valve short circuit to battery SCR Tank heating valve short circuit to ground SCR main relay secondary side open load SCR main relay secondary side Shortcut to battery SCR main relay secondary side shortcut to ground SCR Tank heating valve secundary side open load SCR tank heating valve primary side open load SCR heater relay urea tank powerstage output over temperature Pressure stabilisation error dosing valve SCR Urea pump motor short circuit to battery Urea pump motor short circuit to ground Urea pump motor open load SCR reversing valve short circuit to battery
52. 914 Glow plug control short circuit to ground 639 CAN Bus 0 BusOff Status 1231 CAN Bus 1 BusOff Status 1235 CAN Bus 2 BusOff Status 102 Charged air pressure above warning threshold 102 Charged air pressure above shut off threshold 110 Sensor error coolant temperature signal range check high 110 Sensor error coolant temperature signal range check low 110 High coolant temperature warning threshold exceeded 110 EM High coolant temperature shut off threshold exceeded 111 Coolant level too low 523929 EE Fuel Balance Control integrator injector 1 in firing order maximum value exceeded 523930 Fuel Balance Control integrator injector 2 in firing order maximum value exceeded 523931 Fuel Balance Control integrator injector 3 in firing order maximum value exceeded 523932 Fuel Balance Control integrator injector 4 in firing order maximum value exceeded 523933 Fuel Balance Control integrator injector 5 in firing order maximum value exceeded 523934 Fuel Balance Control integrator injector 6 in firing order maximum value exceeded 523929 Fuel Balance Control integrator injector 1 in firing order minimum value exceeded 523930 Fuel Balance Control integrator injector 2 in firing order minimum value exceeded 523931 Fuel Balance Control integrator injector 3 in firing order minimum value exceeded 523932 Fuel Balance Control integrator injector 4 in firing order minimum valu
53. CUIT 5 Fai Fe M B i 15 2 COLORS LEGENDA LIB Open circuits high pressure lines Ao Diesel engine 1 Hydrostatic transmission E high pressure lines 1 Functions driving lines i Low pressure and transmission Cracking pr ssure _ 4 Cracking press LH charge pressure lines 520 bar 0s 7 540 psi Load sensing and piloting lines i 1 Se es eee l Suction lines cracking press A 555 are _ 95 7 180 psi id Tank lines Hydrostatic transmission X2 pump max displacement 4 rev Hydrostatic transmission _shutoff valve Check valve boost pressure test port r e Suction screen cracking pressure TP 8 bar 116 psi Oil tank capacity 1 Y 75 liters 20 gallons
54. E Tad B E E V 09079780 TEST 570 0907970 2 tT 1 cuo NE eee eee es a 3 E 8 97 W E 58 55 lt 1 ji Er S 1 xl 2 2 422 TNTS ZAA 1 ANSHA E 55 1 1 EI Sz 1 TOT STAN aT STAM TE THSOSTSTHM T 7909 STAM 5 I THOT STAR 1 QNEM 5 8 i E 5 a lt 8 T Ez E E B 1 19075780 119075780 DERE 3 055384 HoE 1 10530 780 zm 5 T 1 s I 5 1 5 5 T 5 54 ee pe A gt s E909 STHA HOSS3HdWOO f HOLMS 3Nnss3ud TOT 2 T3505 STH ES d i E D T 00197 i 0019 gt 00197 7d 75157 TERTIA 9 WunW je 5 ee a 5 lt ea ea From SN GTH5515B 2365 to July 2015 6 17 enie G GTH 5519 Part No 57 4400 9210 Section 6 Schematics July 2015 ELECTRICAL SCHEMATIC Sheet 8 of 8 From SN GTH5515B 2365 J 2 CABIN FUSES RELAY BOARD SGD x1 K5 x2 K7 K8 X4 K10
55. Genie A TEREX BRAND Service Manual Serial Number Range G TH 55 1 9 Deutz Tier 41 From GTH5514B 101 Part No 57 4400 9210 Rev July 2015 July 2015 Introduction Important Read understand and obey the safety rules and operating instructions in the Genie GTH 5519 Operator s Manual before attempting any maintenance or repair procedure This manual provides detailed scheduled maintenance information for the machine owner and user It also provides troubleshooting fault codes and repair procedures for qualified service professionals Basic mechanical hydraulic and electrical skills are required to perform most procedures However several procedures require specialized skills tools lifting equipment and a suitable workshop In these instances we strongly recommend that maintenance and repair be performed at an authorized dealer service center Compliance Machine Classification Group B Type 3 as defined by ISO 16368 Machine Design Life Unrestricted with proper operation inspection and scheduled maintenance Technical Publications Genie has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Genie policy Therefore product specifications are subject to change without notice Readers are encouraged to notify Genie of errors and send in suggestions for improvement All communications will be carefully considered for fu
56. HEMATIC Sheet 5 of 8 Up to SN GTH5515B 2364 1 2 3 4 5 Air Condition Switch Cabin Fan Switch Heating Fan Work Light Work Work fork Flashing Cabin Switch Light Light Front Light Rear Beacon Interior Light rs e 3 z 3l g 2 3 1 E 8 8 1 2 b E E 3 5 amp r3 C gag m 2 E ES El 5 jg e 9 19 SJA sols ss L i a BE 21 8 amp d 2 X21 F E 5 LN e zl Y i s 2 2 2 E 2 2 in n 243 E u 6 v 1 H 3 ada es dedulu da di 1 8 E 5 8 88 g n 24 wl amp 5 L S 8 d 8 8 RD15 25 BKIS 45 a n 1 5 Ay 4 a 2 8 Uum q 21 8 Switch 15 E d BY Fil FB a E pr i 25A BA is A da i b 15 15 15 B105A B ie Temperature 5 8 he Relay Card al 21 E E E 5 E am 5l 5 A l 3 3 co
57. IGHT SWITCH PARKING BRAKE SWITCH e 4 3 _ E r 7 1 Sess IE iat Ex wr 4 y 1 1 1 5 La MN 4 gl E x E M22 2 1 E B m Aun T 3 Ll 4 A 5 s 8 4 B 4 An E 8 E B u LI 081 0119 4 3 E E YL1 2066 z E 2 3i Peri 8 OFT E bae 0815 WHS 017 sae 0 75 6565 ste 0 75 6565 saa 6112 RT ETTI sepe ORIS 6973 x 2 5 5 E 8 5 n 1 n d m C C F19 4 F17 F 10A 10 104 ata F6 Fl 5 5 H 15 15 15 30 F3 F2 15 Cord 1 9 3 B x bn asp Y1 2065 i 1015 20651 15 D D 2007 l sg L1 2003 inim Xn Xm ea aps 1 y 4 nal xo Koad un dm 8 E E 4 2 41 55 1 I 4 58 62 1 4 1 gy E E 1 ks xs i 5 hib X 1 E X39 855 49 1 2 5 x X55 1 2 I F ES dr E S il E BUZZER HORN FRONT LEFT FRONT RIGHT REAR LEFT REAR RIGHT EV PARKING ROAD LIGHT ROAD LIGHT ROAD LIGHT ROAD LIGHT BRAKE
58. ING Bodily injury hazard This 7 Remove the function manifold procedure requires specific VAWARNING Crushing hazard The function repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note When removing a hose assembly or fitting the fitting and or hose end must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications Note Perform this procedure with the engine off and cool to the touch 1 Close the hydraulic tank ball valve 2 Remove the central cover of the machine 3 Remove the lateral cover of cabin 4 Tag disconnect and plug the hoses from the function manifold A WARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 5 Support and secure the function manifold to a suitable lifting device Do not apply lighting pressure Genie manifold will fall if not properly supported when the fasteners are removed from the machine Part No 57 4400 9210 GTH 5519 4 31 Section 4 Repair Procedures July 2015 Se MANIFOLDS How to Test the Function Manifold 1 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge t
59. Inspect for exhaust leaks i e carbon buildup around seams and joints 5 Close the engine access cover Genie 3 12 GTH 5519 B 3 Inspect the Tires Wheels and Lug Nut Torque Genie requires that the first inspection be performed after the first 50 hours of operation Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the tires and wheels in good condition including proper wheel fastener torque is essential to safe operation and good performance Tire and or wheel failure could result in a machine tip over Component damage may also result if problems are not discovered and repaired in a timely fashion AAWARNING Bodily injury hazard An overinflated tire can explode and could result in death or serious injury Tip over hazard Do not use temporary flat tire repair products The tires on some machines are foam filled and do not need air added to them 1 Check all tire treads and sidewalls for cuts cracks punctures and unusual wear 2 Check each wheel for damage bends and cracks 3 Check each lug nut for proper torque Refer to Section 2 Specifications 4 Check the air pressure in each tire Refer to Section 2 Specifications Part No 57 4400 9210 July 2015 Section 3 Scheduled Maintenance Procedures B 4 Perform Hydraulic Oil Analysis Genie requires that this procedure be performed every 250 hours or quarterly whiche
60. N Receive Frame AT1IGCVol1 information factors amp Sensorcalibration for NOX Sensor SCR system upstream cat DPF system downstream cat 3234 EN Timeout Error of CAN Receive Frame 1061 NOX sensor SCR system downstream cat DPF system downstream cat 3234 DLC Error of CAN Receive Frame AT101Vol NOX Sensor SCR system downstream cat DPF system downstream cat length of frame incorrect 3234 Timeout Error of CAN Receive Frame AT10G1Vol NOX sensor SCR system downstream cat DPF system downstream cat 523941 Timeout Error BAM to packet for CAN Receive Frame AT1OGCVol2 information factors amp Sensorcalibration for NOX Sensor SCR system downstream cat DPF system downstream cat 523942 Timeout Error BAM to BAM for CAN Receive Frame AT1OGCVol2 information factors amp Sensorcalibration for NOX Sensor SCR system downstream cat DPF system downstream cat 523943 Timeout Error PCK2PCK for CAN Receive Frame AT1OGCVoI2 information factors amp Sensorcalibration for NOX Sensor SCR system downstream cat DPF system downstream cat 9 Timeout sean 9 Timeout Funcion vode con se 9 Timeout Eroro AN Ree PENO preheat comard sess 9 Timeout Eroro AN RereieFrane VAM AGS ser o Timeout Eroro CANRecene Fame UMa AGS sensora sms 9 Timeout Eroro aN erste Frame Seus tunera aree 9
61. Perform this procedure with the engine off and cool to the touch 1 2 3 4 Open the engine cover Remove the cover that is under engine Install the boom function pump on the engine Install the hoses onto the pump Install the hoses retaining rings and fasteners AWARNING Bodily injury hazard Spraying 5 hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Open the hydraulic tank ball valve Check the hydraulic fluid level in the hydraulic tank Add fluid if needed Start the engine and prime the pump See 6 1 How to Prime the Boom and Steering Function Pump Inspect for leaks Adjust the pump pressure See 6 1 How to test the Boom and Steering Function Pump Genie 4 24 GTH 5519 Part No 57 4400 9210 July 2015 Section 4 Repair Procedures 0 HYDRAULIC PUMPS How to Prime the Boom and Steering Function 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 Genie Part No 57 4400 9210 GTH 5519 4 25 Section 4 Repair Procedures IIi HYDRAULIC PUMPS 6 2 Hydrostatic Transmission Pump How to Test the Hydrostatic Transmi
62. Receive Frame ComMS_Sys5TO error memory Slave Master Slave internal CAN message Master Slave internal CAN message Master Slave internal CAN message Master Slave internal CAN message Master Slave internal CAN message Timeout error of CAN Receive Frame ComMS_Sys6TO error memory Slave Master Slave internal CAN message Genie 5 18 GTH 5519 Part No 57 4400 9210 2015 Section 5 Fault Codes FAULT CODES SPN FM ShortTextDetal __ _ _ __ __ Master Slave Message Counter Error of CAN Receive Frame ComMSMoFOvR Master Slave Checksum Error of CAN Receive Frame ComMSMoFOvR 9 Master Slave CAN Messsage Length Error of CAN Receive Frame ComMSMoFOvR 9 Timeout error CAN message ComMSMoFOvR1TO error memory Slave 9 Message copy error in the Master Slave data transfer CAN Transmit Frame ComTrbChActr BusOff Satus Wastegate CAN Transmit Frame ComTrbChActr disable error wastegate CAN Transmit Frame ComTrbChActr plausibility error wastegate Timeout Error of CAN Transmit Frame ComTrbChActr Wastegate Deviation of the exhaust gas temperature setpoint to actual value downstream DOC too high check of missing injector adjustment value programming IMA injector 7 in firing order check of missing injector adjustment value programming IMA injector 8 in firing order njector cylinder bank 2 slave short circuit njector powerstage output Sl
63. SCR reversing valve short circuit to ground SCR reversing valve short circuit to ground SCR reversing valve open load SCR reversing valve open load SCR reversing valve over temperature SCR reversing valve over temperature Physical range check high for exhaust gas temperature upstream DOC Physical range check low for exhaust gas temperature upstream DOC Physical range check high for exhaust gas temperature downstream DOC Physical range check low for exhaust gas temperature downstream DOC Genie Part No 57 4400 9210 GTH 5519 5 31 Section 5 Fault Codes July 2015 FAULT CODES sm Sensor exhaust gas temperature upstream DOC plausibility error Sensor error exhaust gas temperature upstream DOC signal range check high Sensor error exhaust gas temperature upstream DOC signal range check low Sensor exhaust gas temperature downstream DOC plausibility error Sensor exhaust gas temperature OxiCat downstream normal operation plausibility error Sensor exhaust gas temperature OxiCat downstream regeneration plausibility error Sensor error exhaust gas temperature downstream DOC signal range check high Sensor error exhaust gas temperature downstream DOC signal range check low Controller mode switch short circuit to battery Controller mode switch short circuit to ground Manipulation control was triggered Timeout error in Manipulation control Pressure Relief Val
64. Schematic Page Genie iv GTH 5519 Part No 57 4400 9210 July 2015 INTRODUCTION Serial Number legend Genie A TEREX BRAND MODEL GTH 5519 SERIAL NUMBER GTH5514 B xxxxx ATTACHMENT MANUFACTURE DATE 04 10 13 TOTAL TRUCK WEIGHT LBS 10 540 Ibs 4 780 kg MAX LIFT CAPACITY LBS 5 500 LBS LIFT CAPACITY LBS AT MAX LIFT HEIGHT 4 400 LBS OUTRIGGERS UP N A GTH 55 14 B OUTRIGGERS DOWN N A COUNTRY OF MANUFACTURE Italy Model Sequence MANUFACTURER number Terexlift s r l Year of Zona industriale Buzzacchero manufacture 06019 Umbertide PG Italy Facility code THIS FORKLIFT TRUCK COMPLIES WITH ANSI ITSDF B56 6 2011 CSA B335 04 Serial number Serial label located inside chassis Genie Part No 57 4400 9210 GTH 5519 July 2015 X T J mus This page intentionally left blank Genie vi GTH 5519 Part No 57 4400 9210 2015 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 identified in the Operator s Manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless M
65. Section 4 Repair Procedures A OPERATOR S COMPARTMENT How to Remove the Brake How to Remove the Gauge Pedal Assembly Cluster Assembly 1 Remove the front dashboard lower part 1 Open the engine cover and disconnect the battery negative terminal 2 Open the engine cover and disconnect the A WARNING Electrocution burn hazard battery negative terminal Contact with electrically charged A WARNING Electrocution burn hazard circuits could result in death or Contact with electrically charged serious injury Remove all rings circuits could result in death or watches and other jewelry serious injury Remove all rings watches and other jewelry 2 Remove the front dashboard lower part 3 Remove the retaining fasteners securing the 3 Remove the retaining fasteners securing the brake pump to the support gauge cluster 4 Tag and disconnect the brake harness 4 Tag and disconnect the wire harness from the gauge cluster Remove the gauge cluster from 5 Tag disconnect and plug the hydraulic hoses of the machine the brake pedal pump AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to Squirt or spray 6 Remove the pin securing the brake pedal to the brake pump support Remove the brake pedal Genie Part No 57 4400 9210 GTH 5519 4 17 Section 4 Repair Procedures July 2015
66. Serial Number Legend sse nennen Safety Rules General Safety Rules ciet titt eed t E n i vii Specifications Machine SpeciflCatiOnsS iccirco ceri euis aae 2 1 Performance 2 2 Hydraulic 2 3 Hydraulic Component 2 4 Function Manifold Specifications sess 2 5 Air Conditioner Refrigerant 2 5 Deutz TD 2 9 L4 00 0 2 6 GOMER AX E cc 2 7 Hydraulic Hose and Fitting Torque Specifications 2 8 Torque 2 9 SAE and Metric Fasteners Torque 2 10 Scheduled Maintenance Procedures Part No 57 4400 9210 Introduction e Doe tette etae 3 1 Pre delivery Preparation Report sess 3 3 Maintenance Inspection 3 4 Genie GTH 5519 ix July 2015 DS TABLE OF CONTENTS Section 3 Scheduled Maintenance Procedures continued Checklist A Procedures A 1 Inspect the Manuals and 3 5 2 Perform Pre operation Inspection
67. Un4 2 Setpoint of metering unit in overrun mode not plausible 70 Maximum rail pressure in limp home mode exceeded PRV esnor error rail pressure signal range check high ensor error rail pressure signal range check low Nox conversion rate insufficient SCR Cat defect bad AdBule quality Nox conversion rate insufficient SCR Cat defect bad AdBule quality temperature range 1 Genie Part No 57 4400 9210 GTH 5519 5 11 Section 5 Fault Codes July 2015 FAULT CODES sm 523633 3234 3224 4345 4343 4374 523723 523632 523632 523632 523632 4365 3241 3241 3361 523720 523720 523721 523721 523981 523330 523721 Nox conversion rate insufficient SCR Cat defect bad AdBule quality temperature range 2 Nox Sensor downstream of SCR Catalysator plausibility error stuk in range Nox sensor upstream of SCR Catalysator low signal not plausible Sensor backflow line pressure SCR plausibility error General pressure check error SCR Pressure stabilisation error dosing valve SCR Detection of AdBlue filled SCR system in Int State Pump pressure SCR metering unit too high Pump pressure SCR metering unit too low EN Pressure overload of SCR System Pressure build up error SCR System Urea tank temperature too high Sensor SCR catalyst upstream temperature too high plausibility error Sensor SCR catalyst upstream temperature too low plausibility error AdBlue dosing valve
68. You are trained and qualified to perform maintenance on this machine M You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulations M You have the appropriate tools lifting equipment and a suitable workshop Genie Part No 57 4400 9210 GTH 5519 vii Section 1 Safety Rules July 2015 SAFETY RULES Personal Safety Any person working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe operation of the machine should be your top priority Read each procedure thoroughly This manual and the decals on the machine use signal words to identify the following Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death 7111958 Indicates an imminently hazardous situation which if not avoided will result in death or serious injury Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous situation which if not avoided may cause minor or moderate injury se indicates a potentially hazardous situation which if not avoided may result in property damage Be sure to wear protective eye wear and other protective clothing if the situation warran
69. aintenance procedures and additional axle information is available in the Comer Axle S128 Service Manual Comer Axle Service Manual Genie part number 57 4700 0020 Genie 3 10 GTH 5519 Part No 57 4400 9210 July 2015 Section 3 Scheduled Maintenance Procedures B 1 Inspect the Electrical Wiring Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining electrical wiring in good condition is essential to safe operation and good machine performance Failure to find and replace burnt chafed corroded or pinched wires could result in unsafe operating conditions and may cause component damage AWARNING Electrocution burn hazard Contact with hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Inspect the following areas for burnt chafed corroded and loose wires Inside of the operator s compartment Underside of the chassis Boom assembly 2 Inspect for a liberal coating of dielectric grease in the following locations All harness connectors 3 Start the engine and raise the boom so there is enough room to access and remove all the covers attached to the chassis Part No 57 4400 9210 Genie GTH 5519 3 11 Checklist B Procedures 4 Attach a lifting strap from an overhead crane to the boom Support the boom Do not apply any lifting pressure 5 Remove all engine covers and chassi
70. airpump pressure plausibility error 2 Sensor air pump airpressure plausibility error Sensor error airpump pressure signal range check high Sensor error airpump pressure signal range check low Physical range check high for exhaustgas back pressure burner shut off regeneration Physical range check low for exhaustgas back pressure burner shut off regeneration 20 Sensor exhaustgas back pressure plausibility error 2 Sensor exhaust gas back pressure burner plausibility error Sensor error exhaustgas back pressure burner signal range check high 4 Sensor error exhaustgas back pressure burner signal range check low Physical range check high for burner temperature Physical range check low for burner temperature Sensor burner temperature plausibility error Genie Part No 57 4400 9210 GTH 5519 5 37 Section 5 Fault Codes July 2015 FAULT CODES 50392 523921 0 Fuel Balanoe Control integrator injector 1 in tiing order maximum value exceeded 523930 0 Fuel Balance Control integrator injector 2 in firing order maximum value exceeded 523930 523931 Fuel Balance Control integrator injector 3 in firing order maximum value exceeded 523931 523932 0 Fuel Balance Control integrator injector 4 i fing order maximum value exceeded 523932 52393 Fuel Balance Control integrator injector 5 in firing order maximum value exceeded 52393 52994 0 Fuel Balanoe Control
71. alve 1180 Physical range check high for exhaust gas temperature upstream turbine 1180 Physical range check low for exhaust gas temperature upstream turbine Actuator EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 open load 5 6 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 over temperature EGR Valve 2 9 3 6 or Throttle Valve 6 17 8 short circuit to battery A02 EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 short circuit to battery A67 EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 short circuit to ground A02 EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 short circuit to ground A67 Actuator error EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 Overload by short circuit Actuator error EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 Power stage overtemperature due to high current Actuator error EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 Voltage below threshold 523988 Charging lamp open load 523988 Charging lamp over temperature Genie Part No 57 4400 9210 GTH 5519 5 17 Section 5 Fault Codes July 2015 FAULT CODES SPN Short Text Detail Charging lamp short circuit to battery Charging lamp short circuit to ground Air Pump air lines blocked Air Pump CAN communication lost Air pump CAN communication interrupted no purge function available Air Pump internal error Air Pump powers
72. ank powerstage output over temperature 4366 SCR Tank heating valve short circuit to battery 4366 SCR Tank heating valve short circuit to ground 4375 Urea pump motor open load 4375 Urea pump motor short circuit to battery 4375 Urea pump motor short circuit to ground 4334 Physical range check high for Urea Pump Pressure 4334 Physical range check low for Urea Pump Pressure 4334 Urea pump pressure sensor high signal not plusible 4334 Urea pump pressure sensor low signal not plausible 4334 Sensor error urea pump pressure signal range check high 4334 Sensor error urea pump pressure signal range check low 4376 SCR reversing valve open load 4376 SCR reversing valve over temperature 4376 SCR reversing valve short circuit to battery 4376 SCR reversing valve short circuit to ground 3031 AdBlue Tank temperature maximum exceeded 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 97 Water in fuel level prefilter maximum value exceeded 523946 Zerofuel calibration injector 1 in firing order maximum value exceeded 523947 Zerofuel calibration injector 2 in firing order maximum value exceeded 523948 Zerofuel calibration injector 3 in firing order maximum value exceeded 523949 Zerofuel calibration injector 4 in firing order maximum value exceeded 523950 0 Zerofuel calibration inject
73. are available and ready for use problem still exists Return to Inspect Perform service and test Repair problem solved Genie Part No 57 4400 9210 GTH 5519 6 1 Section 6 Schematics July 2015 Electrical and Hydraulic Symbols Legends Electrical Schematic Symbols Hydraulic Schematic Symbols our P eu LA dh IKS1 Po Pressure switch pM Hydraulic cylinder Axle Key switch Engine star j X X lt gt Ll Orifice Adjustable orifice Filter B 2m 5 Control relay Alternator De DE HW Check valve Flow regulator Relief alus C Fuse Circuit breaker TTIM ha Q 2 position3 way 3 position 4 way Horn or Alarm Light 3 position 4 way directional valva solenoid dy E IT y X II 2 2 position 4 way 2 position 2 way with diode solenoid valve solenoid valve 21194 Diode SS Switch QM E 2 2 Joystick a Ld WIE I UP a LALM Q Proximity switch Limit s
74. arts to move Apply the brake Engage the emergency brake and turn the engine off Check for hydraulic leaks Part No 57 4400 9210 Genie GTH 5519 4 29 Section 4 Repair Procedures July 2015 Manifolds 7 1 8 Turn the machine off Remove the pressure Function Manifold gauge from the test port 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 2 Start the engine Allow the engine to idle 3 Fully turn and hold the steering wheel in the left direction and allow the wheels to fully turn to the left Continue holding the steering while observing the pressure reading on the pressure gauge Result the pressure gauge reads 2030 psi 140 bar The pressure setting is correct Proceed to step 8 W Pressure is not within specification The pressure setting needs to be adjusted Proceed to step 4 4 Turn the engine off spot the valve on the power Steering and open the cap 5 Adjust the internal hex socket Turn clockwise to increase the pressure turn counterclockwise to decrease the pressure 6 Capthe valve 7 Repeat this procedure beginning with step 2 4 30 GTH 5519 Part No 57 4400 9210 2015 Section 4 Repair Procedures MANIFOLDS How to Remove the Function 6 Remove the retaining fasteners securing the x function manifold Manifold AWARN
75. asis for an engine fault code The SPN number indicates the affected component the FMI number reveals the type of failure that has occurred Comparing the combination of numbers to the fault code chart on the following pages will help to determine the exact engine fault and a corrective course of action For additional information refer to the engine operator s manual which came with your machine Gene 1230 engine rpm 000000 0 9 GD i Gauge Cluster LCD screen b amber warning light stop engine light d diagnostic button Genie Part No 57 4400 9210 2015 Section 5 Fault Codes FAULT CODES Engine Fault Codes Models with Deutz TD 2 9 L4 SPN FM Short Text Detail ____ 523911 0 Bumer dosing valve 0 2 overcurrent at the end of the injection phase Burner dosing valve 0 2 short circuit high side powerstage 523912 Physical range check high for burner dosing valve 0 2 downstream pressure shut off regeneration 523912 Physical range check low for burner dosing valve DV2 downstream pressure shut off regeneration When burner injector is actuated the measured pressure does not rise above ca 1250mbar abs expected ca 2400mbar Genie Part No 57 4400 9210 GTH 5519 5 3 Section 5 Fault Codes July 2015 FAULT CODES sm 523914 Glow plug control short circuit to battery 523
76. ate 523788 CAN Transmit Frame ComTrbChActr plausibility error wastegate 523788 0 Timeout Error of CAN Transmit Frame ComTrbChActr Wastegate Timeout Error of CAN Transmit Frame TroCH Status Wastegate 523793 9 Timeout Error of CAN Receive Frame UAA10 AGS sensor service message 523794 9 Timeout Error of CAN Receive Frame UAA11 AGS sensor data 523803 Timeout Error of CAN Receive Frame RxEngPres Status burner airpump 523867 Timeout Error of CAN Transmit Frame UAA1 on CAN 2 Burner Air Pump Control 523895 Check of missing injector adjustment value programming IMA injector 1 in firing order 523896 check of missing injector adjustment value programming 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 Genie Part No 57 4400 9210 GTH 5519 5 35 Section 5 Fault Codes July 2015 FAULT CODES sm check of missing injector adjustment value programming IMA injector 5 in firing order check of missing injector adjustment value programming IMA injector 6 in firing order Air Pump powerstage over temperature Air Pump operating voltage error Air Pump over current Air pump CAN communication interrupted no purge function available Air Pump CAN communication lost Air Pump i
77. aulic Hose and Fitting Torque Specifications 1 Lift the boom until the pin locking the lift cylinder rod side is in a position above the cab roof 2 Attach a lifting strap from an overhead 22045 lbs 10 000 kg crane to the fork end of the boom Support the boom Do not apply any lifting pressure 3 Tag disconnect and plug the hydraulic hoses connected to the shut off valve Cap the fittings AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray NOTICE Component damage hazard 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 Genie 4 6 GTH 5519 5 Place a suitably dimensioned wooden block before the hydraulic oil tank This block will be used to support the weight of the lift cylinder first and the boom afterwards 6 Remove the fasteners securing the lift cylinder rod end pivot pin to the boom 5 Crushing hazard The boom will fall if not properly supported when the pivot pin is removed from the machine 7 Lower the lift cylinder and place it on the wooden block previously positioned 8 Remove the fasteners securing the lift cylinder barrel end pivot pin to the chassis 9 Use a soft m
78. ave defect njector 7 in firing order interruption of electric connection njector 8 in firing order interruption of electric connection njector 7 in firing order short circuit njector 8 in firing order short circuit High side to low side short circuit in the injector 7 in firing order High side to low side short circuit in the injector 8 in firing order njector diagnostics timeout error of short circuit to ground measurement cyl Bank 0 njector diagnostics timeout error of short circuit to ground measurement cyl Bank 1 njector diagnostics short circuit to ground monitoring Test in Cyl Bank 0 njector diagnostics short circuit to ground monitoring Test in Cyl Bank 1 njector diagnostics time out error in the SPI communication njector diagnostics Slave time out error in the SPI communication Too many recognized misfires in cylinder 7 in firing order Too many recognized misfires in cylinder 8 in firing order Timeout Error of CAN Receive Frame MSMon_FidFCCTO Master Slave CAN communication faulty Error memory Slave reports FID MSMonFC2 Shut Off Path test error of fuel injection system Error memory Slave reports FID MSMonFC3 timeout of engine state messages ComMS_Sys17 from master ECU EH Sensor air pump airpressure plausibility error 20 Sensor exhaust gas back pressure bumer plausibility error Sensor differential pressure DPF plausibility error Genie Part No 57 4400 9210 GTH 5519 5 19
79. avoided will result in death or serious injury Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous situation which if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage Indicates that a specific result is expected after performing a series of steps Indicates that an incorrect result has occurred after performing a series of steps Section 3 Scheduled Maintenance Procedures July 2015 SCHEDULED MAINTENANCE PROCEDURES Maintenance Symbols Legend Note The following symbols have been used in this manual to help communicate the intent of the instructions When one or more of the symbols appear at the beginning of a maintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Indicates that a cold engine will be required to perform this procedure Indicates that a warm engine will be required to perform this procedure Indicates that dealer service will be required to perform this procedure cs EE Genie 3 2 5519 Pre delivery Preparation Report The pre delivery preparation report contains checklists for each type of scheduled inspection Make copies of the Pre delive
80. connect attachment enabling valve Forks tilt function enabling valve 110 E 1x18 Parking brake minimum pressure d pressure switch i activating pressure 20 bar 290 psi 1 1 Decree Parking brake selector valve 49 7 F 1 T 4 0 04 in 10 mm 0 04 in X p p2p3 TIT T2 Quick coupling CARO e D N 1 hydraulic ports i sull Anticavitation valves cracking pressure 5 bar 72 psi N Double overcenter gafety valve piloting ratio 4 2 1 B cracking pressure 350 bar lift cylinder 5 075 psi TP mE Parking brake circuit test port Hydraulically piloted double check valve piloting ratio 4 1 Single overcenter safety valve piloting ratio 4 2 1 cracking pressure 350 bar 5 075 psi oom PSO telescoping cylinder
81. cu gt 5 5 E 1 4461 sjaeym LNO 25 gt lt 8 e spain o4 jun buts HN agr T _ E P El plouayes LNO 21 Trees js E 8 PES Rat sio id 9 dp uwase SAINI DAMS N EYE T ETRA B E x bs a gt inf 2 ER Xu EU am g B 22 189075100 1 81 a plouajos 5 sjaaya unog 110 si C793 pat DE EH 18 NE 8 Sus ga amp amp m SEES lt ea From SN GTH5515B 2365 to July 2015 Part No 57 4400 9210 Section 6 Schematics July 2015 Ee ELECTRICAL SCHEMATIC Sheet 8 of 8 From SN GTH5515B 2365 I 2 3 4 5 WASHER PUMP WIPER MOTOR ROOF WIPER REAR WIPER WINDSCREEN WINDSCREEN WINDSCREEN WINDSCREEN ROAD L
82. cuit high side powerstage dosing valve DV1 powerstage over temperature Physical range check high for dosing valve DV1 downstream pressure shut off regeneration Physical range check low for dosing valve DV1 downstream pressure shut off regeneration Sensor dosing valve DV1 downstream pressure plausibility error Sensor error dosing valve DV1 downstream pressure signal range check high Sensor error dosing valve DV1 downstream pressure signal range check low Physical range check high for DV1 amp DV2 upstream pressure shut off regeneration Physical range check low for DV1 amp DV2 upstream pressure shut off regeneration 2 Sensor DV1 amp DV2 upstream pressure plausibility error Sensor error DV1 amp DV2 upstream pressure signal range check high 4 Sensor error DV1 amp DV2 upstream pressure signal range check low Physical range check high for DV1 amp DV2 upstream temperature shut off regeneration Physical range check low for DV1 amp DV2 upstream temperature shut off regeneration 2 Sensor DV1 amp DV2 upstream temperature plausibility error 30 Sensor error DV1 8 DV2 upstream temperature signal range check high 4 Sensor error DV1 amp DV2 upstream temperature signal range check low Physical range check high for airpump pressure shut off regeneration Physical range check low for airpump pressure shut off regeneration 2 Sensor
83. d by the word SERVICE replacing GENIE on the LCD display which is located on the gauge cluster in the operator s compartment The gauge cluster also includes two warning lights They are an amber colored light which signals an abnormal engine condition which should be corrected as soon as possible and a red colored light which signals an engine condition which requires the operator to shut down the engine as soon as possible The ECM will in some cases automatically shut down the engine when the red light is displayed Active Fault Codes To make the active fault codes visible start the engine press the diagnostic button d and hold it pressed for at least 5 seconds To quit the active fault codes page press the diagnostic button d and hold it pressed for at least 5 seconds Active Codes vs Stored Codes 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 5 2 GTH 5519 Stored fault codes are the cumulative history of fault codes which the ECM has detected These fault codes may be recalled by service personnel at a later time even if the condition which caused the engine fault has ceased to exist Note Additional hardware will be necessary to access stored codes Decoding Fault Codes The Suspect Parameter Number SPN and the Failure Mode Identifier FMI when combined are the b
84. d 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 flow sensor load correction factor exceeding the maximum drift limit plausibility error Air flow sensor load correction factor exceeding drift limit plausibility error Air flow sensor low idle correction factor exceeding the maximum drift limit 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 Genie 5 24 GTH 5519 Part No 57 4400 9210 2015 Section 5 Fault Codes FAULT CODES sm 168 Physikal range check high for battery voltage 168 Physikal range check low for battery voltage 168 High battery voltage warning threshold exceeded 168 EM Low battery voltage warning threshold exceeded 168 Sensor error battery voltage signal range check high 168 Sensor error battery voltage signal range check low 171 Sensor error environment temperature signal range check high 171 Sensor error environment temperature signal range check low 172 Physical range check high for intake air temperature 172 Physical range check low for intake air temperature 172 Sensor ambient air temperature plausibility er
85. e gradually Do not allow oil to squirt or spray NOTICE Component damage hazard Hoses can be damaged if they are kinked or pinched Genie GTH 5519 Part No 57 4400 9210 could fall if not properly supported when removed from the machine July 2015 Section 4 Repair Procedures 1 5 Fork Tilt Cylinder How to Remove the Fork Tilt Cylinder Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Raise the boom to a horizontal position 2 Remove the forks from the frame 3 Remove the retaining fasteners securing the fork tilt cylinder rod end pivot pin 4 Using a soft metal drift and a hammer remove the pivot pin 5 Using a lifting strap and an overhead crane support the cylinder Part No 57 4400 9210 Genie GTH 5519 4 9 BOOM COMPONENTS 6 Remove the protective guard a of the shut off valve 7 Place acontainer of suitable size under the hydraulic hoses before disconnecting 8 Tag disconnect and plug the hydraulic hoses from the level cylinder Cap the cylinder fittings AAWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray NOTICE Componen
86. e 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 July 2015 Genie 4 22 GTH 5519 Part No 57 4400 9210 July 2015 Section 4 Repair Procedures How to Remove the Boom and Steering Function Pump AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note When removing a hose assembly or fitting the fitting and or hose end must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications Note Perform this procedure with the engine off and cool to the touch 1 Close the hydraulic tank ball valve 2 Open the engine cover and disconnect the battery negative terminal A WARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 3 Remove the cover that is under engine Part No 57 4400 9210 Genie GTH 5519 4 23 HYDRAULIC PUMPS 4 Tag disconnect and plug the hoses located at the right side of the pump Cap the fitting on the pump AWARNING Bodily injury hazard Spraying hydraulic oi
87. e exceeded 523933 Ea Fuel Balance Control integrator injector 5 in firing order minimum value exceeded 523934 1 Fuel Balance Control integrator injector 6 in firing order minimum value exceeded 1109 Engine shut off demand ignored 523698 Shut off request from supervisory monitoring function 523717 Timeout Error of CAN Transmit Frame AmbCon Weather environments 523603 Timeout Error of CAN Receive Frame AMB Ambient Temperature Sensor 3224 DLC Error of CAN Receive Frame 1101 NOX Sensor SCR system upstream cat DPF system downstream cat length of frame incorrect 3224 9 Timeout Error of CAN Receive Frame AT1IG1 NOX sensor upstream 3224 2 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 Genie 5 4 GTH 5519 Part No 57 4400 9210 2015 Section 5 Fault Codes FAULT CODES SPN FM ShortTextDetal __ O 523938 Timeout Error BAM to packet for CAN Receive Frame AT1IGCVol1 information factors amp 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 amp Sensorcalibration for NOX Sensor SCR system upstream cat DPF system downstream cat 523940 Timeout Error PCK2PCK for CA
88. e when coil resistance is outside specification maintaining coils within specification will help ensure proper valve function over a wide range of operating temperatures AAWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Note If the machine has been in operation allow the coil to cool at least 3 hours before performing this test 1 Tag and disconnect the wiring from the coil to be tested 2 Testthe coil resistance using a multimeter set to resistance O Refer to the Valve Coil Resistance Specification table Result If the resistance is not within the adjusted specification plus or minus 1096 replace the coil Genie 4 34 GTH 5519 Valve Coil Resistance Specification Note The following coil resistance specifications 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 increase or decrease by 4 for each 18 F 20 C that your air temperature increases or decreases from 68 F 20 C Description Specification Steering modes selector valve 5 60 3 position 4 way 12V DC with diode Mechanical gear speed Selector 8 80 valve 3 position 4 way 12V DC with diode Forward Reverse Selector valve 8 80 3 position 4 way 12V DC with diode Outrigger Selector valve 8 80 2 position 4 way 12V
89. ea tank temperature short circuit to ground 3224 Nox sensor upstream of SCR Catalysator low signal not plausible 3224 DLC Error of CAN Receive Frame AT1IG1 NOX Sensor SCR system upstream cat DPF system downstream cat length of frame incorrect 3224 2 DLC Error of CAN Receive Frame AT1IG1Vol NOX Sensor SCR system upstream cat DPF system downstream cat length of frame incorrect 3224 Ea Timeout Error of CAN Receive Frame AT1IG1 NOX sensor upstream 3224 Timeout Error of CAN Receive Frame AT1IG1Vol NOX sensor SCR system upstream cat DPF system downstream cat 3234 2 Error of CAN Receive Frame AT101Vol NOX Sensor SCR system downstream cat DPF system downstream cat length of frame incorrect 3234 9 Timeout Error of CAN Receive Frame AT10G1 NOX sensor SCR system downstream cat DPF system downstream cat 3234 Timeout Error of CAN Receive Frame AT10G1Vol NOX sensor SCR system downstream cat DPF system downstream cat 3234 Nox Sensor downstream of SCR Catalysator plausibility error stuk in range 3241 Sensor SCR catalyst upstream temperature too high plausibility error 3241 Sensor SCR catalyst upstream temperature too low plausibility error 3248 Physical range check high for exhaust gas temperature particulate filter downstream 3248 Physical range check high for exhaust gas temperature particulate filter downstream shut off regeneration 3248 Physical range check high for exhaust ga
90. econdary side Shortcut to battery 4366 SCR main relay secondary side shortcut to ground 4341 SCR heater relay urea supplyline secondary side open load 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 open load 4345 SCR heater urea returnline short circuit to battery 4345 SCR heater urea retumline short circuit to ground 4343 SCR heater relay urea pressureline primary side open load 4343 SCR heater urea pressureline short circuit to battery 4343 SCR heater urea pressureline short circuit to ground 523718 SCR main relay primary side open load 523718 SCR main relay primary side short circuit to battery 523718 SCR main relay primary side short circuit to ground 4341 SCR heater relay urea supplyline primary side open load 4341 SCR heater urea supplyline short circuit to battery 4341 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 Genie Part No 57 4400 9210 GTH 5519 5 15 Section 5 Fault Codes July 2015 FAULT CODES SPN FM ShortText Detail __ 4366 SCR tank heating valve primary side open load 4366 SCR heater relay urea t
91. econdary side open load SCR heater relay urea supplymodule primary side open load 5 34 Genie GTH 5519 Part No 57 4400 9210 2015 Section 5 Fault Codes FAULT CODES 8 Urea supply module heater temperature duty cycle in invalid range Sesnor urea supply module temperature plausibility error normal condition Sensor urea supply module temperature plausibility error cold start condition 8 Urea supply module temperature duty cycle in failure range 8 Urea supply module temperature duty cycle in invalid range Urea supply module temperature measurement not available 8 Urea supply module PWM signal period outside valid range 529722 8 Detectfauty PWM signal from Supply Modul ________ 523766 9 Timeout Error of CAN Receive Frame Active TSC1AE 523767 9 Timeout Error of CAN Receive Frame Passive TSC1AE 523768 9 Timeout Error of CAN Receive Frame Active TSC1AR 523769 9 Timeout Error of CAN Receive Frame Passive TSC1AR 523770 9 Timeout Error of CAN Receive Frame Passive TSC1DE 523776 9 Timeout Error of CAN Receive Frame TSC1TE active 523777 9 Passive Timeout Error of CAN Receive Frame TSC1TE Setpoint 523778 9 Active Timeout Errorof CAN Receive Frame TSC1TR 523779 9 Passive Timeout Error of CAN Receive Frame TSC1TR 523788 0 CAN Transmit Frame ComTroChActr BusOff Satus Wastegate 523788 CAN Transmit Frame ComTrbChActr disable error wasteg
92. ef Valve PRV warning condition Pressure Relief Valve PRV is open The PRV can not be opened at this operating point with a pressure shock Rail pressure out of tolerance range Pressure relief valve PRV reached maximun allowed open time Multiple Stage Switch constant speed short circuit to battery Multiple Stage Switch constant speed short circuit to ground Multiple Stage Switch constant speed plausibility error Multiple Stage Switch engine speed control parameter short circuit to battery Multiple Stage Switch engine speed control parameter short circuit to ground Multiple Stage Switch engine speed control parameter plausibility error Multiple Stage Switch engine torque limitation curve short circuit to battery Multiple Stage Switch engine torque limitation curve short circuit to ground Multiple Stage Switch engine torque limitation curve plausibility error Sensor error pressure sensor upstream turbine signal range check high 4 Sensor error pressure sensor downstream turbine signal range check high Maximum positive deviation of rail pressure exceeded RailMeUn0 Maximum positive deviation of rail pressure in metering unit exceeded RailMeUn1 Railsystem leakage detected RailMeUn10 NM Maximum negative deviation of rail pressure in metering unit exceeded RailMeUn2 Negative deviation of rail pressure second stage RailMeUn22 Minimum rail pressure exceeded RailMeUn3 Maximum rail pressure exceeded RailMe
93. enance Procedures July 2015 CHECKLIST E PROCEDURES E 4 Perform Engine Maintenance Engine specifications require that this procedure be performed every 6000 hours Deutz TD 2 9 L4 General engine overhaul Required maintenance procedures and additional engine information is available in the Deutz TD 2 9 L4 Operation and Maintenance Manual Deutz part number 0312 3896 Deutz TD 2 9 L4 Operation and Maintenance Manual Genie part number 57 4700 0006 3 24 GTH 5519 Genie Part No 57 4400 9210 July 2015 Section 4 Repair Procedures Observe and Obey Repair procedures shall be completed by a person trained and qualified on the repair of this machine M Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Repairs Start 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 parts available and ready for use Use only Genie approved replacement parts Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a firm level surface Boom in the stowed position Key sw
94. ent Multi viscosity Viscosity index 200 Cleanliness level minimum 15 13 Water content 200 ppm maximum Chevron Rando HD oil is fully compatible and mixable with Shell Donax TG Dexron lll oils Genie specifications require hydraulic oils which are designed to give maximum protection to hydraulic systems have the ability to perform over a wide temperature range and the viscosity index should exceed 140 They should provide excellent antiwear oxidation corrosion inhibition seal conditioning and foam and aeration suppression properties Part No 57 4400 9210 Genie GTH 5519 2 3 SPECIFICATIONS Optional fluids Biodegradable Petro Canada Environ MV46 Statoil Hydra Way Bio Pa 32 BP Biohyd SE S UCON Hydroluble HP 5046 Quintolubric 822 Shell Tellus 52 32 Shell Tellus S2 V 46 Chevron Aviation A Eni Arnica 32 NOTICE Continued use of Chevron Aviation A hydraulic fluid when ambient temperatures are consistently above 32 F 0 may result in component damage Fire resistant Mineral based Note Use Chevron Aviation A hydraulic fluid when ambient temperatures are consistently below 17 C Note Use Shell Tellus T46 hydraulic oil when oil temperatures consistently exceed 205 F 96 C Genie specifications require additional equipment and special installation instructions for the approved optional fluids Consult the Genie Service Department before use Cont
95. erated power reduction phase 1 manuell regeneration request Air Pump air lines blocked Engine power Not enough oxygen for regeneration fuel line pipe leak behind Shut Off Valve DPF wasn t regenerated power reduction phase 2 manuell regeneration request 5 40 5519 57 4400 9210 2015 Section 5 Fault Codes FAULT CODES sm DPF wasn t regenerated warning condition manuell regeneration mode Deviation of the exhaust gas temperature setpoint to actual value downstream DOC too high DPF system operating voltage error Particulate filter regeneration not succesful CAN message PROEGRActr plausibility error Timeout Error of CAN Receive Frame ComEGRActr exhaust gas recirculation positioner EGR actuator internal error EGR actuator calibration error EGR actuator status message EGRCust is missing EGR actuator due to overload in Save Mode Disc separator short circuit to battery Disc separator short circuit to ground Disc Separator open load Disc Separator powerstage over temperature Injector diagnostics time out error in the SPI communication Injector diagnostics Slave time out error in the SPI communication Ashlamp short circuit to battery Ashlamp short circuit to ground Ashlamp open load Timeout error of CAN Receive Frame ComMS_Sys1TO error memory Slave Master Slave internal CAN message imeout error of CAN Rece
96. erruption of electric connection njector 3 in firing order short circuit High side to low side short circuit in the injector 3 in firing order njector 3 in firing order interruption of electric connection njector 4 in firing order short circuit High side to low side short circuit in the injector 4 in firing order njector 4 in firing order interruption of electric connection njector 5 in firing order short circuit High side to low side short circuit in the injector 5 in firing order njector 5 in firing order interruption of electric connection Genie 5 26 GTH 5519 Part No 57 4400 9210 2015 Section 5 Fault Codes FAULT CODES 656 Injector 6 in firing order short circuit 656 High side to low side short circuit in the injector 6 in firing order 656 Injector 6 in firing order interruption of electric connection 676 Cold start aid relay error 676 Cold start aid relay open load 677 Starter relay high side short circuit to battery 677 tarter relay low side short circuit to battery 677 Starter relay high side short circuit to ground 677 Starter relay low side short circuit to ground 677 Starter relay no load error 677 Starter relay powerstage over temperature 703 Engine running lamp short circuit to battery 703 Engine running lamp short circuit to ground 703 Engine running lamp open load 703 Engine running lamp powerstage over temperature 729 C
97. etal drift to remove the pivot pin 10 Remove the cylinder from the machine Crushing hazard The cylinder could fall if not properly supported when removed from the machine 11 Using the overhead crane raise and place the boom on the wooden block suitably positioned Part No 57 4400 9210 July 2015 Section 4 Repair Procedures 1 3 Boom Extend Cylinder How to Remove the Extend Cylinder Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Raise the boom to a horizontal position 2 Extend the boom until you can access the pin a locking the cylinder rod side Part No 57 4400 9210 BOOM COMPONENTS 3 Tag disconnect and plug the pipes from the cylinder shutoff valve Cap the cylinder fittings AAWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Remove the retaining fasteners securing the extend cylinder barrel end pivot pin Using a soft metal drift and a hammer remove the pivot pin Using a soft metal drift and a hammer remove the pivot pin b using the holes on the chassis at the rear of the machine Partially pull the cylinder
98. eubis bun 28 e s sg a ea NSET 5 o a 1 TS THM Tum Le 2 sg gt E E 0 2 se CMT ee mt Snas Ja SE uasme gt FI 6 e 18119 LHM adco 43 40 27 ip 2 021 16619 SL 0HM 65 6 9 GTH 5519 Part No 57 4400 9210 Section 6 Schematics sees ri ELECTRICAL SCHEMATIC Sheet 8 of 8 Up to SN GTH5515B 2364 July 2015 1 3 4 5 CABIN FUSES AND RELAY BOARD Ref Description AMP F01 WARNING 10A F02 HIGH BEAM 15A F03 LOW BEAM 15 1 F04 15 FOS ROAD JOBSITE 10 06 R FRONT amp L REAR POSITION LIGHTS 5 CH GS F07 L FRONT amp R REAR POSITION LIGHTS 5A ka F08 POWER SUPPLY 10A K4 ED B F09 2 HYDRAULIC CIRCUIT 10A J Ge F10 INSTRUMENT 5A Fil HEATING 25A p 2 FORWARD REVERSE SELECTOR 10A k5 x2 Gs Cre F13 WORK LIGHT 15A x3 F14 REAR AXLE SENSOR 10 Gp F15 FLASHING BEACON 10 F16 STOP LIGHT 10A K6 7 F17 HAZARD WARNING LIGHT 10A PS WP
99. g unit Fuel System short circuit to battery low side 00 many recognized misfires in cylinder 2 in firing order 00 many recognized misfires in cylinder 3 in firing order Too many recognized misfires in cylinder 4 in firing order Too many recognized misfires in cylinder 5 in firing order Too many recognized misfires in cylinder 6 in firing order 00 many recognized misfires in more than one cylinder nternal ECU monitoring detection reported error nternal ECU monitoring detection reported error nternal ECU monitoring detection reported error nternal ECU monitoring detection reported error nternal ECU monitoring detection reported error nternal ECU monitoring detection reported error nternal ECU monitoring detection reported error nternal ECU monitoring detection reported error nternal ECU monitoring detection reported error nternal ECU monitoring detection reported error nternal ECU monitoring detection reported error nternal ECU monitoring detection reported error nternal ECU monitoring detection reported error nternal ECU monitoring detection reported error nternal ECU monitoring detection reported error nternal ECU monitoring detection reported error Manipulation control was triggered Timeout error in Manipulation control Sensor error oil pressure signal range check high Sensor error oil pressure sensor signal range check low High oil pressure warning threshold exceeded 100 NN High oil pressure shut off thresh
100. gas back pressure burner shut off regeneration Sensor error exhaustgas back pressure burner signal range check high Sensor error exhaustgas back pressure burner signal range check low Sensor error charged air pressure signal range check high Sensor error charged air pressure signal range check low Physical range check high for differential pressure Venturiunit EGR Physical range check low for differential pressure Venturiunit EGR Sensor error differential pressure Venturiunit EGR signal range check high Sensor error differential pressure Venturiunit EGR signal range check low Particulate filter regeneration not succesful Sensor differential pressure DPF plausibility error regarding signal offset Em Physical range check high for differential pressure DPF shut off regeneration Physical range check low for differential pressure DPF shut off regeneration Sensor error differential pressure DPF signal range check high Genie 5 10 GTH 5519 Part No 57 4400 9210 2015 Section 5 Fault Codes FAULT CODES SPN FM ShortTextDetal __ Sensor error differential pressure DPF signal range check low Pressure Relief Valve PRV reached maximun allowed opening count 20 Pressure Relief Valve PRV forced to open performed by pressure increase 20 Pressure Relief Valve PRV forced to open performed by pressure shock Open Pressure Relief Valve PRV shut off condition Open Pressure Reli
101. gate actuator EOL calibration not performed correctly 1188 Wastegate actuator calibration deviation too large recalibration required 1188 Wastegate status message from ECU missing 1188 Wastegate actuator blocked 1188 Wastegate actuator over temperature gt 145 C 1188 Wastegate actuator over temperature gt 135 C 1188 Wastegate actuator operating voltage error 524011 Zerofuel calibration injector 7 in firing order maximum value exceeded 524012 Zerofuel calibration injector 8 in firing order maximum value exceeded 524011 1 Zerofuel calibration injector 7 in firing order minimum value exceeded 524012 Zerofuel calibration injector 8 in firing order minimum value exceeded CAN message PROEGRActr plausibility error Timeout Error of CAN Receive Frame ComEGRActr exhaust gas recirculation positioner Disc Separator open load 524034 Disc Separator powerstage over temperature Genie 5 20 GTH 5519 Part No 57 4400 9210 July 2015 Section 5 Fault Codes FAULT CODES sm 524034 524034 524030 524031 524032 524033 2621 2621 2621 2621 175 175 Disc separator short circuit to battery Disc separator short circuit to ground EGR actuator internal error EGR actuator calibration error 2 EGR actuator status message EGRCust is missing 7 EGR actuator due to overload in Save Mode Flush valve burner EPV DPF System open load Flush valve bur
102. he O ring before installation 3 Be sure that the face seal O ring is seated and retained properly 4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight 5 Tighten the nut or fitting to the appropriate torque per given size as shown in the table 6 Operate all machine functions and inspect the hoses and fittings and related components to confirm that there are no leaks JIC 37 fittings 1 Align the tube flare hex nut against the nose of the fitting body body hex fitting and tighten the hex nut to the body hex fitting to hand tight approximately 30 in Ibs 3 4 Nm 2 Make a reference mark on one of the flats of the hex nut and continue it on to the body hex fitting with a permanent ink marker Refer to Figure 1 Part No 57 4400 9210 Genie GTH 5519 2 9 Figure 1 hex nut b reference mark body hex fitting 3 Working clockwise on the body hex fitting make a second mark with a permanent ink marker to indicate the proper tightening position Refer to Figure 2 Note Use the JIC 37 Fittings table on the previous page to determine the correct number of flats for the proper tightening position Note The marks indicate that the correct tightening positions have been determined Use the second mark on the body hex fitting to properly tighten the joint after it has been loosened p 6 Figure 2 body hex fitting b
103. he extend cylinder from inside the boom Refer to Repair Procedure 1 3 How to Remove the Extend Cylinder 5 Remove the fork tilt cylinder Refer to Repair Procedure 1 5 How to Remove the Fork Tilt Cylinder 6 Attach a lifting strap to the front of section b raise it slightly from section a then extend it by 8 12 in 20 30 cm 7 Remove the bottom pads c and the pad supports from the first boom section 8 Release the lifting strap to lay the second section b on the first section a 9 Remove the lateral pads e and the top pads f from the first section 10 Raise again the second section and pull it out slowly from the first one be careful not to make it come out completely Ensure that the second section remains inside the first one and does not come out 11 Attach another lifting straps to the second boom section 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 Genie Part No 57 4400 9210 GTH 5519 4 5 Section 4 Repair Procedures July 2015 BOOM COMPONENTS 1 2 Boom Lift Cylinder How to Remove the Lift Cylinder Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydr
104. high 171 Sensor error environment temperature signal range check low 190 8 Sensor camshaft speed disturbed signal 190 Sensor camshaft speed no signal 190 Offset angle between crank and camshaft sensor is too large 190 8 Sensor crankshaft speed disturbed signal 190 Sensor crankshaft speed no signal 703 Engine running lamp open load 703 Engine running lamp powerstage over temperature 703 Engine running lamp short circuit to battery 703 Engine running lamp short circuit to ground 975 Digital fan control open load 975 Digital fan control powerstage over temperature 975 Digital fan control short circuit to battery 975 Digital fan control short circuit to ground 975 Fan actuator PWM output open load 975 Fan actuator PWM output powerstage over temperature 975 Fan actuator PWM output short circuit to battery Genie 5 6 GTH 5519 Part No 57 4400 9210 2015 Section 5 Fault Codes FAULT CODES SPN FM ShortTextDetal __ 975 Fan actuator PWM output short circuit to ground 1639 Sensor error fan speed signal range check high 1639 Sensor error fan speed signal range check low 523602 High fan speed warning threshold exceeded 523602 0 High fan speed shut off threshold exceeded 97 Sensor error water in fuel signal range check high 97 ensor error water in fuel signal range check low Sensor error low fuel pressure signal range check high Sensor error low fuel pressure s
105. ignal range check low 94 EM Low fuel pressure warning threshold exceeded 94 EN Low fuel pressure shut off threshold exceeded 174 High low fuel temperature warning threshold exceeded 174 High Low fuel temperature shut off threshold exceeded Physical range check high for exhaust gas temperature upstrem SCR CAT dosing valve DV1 overcurrent at the end of the injection phase dosing valve DV1 powerstage over temperature dosing valve DV1 short circuit to battery dosing valve DV1 short circuit to battery high side dosing valve DV1 short circuit to ground dosing valve DV1 short circuit high side powerstage Sensor dosing valve DV1 downstream pressure plausibility error Physical range check high for dosing valve DV1 downstream pressure shut off regeneration Physical range check low for dosing valve DV1 downstream pressure shut off regeneration Sensor error dosing valve DV1 downstream pressure signal range check high Sensor error dosing valve DV1 downstream pressure signal range check low Sensor DV1 amp DV2 upstream pressure plausibility error Physical range check high for DV1 amp DV2 upstream pressure shut off regeneration Physical range check low for DV1 amp DV2 upstream pressure shut off regeneration Sensor error DV1 amp DV2 upstream pressure signal range check high Sensor error DV1 amp DV2 upstream pressure
106. inuous improvement of our products is a Genie policy Product specifications are subject to change without notice Section 2 Specifications July 2015 SPECIFICATIONS Hydraulic Components Hydrostatic Transmission Motor Specifications Type variable displacement piston motor Boom and Steering Functions Pump Displacement 9 puc Type fixed displacement an Flow rate 2600 rpm 30 9 gpm a 117 L min Displacement E Motor pressure maximum 7180 psi measured at test port TP2 495 bar mow rate 2600 Tpm Es gpm Relief valve pressure 7540 psi 70 L min 520 Pump pressure maximum 3915 psi measured at test port TP2 measured at test port TP1 270 bar Continuous improvement of our products Hydrostatic Transmission Pump is a Genie policy Product specifications are Type variable displacement subject to change without notice piston pump Displacement 0 to 2 75 cu in 010 45 cc Flow rate 2600 rpm 30 9 gpm 117 L min Pump pressure maximum 7180 psi measured at test port TP2 495 bar Relief valve pressure 7540 psi maximum 520 bar measured at test port TP2 Pump charge relief valve 360 psi pressure maximum 25 bar measured at test port TP3 Genio 2 4 GTH 5519 Part No 57 4400 9210 2015 Section 2 Specifications EE 027 SPECIFICATIONS Function Manifold Specifications Func
107. is as 5 To veg ERI g E es Sar H eest no ue 9 morose 7 at og tW me 1 YS 5 7 so ufi ue quis X rom 1 p oa 11 5 458 ao ue ov E EE DD as 19 p THOTT H pubis sufus pueys e9 gt i THOT 5080 5 doj5044J9 Sj Send pni 77 52049 1 wn Pd TAZ nod ge dai wy SLOAD Lj 25 11 18775704 Ti Ayddns samod EE FY soned m as ala ES sis E sis EE EE 5 5 EE 1111 wi Section 6 Schematics ELECTRICAL SCHEMATIC Sheet 6 of 8 55e 6 8 Section 6 Schematics July 2015 Sheet 7 of 8 ELECTRICAL SCHEMATIC Up to SN GTH5515B 2364 9 172 13 E THT STOR 2 STOMA 4 39 fsa 01 021 024 gt 45 SECURA 54 15 ae WHO 75 7048 15 ge WHO 75 7047 15 ae WHO 75 7046 amp 12100 SORA Ajeusue paads ujbus yon aunssaud ney paly Engine Control Unit D2 1 yeubis jeubis Keras qeubis ansad je j
108. ission pump will fall if not properly supported when the fasteners are removed from the machine Section 4 Repair Procedures July 2015 HYDRAULIC PUMPS How to Install the Hydrostatic Transmission Pump AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note When removing a hose assembly or fitting the fitting and or hose end must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications Note Perform this procedure with the engine off and cool to the touch 1 Open the engine compartment 2 Remove the cover that is under engine 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 Genie 4 28 GTH 5519 7 Connect the hoses to the pump AAWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 8 Connect the harness to the transmission pump 9 Install the boom and steering function
109. itch in the off position with the key removed Wheels chocked Part No 57 4400 9210 Genie GTH 5519 4 1 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 Perform disassembly procedures to the point where repairs can be completed Then to re assemble perform the disassembly steps in reverse order Symbols Legend Safety alert symbol used to A alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates an imminently hazardous situation which if not avoided will result in death or serious injury Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous situation which if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage Note Used to indicate additional operation or procedure information Indicates that a specific result is expected after performing a series of steps Indicates that an incorrect result has occurred after performing a series of steps Section 4 Repair Procedures July 2015 Boom Components
110. ive Frame ComMS_Sys2TO error memory Slave Master Slave internal CAN message Timeout error of CAN Receive Frame ComMS_Sys3TO error memory Slave Master Slave internal CAN message Timeout error of CAN Receive Frame ComMS_Sys4TO error memory Slave Master Slave internal CAN message Timeout error of CAN Receive Frame ComMS_Sys5TO error memory Slave Master Slave internal CAN message Timeout error of CAN Receive Frame ComMS_Sys6TO error memory Slave Master Slave internal CAN message CAN message ComMS_Sys7 not received from slave Master Slave Message Counter Error of CAN Receive Frame ComMSMoFOvR Master Slave Checksum Error of CAN Receive Frame ComMSMoFOvR Master Slave CAN Messsage Length Error of CAN Receive Frame ComMSMoFOvR Timeout error CAN message ComMSMoFOvR1TO error memory Slave Message copy error in the Master Slave data transfer Error memory Slave reports FID MSMonFC2 Shut Off Path test error of fuel injection system Error memory Slave reports FID MSMonFC3 timeout of engine state messages ComMS_Sys17 from master ECU Master ECU and Slave ECU data sets or software are not identical Genie Part No 57 4400 9210 GTH 5519 5 41 Section 5 Fault Codes July 2015 FAULT CODES sm em sonaa Spark Plug Control Unit SPCU short circuit to ground Electric fuel pump fuel pressure build up error Regeneration inhibit switch n
111. l can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 5 Tag disconnect and plug the hydraulic pump supply hose at the pump located at the left side of the pump Cap the fitting on the pump Note Placing the open end of the case drain hose below the hydraulic oil level in the hydraulic tank will result in excessive hydraulic fluid leaking from the hose Do not lower the open end of the case drain hose below the fluid level of the hydraulic tank until the hose is plugged 6 Remove the fasteners securing the pump then remove the pump by pulling it to the front of the machine A WARNING Crushing hazard The pump will fall if not properly supported when the fasteners are removed from the machine Section 4 Repair Procedures July 2015 HYDRAULIC PUMPS How to Install the Boom and Steering Function Pump AAWARNING Bodily injury hazard This 7 procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure 8 without these skills and tools could result in death or serious 9 injury and significant component damage Dealer service is strongly recommended Note When removing a hose assembly or fitting the fitting and or hose end must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications Note
112. l tank 15 9 gallons Weight rough terrain tire wheel 106 Ibs 60 liters air filled 48 kg Hydraulic tank 16 4 gallons Weight rough terrain tire wheel 320 Ibs 62 liters foam filled 145 kg Hydraulic system 25 gallons Weight rough terrain solid tire 278 105 including tank 95 liters wheel 126 kg Tire pressure 65 psi ae models with air filled tires 4 5 bar For operational specifications refer to the Lug n t torque 295 ft lbs Operator s Manual 400 Nm Lug pattern 8 x 10 827 Wheel diameter 32 8 in 820 mm Wheel width 12 3 in 313 mm Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie Part No 57 4400 9210 GTH 5519 2 1 Section 2 Specifications July 2015 i SPECIFICATIONS Performance Specifications Boom function speeds maximum Boom up 7 seconds Drive speed maximum 16 mph Boom down 7 seconds 25 8 km h _ 7 seconds Draw bar pull 9200 Ibs 4173 kg Boom retract 4 seconds Lift capacity maximum 5500 Ibs 2500 kg Fork tilt down 3 seconds Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie 2 2 5519 57 4400 9210 July 2015 Section 2 Specifications Hydraulic Specifications Hydraulic Oil Specification Hydraulic oil type Viscosity grade Chevron Rando HD equival
113. lace it on a structure capable of supporting it Section 4 Repair Procedures BOOM COMPONENTS How to Disassemble the Boom AAWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended July 2015 Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications Note Perform this procedure on a firm level surface with the boom in the stowed position and the wheels chocked 1 Remove the boom from the machine and lay it on stands checking that it is stable Refer 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 Genie 4 4 GTH 5519 Part No 57 4400 9210 July 2015 Section 4 Procedures __4 6 5 46 574 5 3 Remove the hydraulic hoses from inside the 13 Remove all pads g from the second section boom Refer to Repair Procedure 1 5 How to bp Replace the Fork Tilt Cylinder Hoses 14 Remove the pipes from the first boom section 4 Remove t
114. lug the hydraulic lines of power steering power steering delivery solenoid valve delivery tank draining brake pump power steering delivery from pump joystick no 6 AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 6 Tag disconnect and plug the heater lines n 2 hoses 7 Disconnect the ground wire 8 Remove the 4 retaining fasteners of the cabin 9 Install and secure two eyebolts to the top the cabin in the special seats Part No 57 4400 9210 July 2015 Section 4 Repair Procedures a OPERATOR S COMPARTMENT 10 Using a sling chain and an overhead crane slowly raise the cabin away from the machine and set it on a supporting device Component damage hazard Wrapping a strap around the cab and lifting using an overhead crane can put excessive pressure on the glass windows of the cab causing the windows to break 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 Genie Part No 57 4400 9210 GTH 5519 4 13 Section 4 Repair Procedures July 2015 OPERATOR S COMPARTMENT 2 2 Machine Controls How to Remove the Steering Column 1 Open the engine cover and disconnect the battery negative terminal AWARNING Elect
115. meout error of CAN Transmit Frame ComDPFTstMon imeout error of CAN Transmit Frame ComEGRMsFlw imeout error of CAN Transmit Frame ComEGRTVActr 9 Timeout error of CAN Transmit Frame ComETVActr Timeout ComITVActr Timeout error of CAN Receive Frame ComRxCM1 imeout error of CAN Receive Frame ComRxCustSCR3 imeout error of CAN Receive Frame ComRxDPFBmAirPmpCtl imeout error of CAN Receive Frame ComRxDPFBmAirPmp Handthrottle idle validation switch short circuit to battery Sesnor error handthrottle signal range check high 4 Hanathrottl idle validation switch short circuit to ground 4 Sensor error handthrottle sensor signal range check low Genie 5 22 GTH 5519 Part No 57 4400 9210 2015 Section 5 Fault Codes FAULT CODES SPN Short Text Detail EGR Valve 2 9 6 or Throttle Valve 6 1 7 8 short circuit to battery Position sensor error of actuator EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 signal range check high EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 short circuit to battery 02 EGR Valve 2 9 3 6 Throttle Valve 6 1 7 8 short circuit battery A67 5 EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 short circuit to ground 4 Position sensor error actuator EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 signal range check low ost EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 short circuit to ground A02 EGR Valve 2 9
116. mpressor E Relay Ux E Relay gt amp i Kt f amp 2 8 as Wy A El 3 E E 5 i 6 M196 Mn B B m m E amp 45 7 E e 5 S7 gj T s ATEREX BRAND Part No 57 4400 9210 GTH 5519 6 7 July 2015 57 4400 9210 Up to SN GTH5515B 2364 GTH 5519 1 AA RISI ac S 522 gt voyea sif snega pu Tie 4 9 es 55 jsneuxo ag I gt s3 Er gc 5 a og seb jsneuxo yeubis Sees Sarre ye jw 58 7 _ yon jeubis 35 8 E a m CDU VES SORA ei os ag pe Bi E NN jeubis 10699 SHA P eubis m az 25 3 S err reed pup s3 5 pen du enay pu a3 z Vn SOR TET STORA epad age ag 2 snsuas joao suejoos 7 5 2g 5 eu
117. ms completed Function tests completed Model Serial number Date Machine owner Inspected by print Inspector signature Inspector title Inspector company Section 3 Scheduled Maintenance Procedures July 2015 Maintenance Inspection Report Model Checklist A Checklist D Y N R Serial number A 1 Manuals and decals D 1 Forks Date A 2 Pre operation inspect D 2 Hydraulic return filter Hour meter 3 Function tests D 3 Engine maintenance Machine owner 4 Lubricate the boom D 4 Axle maintenance Inspected by print A 5 Engine maintenance 0 5 Inspect the engine Inspector signature 6 Safety devices alr filter Inspector title Perform after 40 hours Inspector company A 7 30 day service Instructions Perform after 100 hours Make copies of this report to use for each inspection Select the appropriate checklist s for the type of inspection to be performed A 8 Axle maintenance Perform after 200 hours A 9 Axle maintenance Perform every 200 hours A 10 Axle maintenance Daily or 8 hours Inspection A Checklist B Y NR Quarterly or 250 hours B 1 Electrical wiring Inspection A B B 2 Exhaust system Semi annually or 500 hours B 3 Tires and wheels Inspection B 4 Hydraulic oil Annually or 1000 hours B 5 wear pads Inspection A B C D Perform every 300 hours 2 Years or 2000 hours B 6 Axle maintenance
118. ner EPV DPF System powerstage over temperature Flush valve burner EPV DPF System short circuit to battery Flush valve burner DPF System short circuit to ground High customer oil temperature warning threshold exceeded High customer oil temperature shut off threshold exceeded Regeneration temperature PFItRgn LigtOff not reached regeneration aborted Spark Plug Control Unit SPCU short circuit to ground High exhaust gas temperature EGR cooler downstream warning threshold exceeded High exhaust gas temperature EGR cooler downstream shut off threshold exceeded Turbocharger Wastegate CAN feedback warning threshold exceeded Turbocharger Wastegate CAN feedback shut off threshold exceeded Exhaust gas temperature upstream turbine warning threshold exceeded Exhaust gas temperature upstream turbine shut off threshold exceeded Ashlamp open load Sensor vehicle speed plausibility error 30 Ashlamp short circuit battery 4 Ashlamp short circuit to ground Regeneration inhibit switch not available CominhSwtNA Regeneration release switch not available ComRegSwtNA DPF system operating voltage error 9 CAN message ComMS_Sys7 not received from slave Metering control is not performed in time error Master ECU and Slave ECU have been identified as the same types Master ECU and Slave ECU data sets or software are not identical SCR mainrelay open load only CV56B SCR mainrelay powerstage
119. ng fork 4 Use a soft metal drift to remove the pivot pin 5 Remove the screw securing the fork frame pivot pin to the boom 6 Use soft metal drift to remove the pivot pin 7 Using the overhead crane lift and remove the fork frame from the boom Crushing hazard The fork frame could fall if not properly supported when the lock pin is removed from the machine July 2015 Section 4 Repair Procedures How to Remove the Boom AAWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the forks from the boom 2 Disconnect the electric cables from the boom if present 3 Lift the boom until the pin locking the lift cylinder is in a position above the cab roof 4 Place stand under the lift cylinder to properly support it once the pin connecting the cylinder to the boom will be removed 5 Attach a lifting strap from an overhead crane to the fork support and slightly lift the boom Do not apply any lifting pressure 6 Attach a second
120. ng valve short circuit on high side AdBlue dosing valve blocked SCR Sensor error urea tank level signal range check high Sensor error urea tank level signal range check low DPF differential pressure sensor and a further sensor or actuator CRT system defective Temperature sensor us and ds DOC simultaneously defect Maximum stand still duration reached oil exchange required Regeneration temperature PFItRgn LigtOff not reached regeneration aborted SCR system heater diagnostic reports error shut off SCR system Physical range check high for Urea Pump Pressure Urea pump pressure sensor high signal not plusible Physical range check low for Urea Pump Pressure Urea pump pressure sensor low signal not plausible Sensor error urea pump pressure signal range check high Sensor error urea pump pressure signal range check low SCR heater urea supplyline short circuit to battery SCR heater urea supplyline short circuit to ground SCR heater relay urea supplyline secondary side open load SCR heater relay urea supplyline primary side open load SCR heater urea pressureline short circuit to battery SCR heater urea pressureline short circuit to ground SCR heater relay urea pressureline secondary side open load SCR heater relay urea pressureline primary side open load Genie 5 30 GTH 5519 Part No 57 4400 9210 July 2015 Section 5 Fault Codes FAULT CODES sm 4343
121. no abnormal tensions on the hoses Part No 57 4400 9210 Genie GTH 5519 4 11 Section 4 Repair Procedures July 2015 Operator s Compartment 2 1 Operator s Compartment How to Remove the Operator s Compartment The operator s compartment is used to activate machine functions while sitting in the operator s drivers seat Within the operator s compartment there is a transmission column shifter steering selector 4 way controller accelerator pedal and brake pedal All of these components are replaceable For further information or assistance consult the Genie Service Department Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is required 1 Start the diesel engine and raise the boom above the cab 2 Open the engine cover and disconnect the battery negative terminal A WARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 4 12 5519 3 Remove the protective cover next to the cab inner side of the machine 4 Cut the plastic fasteners fixing the electrical cables then disconnect all of the electrical wires 5 Tag disconnect and p
122. nternal error Air pump doesn t achieve air mass flow setpoint Burner dosing valve DV2 overcurrent at the end of the injection phase Burner dosing valve DV2 short circuit to battery Burner dosing valve DV2 short circuit to battery on high side Burner dosing valve DV2 short circuit to ground Burner dosing valve DV2 blocked closed 11 Burner dosing valve 0 2 short circuit high side powerstage Burner dosing valve DV2 powerstage over temperature Physical range check high for burner dosing valve 0 2 downstream pressure shut off regeneration Physical range check low for burner dosing valve DV2 downstream pressure shut off regeneration When burner injector is actuated the measured pressure does not rise above ca 1250mbar abs expected ca 2400mbar 2 Burner dosing valve DV2 downstream pressure sensor plausibility error 3 Sensor error burner dosing valve DV2 downstream pressure sensor signal range check high 4 Sensor error burner dosing valve DV2 downstream pressure sensor signal range check low 523915 0 HCI dosing valve 011 overcurrent atthe end of the injection phase ooo HCI dosing valve DV1 short circuit to ground Genie 5 36 GTH 5519 Part No 57 4400 9210 2015 Section 5 Fault Codes FAULT CODES SPN FM ShortTextDetal __ 7 HCI dosing valve DV1 blocked closed 27 HCI dosing valve DV1 blocked open dosing valve DV1 short cir
123. o battery highside Metering unit Fuel System short circuit to battery low side 4 Metering unit Fuel System short circuit to ground high side Metering Unit Fuel System short circuit to ground low side Metering unit Fuel System open load Metering unit Fuel System powerstage over temperature Physical range check high for exhaust gas temperature upstrem SCR CAT Pressure overload of SCR System Pressure build up error SCR System Metering control is not performed in time error Pump pressure SCR metering unit too high Pump pressure SCR metering unit too low Nox conversion rate insufficient SCR Cat defect bad AdBule quality Nox conversion rate insufficient SCR Cat defect bad AdBule quality temperature range 1 Nox conversion rate insufficient SCR Cat defect bad AdBule quality temperature range 2 Shut off request from supervisory monitoring function Timeout Error of CAN Transmit Frame AmbCon Weather environments SCR main relay primary side short circuit to battery SCR mainrelay short circuit to battery only CV56B SCR main relay primary side short circuit to ground SCR mainrelay short circuit to ground only CV56B SCR main relay primary side open load SCR mainrelay open load only CV56B SCR mainrelay powerstage over temperature only CV56B CR heater urea supplymodule short circuit to battery CR heater urea supplymodule short circuit to ground SCR heater relay urea supply modul s
124. o port TP1 boom and steering functions hydraulic circuit test port 2 Start the engine 3 Increase the engine speed to maximum rpm 4 Moving the joystick retract the boom Result the pressure gauge reads 3915 psi 270 bar The pump is good Pressure is not within specification Adjust the main relief valve placed above the manifold Genie 4 32 GTH 5519 Part No 57 4400 9210 July 2015 Section 4 Repair Procedures MANIFOLDS Function Manifold Components Function Description Schematic TEM Boom up down Hydraulic proportional control A1 B1 Fork tilt Hydraulic proportional control 2 B2 Auxiliary Circuit Hydraulic proportional control Load Sensing Relief Valve 4205 psi 290 bar Valve 3915 psi 270 bar EN Genie Part No 57 4400 9210 GTH 5519 4 33 Section 4 Repair Procedures July 2015 MANIFOLDS 7 2 Valve Coils How to Test a Coil A properly functioning coil provides an electromagnetic force which operates the solenoid valve Critical to normal operation is continuity within the coil Zero resistance or infinite resistance indicates the coil has failed Since coil resistance is sensitive to temperature resistance values outside specification can produce erratic operation When coil resistance decreases below specification amperage increases As resistance rises above specification voltage increases While valves may operat
125. ocedure 1 1 How to Replace the Boom Wear Pads Boom Wear Pad Screws Tightening Specifications Screws M8 18 8 ft lbs 25 Nm Screws M10 37 ft lbs 50 Nm Max wearing thickness Minimum 1 mm Genie 3 14 GTH 5519 Part No 57 4400 9210 July 2015 Section 3 Scheduled Maintenance Procedures B 6 Perform Axle Maintenance Genie specifications require that this procedure be performed every 300 hours or quarterly whichever comes first Differential lubricating oil check add Planetary reduction lubricating oil check add Oil breather clean Required maintenance procedures and additional axle information is available in the Comer Axle S128 Service Manual Comer Axle Service Manual Genie part number 57 4700 0020 Part No 57 4400 9210 Genie GTH 5519 3 15 CHECKLIST B PROCEDURES B 7 Perform Axle Maintenance Axle specifications require that this procedure be performed after 400 hours Oil breather clean Required maintenance procedures and additional axle information is available in the Comer Axle S128 Service Manual Comer Axle Service Manual Genie part number 57 4700 0020 Section 3 Scheduled Maintenance Procedures July 2015 Checklist C Procedures C 1 Perform Engine Maintenance Engine specifications require that this procedure be performed every 500 hours Deutz TD 2 9 L4 Lubricating oil filter change when using De
126. of CAN Receive Frame ComRxUQSens 9 Timeout error of CAN Receive Frame ComSCRHiCtl 9 Timeout error of CAN Receive Frame ComTxAT1IMG 9 Timeout error of CAN Receive Frame ComTxTrbChActr Genie 5 42 GTH 5519 Part No 57 4400 9210 July 2015 Section 6 Schematics Observe and Obey Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine M Immediately tag and remove from service a damaged or malfunctioning machine M Repair any machine damage or malfunction before operating the machine Before Troubleshooting Read understand and obey the safety rules Schematics About This Section There are two groups of schematics in this section Electrical Schematics AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Hydraulic Schematics A WARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray General Repair Process and operating instructions in the appropriate operator s manual on your machine Malfunction Identify Troubleshoot discovered symptoms Be sure that all necessary tools and test equipment
127. old exceeded 100 Low oil pressure warning threshold exceeded Genie Part No 57 4400 9210 GTH 5519 5 9 Section 5 Fault Codes July 2015 FAULT CODES sm 100 175 175 175 175 175 175 175 175 1237 107 107 Low oil pressure shut off threshold exceeded Sensor oil temperature plausibility error Sensor oil temperature plausibility error oil temperature too high Physical range check high for oil temperature Physical range check low for oil temperature Sensor error oil temperature signal range check high Sensor error oil temperature signal range check low High oil temperature warning threshold exceeded High oil temperature shut off threshold exceeded Override switch plausibility error Sensor error airfilter differential pressure short circuit to battery Sensor error airfilter differential pressure short circuit to ground High air filter differential pressure warning threshold exceeded Sensor airpump pressure plausibility error Physical range check high for pressure shut off regeneration Physical range check low for airpump pressure shut off regeneration Sensor error airpump pressure signal range check high Sensor error airpump pressure signal range check low Sensor exhaustgas back pressure plausibility error Physical range check high for exhaustgas back pressure burner shut off regeneration Physical range check low for exhaust
128. old start aid relay open load 729 Cold start aid relay over temperature error 898 9 Timeout Error of CAN Receive Frame 9 Setpoint 975 Digital fan control short circuit to battery 975 Fan actuator PWM output short circuit to battery 975 Digital fan control short circuit to ground 975 Fan actuator PWM output short circuit to ground 975 Digital fan control open load 975 Fan actuator PWM output open load 975 Digital fan control powerstage over temperature 975 Fan actuator PWM output powerstage over temperature 1079 Sensor supply voltage monitor 1 error ECU 1080 Sensor supply voltage monitor 2 error ECU 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 signal range check low 1176 Sensor error pressure sensor upstream turbine signal range check high Genie Part No 57 4400 9210 GTH 5519 5 27 Section 5 Fault Codes July 2015 FAULT CODES sm J Fm sron Tenoa 1176 1180 1180 1180 1180 1180 1180 1180 1180 1180 1188 1188 1188 1188 1188 1188 1188 1188 1231 1235 1237 1322 1323 1324 1325 1326 1327 1328 1639 1639 1761 2621 2621 2621 Sensor error pressure sensor downstream turbine signal range check high Physical range check high for exhaust gas tempera
129. or nternal ECU monitoring detection reported error nternal ECU monitoring detection reported error nternal ECU monitoring detection reported error nternal ECU monitoring detection reported error nternal ECU monitoring detection reported error nternal ECU monitoring detection reported error nternal ECU monitoring detection reported error nternal ECU monitoring detection reported error nternal ECU monitoring detection reported error nternal ECU monitoring detection reported error nternal ECU monitoring detection reported error nternal ECU monitoring detection reported error nternal ECU monitoring detection reported error nternal ECU monitoring detection reported error nternal ECU monitoring detection reported error nternal software error ECU 523613 0 Maximum deviation of rail pressure exceeded RaiMeUnd F 52361 0 postive devon ofl pressure in meting unt exceeded Genie Part No 57 4400 9210 GTH 5519 5 33 Section 5 Fault Codes July 2015 FAULT CODES SPN FM ShortTextDetal __ 0 Railsystem leakage detected RailMeUn10 Maximum negative deviation of rail pressure in metering unit exceeded RailMeUn2 Negative deviation of rail pressure second stage RailMeUn22 Maximum rail pressure exceeded RailMeUn4 Minimum rail pressure exceeded RailMeUn3 Setpoint of metering unit in overrun mode not plausible Metering unit Fuel System short circuit t
130. or 5 in firing order 523051 0 Zerofuel calibration injector 6 in firing order 1 Zerofuel calibration injector 1 in firing order EN Zerofuel calibration injector 2 in firing order Zerofuel calibration injector 3 in firing order Zerofuel calibration injector 4 in firing order 523950 EM Zerofuel calibration injector 5 in firing order minimum value exceeded 523951 Zerofuel calibration injector 6 in firing order minimum value exceeded maximum value exceeded maximum value exceeded minimum value exceeded minimum value exceeded minimum value exceeded minimum value exceeded Genie 5 16 GTH 5519 Part No 57 4400 9210 2015 Section 5 Fault Codes FAULT CODES SPN FM ShortText Detail 00 005 523612 Internal software error ECU 175 Customer oiltemperature signal unplausible 523973 SCR Tamper detection derating timer below limit 1 523974 SCR Tamper detection derating timer below limit 2 523075 Urea quality derating timer below limit 1 Urea qulaity derating timer below limit 2 Urea tank level derating timer below limit 1 Urea tank level derating timer below limit 2 Physikal range check high for battery voltage Physikal range check low for battery voltage Physical range check high for intake air temperature Physical range check low for intake air temperature 523980 Bad quality of reduction agent detected 523922 Over temperature error on burner shut of v
131. ostatic Transmission Pump AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note When removing a hose assembly or fitting the fitting and or hose end must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications Note Perform this procedure with the engine off and cool to the touch 1 Open the engine compartment 2 Remove the cover that is under engine 3 Disconnect the battery negative terminal Part No 57 4400 9210 Genie GTH 5519 4 27 HYDRAULIC PUMPS 4 Tag disconnect and plug the hoses that are connected to the hydrostatic transmission pump Cap the fittings AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 5 Remove the boom and steering function pump from the hydrostatic transmission pump 6 Tag and disconnect the harness from the transmission 7 Support and secure the transmission pump to a suitable lifting device Do not apply lighting pressure 8 Remove the hydrostatic transmission pump Crushing hazard The hydrostatic transm
132. ot allow oil to squirt or spray 4 Remove the steer rotation actuator Genie Part No 57 4400 9210 GTH 5519 4 15 Section 4 Repair Procedures or OPERATOR S COMPARTMENT How to Remove the Joystick 1 2 3 Lift the boom Remove the guard underneath the boom that is located in the central part in the machine Open the engine cover and disconnect the battery negative terminal AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Raise the joystick protective guard Remove the retaining fasteners that secure the joystick to the mount panel Reach the center of the machine next to the cab Tag and disconnect the joystick harness connector from the machine Tag disconnect and plug the hoses from ports 1 2 3 4 P and T of the joystick Cap the ut Joystick port orientation 4 16 GTH 5519 Part No 57 4400 9210 July 2015 Note Removing the hydraulic hose from port T of the joystick with the joystick below the hydraulic oil level in the hydraulic tank will result in excessive hydraulic fluid leaking from the hose Do not disconnect the hose from the port if the joystick is below the hydraulic oil level in the hydraulic tank 9 Get back into the cab and remove the fasteners securing the joystick to the mount panel Remove the joystick 2015
133. ot available ComlnhSwtNA Regeneration release switch not available ComRegSwtNA Master ECU and Slave ECU have been identified as the same types Timeout Error of CAN Receive Frame MSMon_FidFCCTO Master Slave CAN communication faulty imeout error of CAN Transmit Frame DPFBrnAirPmpCtl imeout error of CAN Transmit Frame ComDPFBrnPT imeout error of CAN Transmit Frame ComDPFC1 imeout error of CAN Transmit Frame ComDPFHisDat imeout error of CAN Transmit Frame ComDPFTstMon imeout error of CAN Receive Frame ComRxDPFBrnAirPmpCtl imeout error of CAN Receive Frame ComRxDPFBrnAirPmp imeout error of CAN Receive Frame ComRxDPFCil imeout error of CAN Transmit Frame ComEGRMsFlw imeout error of CAN Receive Frame ComRxEGRMsFiw1 imeout error of CAN Receive Frame ComRxEGRMsFlw2 Timeout error of CAN Transmit Frame ComEGRTVActr Timeout error of CAN Receive Frame ComRxEGRTVActr imeout error of CAN Transmit Frame ComETVActr imeout error of CAN Receive Frame ComRxETVActr Timeout ComITVActr Timeout error of CAN Receive Frame ComRxITVActr 9 Timeout error of CAN Transmit Frame A1DOC Timeout error of CAN Transmit Frame AT1S Timeout error of CAN Transmit Frame SCR2 Timeout error of CAN Transmit Frame SCR3 9 Timeout error of CAN Receive Frame ComRxCM1 Timeout error of CAN Receive Frame ComRxCustSCR3 9 Timeout error of CAN Receive Frame ComRxSCRHtDiag Timeout error of CAN Receive Frame ComRxTrbChActr Timeout error
134. out Using a lifting strap and an overhead crane remove the cylinder Crushing hazard The cylinder could fall if not properly supported when removed from the machine GTH 5519 4 7 Section 4 Repair Procedures or BOOM COMPONENTS 1 4 Fork Level Cylinder How to Remove the Fork Level Cylinder Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the retaining fasteners securing the level cylinder rod end pivot pin July 2015 Remove the retaining fasteners securing the level cylinder barrel end pivot pin Using a soft metal drift and a hammer remove the pivot pin using the holes on the chassis on the rear left side of the machine Carefully lift and remove the cylinder from the machine Crushing hazard The cylinder Using a soft metal drift and a hammer remove the pivot pin Using a lifting strap and an overhead crane support the cylinder Place a container of suitable size under the hydraulic hoses before disconnecting Tag disconnect and plug the hydraulic hoses from the level cylinder Cap the cylinder fittings AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipat
135. over temperature only CV56B SCR mainrelay short circuit to battery only CV56B Genie Part No 57 4400 9210 GTH 5519 5 21 Section 5 Fault Codes July 2015 FAULT CODES sm sron Tenoa 523718 4376 4376 4376 524057 2659 2659 2659 2659 2659 3699 3699 3699 524114 524115 524116 524117 524097 SCR mainrelay short circuit to ground only CV56B SCR reversing valve open load SCR reversing valve over temperature SCR reversing valve short circuit to ground Electric fuel pump fuel pressure build up error EN Exhaust gas recirculation AGS sensor plausibility error Physical range check high for EGR exhaust gas mass flow Physical range check low for EGR exhaust gas mass flow Exhaust gas recirculation AGS sensor has burn off not performed AGS sensor temperature exhaust gas mass flow plausibility error Maximum stand still duration reached oil exchange required DPF differential pressure sensor and a further sensor or actuator CRT system defective Temperature sensor us and ds DOC simultaneously defect Timeout error of CAN Transmit Frame A1DOC Timeout error of CAN Transmit Frame 15 Timeout error of CAN Transmit Frame SCR2 Timeout error of CAN Transmit Frame 5083 Timeout error of CAN Transmit Frame DPFBmAirPmpCtl imeout error of CAN Transmit Frame ComDPFBrnPT imeout error of CAN Transmit Frame ComDPFC1 imeout error of CAN Transmit Frame ComDPFHisDat i
136. r downstream check of missing injector adjustment value programming IMA injector 7 in firing order check of missing injector adjustment value programming IMA injector 8 in firing order njector cylinder bank 2 slave short circuit njector powerstage output Slave defect njector 7 in firing order short circuit High side to low side short circuit in the injector 7 in firing order njector 7 in firing order interruption of electric connection njector 8 in firing order short circuit High side to low side short circuit in the injector 8 in firing order njector 8 in firing order interruption of electric connection Too many recognized misfires in cylinder 7 in firing order Too many recognized misfires in cylinder 8 in firing order Zerofuel calibration injector 7 in firing order maximum value exceeded Zerofuel calibration injector 7 in firing order minimum value exceeded Zerofuel calibration injector 8 in firing order maximum value exceeded Zerofuel calibration injector 8 in firing order minimum value exceeded 70 Burner flame unintentional deleted 7 Burner operation is interrupted too often Air pressure glow plug flush line below limit 20 Amount of air is not plausible to pump speed 2 Calculated amount of air is not plausible to HFM reading HFM sensor electrical fault Spark plug control unit SPCU electrical fault Spark plug control unit SPCU internal error DPF wasn t regen
137. rating condition In addition maintaining all of the safety and instructional decals in good condition is mandatory for safe machine operation Decals alert operators and personnel to the many possible hazards associated with using this machine They also provide users with operation and maintenance information An illegible decal will fail to alert personnel of a procedure or hazard and could result in unsafe operating conditions 1 Check to make sure that the operator s and safety manuals are present and complete in the storage container in the operator s compartment 2 Examine the pages of each manual to be sure that they are legible and in good condition Result The operator s manual is appropriate for the machine and all manuals are legible and in good condition Part No 57 4400 9210 Genie GTH 5519 3 5 Checklist A Procedures Result The operator s manual is not appropriate for the machine or all manuals are not in good condition or is illegible Remove the machine from service until the manual is replaced 3 Open the operator s manual to the decals inspection section Carefully and thoroughly inspect all decals on the machine for legibility and damage Result The machine is equipped with all required decals and all decals are legible and in good condition Result The machine is not equipped with all required decals or one or more decals are illegible or in poor condition Remove the machine
138. refer to the maintenance checklists for continued scheduled maintenance 1 Perform the following maintenance procedures B 5 Inspectthe Tires Wheelsand Lug Nut Torque D 3 Replace the Hydraulic Tank Return Filter Element Check Belt Tension Check The Engine Mounts Check Hose Clamps Part No 57 4400 9210 July 2015 Section 3 Scheduled Maintenance Procedures A 8 Perform Axle Maintenance Axle specifications require that this procedure be performed after 100 hours Differential lubricating oil check add Planetary reduction lubricating oil check add Required maintenance procedures and additional axle information is available in the Comer Axle S128 Service Manual Comer Axle Service Manual Genie part number 57 4700 0020 Part No 57 4400 9210 Genie GTH 5519 3 9 CHECKLIST A PROCEDURES A 9 Perform Axle Maintenance Axle specifications require that this procedure be performed after 200 hours Differential lubricating oil change Planetary reduction lubricating oil change Magnetic plug clean Required maintenance procedures and additional axle information is available in the Comer Axle S128 Service Manual Comer Axle Service Manual Genie part number 57 4700 0020 Section 3 Scheduled Maintenance Procedures July 2015 CHECKLIST A PROCEDURES A 10 Perform Axle Maintenance Axle specifications require that this procedure be performed every 200 hours Axle grease Required m
139. rent 267 Frequency 100 Hz Cranking speed 130 200 rpm High idle 2700 rpm Glow Plugs Frequency 270 Hz a Initial load 0 10 sec 40 amps Lubrication system Continuous load gt 10 sec 15 amps Minimum oil pressure 17 4 psi 1 2 bar Battery Maximum oil capacity 2 11 gallons Type 12V DC including filter 8 liters Group G28 Oil viscosity requirements Quantity 1 Units ship with 15W 40 Shell Rimula R4 L Cold cranking ampere 0 F 720A Extreme operating temperatures may require the use Nominal capacity 100 Ah of alternative engine oils For oil requirements refer to the Engine Operation and Maintenance Manual on your machine 2 6 Genie Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice GTH 5519 Part No 57 4400 9210 July 2015 Section 2 Specifications SPECIFICATIONS Comer Axles Steering Integrated steer cylinder Joints Heavy duty double U joints Steering angle 40 Front Axle Lubrication Front differential 1 32 gallons 5 liters Axle planetary end each 0 25 gallons 0 95 liter Drop Box Lubrication Drop Box 0 26 gallons 1 liters Rear Axle Lubrication Rear differential 5 28 quarts 5 liters Axle planetary end each 1 quart 0 95 liters Oil viscosity requirements Differential API GL5 MIL L 2105 Planetary ends API GL5 MIL L 2105 For additional axle information refer
140. rm Engine Maintenance Engine specifications require that this procedure be performed every 8 hours or daily whichever comes first Deutz TD 2 9 L4 Lubricating oil level check add Coolant level check add Exhaust system including exhaust aftertreatment components check for leaks Visual inspection Suction air filter dry air filter check Fuel pre filter check empty water Required maintenance procedures and additional engine information is available in the Deutz TD 2 9 L4 Operation and Maintenance Manual Deutz part number 0312 3896 Deutz TD 2 9 L4 Operation and Maintenance Manual Genie part number 57 4700 0006 Genie part number 09 4693 0000 Genie Part No 57 4400 9210 GTH 5519 3 7 Section 3 Scheduled Maintenance Procedures July 2015 CHECKLIST A PROCEDURES A 6 Safety Devices 1 Emergency Stop button To check the efficiency of this pushbutton simply press it down during a movement The pressure of the pushbutton shall cause the movement to stop and the engine to shut down 2 Pressure Switch On The Parking Brake Engage the parking brake and start the engine The parking brake warning light should come on Attempt to move with the machine The machine must not move Genie 3 8 GTH 5519 A 7 Perform 30 Day Service The 30 day maintenance procedure is a one time sequence of procedures to be performed after the first 30 days or 40 hours of usage After this interval
141. rocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 2 Remove the rear steering column cover 3 Remove the lower part of the dashboard 4 Remove the transmission control lever 5 Remove the light control lever if present 6 Remove the screws which secure the steering column to the frame 7 Remove the steering column Genie 4 14 GTH 5519 How to Remove the Steering Wheel 1 Open the engine cover and disconnect the battery negative terminal AAWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 2 Remove the horn button from the steering wheel Remove the nut securing the steering wheel to the column and remove the steering wheel Part No 57 4400 9210 2015 Section 4 Repair Procedures Ee OPERATOR S COMPARTMENT How to Remove the Steer Rotation Actuator 1 Remove the steering column See 2 2 How to Remove the Steering Column 2 Working under the dashboard locate the hydraulic hoses of the steer rotation actuator 3 Tag disconnect and cap the hydraulic hoses and steer rotation actuator holes AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do n
142. ror 172 Intake air sensor plausibility error 172 Sensor error intake air signal range check high 172 Sensor error intake air sensor signal range check low 174 High low fuel temperature warning threshold exceeded 174 High Low fuel temperature shut off threshold exceeded 175 Physical range check high for oil temperature 175 High oil temperature warning threshold exceeded 175 High oil temperature shut off threshold exceeded 175 High customer oil temperature warning threshold exceeded 175 High customer oil temperature shut off threshold exceeded 175 Physical range check low for oil temperature 175 Sensor oil temperature plausibility error 175 Sensor oil temperature plausibility error oil temperature too high 175 Customer oiltemperature signal unplausible 175 Sensor error oil temperature signal range check high 175 Sensor error oil temperature signal range check low 190 Engine speed above warning threshold FOC Level 1 190 Offset angle between crank and camshaft sensor is too large 190 8 Sensor camshaft speed disturbed signal 190 8 Sensor crankshaft speed disturbed signal 190 Engine speed above warning threshold FOC Level 2 190 Sensor camshaft speed no signal 190 Sensor crankshaft speed no signal Genie Part No 57 4400 9210 GTH 5519 5 25 Section 5 Fault Codes July 2015 FAULT CODES sm sron Teabe 190 190 411 411 411 411
143. ry Preparation report to use for each inspection Store completed forms as required Maintenance Schedule There are five types of maintenance inspections that must be performed according to a schedule daily quarterly semi annually annually and every two years The Scheduled Maintenance Procedures Section and the Maintenance Inspection Report have been divided into five subsections A B C D and E Use the following chart to determine which group s of procedures are required to perform a scheduled inspection Inspection Checklist Daily or every 8 hours A Quarterly or every 250 hours A B Semi annually or every 500 hours Annually or every 1000 A B C4D hours Two years or every 2000 A B C D E hours Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection 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 Part No 57 4400 9210 Pre Delivery Preparation Fundamentals It is the responsibility of the dealer to perform the Pre delivery Preparation The Pre delivery Preparation is performed prior to each delivery The inspection is designed to discover if anything is apparently wrong with a machine before it is put into service A damaged or modified machine mus
144. s covers ADANGER Crushing hazard Death or serious injury could result if the boom should unexpectedly fall while working underneath the boom Do not stand or work beneath a boom that is not properly supported 6 Inspect the following areas for burnt chafed corroded pinched and loose wires Engine Transmission Manifolds Chassis 7 Inspect for a liberal coating of dielectric grease in all connections between the engine transmission and the operator s compartment 8 Install all covers removed in step 5 9 Remove the lifting strap from the overhead crane 10 Start the engine and lower the boom to the Stowed position Turn the machine off Section 3 Scheduled Maintenance Procedures July 2015 CHECKLIST B PROCEDURES B 2 Check the Exhaust System Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the exhaust system is essential to good engine performance and service life Running the engine with a damaged or leaking exhaust system can cause component damage and unsafe operating conditions Bodily injury hazard Do not inspect while the engine is running Remove the key to secure from operation A CAUTION Bodily injury hazard Beware of hot engine components Contact with hot engine components may cause severe burns 1 Open the engine access cover 2 Besure that the fastener is tight 3 Inspect all welds for cracks 4
145. s in cylinder 6 in firing order Sensor error fan speed signal range check high Sensor error fan speed signal range check low Urea tank level warning threshold exceeded Flush valve burner EPV DPF System short circuit to battery Flush valve burner EPV DPF System short circuit to ground Flush valve burner EPV DPF System open load Genie 5 28 GTH 5519 Part No 57 4400 9210 2015 Section 5 Fault Codes FAULT CODES SPN FM ShortTextDetal __ 2621 Flush valve burner EPV DPF System powerstage over temperature 2659 Physical range check high for EGR exhaust gas mass flow 2659 Physical range check low for EGR exhaust gas mass flow 2659 20 Exhaust gas recirculation AGS sensor plausibility error 2659 2 AGS sensor temperature exhaust gas mass flow plausibility error 2659 Exhaust gas recirculation AGS sensor has burn off not performed 2797 4 Injector diagnostics timeout error of short circuit to ground measurement cyl Bank 0 2798 4 Injector diagnostics timeout error of short circuit to ground measurement cyl Bank 1 2798 4 Injector diagnostics short circuit to ground monitoring Test in Cyl Bank 0 2798 40 Injector diagnostics short circuit to ground monitoring Test in Cyl Bank 1 3031 AdBlue Tank temperature maximum exceeded 3031 DEF Tank temperature below minimum 3031 Sensor error urea tank temperature short circuit to battery 3031 Sensor error ur
146. s temperature particulate filter downstream warning 3248 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 Genie Part No 57 4400 9210 GTH 5519 5 29 Section 5 Fault Codes July 2015 FAULT CODES sm 3248 3248 3251 3251 3253 3253 3253 3253 3361 3361 3361 3361 3361 3532 3532 3699 3699 3699 3711 4243 4334 4334 4334 4334 4334 4334 4341 4341 4341 4341 4343 4343 4343 4343 Sensor exhaust gas temperature downstream DPF plausibility error Sensor error particle filter downstream temperature signal range check low Physical range check high for differential pressure DPF shut off regeneration Physical range check low for differential pressure DPF shut off regeneration Sensor differential pressure DPF plausibility error regarding signal offset 20 Sensor differential pressure DPF plausibility error Sensor error differential pressure DPF signal range check high Sensor error differential pressure DPF signal range check low Urea dosing valve short circuit to battery on high side Urea dosing valve short circuit battery or open load on high side Urea dosing valve short circuit to ground or open load on low side Urea dosi
147. signal range check low Sensor DV1 amp DV2 upstream temperature plausibility error Physical range check high for DV1 amp DV2 upstream temperature shut off regeneration Physical range check low for DV1 amp DV2 upstream temperature shut off regeneration Sensor error DV1 amp DV2 upstream temperature signal range check high Genie Part No 57 4400 9210 GTH 5519 5 7 Section 5 Fault Codes July 2015 FAULT CODES sm 0 523918 Sensor error DV1 amp DV2 upstream temperature signal range check low 676 Cold start aid relay error 676 Cold start aid relay open load 729 Cold start aid relay open load 729 Cold start aid relay over temperature error 523895 Check of missing injector adjustment value programming IMA injector 1 in firing order 523896 check of missing injector adjustment value programming 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 523899 check of missing injector adjustment value programming IMA injector 5 in firing order 523900 check of missing injector adjustment value programming IMA injector 6 in firing order 523350 njector cylinder bank 1 short circuit 523352 njector cylinder bank 2 short circuit 523354 njector powerstage output defect 651 njector 1 in firing order interruption of electric
148. ssion Pump Note Perform this procedure on a firm level surface with the boom in the stowed position and service brake pedal engaged 1 Connect 0 to 8700 psi 0 to 600 bar pressure gauge to port TP2 hydrostatic transmission high pressure test port Connect 0 to 870 psi 0 to 60 bar pressure gauge to port TP3 hydrostatic transmission boost pressure test port Start the engine Result the pressure gauge connected to test port TP3 reads 360 psi 25 bar Pressure is not within specification Contact Genie Service Department Increase the engine speed to 1200 rpm 4 26 Genie July 2015 Engage forward or reverse gear Result the pressure gauge connected to test port TP2 reads 725 psi 50 bar Pressure is not within specification Adjust the high pressure relief valve a located above the pump Increase the engine speed to maximum rpm Result the pressure gauge on test port TP2 reads 7180 psi 495 bar Pressure is not within specification Adjust the high pressure relief valve b located above the pump While observing the pressure gauge connected to test port TP3 operate the engine between 1200 rpm and maximum rpm Result the pressure gauge on test port TP3 does not go below 360 psi 25 bar Pressure is not within specification Contact Genie Service Department GTH 5519 Part No 57 4400 9210 July 2015 Section 4 Repair Procedures How to Remove the Hydr
149. system downstream cat DPF system downstream cat 529946 0 Zerotue calibration injector 1 in tring order maximum value exceeded 00 523047 0 Zerotvelclibraton injector 2 n fring order maximum valueexceeded 523048 0 Zerotuel calibration injector 3 i fring order maximum valueexceeded 523049 0 Zerotuel calibration injector 4 i fring order maximum valueexceeded 529950 0 Zerotue calibration injector 5 n tring order maximum value exceeded 523051 0 Zerofuel calibration injector 6 in firing order maximum value exceeded 5290 ange igh for EGR ooer donnsteam empere 202222 529960 0 exhaust gas temperature EGR cooler downstream warning threshold exceeded 529982 0 Powerstage diagnosis disabled high battery votage 000000000002 523989 0 FuelBalance Control integrator injector 7 in fring order maximum value exceeded Genie Part No 57 4400 9210 GTH 5519 5 39 Section 5 Fault Codes July 2015 FAULT CODES SPN FM ShortTextDetal __ Fuel Balance Control integrator injector 7 in firing order minimum value exceeded Fuel Balance Control integrator injector 8 in firing order maximum value exceeded Fuel Balance Control integrator injector 8 in firing order minimum value exceeded 9 Timeout Error of CAN Receive Frame DM19Vol1 NOX sensor upstream Timeout Error of CAN Receive Frame DM19Vol2 NOX senso
150. t damage hazard Hoses can be damaged if they are kinked or pinched 9 Remove the retaining fasteners securing the fork tilt cylinder barrel end pivot pin 10 Using a soft metal drift and a hammer remove the pivot pin b 11 Carefully lift and remove the cylinder from the machine Crushing hazard The cylinder could fall if not properly supported when removed from the machine Section 4 Repair Procedures July 2015 BOOM COMPONENTS How to Replace the Fork Tilt 6 Cylinder Hoses Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during 8 installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Start the engine 2 Raise the boom to a horizontal position 3 Retract the boom until you can see the screws retaining bracket b in the slot located on the boom 4 Turn the machine off and remove the key from the key switch 5 Remove screws a and pull out bracket b from the rear side of the boom Before replacing a hydraulic hose thoroughly clean the machine Remove the protective guard c of the shut off valve Tag disconnect and plug the hydraulic hoses from the fork tilt cylinder A WARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allo
151. t never be used If damage or any variation from factory delivered condition is discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications Scheduled maintenance inspections shall be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual Genie A TEREX BRAND Terex South Dakota Inc USA 500 Oak Wood Road PO Box 1150 Watertown SD 57201 6150 605 882 4000 Genie UK The Maltings Wharf Road Grantham Lincolnshire NG31 6BH England 44 1476 584333 Copyright O 2011 Terex Corporation Genie is a registered trademark of Terex South Dakota Inc 133192 Rev D Instructions Use the operator s manual on your machine The Pre delivery Preparation consists of completing the Pre operation Inspection the Maintenance items and the Function Tests Use this form to record the results Place a check in the appropriate box after each part is completed Follow the instructions in the operator s manual If any inspection receives an N remove the machine from service repair and reinspect it After repair place a check in the R box Legend Y yes completed N no unable to complete repaired Pre Delivery Preparation Pre operation inspection completed Maintenance ite
152. table 16 110 ft lbs 150 Nm fitting Adj 20 140 ft lbs 190 Nm SAE O ring Boss Port 24 180 ft lbs 245 Nm tube fitting installed into Steel SAE Dash size Torque aa 4 ORFS 37 Adj 15 ft lbs 20 3 Nm JIC 37 Fittings swivel nut or hose connection ORFS 26 MIDS so Mm 37 Non adj 22 ft lbs 30 Nm SAE Dash size Thread Size Flats 3 6 ORFS Adj Non adj 35 ft Ibs 47 5 Nm 4 7 220 2 37 Adj Non adj 29 ft lbs 39 3 Nm 6 918 17 8 ORFS 60 ft lbs 81 3 Nm 8 2 16 1 37 52 ft lbs 70 5 Nm 4d 7 44 10 Adj Non adj 100 ft lbs 135 6 Nm 37 Adj Non adj 85 ft lbs 115 3 Nm 12 1 12 1 12 All types 135 ft lbs 183 Nm 16 15 12 1 16 All types 200 ft lbs 271 2 Nm 20 15 12 1 20 All types 250 ft lbs 339 Nm 24 17 12 1 24 All types 305 ft lbs 413 5 Nm Genie 2 8 GTH 5519 Part No 57 4400 9210 July 2015 Section 2 Specifications SPECIFICATIONS Torque Procedure Seal Lok fittings 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 fitting or hose end has been tightened beyond finger tight Note The O rings used in the Parker Seal Lok fittings and hose ends are custom size O rings They are not standard SAE size O rings They are available in the O ring field service kit Genie part number 49612 2 Lubricate t
153. tage over temperature Air Pump operating voltage error Burner dosing valve 0 2 blocked closed Air pressure glow plug flush line below limit Burner operation is interrupted too often 7 HCI dosing valve DV1 blocked closed 7 HCI dosing valve DV1 blocked open HFM sensor electrical fault Amount of air is not plausible to pump speed Calculated amount of air is not plausible to HFM reading 6 Air Pump over current Shut Off Valve blocked closed Bumer fuel line pipe leak behind Shut Off Valve Burner Shut Off Valve blocked open Spark plug control unit SPCU electrical fault Spark plug control unit SPCU internal error Fuel Balance Control integrator injector 7 in firing order maximum value exceeded Fuel Balance Control integrator injector 8 in firing order maximum value exceeded Fuel Balance Control integrator injector 7 in firing order minimum value exceeded Fuel Balance Control integrator injector 8 in firing order minimum value exceeded Timeout Error of CAN Receive Frame DM19Vol1 NOX sensor upstream imeout Error of CAN Receive Frame DM19Vol2 NOX sensor downstream imeout error of CAN Receive Frame ComMS_Sys1TO error memory Slave EM Timeout error of CAN Receive Frame ComMS_Sys2TO error memory Slave Timeout error of CAN Receive Frame ComMS_Sys3TO error memory Slave Timeout error of CAN Receive Frame ComMS_Sys4TO error memory Slave imeout error of CAN
154. tion Manifold System relief valve pressure maximum 3915 psi measured at test port TP1 270 bar Fork tilt relief valve pressure maximum 4205 psi 290 bar Secondary Function Valves Steer relief valve pressure maximum 2030 psi 140 bar Steer anti shock relief valve pressure 2900 psi maximum 200 bar Parking brake relief valve pressure 360 psi maximum measured at test port TP4 25 bar Auxiliary line relief valve pressure 3915 psi maximum measured at test port TP3 270 bar Air Conditioner Refrigerant Specifications System Full Charge R134a 750 g 1 165 10 oz Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie Part No 57 4400 9210 GTH 5519 2 5 Section 2 Specifications July 2015 Deutz TD 2 9 L4 Engine Fuel requirements SPECIFICATIONS For fuel requirements refer to the engine Operation Displacement 2925 cm Manual on your machine Number of cylinders 4 Fuel injection pressure 1595 psi Bore and stroke 3 62 x 4 33 inches pate 92 x 110 mm Engine coolant Horsepower 74 HP 2600 rpm Capacity 3 3 gallons 55 4 kW 2200 rpm 12 5 liters Peak Torque 192 Ib ft 1800 rpm Type Extended Life 260 Nm 1800 rpm Alternator Firing order 1 3 4 2 Output 95 A 12V DC Compression ratio 17 411 Starter Motor Governor Electronic Nominal power 3 2 kW Low idle 1000 rpm Nominal cur
155. tion pedal cycle duration PWM signal signal range check low 1 Sensor error accelerator pedal signal range check low Sensor error handthrottle sensor signal range check low 523921 Sensor error burner temperature signal range check high 3532 Sensor error urea tank level signal range check high 523921 Sensor error burner temperature signal range check low 3532 Sensor error urea tank level signal range check low 1079 Sensor supply voltage monitor 1 error ECU 1080 Sensor supply voltage monitor 2 error ECU 523601 Sensor supply voltage monitor 3 error ECU 677 Starter relay high side short circuit to battery 677 Starter relay high side short circuit to ground 677 Starter relay no load error 677 Starter relay powerstage over temperature 677 Starter relay low side short circuit to battery 677 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 short circuit to ground 624 SVS lamp open load 624 VS lamp powerstage over temperature 624 SVS lamp short circuit to battery 624 SVS lamp short circuit to ground 523612 Softwarereset CPU SWReset 0 523612 Softwarereset CPU SWReset_1 523612 Softwarereset CPU SWReset_2 91 Plausibiliy error between APP and APP or APP1 and idle switch 523550 T50 start switch active for too long 172 Sensor error intake air signal range check high 172 Sensor error intake air sensor signal range check
156. to the Comer Axle S128 Service Manual Comer Axle Service Manual Genie part number 57 4700 0020 Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie Part No 57 4400 9210 GTH 5519 2 7 Section 2 Specifications July 2015 Se SPECIFICATIONS Hydraulic Hose and Fitting SAE O ring Boss Port api tube fitting installed into Aluminum Torque Specifications all pas 2 SAE Dash si Your machine is equipped with Parker Seal Lok S STER ORFS or 37 JIC fittings and hose ends 4 14 ft lbs 19 Nm Genie specifications require that fittings and hose 6 23 ft lbs 31 2 Nm ends be torqued to specification when they are removed and installed or when new hoses or 8 36 ft lbs 54 2 Nm fittings are installed 10 62 ft lbs 84 Nm 12 84 ft lbs 114 Nm Seal Lok Fittings hose end ORFS 16 125 ft lbs 169 5 Nm SAE Dash size Torque 20 151 ft lbs 204 7 Nm 4 10 ft lbs 13 6 Nm 24 184 ft lbs 249 5 Nm 6 30 ft lbs 40 7 Nm gt Non adjustable 8 40 ft lbs 54 2 Nm iw Jamb nut 7 fitting Non 10 60 ft lbs 81 3 Nm adj 12 85 ft lbs 115 Nm Adjus
157. ts it such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Be aware of potential crushing hazards 3l Genie viii GTH 5519 Workplace Safety Be sure to keep sparks flames and lighted tobacco away from flammable and combustible materials like battery gases and engine fuels Always have an approved fire extinguisher within easy reach are properly maintained and ready for use Keep work surfaces clean and free of debris that could get into machine components and cause damage Be sure that tools and working areas other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted Use only chains or straps that are in good condition and of ample capacity Be sure any forklift overhead crane or Be sure that fasteners intended for one time use i e cotter pins and self locking nuts are not reused These components may fail if they are used a second time Be sure to properly dispose of old oil or 69 other fluids Use an approved container Please be environmentally safe SIN sure that your workshop or work area B is properly ventilated and well lit Part No 57 4400 9210 July 2015 Introduction Section 1 Section 2 Section 3 Table of Contents Important Information 2 ii Revision dices iii
158. ture printings of this and all other manuals Contact Us http www genielift com e mail awp techpub terex com Genie i GTH 5519 Serial Number Information Genie offers the following Service Manuals for these models Title Part No Copyright 2015 by Terex Corporation 57 4400 9210 Rev B July 2015 First Edition First Printing Genie and GTH are registered trademarks of Terex South Dakota Inc in the USA and many other countries 6 Printed on recycled paper Part No 57 4400 9210 July 2015 Revision History Revision Procedure Schematic Page Description 22 63 618 O 10 2013 Initial Release 07 2015 6 3 6 18 REFERENCE EXAMPLES Kubota Engine_Section 2_Specifications Electronic Version A 6 B 3 C 7_Section 3_Maintenance Procedure 3 2 6 4 9 1 Section 4 Repair Procedure Click on any procedure or page number Fault Codes Section 5 highlighted in blue to view the update 6 35 6 56 6 104 Section 6 Schematic Page Genie Part No 57 4400 9210 GTH 5519 ii July 2015 REVISION HISTORY CONTINUED Revision Procedure Schematic Page Description Kubota Engine_Section 2_ Specifications Electronic Version A 6 B 3 C 7_Section 3_Maintenance Procedure 3 2 6 4 9 1_ Section 4_Repair Procedure Click on any procedure or page number Fault Codes_ Section 5 highlighted in blue to view the update 6 35 6 56 6 104 Section 6
159. ture upstream turbine Turbocharger Wastegate CAN feedback warning threshold exceeded Exhaust gas temperature upstream turbine warning threshold exceeded Physical range check low for exhaust gas temperature upstream turbine Turbocharger Wastegate CAN feedback shut off threshold exceeded Exhaust gas temperature upstream turbine shut off threshold exceeded Sensor error exhaust gas temperature upstream turbine signal range check high Sensor error exhaust gas temperature upstream turbine signal range check low Sensor exhaust gas temperature upstream turbine plausibility error Wastegate status message from ECU missing Wastegate actuator blocked Wastegate actuator internal error Wastegate actuator EOL calibration not performed correctly Wastegate actuator over temperature gt 145 Wastegate actuator over temperature gt 135 C Wastegate actuator operating voltage error Wastegate actuator calibration deviation too large recalibration required CAN Bus 1 BusOff Status CAN Bus 2 BusOff Status Override switch plausibility error Too many recognized misfires in more than one cylinder Too many recognized misfires in cylinder 1 in firing order Too many recognized misfires in cylinder 2 in firing order Too many recognized misfires in cylinder 3 in firing order Too many recognized misfires in cylinder 4 in firing order Too many recognized misfires in cylinder 5 in firing order Too many recognized misfire
160. urs Deutz TD 2 9 L4 Charge air cooler entry area drain lube oil condensate Battery and cable connectors check Cold starting device check Engine mounts check Fastening hose unions clips check V rib belt and tensioning pulley check Fuel filter cartridge replace Fuel pre filter replace V belts replace Required maintenance procedures and additional engine information is available in the Deutz TD 2 9 L4 Operation and Maintenance Manual Deutz part number 0312 3896 Deutz TD 2 9 L4 Operation and Maintenance Manual Genie part number 57 4700 0006 Part No 57 4400 9210 Genie GTH 5519 3 19 CHECKLIST D PROCEDURES D 4 Perform Axle Maintenance Axle specifications require that this procedure be performed every 1000 hours or annually whichever comes first Differential lubricating oil change Planetary reduction lubricating oil change Magnetic plug clean Required maintenance procedures and additional axle information is available in the Comer Axle S128 Service Manual Comer Axle Service Manual Genie part number 57 4700 0020 Section 3 Scheduled Maintenance Procedures July 2015 CHECKLIST D PROCEDURES D 5 Inspect the Engine Air Filter Genie requires that this procedure be performed every 1000 hours Perform this procedure more often if dusty conditions exist Maintaining the engine air filter in good condition is essential to good engine performance and service
161. utz approved oil rated III or better Coolant additive concentration check Intake air pipes check for damage V belts check Fuel pre cleaner fuel pre filter clean Required maintenance procedures and additional engine information is available in the Deutz TD 2 9 L4 Operation and Maintenance Manual Deutz part number 0312 3896 Deutz TD 2 9 L4 Operation and Maintenance Manual Genie part number 57 4700 0006 3 16 GTH 5519 Genie Part No 57 4400 9210 July 2015 Section 3 Scheduled Maintenance Procedures Checklist D Procedures D 1 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 Failure to detect damage to the forks could result in a hazardous operating condition 1 Thoroughly clean the lifting forks 2 Inspect the forks for the following Surface cracks e Straightness of the blade and shank Fork angle at 90 3 degrees Relative height of fork tips shall not differ more than 3 of blade length Excessive wear to the forks fork mount or legible markings Result If any of the above are not met forks shall be removed from service until they are repaired or replaced a shank b blade
162. ve PRV reached maximun allowed opening count Pressure relief valve PRV reached maximun allowed open time Timeout Error of CAN Receive Frame ComEngPrt Engine Protection Timeout Error of CAN Receive Frame PrHtEnCmd pre heat command engine command Timeout CAN message FunModCtl Function Mode Control Immobilizer status fuel blocked 4 Injector cylinder bank 1 short circuit 4 Injector cylinder bank 2 short circuit Injector powerstage output defect Multiple Stage Switch constant speed plausibility error Multiple Stage Switch constant speed short circuit to battery Multiple Stage Switch constant speed short circuit to ground Genie 5 32 GTH 5519 Part No 57 4400 9210 2015 Section 5 Fault Codes FAULT CODES SPN FMI Short Text Detail Rail pressure out of tolerance range Open Pressure Relief Valve PRV shut off condition Open Pressure Relief Valve PRV warning condition Pressure Relief Valve PRV is open T50 start switch active for too long Sensor supply voltage monitor 3 error ECU High fan speed warning threshold exceeded High fan speed shut off threshold exceeded Timeout Error of CAN Receive Frame Ambient Temperature Sensor Timeout Error of CAN Receive Frame TSC1AE Traction Control Timeout Error of CAN Receive Frame TSC1AR Retarder nternal software error ECU injection cut off nternal ECU monitoring detection reported err
163. ver comes first Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more often Refer to Section 2 Specifications Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary If the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test See E 1 Test or Replace the Hydraulic Oil Part No 57 4400 9210 GTH 5519 Genie CHECKLIST B PROCEDURES Section 3 Scheduled Maintenance Procedures July 2015 CHECKLIST B PROCEDURES B 5 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 1 Extend the boom until the wear pads accessible 2 Inspect each pad and ensure that pad thickness is more than 0 04 inches 1 mm see figure Result If thickness is above 0 04 inches 1 mm the pad can be re used Result if thickness is less than 0 04 inches 1 mm replace the worn pad Refer to Repair Pr
164. w oil to squirt or spray Genie 4 10 GTH 5519 Part No 57 4400 9210 July 2015 Section 4 Repair Procedures 9 Securely attach a resistant guide rope length about 33 feet 10 m to the hydraulic hose one for each hose This will be used to install the new hoses 10 Reach the back of the machine and remove the cover 11 Pull hoses e and f outward one at atime until they come out completely 12 Move to the front bottom of the boom and remove comb d 13 Tag disconnect and plug the hydraulic hoses from the pipes A WARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray BOOM COMPONENTS 14 Pull hoses e and f outward one at a time until they come out completely 15 Remove the rope from the old hydraulic hoses and attach it to the new hydraulic hoses straight end side 16 Connect the ends of the new hoses to the pipes 17 Install the hoses e e f from underneath the boom pull them from the rear side of the boom 18 Install the hoses e e f from behind the boom pull them from the front side of the boom to connect the straight ends to the shut off valve NOTICE Component damage hazard Hoses can be damaged if they are kinked or pinched 19 Start the engine and extend and retract the boom Verify that there are
165. witch Counterbalance a4 valve Temperature switch Fuel level sender _ 5 Pressure switch Batte Genie 6 2 GTH 5519 Part No 57 4400 9210 2015 Section 6 Schematics Electrical Schematic Sheet 1 of 8 Up to SN GTH5515B 2364 1 2 3 4 5 Main Gouge Cluster 088 0F30 5 Deutz Diognostic Engine Ignition Key bh de ded dads x157 e Y Si sles a se 5 5 3 4 55 5 S 30A 3 te E 3 8 8 1 RDA F200 Bede be be de diode de de hs be fee be ed 3333533898233333 4218 _ _ E g 2245 3325343425325 s 855 833535552352 s e YO gt 61 He WHO 75 6099 WHO 6 S 34 75 3028 0 75 2065 ia NATS 3065 gt GNOTS 3021 31 BK 41 4 WHOS 65657 gt 34 125 03 gt p1 s 8 E 1 2 T x h h a ro F 30 15 m 1 F20 ma 15 H gt 21 15 Le
166. witch in the off position with the key removed Wheels chocked 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 equipment are available and ready for use Be aware of the following hazards and follow generally accepted safe workshop practices Crushing hazard When testing or replacing any hydraulic component always support the structure and secure it from movement JAWARNING F ectrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry ZAWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to Squirt or spray General Repair Process Malfunction Identify Troubleshoot discovered symptoms problem still exists Return to Inspect Perform service and test Repair problem solved Genie Part No 57 4400 9210 GTH 5519 5 1 Section 5 Fault Codes July 2015 FAULT CODES Diagnostic Display When the engine Electronic Control Module ECM detects an abnormal operating condition a fault code is immediately stored in the ECM memory The presence of faults is indicate

Service Manual - Genie Industries

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