Service Manual GTH-5519
Service Manual GTH-5519
Service Manual GTH-5519
Introduction
Important Technical Publications
Read, understand and obey the safety rules and Genie has endeavored to deliver the highest
operating instructions in the Genie GTH-5519 degree of accuracy possible. However, continuous
Operator's Manual before attempting any improvement of our products is a Genie policy.
maintenance or repair procedure. Therefore, product specifications are subject to
change without notice.
This manual provides troubleshooting and repair
procedures for qualified service professionals. Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
Basic mechanical, hydraulic and electrical communications will be carefully considered for
skills are required to perform most procedures. future printings of this and all other manuals.
However, several procedures require specialized
skills, tools, lifting equipment and a suitable
workshop. In these instances, we strongly Contact Us:
recommend that maintenance and repair be
http://www.genielift.com
performed at an authorized dealer service center.
e-mail: [email protected]
Revision History
Revision Date Section Procedure / Page / Description
A 03/2016 Initial Release
A1 09/2016 Introduction Serial Number Legend
A2 03/2019 Section 2,5 Specifications 2-1, Schematics from 5-27 to 5-42
REFERENCE EXAMPLES:
REFERENCE EXAMPLES:
INTRODUCTION
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.
SAFETY RULES
WARNING Indicates a potentially hazardous Be sure that fasteners intended for one
situation which, if not avoided, time use (i.e., cotter pins and self-locking
could result in death or serious nuts) are not reused. These components
injury. may fail if they are used a second time.
Table of Contents
Introduction
Important Information .................................................................................. ii
Revision History...........................................................................................iii
Serial Number Legend................................................................................. v
Section 2 Specifications
Machine Specifications ...........................................................................2 - 1
Performance Specifications ....................................................................2 - 2
Hydraulic Specifications .........................................................................2 - 3
Hydraulic Components Specifications ....................................................2 - 4
Function Manifold Specifications ............................................................2 - 5
Air Conditioner Refrigerant Specifications ..............................................2 - 5
Deutz TD 2.9 L4 Engine .........................................................................2 - 6
Comer Axle .............................................................................................2 - 7
Hydraulic Hose and Fitting Torque Specifications ..................................2 - 8
Torque Procedure...................................................................................2 - 9
SAE and Metric Fasteners Torque Charts............................................2 - 10
TABLE OF CONTENTS
Engines
4-1 Engines ......................................................................................3 - 20
4-2 Engine Fault Codes ....................................................................3 - 20
Axle
5-1 Axle ............................................................................................3 - 21
Hydraulic pumps
6-1 Boom and Steering Function Pump ...........................................3 - 22
6-2 Hydrostatic Transmission Pump.................................................3 - 26
Manifolds
7-1 Function Manifold .......................................................................3 - 30
7-2 Valve Coils .................................................................................3 - 34
TABLE OF CONTENTS
Section 5 Schematics
Introduction .............................................................................................5 - 1
Electrical and Hydraulic Symbol Legends ..............................................5 - 2
Electrical Schematic ...............................................................................5 - 3
Hydraulic Schematic .............................................................................5 - 43
TABLE OF CONTENTS
Specifications
SPECIFICATIONS
SPECIFICATIONS
Chevron Rando HD oil is fully compatible and NOTICE Continued use of Chevron Aviation
A hydraulic fluid when ambient
mixable with Shell Donax TG (Dexron III) oils.
temperatures are consistently
Genie specifications require hydraulic oils which
above 32°F / 0°C may result in
are designed to give maximum protection to
component damage.
hydraulic systems, have the ability to perform over
a wide temperature range, and the viscosity index
should exceed 140. They should provide excellent
Note: Use Chevron Aviation A hydraulic fluid when
antiwear, oxidation, corrosion inhibition, seal
ambient temperatures are consistently below
conditioning, and foam and aeration suppression
0°F / -17°C.
properties.
Note: Use Shell Tellus T46 hydraulic oil when oil
temperatures consistently exceed 205°F / 96°C.
SPECIFICATIONS
SPECIFICATIONS
Function Manifold
Specifications
Function 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
SPECIFICATIONS
SPECIFICATIONS
Comer Axles
Steering Integrated steer cylinder
Joints Heavy duty double
U-joints
Steering angle, 40 °
maximum
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 to the Comer
Axle S128 Service Manual
Comer Axle Service Manual
Genie part number 57.4700.0020
SPECIFICATIONS
-6 30 ft-lbs / 40.7 Nm
-6 9
/16-18 1 1/4 -8 ORFS (Adj / Non-adj) 60 ft-lbs / 81.3 Nm
37° (Adj / Non-adj) 52 ft-lbs / 70.5 Nm
-8 3
/4-16 1
-10 ORFS (Adj / Non-adj) 100 ft-lbs / 135.6 Nm
-10 7
/8-14 1
37° (Adj / Non-adj) 85 ft-lbs / 115.3 Nm
-12 1 1/16-12 1
-12 (All types) 135 ft-lbs / 183 Nm
-16 1 /16-12
5
1
-16 (All types) 200 ft-lbs / 271.2 Nm
-20 1 5/8-12 1
-20 (All types) 250 ft-lbs / 339 Nm
-24 1 7/8-12 1
-24 (All types) 305 ft-lbs / 413.5 Nm
SPECIFICATIONS
Torque Procedure
Seal-LokTM fittings
a
1 Replace the O-ring. The O-ring must be
c b
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 Figure 1
tight.
a hex nut
b reference mark
Note: The O-rings used in the Parker Seal Lok™ c body hex fitting
fittings and hose ends are custom-size O-rings.
They are not standard SAE size O-rings. They are 3 Working clockwise on the body hex fitting,
available in the O-ring field service kit (Genie part make a second mark with a permanent ink
number 49612). marker to indicate the proper tightening
position. Refer to Figure 2.
2 Lubricate the O-ring before installation.
Note: Use the JIC 37° Fittings table on the
3 Be sure that the face seal O-ring is seated and previous page to determine the correct number of
retained properly. flats for the proper tightening position.
4 Position the tube and nut squarely on the face Note: The marks indicate that the correct
seal end of the fitting and tighten the nut finger tightening positions have been determined. Use
tight. the second mark on the body hex fitting to properly
tighten the joint after it has been loosened.
5 Tighten the nut or fitting to the appropriate
torque per given size as shown in the table.
SPECIFICATIONS
Size Class 4.6 4.6 C lass 8.8 8.8 Class 10.9 10.9 C lass 12.9 12.9
Repair Procedures
Boom Components
4 Remove the wear pad retainer plates and 3 Remove the screw securing the fork level
remove the wear pads from the boom. cylinder pivot pin to the lifting fork.
5 Lubricate the wear surface of the new pads. 4 Use a soft metal drift to remove the pivot pin.
Refer to Maintenance Procedure A-4, Lubricate
the Boom. 5 Remove the screw securing the fork frame
pivot pin to the boom.
Note: Do not lubricate the side wear pads.
6 Use a soft metal drift to remove the pivot pin.
6 Install the wear pads. Install and securely
tighten the retainer plates. Do not over tighten. 7 Using the overhead crane, lift and remove the
fork frame from the boom.
CAUTION Crushing hazard. The fork
frame could fall if not properly
supported when the lock pin is
removed from the machine.
BOOM COMPONENTS
How to Remove the Boom 8 Flip the slave cylinder towards the cab.
4 Place a stand under the lift cylinder to properly 13 Using a soft metal drift, remove the pin
support it once the pin connecting the cylinder securing the boom to the machine.
to the boom will be removed. DANGER Crushing hazard. The boom
will fall if not properly supported
5 Attach a lifting strap from an overhead crane to when the pivot pin is removed
the fork support and slightly lift the boom. Do from the machine.
not apply any lifting pressure.
14 Carefully remove the boom assembly from the
6 Attach a second strap from the overhead crane machine and place it on a structure capable of
to the lifting cylinder, rod side, and put some supporting it.
tension on it.
BOOM COMPONENTS
How to Disassemble the Boom 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
WARNING Bodily injury hazard. This installation. Refer to Section 2, Hydraulic Hose
procedure requires specific and Fitting Torque Specifications.
repair skills, lifting equipment
and a suitable workshop. Note: Perform this procedure on a firm, level
Attempting this procedure surface with the boom in the stowed position and
without these skills and tools the wheels chocked.
could result in death or serious
injury and significant component 1 Remove the boom from the machine and lay
damage. Dealer service is it on stands, checking that it is stable. Refer
strongly recommended. to Repair Procedure 1-1, How to Remove the
Boom..
Boom
f
a
e
d g
BOOM COMPONENTS
3 Remove the hydraulic hoses from inside the 13 Remove all pads "g
"g" from the second section
boom. Refer to Repair Procedure 1-5, How to "b".
Replace the Fork Tilt Cylinder Hoses.
Hoses.
14 Remove the pipes from the first boom section
4 Remove the extend cylinder from inside the "a".
boom. Refer to Repair Procedure 1-3, How to
Remove the Extend Cylinder.
Cylinder.
9 Remove the lateral pads "e "e" and the top pads
"f" from the first section.
BOOM COMPONENTS
How to Remove the Lift 6 Remove the fasteners securing the lift cylinder
Cylinder rod-end pivot pin to the boom.
DANGER Crushing hazard. The boom
Note: When removing a hose assembly or fitting, will fall if not properly supported
the O-ring on the fitting and/or hose end must be when the pivot pin is removed
replaced and then torqued to specification during from the machine.
installation. Refer to Section 2, Hydraulic Hose
and Fitting Torque Specifications. 7 Lower the lift cylinder and place it on the
wooden block previously positioned.
1 Lift the boom until the pin locking the lift
cylinder - rod side - is in a position above the 8 Remove the fasteners securing the lift cylinder
cab roof. . barrel-end pivot pin to the chassis.
2 Attach a lifting strap from an overhead 22045 9 Use a soft metal drift to remove the pivot pin.
lbs / 10,000 kg crane to the fork end of the
boom. Support the boom. Do not apply any 10 Remove the cylinder from the machine.
lifting pressure. Crushing hazard. The cylinder
DANGER
could fall if not properly
3 Tag, disconnect and plug the hydraulic hoses supported when removed from
connected to the shut-off valve. Cap the fittings. the machine.
WARNING Bodily injury hazard. Spraying
hydraulic oil can penetrate and 11 Using the overhead crane, raise and place the
burn skin. Loosen hydraulic boom on the wooden block suitably positioned.
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
BOOM COMPONENTS
2 Extend the boom until you can access the pin 6 Using a soft metal drift and a hammer, remove
"a" locking the cylinder - rod side. the pivot pin "b" using the holes on the chassis
at the rear of the machine.
BOOM COMPONENTS
BOOM COMPONENTS
2 Remove the forks from the frame. NOTICE Component damage hazard.
Hoses can be damaged if they
3 Remove the retaining fasteners securing the are kinked or pinched.
fork tilt cylinder rod end pivot pin.
9 Remove the retaining fasteners securing the
4 Using a soft metal drift and a hammer, remove fork tilt cylinder barrel end pivot pin.
the pivot pin.
10 Using a soft metal drift and a hammer, remove
5 Using a lifting strap and an overhead crane, the pivot pin "b".
support the cylinder.
11 Carefully lift and remove the cylinder from the
machine.
DANGER Crushing hazard. The cylinder
b could fall if not properly
supported when removed from
the machine.
BOOM COMPONENTS
How to Replace the Fork Tilt 6 Before replacing a hydraulic hose, thoroughly
clean the machine.
Cylinder Hoses
7 Remove the protective guard "c
"c" of the shut-off
Note: When removing a hose assembly or fitting, valve.
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during 8 Tag, disconnect and plug the hydraulic hoses
installation. Refer to Section 2, Hydraulic Hose from the fork tilt cylinder.
and Fitting Torque Specifications.
WARNING Bodily injury hazard. Spraying
hydraulic oil can penetrate and
1 Start the engine. burn skin. Loosen hydraulic
connections very slowly to allow
2 Raise the boom to a horizontal position. the oil pressure to dissipate
gradually. Do not allow oil to
3 Retract the boom until you can see the screws squirt or spray.
"a" retaining bracket "b
"b" in the slot located on
the boom.
BOOM COMPONENTS
9 Securely attach a resistant guide rope (length 14 Pull hoses "e"e" and "f
"f" outward - one at a time -
about 33 feet / 10 m) to the hydraulic hose, one until they come out completely.
for each hose. This will be used to install the
new hoses. 15 Remove the rope from the old hydraulic hoses
and attach it to the new hydraulic hoses
10 Reach the back of the machine and remove the (straight end side).
cover.
16 Connect the ends of the new hoses to the
11 Pull hoses "e
"e" and "f
"f" outward - one at a time - pipes.
until they come out completely.
17 Install the hoses "e
"e" e ""ff" from underneath the
12 Move to the front bottom of the boom and boom: pull them from the rear side of the boom.
remove comb "d"d".
18 Install the hoses "e
"e" e ""ff" from behind the
13 Tag, disconnect and plug the hydraulic hoses boom: pull them from the front side of the boom
from the pipes. to connect the straight ends to the shut-off
Bodily injury hazard. Spraying valve.
WARNING
hydraulic oil can penetrate and NOTICE Component damage hazard.
burn skin. Loosen hydraulic Hoses can be damaged if they
connections very slowly to allow are kinked or pinched.
the oil pressure to dissipate
gradually. Do not allow oil to 19 Start the engine, and extend and retract the
squirt or spray. boom. Verify that there are no abnormal
tensions on the hoses.
e f
Operator's Compartment
OPERATOR'S COMPARTMENT
OPERATOR'S COMPARTMENT
OPERATOR'S COMPARTMENT
OPERATOR'S COMPARTMENT
How to Remove the Joystick Note: Removing the hydraulic hose from port T of
the joystick with the joystick below the hydraulic oil
1 Lift the boom. level in the hydraulic tank will result in excessive
hydraulic fluid leaking from the hose. Do not
2 Remove the guard underneath the boom that is disconnect the hose from the port if the joystick is
located in the central part in the machine. below the hydraulic oil level in the hydraulic tank.
3 Open the engine cover and disconnect the 9 Get back into the cab and remove the fasteners
battery negative (-) terminal. securing the joystick to the mount panel.
Remove the joystick.
WARNING Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.
2 T
3 1
4
P
Joystick port orientation
OPERATOR'S COMPARTMENT
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.
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.
DANGER Explosion and fire hazard. Never 5 Disconnect the ground wire.
wire
drain or store fuel in an open
container due to the possibility 6 Remove the filler cap from the fuel tank.
of fire.
7 Using an approved hand-operated pump,
Explosion and fire hazard. drain the fuel tank into a container of suitable
DANGER capacity. Refer to Section 2, Specifications.
When transferring fuel, connect
a grounding wire between the WARNING Explosion and fire hazard. When
machine and pump or container. transferring fuel, connect a
grounding wire between the
Bodily injury hazard. This machine and pump or container.
WARNING
procedure requires specific Be sure to only use a hand operated pump
repair skills, lifting equipment suitable for use with gasoline and/or diesel fuel.
and a suitable workshop.
Attempting this procedure
8 Loosen all the clamps and pull out the hoses.
without these skills and tools
could result in death or serious
9 Remove the retaining fasteners securing the
injury and significant component
tanks to the machine.
damage. Dealer service is
strongly recommended.
10 Remove the tank from the machine.
NOTICE The reduced weight of the empty
tank makes it possible to handle
it manually.
2 Open the engine cover and disconnect the 14 Attach a lifting strap from an overhead crane to
battery negative (-) terminal. the lifting points of the tank.
Electrocution/burn hazard. DANGER Crushing hazard. The tank could
WARNING become unbalanced and fall if
Contact with electrically charged
circuits could result in death or not properly supported when
serious injury. Remove all rings, removed from the machine.
watches and other jewelry.
15 Remove the retaining fasteners securing the
3 Close the oil intake valve. tanks to the machine.
4 Remove the filler cap from the hydraulic tank. 16 Lift the tank slightly and push it forward
manually, until you can lower it on the ground.
5 Place a drain pan or other suitable container
under the hydraulic tank. Refer to Section 2,
Specifications.
Engines
4-1 4-2
Engines Engine Fault Codes
Axle
5-1 5 Raise the end of the machine until the tires are
off the ground. Place blocks under the chassis
Axle for support.
WARNING Crushing hazard. The chassis
will fall if not properly supported.
How to Remove the Axle
WARNING Bodily injury hazard. This 6 Remove the lug nuts. Remove the tire and
procedure requires specific wheel assembly from both ends of the axle.
repair skills, lifting equipment
and a suitable workshop. 7 Support and secure the axle to an appropriate
Attempting this procedure lifting device.
without these skills and tools
could result in death or serious 8 Use a soft metal drift to remove the pivot pin.
injury and significant component
damage. Dealer service is 9 Remove the fasteners securing the axle to the
required. chassis. Remove the axle from the machine.
WARNING Crushing hazard. The axle will
1 Chock the wheels.
fall if not properly supported
when the fasteners are removed
2 Remove the fasteners securing the driveshaft
from the machine.
to the axle. Remove the driveshaft from the
machine.
Bolt torque specification
3 Tag and remove the hydraulic hoses from the Axle mounting bolts 515 ft-lbs
axle. 700 Nm
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.
Hydraulic Pumps
6-1
Boom and Steering Function
Pump
HYDRAULIC PUMPS
How to Remove the Boom and 4 Tag, disconnect and plug the hoses located at
the right side of the pump. Cap the fitting on the
Steering Function Pump pump.
WARNING Bodily injury hazard. This Bodily injury hazard. Spraying
WARNING
procedure requires specific hydraulic oil can penetrate and
repair skills, lifting equipment burn skin. Loosen hydraulic
and a suitable workshop. connections very slowly to allow
Attempting this procedure the oil pressure to dissipate
without these skills and tools gradually. Do not allow oil to
could result in death or serious squirt or spray.
injury and significant component
damage. Dealer service is 5 Tag, disconnect and plug the hydraulic pump
strongly recommended. supply hose at the pump, located at the left
side of the pump. Cap the fitting on the pump.
Note: When removing a hose assembly or fitting,
the fitting and/or hose end must be torqued to Note: Placing the open end of the case drain hose
specification during installation. Refer to Section 2, below the hydraulic oil level in the hydraulic tank
Hydraulic Hose and Fitting Torque Specifications. will result in excessive hydraulic fluid leaking from
the hose. Do not lower the open end of the case
Note: Perform this procedure with the engine off drain hose below the fluid level of the hydraulic
and cool to the touch. tank until the hose is plugged.
1 Close the hydraulic tank ball valve. 6 Remove the fasteners securing the pump, then
remove the pump by pulling it to the front of the
2 Open the engine cover and disconnect the machine.
battery negative (-) terminal.
WARNING Crushing hazard. The pump
WARNING Electrocution/burn hazard. will fall if not properly supported
Contact with electrically charged when the fasteners are removed
circuits could result in death or from the machine.
serious injury. Remove all rings,
watches and other jewelry.
HYDRAULIC PUMPS
How to Install the Boom and 6 Check the hydraulic fluid level in the hydraulic
tank. Add fluid if needed.
Steering Function Pump
WARNING Bodily injury hazard. This 7 Start the engine and prime the pump. See 6-1,
procedure requires specific How to Prime the Boom and Steering Function
repair skills, lifting equipment Pump.
and a suitable workshop.
Attempting this procedure 8 Inspect for leaks.
without these skills and tools
could result in death or serious 9 Adjust the pump pressure. See 6-1, How to test
injury and significant component the Boom and Steering Function Pump.
damage. Dealer service is
strongly recommended.
HYDRAULIC PUMPS
HYDRAULIC PUMPS
1 Connect a 0 to 8700 psi / 0 to 600 bar pressure Pressure is not within specification.
gauge to port TP2 (hydrostatic transmission Adjust the high pressure relief valve "b" located
high pressure test port). above the pump.
2 Connect a 0 to 870 psi / 0 to 60 bar pressure 7 While observing the pressure gauge connected
gauge to port TP3 (hydrostatic transmission to test port TP3, operate the engine between
boost pressure test port). 1200 rpm and maximum rpm.
3 Start the engine. Result: the pressure gauge on test port TP3
does not go below 360 psi / 25 bar.
Result: the pressure gauge connected to test
port TP3 reads 360 psi / 25 bar. Pressure is not within specification.
Contact Genie Service Department.
Pressure is not within specification.
Contact Genie Service Department.
HYDRAULIC PUMPS
How to Remove the Hydrostatic 4 Tag, disconnect and plug the hoses that are
connected to the hydrostatic transmission
Transmission Pump pump. Cap the fittings.
WARNING Bodily injury hazard. This Bodily injury hazard. Spraying
WARNING
procedure requires specific hydraulic oil can penetrate and
repair skills, lifting equipment burn skin. Loosen hydraulic
and a suitable workshop. connections very slowly to allow
Attempting this procedure the oil pressure to dissipate
without these skills and tools gradually. Do not allow oil to
could result in death or serious squirt or spray.
injury and significant component
damage. Dealer service is 5 Remove the boom and steering function pump
strongly recommended. from the hydrostatic transmission pump.
Note: When removing a hose assembly or fitting, 6 Tag and disconnect the harness from the
the fitting and/or hose end must be torqued to transmission.
specification during installation. Refer to Section 2,
Hydraulic Hose and Fitting Torque Specifications. 7 Support and secure the transmission pump to
a suitable lifting device. Do not apply lighting
Note: Perform this procedure with the engine off pressure.
and cool to the touch.
8 Remove the hydrostatic transmission pump.
1 Open the engine compartment.
WARNING Crushing hazard. The
hydrostatic transmission pump
2 Remove the cover that is under engine.
will fall if not properly supported
when the fasteners are removed
3 Disconnect the battery negative (-) terminal.
from the machine.
HYDRAULIC PUMPS
Note: When removing a hose assembly or fitting, 10 Start the engine and prime the pump. See 6-2,
the fitting and/or hose end must be torqued to How to Prime the Hydrostatic Transmission
specification during installation. Refer to Section 2, Pump.
Hydraulic Hose and Fitting Torque Specifications.
11 Inspect for leaks.
Note: Perform this procedure with the engine off
and cool to the touch. 12 Adjust the pump pressure. See 6-2, How to test
the Hydrostatic Transmission Pump.
1 Open the engine compartment.
HYDRAULIC PUMPS
How to Prime the Hydrostatic 7 Shift the transmission into reverse. Release
the brake pedal and slowly increase the engine
Transmission Pump rpm until the machine starts to move. Apply the
WARNING Bodily injury hazard. This brake.
procedure requires specific
repair skills, lifting equipment 8 Engage the emergency brake and turn the
and a suitable workshop. engine off. Check for hydraulic leaks.
Attempting this procedure
without these skills and tools
could result in death or serious
injury and significant component
damage. Dealer service is
strongly recommended.
Manifolds
MANIFOLDS
How to Remove the Function 6 Remove the retaining fasteners securing the
function manifold.
Manifold
WARNING Bodily injury hazard. This 7 Remove the function manifold.
procedure requires specific Crushing hazard. The function
WARNING
repair skills, lifting equipment manifold will fall if not properly
and a suitable workshop. supported when the fasteners
Attempting this procedure are removed from the machine.
without these skills and tools
could result in death or serious
injury and significant component
damage. Dealer service is
strongly recommended.
MANIFOLDS
MANIFOLDS
c
e
b
MANIFOLDS
MANIFOLDS
+
b
the electrical system, resulting in a tripped circuit 10 9V
RESISTOR BATTERY
breaker or component damage.
c
b
+
WARNING Electrocution/burn hazard.
Contact with electrically charged
-
circuits could result in death or
a multimeter
serious injury. b 9V DC battery
Remove all rings, watches and c 10 resistor
d coil
other jewelry.
Note: Dotted lines in illustration indicate a
reversed connection as specified in step 6
1 Test the coil for resistance. See 7-2, How to
Test a Coil.
5 Momentarily connect the positive lead from the
2 Connect a 10 resistor to the negative terminal
multimeter to the positive terminal on the 9V
of a known good 9V DC battery. Connect the
battery. Note and record the current reading.
other end of the resistor to a terminal on the
coil.
6 At the battery or coil terminals, reverse the
connections. Note and record the current
Resistor. 10 reading.
Genie part number 27287
Result: Both current readings are greater than
Note: The battery should read 9V DC or more 0 mA and are different by a minimum of 20%.
when measured across the terminals. The coil is good.
3 Set a multimeter to read DC current. Result: If one or both of the current readings
are 0 mA, or if the two current readings do not
Note: The multimeter, when set to read DC differ by a minimum of 20%, the coil and/or its
current, should be capable of reading up to 800 internal diode are faulty and the coil should be
mA. replaced.
Fault Codes
Before Troubleshooting:
Read, understand and obey the safety rules
and operating instructions in the appropriate
operator's manual on your machine.
Be sure that all necessary tools and test
Observe and Obey: equipment are available and ready for use.
Be aware of the following hazards and follow
Troubleshooting and repair procedures shall be generally accepted safe workshop practices.
completed by a person trained and qualified on
the repair of this machine. Crushing hazard. When testing
DANGER
Immediately tag and remove from service a or replacing any hydraulic
damaged or malfunctioning machine. component, always support
Repair any machine damage or malfunction the structure and secure it from
before operating the machine. movement.
problem
still exists
FAULT CODES
a b c
Gauge Cluster
a LCD screen
b amber warning light
c stop engine light
d diagnostic button
FAULT CODES
FAULT CODES
FAULT CODES
FAULT CODES
FAULT CODES
FAULT CODES
FAULT CODES
FAULT CODES
FAULT CODES
FAULT CODES
FAULT CODES
FAULT CODES
FAULT CODES
FAULT CODES
FAULT CODES
FAULT CODES
FAULT CODES
FAULT CODES
FAULT CODES
FAULT CODES
FAULT CODES
FAULT CODES
FAULT CODES
FAULT CODES
FAULT CODES
FAULT CODES
FAULT CODES
FAULT CODES
FAULT CODES
FAULT CODES
FAULT CODES
FAULT CODES
FAULT CODES
FAULT CODES
FAULT CODES
FAULT CODES
FAULT CODES
FAULT CODES
FAULT CODES
FAULT CODES
Schematics
Electrical Schematics
WARNING Electrocution/burn hazard.
Contact with electrically charged
Observe and Obey: circuits could result in death or
serious injury. Remove all rings,
Troubleshooting and repair procedures shall be
watches and other jewelry.
completed by a person trained and qualified on
the repair of this machine.
Hydraulic Schematics
Immediately tag and remove from service a WARNING Bodily injury hazard. Spraying
damaged or malfunctioning machine. hydraulic oil can penetrate and
burn skin. Loosen hydraulic
Repair any machine damage or malfunction connections very slowly to allow
before operating the machine. the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
Before Troubleshooting:
General Repair Process
Read, understand and obey the safety rules
and operating instructions in the appropriate
operator's manual on your machine. Malfunction Identify Troubleshoot
discovered symptoms
ACC
BAT
86 30
B Orifice Adjustable orifice Filter
D1
ALT
85 87 87A
G
Diode
Switch P
1 3 2 4
Joystick
Proximity switch Limit switch
Counterbalance
valve
Temperature switch Fuel level sender
Pressure switch
Battery
Electrical Schematic
Sheet 1 of 8
Up to SN GTH5515B-2364
12
GENIE
a Terex brand 14
15
°C GENIE
105 b
31 16
ENGINE RPM
60 hour °C
17 18 7 22 20 24
33 a 10 11 13 f e d c g h
! !
ELECTRICAL SCHEMATIC
Sheet 2 of 8
Up to SN GTH5515B-2364
ELECTRICAL SCHEMATIC
Sheet 3 of 8
Up to SN GTH5515B-2364
ELECTRICAL SCHEMATIC
Sheet 4 of 8
Up to SN GTH5515B-2364
ELECTRICAL SCHEMATIC
Sheet 5 of 8
Up to SN GTH5515B-2364
ELECTRICAL SCHEMATIC
Sheet 6 of 8
Up to SN GTH5515B-2364
ELECTRICAL SCHEMATIC
Sheet 7 of 8
Up to SN GTH5515B-2364
ELECTRICAL SCHEMATIC
Sheet 8 of 8
Up to SN GTH5515B-2364
F 11 F 01
F 12 F 02
F 13 F 03
F 14 F 04
F 15 F 05
F 16 F 06
F 17 F 07
F 18 F 08
F 19 F 09
F 20 F 10
ELECTRICAL SCHEMATIC
Sheet 1 of 8
From SN GTH5515B-2365 to SN GTH5516M-4630
ELECTRICAL SCHEMATIC
Sheet 2 of 8
From SN GTH5515B-2365 to SN GTH5516M-4630
ELECTRICAL SCHEMATIC
Sheet 3 of 8
From SN GTH5515B-2365 to SN GTH5516M-4630
ELECTRICAL SCHEMATIC
Sheet 4 of 8
From SN GTH5515B-2365 to SN GTH5516M-4630
ELECTRICAL SCHEMATIC
Sheet 5 of 8
From SN GTH5515B-2365 to SN GTH5516M-4630
ELECTRICAL SCHEMATIC
Sheet 6
8 of 8
From SN GTH5515B-2365 to SN GTH5516M-4630
ELECTRICAL SCHEMATIC
Sheet 7 of 8
From SN GTH5515B-2365 to SN GTH5516M-4630
ELECTRICAL SCHEMATIC
Sheet 8 of 8
From SN GTH5515B-2365 to SN GTH5516M-4630
ELECTRICAL SCHEMATIC
Sheet 1 of 8
From SN GTH5516M-4631 to SN GTH5516M-5474
12
GENIE
a Terex brand 14
15
°C GENIE
105 b
31 16
ENGINE RPM
60 hour °C
17 18 7 22 20 24
33 a 10 11 13 f e d c g h
! !
ELECTRICAL SCHEMATIC
Sheet 2 of 8
From SN GTH5516M-4631 to SN GTH5516M-5474
ELECTRICAL SCHEMATIC
Sheet 3 of 8
From SN GTH5516M-4631 to SN GTH5516M-5474
ELECTRICAL SCHEMATIC
Sheet 4 of 8
From SN GTH5516M-4631 to SN GTH5516M-5474
Optional Part
ELECTRICAL SCHEMATIC
Sheet 5 of 8
From SN GTH5516M-4631 to SN GTH5516M-5474
Optional Part
ELECTRICAL SCHEMATIC
Sheet 6 of 8
From SN GTH5516M-4631 to SN GTH5516M-5474
Optional Part
ELECTRICAL SCHEMATIC
Sheet 7 of 8
From SN GTH5516M-4631 to SN GTH5516M-5474
Optional Part
ELECTRICAL SCHEMATIC
Sheet 8 of 8
From SN GTH5516M-4631 to SN GTH5516M-5474
F 11 F 01
F 12 F 02
F 13 F 03
F 14 F 04
F 15 F 05
F 16 F 06
F 17 F 07
F 18 F 08
F 19 F 09
F 20 F 10
F1
ELECTRICAL SCHEMATIC
Sheet 1 of 8
From SN GTH5516M-5475 to SN GTH55M-10886
12
GENIE
a Terex brand 14
15
°C GENIE
105 b
31 16
ENGINE RPM
60 hour °C
17 18 7 22 20 24
33 a 10 11 13 f e d c g h
! !
ELECTRICAL SCHEMATIC
Sheet 2 of 8
From SN GTH5516M-5475 to SN GTH55M-10886
ELECTRICAL SCHEMATIC
Sheet 3 of 8
From SN GTH5516M-5475 to SN GTH55M-10886
ELECTRICAL SCHEMATIC
Sheet 4 of 8
From SN GTH5516M-5475 to SN GTH55M-10886
Optional Part
ELECTRICAL SCHEMATIC
Sheet 5 of 8
From SN GTH5516M-5475 to SN GTH55M-10886
Optional Part
ELECTRICAL SCHEMATIC
Sheet 6 of 8
From SN GTH5516M-5475 to SN GTH55M-10886
Optional Part
ELECTRICAL SCHEMATIC
Sheet 7 of 8
From SN GTH5516M-5475 to SN GTH55M-10886
Optional Part
ELECTRICAL SCHEMATIC
Sheet 8 of 8
From SN GTH5516M-5475 to SN GTH55M-10886
F 11 F 01
F 12 F 02
F 13 F 03
F 14 F 04
F 15 F 05
F 16 F 06
F 17 F 07
F 18 F 08
F 19 F 09
F 20 F 10
FUSE1
ELECTRICAL SCHEMATIC
Sheet 1 of 8
From SN GTH55M-10887 and GTH55M-10851, GTH55M-10854, GTH55M-10860,
GTH55M-10862, GTH55M-10863, GTH55M-10864, GTH55M-10866, GTH55M-10867,
GTH55M-10869, from GTH55M-10872 to GTH55M-10882, and GTH55M-10884,GTH55M-10885
12
GENIE
a Terex brand 14
15
°C GENIE
105 b
31 16
ENGINE RPM
60 hour °C
17 18 7 22 20 24
33 a 10 11 13 f e d c g h
! !
ELECTRICAL SCHEMATIC
Sheet 2 of 8
From SN GTH55M-10887 and GTH55M-10851, GTH55M-10854, GTH55M-10860,
GTH55M-10862, GTH55M-10863, GTH55M-10864, GTH55M-10866, GTH55M-10867,
GTH55M-10869, from GTH55M-10872 to GTH55M-10882, and GTH55M-10884,GTH55M-10885
ELECTRICAL SCHEMATIC
Sheet 3 of 8
From SN GTH55M-10887 and GTH55M-10851, GTH55M-10854, GTH55M-10860,
GTH55M-10862, GTH55M-10863, GTH55M-10864, GTH55M-10866, GTH55M-10867,
GTH55M-10869, from GTH55M-10872 to GTH55M-10882, and GTH55M-10884,GTH55M-10885
ELECTRICAL SCHEMATIC
Sheet 4 of 8
From SN GTH55M-10887 and GTH55M-10851, GTH55M-10854, GTH55M-10860,
GTH55M-10862, GTH55M-10863, GTH55M-10864, GTH55M-10866, GTH55M-10867,
GTH55M-10869, from GTH55M-10872 to GTH55M-10882, and GTH55M-10884,GTH55M-10885
Optional Part
ELECTRICAL SCHEMATIC
Sheet 5 of 8
From SN GTH55M-10887 and GTH55M-10851, GTH55M-10854, GTH55M-10860,
GTH55M-10862, GTH55M-10863, GTH55M-10864, GTH55M-10866, GTH55M-10867,
GTH55M-10869, from GTH55M-10872 to GTH55M-10882, and GTH55M-10884,GTH55M-10885
Optional Part
ELECTRICAL SCHEMATIC
Sheet 6 of 8
From SN GTH55M-10887 and GTH55M-10851, GTH55M-10854, GTH55M-10860,
GTH55M-10862, GTH55M-10863, GTH55M-10864, GTH55M-10866, GTH55M-10867,
GTH55M-10869, from GTH55M-10872 to GTH55M-10882, and GTH55M-10884,GTH55M-10885
Optional Part
ELECTRICAL SCHEMATIC
Sheet 7 of 8
From SN GTH55M-10887 and GTH55M-10851, GTH55M-10854, GTH55M-10860,
GTH55M-10862, GTH55M-10863, GTH55M-10864, GTH55M-10866, GTH55M-10867,
GTH55M-10869, from GTH55M-10872 to GTH55M-10882, and GTH55M-10884,GTH55M-10885
Optional Part
ELECTRICAL SCHEMATIC
Sheet 8 of 8
From SN GTH55M-10887 and GTH55M-10851, GTH55M-10854, GTH55M-10860,
GTH55M-10862, GTH55M-10863, GTH55M-10864, GTH55M-10866, GTH55M-10867,
GTH55M-10869, from GTH55M-10872 to GTH55M-10882, and GTH55M-10884,GTH55M-10885
F 11 F 01
F 12 F 02
F 13 F 03
F 14 F 04
F 15 F 05
F 16 F 06
F 17 F 07
F 18 F 08
F 19 F 09
F 20 F 10
FUSE1
Hydraulic Schematic
5-43 5-44
Section 5 • Schematics March 2019
Hydraulic Schematic
X18 Parking brake
minimum pressure Quick connect/disconnect
Auxiliary continous flow attachment enabling valve
Service brake X45 pressure switch metering valve
pressure switch Service brake Boom functions activating pressure: Forks tilt function
20 bar (290 psi) Auxiliary continous flow
activating pressure: circuit reservoir control lever X selector valve
enabling valve
Tp 5 2,8-6,3 bar F1 P1
Service brake (40-90 psi)
Service brake Parking brake
circuit test port pedal pump X53B
selector valve
T R max operating X54A
pressure: 80 bar
(1 ,160 psi)
M2
X49
Front axle
/
Double overcenter safety valve
piloting ratio: 4.2 1/ Y F
Forks tilt cylinder cracking pressure: 350 bar 1 mm (0,04 in.)
( 5 ,0 7 5 p s i)
X42 X37
Forks attachment 1,0 mm (0,04 in.)
quick coupling cylinder 3 2 T P 1 4 T1 T T2 Ax1 Ax2 1 2 C1 C2 B1 B2
P P2 P3
Quick coupling
hydraulic ports
Rear axle
steering cylinder
TP 4 Parking brake
B A
circuit test port
X51 X52
Steering mode T P
selector valve
4 ways / 3 positions
Forks levelling Hydraulically piloted
slave cylinder double check valve
Anti-shock piloting ratio: 4/1
valves
Front axle
cracking Single overcenter/ safety valve C
steering cylinder pressure: piloting ratio: 4.2 1/
200 bar cracking pressure: 350 bar
(2,900 psi) ( 5 ,0 7 5 p s i) B4
R L Anticavitation valves
cracking pressure A4
5 bar (72 psi)
X4 Y4
Steering rotating actuator
B3
displacement: 1 60cc / rev. A3
/
Double overcenter safety valve 2 9 0 b a r ( 4 ,2 0 5 p s i) Heat exchanger
Boom lift cylinder piloting ratio: 4.2 1/
Boom telescoping cylinder X3 Y3
cracking pressure: 350 bar Return filter
( 5 ,0 7 5 p s i) B2 2 9 0 b a r ( 4 ,2 0 5 p s i) with suction line
A2 pressurized at 0,5 bar
LS (8 psi)
X2 Y2
B1
X26
A1
P Max relief valve T
cracking
TP 1 X1 Y1
pressure: Single overcenter/ safety valve Boom functions hydraulic 270 bar
140 bar piloting ratio: 4.2:1 circuit test port ( 3 ,9 1 5 p s i)
( 2 ,0 3 0 p s i) T
cracking pressure: 350 bar
( 5 ,0 7 5 p s i) P
Boom functions
main valve
(4 sections)
M Cracking pressure
520 bar
Cracking press.
25 bar
( 3 6 0 p s i)
Low pressure and transmission
charge pressure lines
(7,540 psi) Load sensing and piloting lines
Suction lines
Cracking press. A
495 bar (7,180 psi) A G T
MH S FS Tank lines
Hydrostatic transmission X2 X1 G MA
pump max displacement: 45cc / rev
Hydrostatic transmission Shutoff valve Check valve
boost pressure test port Suction screen cracking pressure
8 bar (116 psi)
TP 3 Oil tank capacity
75 liters (20 gallons)