Genie GTH-1544 Installation and operating manual

1.
Service and Repair Manual
GTH-1544 (Perkins Tier 4i)
Serial Number Range
GTH-1544 (Deutz Tier 4i)
From GTH1513B-001
To GTH1515B-339
From GTH1516M-340
To GTH1516M-599
From GTH15M-600
Part No. 1272857
Rev A1
September 2016
This manual includes:
Repair procedures
Fault Codes
Electrical and Hydraulic
Schematics
For detailed maintenance
procedures, Refer to the
appropriate Maintenance
Manual for your machine.
From GTH1513B-001
To GTH1515B-339
plus 24273
From GTH1516M-340
To GTH1516M-599
From GTH15M-600

ii GTH-1544 Part No. 1272857
September 2016
Compliance
Machine Classification
Group B/Type 3 as defined by ISO 16368
Machine Design Life
Unrestricted with proper operation, inspection and
scheduled maintenance.
Important
Read, understand and obey the safety rules and
operating instructions in the Genie GTH-1544
Operator's Manual before attempting any
maintenance or repair procedure.
This manual provides troubleshooting 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.
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
future printings of this and all other manuals.
Contact Us:
http://www.genielift.com
e-mail: [email protected]
Introduction
Copyright © 2016 by Terex Industries
1272857 Rev A1 September 2016
First Edition, First Printing
"Genie" and "GTH" are registered trademarks of
Terex South Dakota, Inc. in the USA and many other
countries.
Printed on recycled paper
Find a Manual for this Model
Go to http://www.genielift.com
Use the links to locate Operator's, Parts or Service
Manuals.

September 2016
Part No.1272857 GTH-1544 iii
Revision History
Revision Date Section Procedure / Page / Description
A 03/2016 Initial Release
A1 09/2016 Introduction Serial Number Legend
REFERENCE EXAMPLES:
Section 2_Specifications, Machine Specifications
Section 3_Repair Procedure, 3-2
Section 4_Fault Codes, 4-3
Section 5_Schematics, 5-3
Electronic Version
Click on any procedure or page number
highlighted in blue to view the update.

iv GTH-1544 Part No. 1272857
September 2016
REVISION HISTORY, CONTINUED
Revision Date Section Procedure / Page / Description
REFERENCE EXAMPLES:
Section 2_Specifications, Machine Specifications
Section 3_Repair Procedure, 3-2
Section 4_Fault Codes, 4-3
Section 5_Schematics, 5-3
Electronic Version
Click on any procedure or page number
highlighted in blue to view the update.

September 2016
Part No.1272857 GTH-1544 v
Serial Number Legend
6
5
5

vi GTH-1544 Part No. 1272857
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September 2016
Part No.1272857 GTH-1544 vii
Section 1 • 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:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
- manufacturer’s instructions and safety rules
- employer’s safety rules and worksite
regulations
- applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.
Safety Rules

viii GTH-1544 Part No. 1272857
September 2016
Section 1 • 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.
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.
Be sure to wear protective eye wear and
other protective clothing if the situation
warrants it.
Be aware of potential crushing hazards
such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved
steel-toed shoes.
DANGER
WARNING
CAUTION
NOTICE
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.
Be sure that all tools and working areas
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 any forklift, overhead crane or
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 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
other fluids. Use an approved container.
Please be environmentally safe.
Be sure that your workshop or work area
is properly ventilated and well lit.
SAFETY RULES

September 2016
Part No.1272857 GTH-1544 ix
Introduction
Important Information .................................................................................. ii
Revision History...........................................................................................iii
Serial Number Legend................................................................................. v
Section 1 Safety Rules
General Safety Rules .................................................................................vii
Section 2 Specifications
Machine Specifications...........................................................................2 - 1
Performance Specifications....................................................................2 - 2
Hydraulic Specifications .........................................................................2 - 3
Hydraulic Component Specifications......................................................2 - 4
Function Manifold Specifications............................................................2 - 5
Air Conditioner Refrigerant Specifications..............................................2 - 5
Perkins 1204E-E44TA Engine ................................................................2 - 6
Deutz TCD 4.1 L4 Engine.......................................................................2 - 7
Dana Integral Gear Box Shift on Fly.......................................................2 - 8
Dana Axle ...............................................................................................2 - 8
Hydraulic Hose and Fitting Torque Specifications ..................................2 - 9
Torque Procedure.................................................................................2 - 10
SAE and Metric Fasteners Torque Charts............................................ 2 - 11
Section 3 Repair Procedures
Introduction.............................................................................................3 - 1
Boom Components
1-1 Boom Proximity Switch.................................................................3 - 2
1-2 Boom............................................................................................3 - 3
1-3 Boom Lift Cylinder...................................................................... 3 - 11
1-4 Boom Extend Cylinder................................................................3 - 12
Table of Contents

x GTH-1544 Part No. 1272857
September 2016
TABLE OF CONTENTS
Section 3
Repair Procedures, continued
1-5 Fork Level Cylinder ....................................................................3 - 13
1-6 Fork Tilt Cylinder ........................................................................3 - 15
Operator's compartment
2-1 Operator’s Compartment............................................................3 - 17
2-2 Machine Controls .......................................................................3 - 19
Fuel and Hydraulic Tanks
3-1 Fuel and hydraulic tanks ............................................................3 - 22
Engines
4-1 Engines ......................................................................................3 - 24
4-2 Engine Fault Codes....................................................................3 - 24
Transmission
5-1 Gearbox......................................................................................3 - 25
5-2 Axle ............................................................................................3 - 25
Hydraulic pumps
6-1 Boom and Steering Function Pump ...........................................3 - 27
6-2 Auxiliary Gear Pump ..................................................................3 - 32
6-3 Hydrostatic Transmission Pump.................................................3 - 35
Manifolds
7-1 Function Manifold.......................................................................3 - 39
7-2 Valve coils ..................................................................................3 - 46
Section 4 Fault Codes
Introduction.............................................................................................4 - 1
Diagnostic Display..................................................................................4 - 2
Engine Fault Codes - Models with Deutz TCD 4.1 L4............................4 - 3
How to Troubleshoot the Perkins 1204E-E44TA Engine ......................4 - 42

September 2016
Part No.1272857 GTH-1544 xi
Section 5 Schematics
Introduction.............................................................................................5 - 1
Electrical and Hydraulic Symbol Legends ..............................................5 - 2
Electrical Schematic ...............................................................................5 - 3
Hydraulic Schematic - Deutz Engine....................................................5 - 34
Hydraulic Schematic - Perkins Engine .................................................5 - 36
TABLE OF CONTENTS

xii GTH-1544 Part No. 1272857
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September 2016
Part No.1272857 GTH-1544 2-1
Section 2 • Specifications
Machine Specifications
Fluid capacities
Fuel tank 47 gallons
180 liters
Hydraulic tank 48 gallons
182 liters
Hydraulic system
(including tank)
77 gallons
290 liters
For operational specifications, refer to the
Operator's Manual.
Tires and wheels
Tire size 17.5 x 25
Tire ply rating 22
Weight, rough terrain tire
(air filled)
427 lbs
194 kg
Weight, rough terrain tire
(foam filled)
1275 lbs
578 kg
Tire pressure
(models with air-filled tires)
87 psi
6 bar
Lug nut torque 465 ft-lbs
630 Nm
Lug pattern 10 x 13.189
Wheel diameter 53 in
135 cm
Wheel width 18 in
46.5 cm
Continuous improvement of our products
is a Genie policy. Product specifications are
subject to change without notice.
Specifications

2-2 GTH-1544 Part No. 1272857
September 2016
Section 2 • Specifications
Performance Specifications
Drive speed, maximum 18 mph
29 km/h
Draw bar pull 22500 lbs
10206 kg
Lift capacity, maximum 15000 lbs
6804 kg
Boom function speeds, maximum
Boom up 19 seconds
Boom down 15 seconds
Boom extend 17 seconds
Boom retract 14 seconds
Fork tilt up 7 seconds
Fork tilt down 7 seconds
Continuous improvement of our products
is a Genie policy. Product specifications are
subject to change without notice.
SPECIFICATIONS

September 2016
Part No.1272857 GTH-1544 2-3
Section 2 • Specifications
Hydraulic Specifications
Hydraulic Oil Specification
Hydraulic oil type
Viscosity grade
Viscosity index
Chevron Rando HD equivalent
Multi-viscosity
200
Cleanliness level,
minimum 15/13
Water content,
maximum 200 ppm
Chevron Rando HD oil is fully compatible and
mixable with Shell Donax TG (Dexron III) 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.
Optional fluids
Biodegradable Petro Canada Environ MV46
Statoil Hydra Way Bio Pa 32
BP Biohyd SE-S
Fire resistant UCON Hydroluble HP-5046
Quintolubric 822
Mineral based Shell Tellus S2 V 32
Shell Tellus S2 V 46
Chevron Aviation A
Eni Arnica 32
Continued use of Chevron Aviation
A hydraulic fluid when ambient
temperatures are consistently
above 32°F / 0°C may result in
component damage.
Note: Use Chevron Aviation A hydraulic fluid when
ambient temperatures are consistently below
0°F / -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.
Continuous improvement of our products
is a Genie policy. Product specifications are
subject to change without notice.
NOTICE
SPECIFICATIONS

2-4 GTH-1544 Part No. 1272857
September 2016
Section 2 • Specifications
Hydraulic Components
Specifications
Boom and Steering Functions Pump
Type: variable displacement
piston pump
Displacement 0 to 3.7 cu in
0 to 60 cc
Flow rate @ 2200 rpm 35 gpm
132 L/min
Pump pressure, maximum
(measured at test port TP1)
3915 psi
270 bar
Pressure compensator
(measured at test port TP1)
3915 psi
270 bar
Stand-by pressure
(measured at test port TP5)
290 psi
20 bar
Auxiliary Gear Pump
Type: fixed displacement
gear pump
Displacement 1.53 cu in
25 cc
Flow rate @ 2200 rpm 15 gpm
56 L/min
Pump pressure, maximum
(measured at test port TP2)
3625 psi
250 bar
Relief valve pressure, maximum
(measured at test port TP2)
3625 psi
250 bar
Hydraulic Oil Radiator Fan Pump
Type: fixed displacement
gear pump
Displacement
(Deutz Configuration)
0.73 cu in
12 cc
Flow rate @ 2200 rpm
(Deutz Configuration)
8 gpm
31 L/min
Displacement
(Perkins Configuration)
0.98 cu in
16 cc
Flow rate @ 2200 rpm
(Perkins Configuration)
9 gpm
35 L/min
Hydraulic Oil Radiator Fan Pump
Pump pressure, maximum 1740 psi
120 bar
Relief valve pressure, maximum 1740 psi
120 bar
Hydrostatic Transmission Pump
Type: variable displacement
piston pump
Displacement 0 to 5.5 cu in
0 to 90 cc
Flow rate @ 2200 rpm 52 gpm
198 L/min
Pump pressure, maximum
(measured at test port TP4)
6450 psi
445 bar
Relief valve pressure,
maximum
(measured at test port TP4)
6890 psi
475 bar
Pump charge relief valve
pressure, maximum
(measured at test port TP3)
290 psi
20 bar
Hydrostatic Transmission Motor
Type: variable displacement
piston motor
Displacement 0 to 6.5 cu in
0 to 107 cc
Flow rate @ 2200 rpm 52 gpm
198 L/min
Motor pressure, maximum
(measured at test port TP4)
6450 psi
445 bar
Relief valve pressure,
maximum
(measured at test port TP4)
6890 psi
475 bar
Continuous improvement of our products
is a Genie policy. Product specifications are
subject to change without notice.
SPECIFICATIONS

September 2016
Part No.1272857 GTH-1544 2-5
Section 2 • Specifications
Function Manifold
Specifications
Function Manifold
System relief valve pressure, maximum
(measured at test port TP1)
3770 psi
260 bar
Fork tilt relief valve pressure, maximum 4060 psi
280 bar
Secondary Function Valves
Steer relief valve pressure, maximum 2610 psi
180 bar
Parking brake relief valve pressure,
maximum (measured at test port TP3)
406 psi
28 bar
Diff lock relief valve pressure, maximum
(measured at test port TP3)
406 psi
28 bar
Rear lock-up relief valve pressure,
maximum (measured at test port TP3)
406 psi
28 bar
Sway relief valve pressure, maximum
(measured at test port TP2)
3335 psi
230 bar
Auxiliary line relief valve pressure,
maximum (measured at test port TP3)
3335 psi
230 bar
Transmission gearbox speed shifting
relief valve pressure, maximum
(measured at test port TP3)
406 psi
28 bar
Air Conditioner Refrigerant
Specifications
System Full Charge
R134a 2 lbs 3 oz
Continuous improvement of our products
is a Genie policy. Product specifications are
subject to change without notice.
SPECIFICATIONS

2-6 GTH-1544 Part No. 1272857
September 2016
Section 2 • Specifications
Perkins 1204E-E44TA Engine
Displacement 269 cu in
4.4 liters
Number of cylinders 4
Bore and stroke 4.13 x 5 inches
105 x 127 mm
Horsepower
Peak Torque
Firing order 1 - 3 - 4 - 2
Compression ratio 16.5:1
Combustion
Governor
Low idle
Frequency
800 rpm
High idle
Frequency
2200 rpm
Lubrication system
Oil pressure (hot @ 2300
rpm)
Minimum pressure
Oil capacity
(including filter)
Oil viscosity requirements
Units ship with 15W-40 API CJ4 low ash oil.
Extreme operating temperatures may require the use
of alternative engine oils. For oil requirements, refer
to the Engine Operation and Maintenance Manual on
your machine.
Fuel requirements
For fuel requirements, refer to the engine Operation
Manual on your machine.
Fuel injection pressure
Engine coolant
Capacity
Type TEREX PRO COOL
Ethylene Glycol
(ASTM D3306, ASTM
D1384, FORD, G.M,
FIAT)
Alternator
Output 12 V, 120 Amp
Starter Motor
Relay max 68 A
Relay continuous 20 A
Cranking speed 130 rpm
Glow Plugs
Initial load (0-4 sec) 82 A (EA)
Continuous load (>4 sec) 64 A (EA)
Battery
Type 12V DC
Group C31
Quantity 1
Cold cranking ampere @
0°F
1000 A
Reserve capacity @ 25A
rate
200 minutes
Continuous improvement of our products
is a Genie policy. Product specifications are
subject to change without notice.
SPECIFICATIONS

September 2016
Part No.1272857 GTH-1544 2-7
Section 2 • Specifications
Deutz TCD 4.1 L4 Engine
Displacement 4038 cm3
Number of cylinders 4
Bore and stroke 4 x 5 inches
101 x 126 mm
Horsepower 154 hp @ 2200 rpm
115 kW @ 2200 rpm
Peak Torque 826 lb-ft @ 1600 rpm
609 Nm @ 1600 rpm
Firing order 1 - 3 - 4 - 2
Compression ratio 18:1
Governor Electronic
Low idle
Frequency
920 rpm
15.34 Hz
High idle
Frequency
2300 rpm
38.34 Hz
Lubrication system
Minimum oil pressure 11.6 psi
0.8 bar
Maximum oil capacity
(including filter)
12.1 quarts
11.5 liters
Oil viscosity requirements
Units ship with 15W-40 API CJ4 low ash oil.
Extreme operating temperatures may require the use
of alternative engine oils. For oil requirements, refer
to the Engine Operation and Maintenance Manual on
your machine.
Fuel requirements
For fuel requirements, refer to the engine Operation
Manual on your machine.
Fuel injection pressure
Engine coolant
Capacity
Type TEREX PRO COOL
Ethylene Glycol
(ASTM D3306, ASTM
D1384, FORD, G.M, FIAT)
Alternator
Output
Starter Motor
Normal load
Relay max
Relay continuous
Cranking speed
Glow Plugs
Initial load (0-10 sec)
Continuous load (>10
sec)
Battery
Type 12V DC
Group C31
Quantity 1
Cold cranking ampere
@ 0°F
1000A
Reserve capacity @ 25A
rate
200 minutes
Continuous improvement of our products
is a Genie policy. Product specifications are
subject to change without notice.
SPECIFICATIONS

2-8 GTH-1544 Part No. 1272857
September 2016
Section 2 • Specifications
Dana Integral Gear Box Shift
on Fly
Transmission Type Hydrostatic with
Mechanical Gear,
2 speed
Transmission ratio - 1st speed 4.53
Transmission ratio - 2nd speed 1.62
Lubrication
Oil capacity, gear box 1.69 quarts
1.6 liters
Oil viscosity requirements
Units ship with SAE 85W90 API GL4.
Refer to the Dana Integral Gear Box Shift on Fly
Maintenance and Repair Manual
(Dana part number MO367I10).
Dana Integral Gear Box Shift on Fly
Maintenance and Repair Manual
Genie part number 57.4700.0007
Dana Axle
Steering Integrated steer cylinder
Joints Heavy duty double
U-joints
Steering angle,
maximum
35 °
Front Axle Lubrication
Front differential 22.19 quarts
21 liters
Axle planetary end (each) 2 quarts
1.9 liters
Rear Axle Lubrication
Rear differential 21.13 quarts
20 liters
Axle planetary end (each) 1.95 quarts
1.85 liters
Oil viscosity requirements
Differential API GL4
(MIL L-2105)
Planetary ends API GL4
(MIL L-2105)
For additional axle information, refer to the Dana
Axle Maintenance and Repair Manual
(Dana part number MO213S20).
Dana Axle Maintenance and Repair Manual
Genie part number
(Genie Instructions Library)
57.4700.0008
Continuous improvement of our products
is a Genie policy. Product specifications are
subject to change without notice.
SPECIFICATIONS