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Genie GTH-1544 User Manual

Genie GTH-1544
151 pages
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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

Table of Contents

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Genie GTH-1544 Specifications

General IconGeneral
BrandGenie
ModelGTH-1544
CategoryLifting Systems
LanguageEnglish

Summary

Service and Repair Manual

Introduction

Important Information

Key safety and operational guidelines for manual use.

Safety Rules

Danger

Critical warning about severe injury or death from improper maintenance.

Do Not Perform Maintenance Unless:

Prerequisites for performing maintenance safely and correctly.

Personal Safety

Workplace Safety

Guidelines for ensuring a safe and organized work area.

Section 2 • Specifications

Machine Specifications

Covers fluid capacities, tire specs, weight, and torque values.

Performance Specifications

Details drive speed, draw bar pull, lift capacity, and boom speeds.

Hydraulic Specifications

Information on hydraulic oil type, viscosity, and optional fluids.

Hydraulic Components Specifications

Specs for hydraulic pumps and motors.

Function Manifold Specifications

Pressure ratings for manifold and secondary valves.

Hydraulic Hose and Fitting Torque Specifications

Torque values for various hydraulic hose fittings.

Section 3 • Repair Procedures

Before Repairs Start

Checks and preparations before commencing any repair procedure.

Boom Components

1-2 Boom

Procedures related to the boom structure itself.

How to Remove the Lifting Fork Frame

Steps to safely remove the lifting fork frame from the boom.

How to Replace the Boom Extend Chains

Procedure for replacing the boom extend chains.

How to Test The Boom Proximity Switch

Procedure for testing the boom proximity switch.

How to Replace the Boom Wear Pads

Steps for replacing wear pads on the boom.

How to Replace the Boom Retract Chains

Instructions for replacing the boom retract chains.

How to Adjust The Boom Angle Proximity Switch

Procedure for calibrating the boom angle proximity switch.

Operator's Compartment

2-1 Operator's Compartment

Description of the operator's compartment and its components.

2-2 Machine Controls

Procedures for removing steering column and wheel.

Fuel and Hydraulic Tank

3-1 Fuel and Hydraulic Tank

Description of the fuel and hydraulic tank system.

Engines

4-1 Engines

Information on repairing the Perkins 1204E-E44TA engine.

4-2 Engine Fault Codes

How to retrieve and understand engine fault codes.

Section 4 • Fault Codes

Fault Codes

Diagnostic Display

Information about the engine diagnostic display and warning lights.

Engine Fault Codes - Models with Deutz TCD 4.1 L4

List of fault codes specific to Deutz TCD 4.1 L4 engine models.

Decoding Fault Codes

How to interpret fault codes using SPN and FMI numbers.

Section 5 • Schematics

Observe and Obey

General safety and procedural guidelines for working with schematics.

Before Troubleshooting

Prerequisites for understanding and using schematics.

Electrical Schematics

Safety warning for electrical schematics.

Hydraulic Schematics

Safety warning for hydraulic schematics.

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