Genie GTH-1544 Page 20 Service And Repair Manual Download

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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 - 1

speed

4.53

Transmission ratio - 2

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 speci

cations are

subject to change without notice.

SPECIFICATIONS

Summary of Contents for GTH-1544

Page 1: ...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 t...

Page 2: ...t 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 improveme...

Page 3: ...3 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...

Page 4: ...e 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 Ver...

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

Page 6: ...vi GTH 1544 Part No 1272857 September 2016 This page intentionally left blank...

Page 7: ...tified 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 t...

Page 8: ...othing 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 shoe...

Page 9: ...fications 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 Dan...

Page 10: ...d 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...

Page 11: ...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...

Page 12: ...xii GTH 1544 Part No 1272857 September 2016 This page intentionally left blank...

Page 13: ...perator 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...

Page 14: ...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 ti...

Page 15: ...on 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...

Page 16: ...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...

Page 17: ...ef 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 te...

Page 18: ...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...

Page 19: ...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 requirement...

Page 20: ...a 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...

Page 21: ...8 14 1 12 1 1 16 12 1 16 1 5 16 12 1 20 1 5 8 12 1 24 1 7 8 12 1 SAE O ring Boss Port tube fitting installed into Aluminum all types SAE Dash size Torque 4 14 ft lbs 19 Nm 6 23 ft lbs 31 2 Nm 8 36 ft...

Page 22: ...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 lbs 3 4 Nm 2 Make a reference mar...

Page 23: ...EAD i n l bs N m i n l bs N m i n l bs N m i n l bs N m i n l bs N m 20 80 9 100 11 3 110 12 4 140 15 8 130 14 7 28 90 10 1 120 13 5 120 13 5 160 18 140 15 8 ft l bs N m ft l bs N m ft l bs N m ft l b...

Page 24: ...2 12 GTH 1544 Part No 1272857 September 2016 Section 2 Specifications This page intentionally left blank...

Page 25: ...ost 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 probl...

Page 26: ...fail safe design Should the switch or the switch wire circuit be faulty the machine will not function outside its designed range of use The boom proximity switch is a component of the drive circuit an...

Page 27: ...angle proximity switch is attached to a mounting bracket located between the boom and the chassis directly beneath the boom pivot pin The switch location is adjustable 1 Start the engine 2 Raise the b...

Page 28: ...remove the pivot pin 5 Remove the screw securing the fork frame pivot pin to the boom 6 Use a soft metal drift to remove the pivot pin 7 Using the overhead crane lift and remove the fork frame from t...

Page 29: ...y 80 in 2 m 10 Remove the screws f securing the chain anchor plates g and remove the chains 11 Remove the screws a securing the chain anchor plates b and remove the chains 12 Securely attach a guide r...

Page 30: ...B B 1 BOOM SECTION CHAINS ANCHORAGE 3 BOOM SECTION CHAINS ANCHORAGE a b f g i h d c m e 8 Remove the screws g securing the chain anchor plates h of the retract chains 9 At the pivot end of the boom re...

Page 31: ...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...

Page 32: ...structure capable of supporting it How to Disassemble the Boom WARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this pro...

Page 33: ...the extend chain tensioners and pull it out of the boom 15 Reach the upper area of the boom fork end and remove the 4 screws h securing the boom retract chains then pull out the end of the chain retai...

Page 34: ...lifting straps from an overhead crane to pull the third boom section out of the second by approximately 16 19 in 40 50 cm 24 Remove all the front pads in the second boom section 25 Attach lifting str...

Page 35: ...wly 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 3 Attach a lifting strap from...

Page 36: ...t The third section features some holes matching the cylinder retaining screws when the boom is retracted 3 Tag disconnect and plug the hydraulic hoses from the extend cylinder Cap the cylinder fittin...

Page 37: ...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 2...

Page 38: ...rt the engine 2 Raise the boom to a horizontal position 3 Fully retract the boom 4 Turn the machine off and remove the key from the key switch 5 Before replacing a hydraulic hose thoroughly clean the...

Page 39: ...e no abnormal tensions on the hoses 1 6 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...

Page 40: ...d if they are kinked or pinched 7 Remove the retaining fasteners securing the fork tilt cylinder barrel end pivot pin 8 Using a soft metal drift and a hammer remove the pivot pin 9 Carefully lift and...

Page 41: ...tion burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 3 Remove the protective cover next to the cab inner side...

Page 42: ...n and an overhead crane slowly raise the cabin away from the machine and set it on a supporting device NOTICE Component damage hazard Wrapping a strap around the cab and lifting using an overhead cran...

Page 43: ...the nut securing the steering wheel to the column and remove the steering wheel 2 2 Machine Controls How to Remove the Steering Column 1 Get behind the front right wheel and disconnect the battery fro...

Page 44: ...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 5 Remove t...

Page 45: ...isconnect and plug the hydraulic hoses of 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...

Page 46: ...n death or serious injury and significant component damage Dealer service is strongly recommended 1 Get behind the front right wheel and disconnect the battery from the machine WARNING Electrocution b...

Page 47: ...el 12 Remove all the screws 13 Loosen all the clamps and pull out the hoses 14 Disconnect the electrical harnesses 15 Remove the wire harness from bulb on the hydraulic filter 16 Place a container of...

Page 48: ...4 1 Engines How to Repair the Perkins 1204E E44TA Engine Repair procedures and additional engine information is available in the Perkins 1204E E44TA Operation and Maintenance Manual Perkins part numbe...

Page 49: ...op 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 fastener...

Page 50: ...y from both ends of the axle 8 Support and secure the axle to an appropriate lifting device 9 Remove the fasteners securing the sway cylinder rod end pivot pin to the chassis 10 Use a soft metal drift...

Page 51: ...the throttle pedal Result the pressure gauge reads 3770 psi 260 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 need...

Page 52: ...d plug the case drain hose located at the top of the pump Cap the fitting on the pump WARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very...

Page 53: ...p on the transmission pump 2 Install the high pressure hose onto the pump outlet WARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowl...

Page 54: ...With the engine running move the joystick slowly to verify that the movements are performed correctly 6 Shut off the engine and inspect for oil leaks How to Adjust the Boom and Steering Function Pump...

Page 55: ...rning the valve on the function manifold when the pressure gauge reading is stable Result the pressure gauge reads 3915 psi 270 bar The pump is good Proceed to step 9 Pressure is not within specificat...

Page 56: ...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 h...

Page 57: ...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 Install the...

Page 58: ...ow to Prime the Auxiliary Gear Pump 1 Start the engine allow the engine to run at low idle for 15 seconds then shut off the engine 2 Wait 15 seconds then start the engine again 3 Allow the engine to r...

Page 59: ...pressure gauge connected to test port TP3 reads 406 psi 28 bar Pressure is not within specification Adjust the boost pressure valve c located under the pump 5 Increase the engine speed to 1100 rpm 6...

Page 60: ...ove the cover that is under engine 4 Locate the battery disconnect switch and disconnect the battery from the machine 5 Remove the retaining fasteners that secure the battery disconnect switch mountin...

Page 61: ...cover of the engine housing 3 Remove the cover that is under engine 4 Attach a lifting strap and lift the transmission pump using a overhead crane 5 Install the hydrostatic transmission pump on the e...

Page 62: ...ngine Run at low idle for 5 seconds Shut the engine off and wait for 15 seconds 3 Start the engine Run at low idle for 10 seconds Shut the engine off and wait for 15 seconds 4 Note Repeat step 4 until...

Page 63: ...the left Continue holding the steering while observing the pressure reading on the pressure gauge Result the pressure gauge reads 2610 psi 180 bar The pressure setting is correct Proceed to step 8 Pre...

Page 64: ...e 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 Tag disconnect and plug the hos...

Page 65: ...i 0 to 350 bar pressure gauge to port TP1 boom and steering functions hydraulic circuit test port 2 Start the engine 3 Increase the engine speed to maximum rpm 4 Moving the joystick retract the boom R...

Page 66: ...ote Perform this procedure with the engine off and cool to the touch 1 Close the hydraulic tank ball valve 2 Raise the boom 3 Tag disconnect and plug the hoses from the function manifold WARNING Bodil...

Page 67: ...ct a 0 to 5000 psi 0 to 350 bar pressure gauge to port TP2 2 Start the engine 3 Increase the engine speed to maximum rpm 4 Move the joystick to lock unlock the attachment Result the pressure gauge rea...

Page 68: ...ANIFOLDS Function Manifold Components a b c d Pos Function Description Schematic ITEM a Boom up down Hydraulic proportional control A1 B1 b Boom in out Hydraulic proportional control A2 B2 c Fork tilt...

Page 69: ...1544 3 45 Section 3 Repair Procedures Auxiliary Function Manifold Components MANIFOLDS c a b Pos Function Description Schematic ITEM a Chassis sway function b Boom auxiliary line ON OFF solenoid valve...

Page 70: ...y 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...

Page 71: ...attery should read 9V DC or more when measured across the terminals 3 Set a multimeter to read DC current Note The multimeter when set to read DC current should be capable of reading up to 800 mA 4 Co...

Page 72: ...3 48 GTH 1544 Part No 1272857 September 2016 Section 3 Repair Procedures This page intentionally left blank...

Page 73: ...ions 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 acc...

Page 74: ...on 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 displ...

Page 75: ...24020 14 Engine power Not enough oxygen for regeneration 523911 0 Burner dosing valve DV2 overcurrent at the end of the injection phase 523911 12 Burner dosing valve DV2 powerstage over temperature 52...

Page 76: ...ue exceeded 523934 0 Fuel Balance Control integrator injector 6 in firing order maximum value exceeded 523929 1 Fuel Balance Control integrator injector 1 in firing order minimum value exceeded 523930...

Page 77: ...cat 523943 9 Timeout Error PCK2PCK for CAN Receive Frame AT1OGCVol2 information factors Sensorcalibration for NOX Sensor SCR system downstream cat DPF system downstream cat 523935 12 Timeout Error of...

Page 78: ...ssure signal range check low 171 3 Sensor error environment temperature signal range check high 171 4 Sensor error environment temperature signal range check low 190 8 Sensor camshaft speed disturbed...

Page 79: ...sing valve DV1 downstream pressure plausibility error 523916 0 Physical range check high for HCI dosing valve DV1 downstream pressure shut off regeneration 523916 1 Physical range check low for HCI do...

Page 80: ...erruption of electric connection 656 5 Injector 6 in firing order interruption of electric connection 651 3 Injector 1 in firing order short circuit 652 3 Injector 2 in firing order short circuit 653...

Page 81: ...ion reported error 523612 12 Internal ECU monitoring detection reported error 523612 12 Internal ECU monitoring detection reported error 523612 12 Internal ECU monitoring detection reported error 5236...

Page 82: ...sor error charged air pressure signal range check low 411 0 Physical range check high for differential pressure Venturiunit EGR 411 1 Physical range check low for differential pressure Venturiunit EGR...

Page 83: ...613 0 Maximum negative deviation of rail pressure in metering unit exceeded RailMeUn2 523613 0 Negative deviation of rail pressure second stage RailMeUn22 523613 1 Minimum rail pressure exceeded RailM...

Page 84: ...ycle in failure range 523721 8 Urea supply module temperature duty cycle in invalid range 29 3 Handthrottle idle validation switch short circuit to battery 91 8 Accelerator pedal duty cycle PWM signal...

Page 85: ...emperature 523921 1 Physical range check low for burner temperature 105 3 Sensor error charged air temperature signal range check high 105 4 Sensor error charged air temperature signal range check low...

Page 86: ...gh 4768 4 Sensor error exhaust gas temperature upstream DOC signal range check low 3248 4 Sensor error particle filter downstream temperature signal range check low 1180 11 Sensor exhaust gas temperat...

Page 87: ...cuit to ground 523719 5 SCR heater relay urea supplymodule primary side open load 523719 3 SCR heater urea supplymodule short circuit to battery 523719 4 SCR heater urea supplymodule short circuit to...

Page 88: ...ation injector 5 in firing order minimum value exceeded 523951 1 Zerofuel calibration injector 6 in firing order minimum value exceeded 523612 12 Internal software error ECU 175 2 Customer oiltemperat...

Page 89: ...r EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 Voltage below threshold 523988 5 Charging lamp open load 523988 12 Charging lamp over temperature 523988 3 Charging lamp short circuit to battery 523988 4...

Page 90: ...9 Timeout error of CAN Receive Frame ComMS_Sys6TO error memory Slave Master Slave internal CAN message 524045 9 Master Slave CAN Message Counter Error of CAN Receive Frame ComMSMoFOvR 524046 9 Master...

Page 91: ...usibility error 523920 2 Sensor exhaust gas back pressure burner plausibility error 3253 2 Sensor differential pressure DPF plausibility error 164 2 Rail pressure safety function is not executed corre...

Page 92: ...or open load 524034 12 Disc Separator powerstage over temperature 524034 3 Disc separator short circuit to battery 524034 4 Disc separator short circuit to ground 524030 7 EGR actuator internal error...

Page 93: ...sing valve open load 4376 12 SCR reversing valve over temperature 4376 4 SCR reversing valve short circuit to ground 524057 2 Electric fuel pump fuel pressure build up error 2659 2 Exhaust gas recircu...

Page 94: ...Valve 2 9 3 6 or Throttle Valve 6 1 7 8 short circuit to ground 51 4 Position sensor error actuator EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 signal range check low 51 4 EGR Valve 2 9 3 6 or Thrott...

Page 95: ...ge check low 97 12 Water in fuel level prefilter maximum value exceeded 100 0 High oil pressure warning threshold exceeded 100 0 High oil pressure shut off threshold exceeded 100 1 Low oil pressure wa...

Page 96: ...8 2 Low battery voltage warning threshold exceeded 168 3 Sensor error battery voltage signal range check high 168 4 Sensor error battery voltage signal range check low 171 3 Sensor error environment t...

Page 97: ...ge check low for EGR differential pressure 411 4 Sensor error differential pressure Venturiunit EGR signal range check low 412 3 Sensor error EGR cooler downstream temperature signal range check high...

Page 98: ...to battery 677 3 Starter relay low side short circuit to battery 677 4 Starter relay high side short circuit to ground 677 4 Starter relay low side short circuit to ground 677 5 Starter relay no load...

Page 99: ...gas temperature upstream turbine signal range check low 1180 11 Sensor exhaust gas temperature upstream turbine plausibility error 1188 2 Wastegate status message from ECU missing 1188 7 Wastegate act...

Page 100: ...Sensor error urea tank temperature short circuit to battery 3031 4 Sensor error urea tank temperature short circuit to ground 3224 1 Nox sensor upstream of SCR Catalysator low signal not plausible 32...

Page 101: ...al range check low 3361 3 Urea dosing valve short circuit to battery on high side 3361 3 Urea dosing valve short circuit to battery or open load on high side 3361 4 Urea dosing valve short circuit to...

Page 102: ...360 4 Sensor error urea catalyst exhaust gas temperature upstream signal range check low 4365 0 Urea tank temperature too high 4366 3 SCR Tank heating valve short circuit to battery 4366 4 SCR Tank he...

Page 103: ...23009 10 Pressure relief valve PRV reached maximun allowed open time 523212 9 Timeout Error of CAN Receive Frame ComEngPrt Engine Protection 523216 9 Timeout Error of CAN Receive Frame PrHtEnCmd pre h...

Page 104: ...onitoring detection reported error 523612 12 Internal ECU monitoring detection reported error 523612 12 Internal ECU monitoring detection reported error 523612 12 Internal ECU monitoring detection rep...

Page 105: ...rsion rate insufficient SCR Cat defect bad AdBule quality 523633 11 Nox conversion rate insufficient SCR Cat defect bad AdBule quality temperature range 1 523633 11 Nox conversion rate insufficient SC...

Page 106: ...Timeout Error of CAN Receive Frame TSC1TR 523788 0 CAN Transmit Frame ComTrbChActr BusOff Satus Wastegate 523788 0 CAN Transmit Frame ComTrbChActr disable error wastegate 523788 0 CAN Transmit Frame C...

Page 107: ...DV2 downstream pressure sensor plausibility error 523912 3 Sensor error burner dosing valve DV2 downstream pressure sensor signal range check high 523912 4 Sensor error burner dosing valve DV2 downstr...

Page 108: ...nge check high for airpump pressure shut off regeneration 523919 1 Physical range check low for airpump pressure shut off regeneration 523919 2 Sensor airpump pressure plausibility error 523919 2 Sens...

Page 109: ...rror of CAN Transmit Frame EEC3VOL1 Engine send messages 523936 12 Timeout Error of CAN Transmit Frame EEC3VOL2 Engine send messages 523938 9 Timeout Error BAM to packet for CAN Receive Frame AT1IGCVo...

Page 110: ...erating timer below limit 2 523980 14 Bad quality of reduction agent detected 523981 11 Urea tank without heating function heating phase 523982 0 Powerstage diagnosis disabled high battery voltage 523...

Page 111: ...ir is not plausible to HFM reading 524016 11 HFM sensor electrical fault 524017 12 Spark plug control unit SPCU electrical fault 524017 12 Spark plug control unit SPCU internal error 524018 14 DPF was...

Page 112: ...ge 524044 9 CAN message ComMS_Sys7 not received from slave 524045 9 Master Slave CAN Message Counter Error of CAN Receive Frame ComMSMoFOvR 524046 9 Master Slave CAN Checksum Error of CAN Receive Fram...

Page 113: ...f CAN Receive Frame ComRxEGRTVActr 524110 9 Timeout error of CAN Transmit Frame ComETVActr 524111 9 Timeout error of CAN Receive Frame ComRxETVActr 524112 9 Timeout ComITVActr 524113 9 Timeout error o...

Page 114: ...ow to Troubleshoot the Perkins 1204E E44TA Engine Troubleshooting procedures and additional engine information is available in the Perkins 1204E E44TA Troubleshooting Manual Perkins part number KENR91...

Page 115: ...est equipment are available and ready for use About This Section There are two groups of schematics in this section An illustration legend precedes each group of drawings Electrical Schematics WARNING...

Page 116: ...w regulator Relief valve 3 position 4 way proportional directional valve 2 position 3 way directional valve 3 position 4 way solenoid valve 2 position 4 way solenoid valve 2 position 2 way solenoid va...

Page 117: ...f g h 12 13 24 20 wel4 wel3 wel11 deutz cable deutz cable deutz cable deutz cable deutz cable M ecm AGS deutz cable deutz cable deutz cable deutz cable deutz cable deutz cable deutz cable deutz cable...

Page 118: ...e engine engine deutz cable deutz cable engine t engine engine deutz cable deutz cable engine deutz cable p M ECU deutz cable engine deutz cable engine deutz cable engine deutz cable engine deutz cabl...

Page 119: ...eutz cable engine deutz cable engine p t deutz cable engine deutz cable deutz cable deutz cable deutz cable deutz cable deutz cable engine deutz cable deutz cable deutz cable engine deutz cable deutz...

Page 120: ...6 GTH 1544 Part No 1272857 September 2016 Section 5 Schematics ELECTRICAL SCHEMATIC DEUTZ Sheet 4 of 8 R F N 1 2 3 4 5 A B C D E F A B C D E F GEAR 7 9 I R A F N N 3 8 N N 6 12 HORN Up to SN GTH1513 B...

Page 121: ...tember 2016 Part No 1272857 GTH 1544 5 7 Section 5 Schematics ELECTRICAL SCHEMATIC DEUTZ Sheet 5 of 8 1 2 3 4 5 A B C D E F A B C D E F X129 sal7 wel7 wel7 sal3 sal3 wel8 wel18 wel19 Up to SN GTH1513...

Page 122: ...5 8 GTH 1544 Part No 1272857 September 2016 Section 5 Schematics ELECTRICAL SCHEMATIC DEUTZ Sheet 6 of 8 1 2 3 4 5 A B C D E F A B C D E F wel1 wel2 wel4 Up to SN GTH1513 B 5...

Page 123: ...ember 2016 Part No 1272857 GTH 1544 5 9 Section 5 Schematics ELECTRICAL SCHEMATIC DEUTZ Sheet 7 of 8 1 2 3 4 5 A B C D E F A B C D E F Dx R Sx L Dx R Sx L HORN wel1 0 Rear CCTV Camera Up to SN GTH1513...

Page 124: ...5 10 GTH 1544 Part No 1272857 September 2016 Section 5 Schematics ELECTRICAL SCHEMATIC DEUTZ Sheet 8 of 8 1 2 3 4 5 A B C D E F A B C D E F Up to SN GTH1513 B 5...

Page 125: ...September 2016 Part No 1272857 GTH 1544 5 11 Section 5 Schematics ELECTRICAL SCHEMATIC DEUTZ Sheet 1 of 8 From SN GTH1513 B 6...

Page 126: ...5 12 GTH 1544 Part No 1272857 September 2016 Section 5 Schematics ELECTRICAL SCHEMATIC DEUTZ Sheet 2 of 8 From SN GTH1513 B 6...

Page 127: ...September 2016 Part No 1272857 GTH 1544 5 13 Section 5 Schematics ELECTRICAL SCHEMATIC DEUTZ Sheet 3 of 8 From SN GTH1513 B 6...

Page 128: ...5 14 GTH 1544 Part No 1272857 September 2016 Section 5 Schematics ELECTRICAL SCHEMATIC DEUTZ Sheet 4 of 8 From SN GTH1513 B 6...

Page 129: ...September 2016 Part No 1272857 GTH 1544 5 15 Section 5 Schematics ELECTRICAL SCHEMATIC DEUTZ Sheet 5 of 8 From SN GTH1513 B 6...

Page 130: ...5 16 GTH 1544 Part No 1272857 September 2016 Section 5 Schematics ELECTRICAL SCHEMATIC DEUTZ Sheet 6 of 8 From SN GTH1513 B 6...

Page 131: ...September 2016 Part No 1272857 GTH 1544 5 17 Section 5 Schematics ELECTRICAL SCHEMATIC DEUTZ Sheet 7 of 8 From SN GTH1513 B 6...

Page 132: ...5 18 GTH 1544 Part No 1272857 September 2016 Section 5 Schematics ELECTRICAL SCHEMATIC DEUTZ Sheet 8 of 8 From SN GTH1513 B 6...

Page 133: ...September 2016 Part No 1272857 GTH 1544 5 19 Section 5 Schematics ELECTRICAL SCHEMATIC PERKINS Sheet 1 of 7 Up to SN GTH1513 B 5...

Page 134: ...5 20 GTH 1544 Part No 1272857 September 2016 Section 5 Schematics Sheet 2 of 7 Up to SN GTH1513 B 5 ELECTRICAL SCHEMATIC PERKINS...

Page 135: ...September 2016 Part No 1272857 GTH 1544 5 21 Section 5 Schematics Sheet 3 of 7 Up to SN GTH1513 B 5 ELECTRICAL SCHEMATIC PERKINS...

Page 136: ...5 22 GTH 1544 Part No 1272857 September 2016 Section 5 Schematics Sheet 4 of 7 Up to SN GTH1513 B 5 ELECTRICAL SCHEMATIC PERKINS...

Page 137: ...September 2016 Part No 1272857 GTH 1544 5 23 Section 5 Schematics Sheet 5 of 7 Up to SN GTH1513 B 5 ELECTRICAL SCHEMATIC PERKINS...

Page 138: ...5 24 GTH 1544 Part No 1272857 September 2016 Section 5 Schematics Sheet 6 of 7 Up to SN GTH1513 B 5 ELECTRICAL SCHEMATIC PERKINS...

Page 139: ...September 2016 Part No 1272857 GTH 1544 5 25 Section 5 Schematics Sheet 7 of 7 Up to SN GTH1513 B 5 ELECTRICAL SCHEMATIC PERKINS...

Page 140: ...5 26 GTH 1544 Part No 1272857 September 2016 Section 5 Schematics ELECTRICAL SCHEMATIC PERKINS Sheet 1 of 7 From GTH1513 B 6...

Page 141: ...September 2016 Part No 1272857 GTH 1544 5 27 Section 5 Schematics ELECTRICAL SCHEMATIC PERKINS Sheet 2 of 7 From SN GTH1513 B 6...

Page 142: ...5 28 GTH 1544 Part No 1272857 September 2016 Section 5 Schematics Sheet 3 of 7 From GTH1513 B 6 ELECTRICAL SCHEMATIC PERKINS...

Page 143: ...September 2016 Part No 1272857 GTH 1544 5 29 Section 5 Schematics Sheet 4 of 7 From SN GTH1513 B 6 ELECTRICAL SCHEMATIC PERKINS...

Page 144: ...5 30 GTH 1544 Part No 1272857 September 2016 Section 5 Schematics Sheet 5 of 7 From GTH1513 B 6 ELECTRICAL SCHEMATIC PERKINS...

Page 145: ...September 2016 Part No 1272857 GTH 1544 5 31 Section 5 Schematics Sheet 6 of 7 From SN GTH1513 B 6 ELECTRICAL SCHEMATIC PERKINS...

Page 146: ...5 32 GTH 1544 Part No 1272857 September 2016 Section 5 Schematics ELECTRICAL SCHEMATIC PERKINS Sheet 7 of 7 From GTH1513 B 6...

Page 147: ...September 2016 Section 5 Schematics 5 33 5 34 Hydraulic Schematic Deutz Engine Deutz engine Sheet 1 of 2...

Page 148: ...1 B X ctions port Pump stand by pressure test port 290 psi Hydraulically piloted double check valve piloting ratio 4 1 Single overcenter safety valve piloting ratio 4 1 cracking pressure 350 bar g p...

Page 149: ...valve piloting ratio 4 1 Single overcenter safety valve piloting ratio 4 1 cracking pressure 350 bar Double overcenter safety valve piloting ratio 1 4 cracking pressure 5 075 psi Double overcenter saf...

Page 150: ...5 37 5 38 September 2016 Section 5 Schematics Hydraulic Schematic Perkins Engine Perkins engine Sheet 2 of 2...

Page 151: ......

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