Terex Genie GTH-5519 Full Service & Repair Manual

1. Service Manual GTH-5519 (Deutz Tier 4i) Part No. 57.4400.9210 Rev A October 2013 From GTH5514B-101 Serial Number Range

ii GTH-5519 Part No. 57.4400.9210 October 2013 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-5519 Operator's Manual before attempting any maintenance or repair procedure. This manual provides detailed scheduled maintenance information for the machine owner and user. It also provides troubleshooting fault codes and repair procedures for qualified service professionals. Basic mechanical, hydraulic and electrical skills are required to perform most procedures. However, several procedures require specialized skills, tools, lifting equipment and a suitable workshop. In these instances, we strongly recommend that maintenance and repair be performed at an authorized dealer service center. 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. Serial Number Information Genie offers the following Service Manuals for these models: Title Part No. Contact Us: Introduction Copyright © 2013 by Terex Corporation 57.4400.9210 Rev A October 2013 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

October 2013 Part No. 57.4400.9210 GTH-5519 iii Revision Date Section Procedure / Schematic Page / Description A 10/2013 Initial Release REFERENCE EXAMPLES: Kubota Engine_Section 2_Specifications. A-6,B-3,C-7_Section 3_Maintenance Procedure. 3-2, 6-4, 9-1_Section 4_Repair Procedure. Fault Codes_Section 5. 6-35, 6-56, 6-104_Section 6_Schematic Page #. Electronic Version Click on any procedure or page number highlighted in blue to view the update. Revision History

iv GTH-5519 Part No. 57.4400.9210 October 2013 REVISION HISTORY, CONTINUED Revision Date Section Procedure / Schematic Page / Description REFERENCE EXAMPLES: Kubota Engine_Section 2_Specifications. A-6,B-3,C-7_Section 3_Maintenance Procedure. 3-2, 6-4, 9-1_Section 4_Repair Procedure. Fault Codes_Section 5. 6-35, 6-56, 6-104_Section 6_Schematic Page #. Electronic Version Click on any procedure or page number highlighted in blue to view the update.

October 2013 Part No. 57.4400.9210 GTH-5519 v A TEREX BRAND INTRODUCTION Serial Number legend GTH-55 14 xxxxx - Model Year of manufacture Sequence number Facility code MODEL: GTH-5519 SERIAL NUMBER: GTH5514 B-xxxxx B Serial label (located inside chassis) Serial number

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October 2013 Part No. 57.4400.9210 GTH-5519 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-5519 Part No. 57.4400.9210 October 2013 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

October 2013 Part No. 57.4400.9210 GTH-5519 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 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 Section 3 Scheduled Maintenance Procedures Introduction ............................................................................................. 3 - 1 Pre-delivery Preparation Report ............................................................. 3 - 3 Maintenance Inspection Report .............................................................. 3 - 4 Table of Contents

x GTH-5519 Part No. 57.4400.9210 October 2013 TABLE OF CONTENTS Section 3 Scheduled Maintenance Procedures, continued Checklist A Procedures A-1 Inspect the Manuals and Decals .................................................. 3 - 5 A-2 Perform Pre-operation Inspection ................................................ 3 - 6 A-3 Perform Function Tests ................................................................ 3 - 6 A-4 Lubricate the Boom ...................................................................... 3 - 7 A-5 Perform Engine Maintenance ....................................................... 3 - 7 A-6 Safety Devices ............................................................................. 3 - 8 A-7 Perform 30 Day Service ............................................................... 3 - 8 A-8 Perform Axle Maintenance ........................................................... 3 - 9 A-9 Perform Axle Maintenance ........................................................... 3 - 9 A-10 Perform Axle Maintenance ......................................................... 3 - 10 Checklist B Procedures B-1 Inspect the Electrical Wiring ....................................................... 3 - 11 B-2 Check the Exhaust System ........................................................ 3 - 12 B-3 Inspect the Tires, Wheels and Lug Nut Torque .......................... 3 - 12 B-4 Perform Hydraulic Oil Analysis ................................................... 3 - 13 B-5 Check the Boom Wear Pads ...................................................... 3 - 14 B-6 Perform Axle Maintenance ......................................................... 3 - 15 B-7 Perform Axle Maintenance ......................................................... 3 - 15

Terex Genie GTH-5519 Full Service & Repair Manual

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