Genie GTH-844 Service And Repair Manual
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Genie GTH-844 Service And Repair Manual

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from
Service and Repair Manual
GTH-844
Serial Number Range
from GTH0813-16606 to
GTH0816-21572
from GTH0816E-10000 to
GTH0816E-10699
from GTH08E-10700
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
Part No. 1272854
Rev A2
April 2017

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Summary of Contents for Genie GTH-844

  • Page 1 Service and Repair Manual Serial Number Range GTH-844 from GTH0813-16606 to This manual includes: GTH0816-21572 Repair procedures from GTH0816E-10000 to Fault Codes GTH0816E-10699 Electrical and from GTH08E-10700 Hydraulic Schematics For detailed maintenance procedures, refer to the appropriate Maintenance Manual for your machine.

  • Page 2: Find A Manual For This Model

    Copyright © 2016 by Terex Corporation 1272854 Rev A2, April 2017 First Edition, First Printing Genie is a registered trademark of Terex South Dakota, Inc. in the U.S.A. and many other countries. "GTH" is a trademark of Terex South Dakota, Inc.
  • Page 3 Reference Examples: Electronic Version Section – Repair Procedure, 4-2 Click on any content or procedure in the Table of Contents to view Section – Fault Codes, All charts the update. Section – Schematics, Legends and schematics Part No. 1272854 GTH-844...

  • Page 4: Serial Number Legend

    4 Sequence number From September 1, 2016 1 Model 1 Serial label (located inside fork frame) 2 Facility code 2 Serial number (stamped on chassis) 3 Sequence number 3 Serial label (located inside riser, cab side) GTH-844 Part No. 1272854...

  • Page 5: Safety Rules

     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. Part No. 1272854 GTH-844...

  • Page 6: April

    Be sure that your workshop or work area warrants it. is properly ventilated and well lit. 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. GTH-844 Part No. 1272854...

  • Page 7: Table Of Contents

    How to Adjust the Boom Angle Proximity Switch ..........20 1-2 Boom ......................20 How to Replace the Boom Wear Pads ............20 How to Remove the Lifting Fork Frame ............21 How to Replace the Retraction Chain ............. 21 Part No. 1272854 GTH-844...
  • Page 8 5-1 Transmission ....................43 Hydraulic Pump ....................43 6-1 Hydraulic Pump ....................43 How to Test the Function Pump ..............43 How to Remove the Function Pump ............... 44 How to Install the Function ................45 viii GTH-844 Part No. 1272854...
  • Page 9 Deutz TCD3.6 T4F Module (from 21536, 16E-10000) ......... 95 Electrical Component & Wire Color Abbreviation Legend ........96 Telematics Connector Pin Legend ............... 99 Electrical Symbol Legend ................... 101 Hydraulic Symbols Legend ................. 102 Electrical Schematics - Harness Maps ............103 Part No. 1272854 GTH-844...
  • Page 10 Harness Map - Options Enclosed Cab with HVAC..........149 Electrical Schematics ..................151 Electrical Schematic - View 1 (to 15-20661) ............152 Electrical Schematic - View 2 (to 15-20661) ............153 Electrical Schematic - View 1 (from 15-20662 to 21456) ........156 GTH-844 Part No. 1272854...
  • Page 11 Hydraulic Schematic - Single Joystick (to 19528) ..........168 Hydraulic Schematic - Single Joystick (from 19529, 16E-10000) ...... 169 Hydraulic Schematic - Dual Joystick (to 19528) ..........172 Hydraulic Schematic - Dual Joystick (from 19529, 16E-10000) ......173 Part No. 1272854 GTH-844...

  • Page 13: Specifications

    295 ft-lbs 132.5 liters 400 Nm Lug Pattern 8 x 10.826 Hydraulic system 50 gallons (including tank) 189.3 liters Wheel diameter 24 in 60.1 cm DEF tank 2.6 gallons 10 liters Wheel width 9 in 22.9 cm Part No. 1272854 GTH-844...

  • Page 14: Performance Specifications

    Perkins 854E T4i Engine 16 mph Fork tilt up 6 to 8 seconds 25.7 mph Fork tilt down 5 to 7 seconds Draw bar pull 21,000 lbs 9525 kg Lift capacity, maximum 8000 lbs 3629 kg GTH-844 Part No. 1272854...

  • Page 15: Hydraulic Oil Specifications

    Hydraulic fluids may be incompatible due to the Hydraulic Fluid Specifications differences in base additive Genie specifications require hydraulic oils which are chemistry. When incompatible designed to give maximum protection to hydraulic fluids are mixed, insoluble systems, have the ability to perform over a wide...
  • Page 16 Note: Do not operate the machine when the 5606A hydraulic fluid, or equivalent, when ambient ambient temperature is below -20°F / -29°C with temperatures are consistently Rando HD Premium MV. above 32°F / 0°C may result in component damage GTH-844 Part No. 1272854...
  • Page 17 @ 104°F / 40°C 33.8 Brookfield Viscosity cSt @ -4°F / -20°C cSt @ -13°F / -25°C 702.4 cSt @ -40°F / -40°C 2624 Flash point >100 Pour point -76°F / -60°C Maximum continuous operating 103°F / 75°C temperature Part No. 1272854 GTH-844...

  • Page 18: Hydraulic Component Specifications

    Diff lock relief valve pressure, maximum 400 psi Standby pressure 450 psi (measured at test port TJ) 27.5 bar 31 bar Rear lock-up relief valve pressure, 50 psi 3.4 bar maximum (measured at test port TR) GTH-844 Part No. 1272854...

  • Page 19: Manifold Component Specifications

    13 ft-lbs / 18 Nm SAE No. 6 18 ft-lbs / 24 Nm SAE No. 8 50 ft-lbs / 68 Nm SAE No. 10 55 ft-lbs / 75 Nm SAE No. 12 75 ft-lbs / 102 Nm Part No. 1272854 GTH-844...

  • Page 20: Def Storage Specifications

    Indefinite 50°F / 10°C 75 years 68°F / 20°C 11 years 86°F / 30°C 23 months 95°F / 35°C 10 months 104°F / 40°C 4 months 122°F / 50°C 1 month 140°F / 60°C 1 week GTH-844 Part No. 1272854...

  • Page 21: Deutz Tcd3.6 L4 Engine Specifications

    9 liters Oil viscosity requirements Unit ships 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 Operator Manual for your engine. Part No. 1272854 GTH-844...

  • Page 22: Deutz Tcd3.6 L4 T4F Engine Specifications

    9 liters Oil viscosity requirements Unit ships 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 Operator Manual for your engine. GTH-844 Part No. 1272854...

  • Page 23: Perkins 1104D-E44Ta Engine Specifications

    85A @ 12V DC 9.6 liters Oil viscosity requirements Unit ships with 15W-40. Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Manual for your engine. Part No. 1272854 GTH-844...

  • Page 24: Perkins 854E-E34Ta Engine Specifications

    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. GTH-844 Part No. 1272854...

  • Page 25: Dana Vdt12000 Transmission Specifications

    Planetary ends Chevron Supreme 80W90 LS Manual. For additional axle information, refer to the Carraro Dana VDT12000 Service Manual 26.27M Axle Maintenance and Repair Manual Genie part number 218706 Carraro 26.27M Axle Maintenance and Repair Instructions Genie part number 218710 Part No.

  • Page 26: Hydraulic Hose And Fitting Torque Specifications

    SAE O-ring Boss Port (tube fitting - installed into Aluminum) Your machine is equipped with Parker Seal-Lok™ (all types) ORFS or 37° JIC fittings and hose ends. Genie SAE Dash Size Torque specifications require that fittings and hose ends be...

  • Page 27: Torque Procedure

    Refer to Illustration 1. hose end are custom-size O-rings. They are not standard size O-rings. They are available in the O-ring field service kit (Genie part number 49612). Lubricate the O-ring before installation. Be sure the O-ring face seal is seated and retained properly.
  • Page 28 Tighten the hex nut until the mark on the hex nut is aligned with the second mark on the body hex fitting. Operate all machine functions and inspect the hose, fittings and related components to confirm there are no leaks. GTH-844 Part No. 1272854...

  • Page 29: Repair Procedures

     Be sure that all necessary tools and parts are available and ready for use.  Use only Genie approved replacement parts.  Read each procedure completely and adhere to the instructions. Attempting shortcuts may produce hazardous conditions.
  • Page 30 Indicates that a specific result is expected after performing a series of steps. Indicates that an incorrect result has occurred after performing a series of steps. GTH-844 Part No. 1272854...

  • Page 31: Boom Components

    The boom proximity switch is a component of the drive circuit and the chassis sway circuit. Both the drive and the chassis sway functions are disabled when the boom is raised to 60° or higher. 1 boom angle proximity switch (located on engine side) Part No. 1272854 GTH-844...

  • Page 32: How To Adjust The Boom Angle Proximity Switch

    Result: The light of the proximity switch assembly is not illuminated. The proximity switch is properly calibrated. Result: The light of the proximity switch assembly is illuminated. The proximity switch is not calibrated correctly. Repeat this procedure beginning with step 4. GTH-844 Part No. 1272854...

  • Page 33: How To Remove The Lifting Fork Frame

    1. from the machine. Note: When installing the new chain, the chain tensioner should be mounted in the two most rearward holes. 1 retract chain anchor Part No. 1272854 GTH-844...

  • Page 34: April

    12 Working at the fork end of the boom, use the tape to carefully pull the chain through the boom just until the end of the chain is accessible. Remove the tape from the chain. GTH-844 Part No. 1272854...

  • Page 35: How To Replace The Extension Chains

    14 Remove the rope from the end of the old chain and securely attach the rope to the new chain. 1 extension chains 2 single-chain tensioner 3 boom tube number 1 4 boom tube number 2 5 boom tube number 3 Part No. 1272854 GTH-844...

  • Page 36: How To Remove The Boom

    Do not apply any lifting pressure. are out of adjustment. Do not Use a soft metal drift to remove the fork level return the machine to use until cylinder pivot pin. the chains have been correctly adjusted. GTH-844 Part No. 1272854...
  • Page 37 13 Using the overhead crane, raise the boom to a horizontal position. Crushing hazard. The lift cylinder will fall if not properly supported when the boom is raised. 14 Remove the fasteners securing the boom pivot pin to the chassis. Part No. 1272854 GTH-844...

  • Page 38: How To Disassemble The Boom

    14 Remove the hose keepers from the hose roller machine. assembly. Repeat this procedure beginning with step Note: The hose keepers ensure that the hoses do 3 for the other lift cylinder. not jump off the hose rollers. GTH-844 Part No. 1272854...
  • Page 39 2. Remove the chain roller from the boom. Note: During removal, the overhead crane strap will need to be adjusted for proper balancing. Part No. 1272854 GTH-844...

  • Page 40: Boom Lift Cylinder

    Attach a lifting strap from an overhead crane to the rod end of the lift cylinder. Support the cylinder. Do not apply any lifting pressure. Remove the fasteners securing the lift cylinder barrel-end pivot pin to the chassis. GTH-844 Part No. 1272854...

  • Page 41: Boom Extension Cylinder

    Support the extension cylinder with a suitable lifting device and remove from the boom assembly. Note: During removal, the overhead crane strap will need to be adjusted for proper balancing. Part No. 1272854 GTH-844...

  • Page 42: Hydraulic Hoses

    Use a soft metal drift to remove the pivot pin. place. Remove the cylinder from the machine. Crushing hazard. The cylinder could fall if not properly supported when the pivot pin is removed from the machine. GTH-844 Part No. 1272854...

  • Page 43: How To Replace The Fork Level Cylinder And/Or Auxiliary Hoses

    Working near the center of the boom assembly, tag, disconnect and plug the hydraulic hoses from the hydraulic hard lines under boom tube number number 1. Cap the hard lines. Part No. 1272854 GTH-844...
  • Page 44 5. 18 Remove the lifting strap from the fork frame. 19 Install hose sheave covers removed in step 9. 20 Install the covers onto both ends of the boom. Install and securely tighten the retaining fasteners. GTH-844 Part No. 1272854...

  • Page 45: Operator's Compartment

    Do not allow oil to For further information or assistance, consult the squirt or spray. Genie Product Support. Bodily injury hazard. This Tag, disconnect and plug the hydraulic hose at procedure requires specific repair port SULS of the primary function manifold.
  • Page 46 16 Working inside the chassis, tag and disconnect Bolt torque specification the wire harnesses at the connectors next to the operator's compartment. Operator's cab mounting bolts 750 ft-lbs 1017 Nm GTH-844 Part No. 1272854...

  • Page 47: Machine Controls

    11 Support and secure the steer orbitral to the dash frame. 12 Remove the fasteners securing the steer column and steer orbitral to the dash frame. 13 Lower the steer orbitral and remove the steer column from the machine. Part No. 1272854 GTH-844...

  • Page 48: How To Remove The Steer Orbitral

    Cap the fitting. Slowly move the steer orbitral away from the Remove the fasteners securing the joystick to dash frame while feeding all loose hoses the mount panel. Remove the joystick. through the opening of the chassis. GTH-844 Part No. 1272854...

  • Page 49: How To Remove The Joystick - Models With Dual Joysticks

    Remove the fasteners securing the joystick to the mount panel. Remove the joystick. Part No. 1272854 GTH-844...

  • Page 50: How To Remove The Gauge Cluster Assembly

    Carefully separate the lever from the column. Grasp the edge of the dash cluster and pull the cluster through the opening in the dashboard. Tag and disconnect the wire harness from the dash cluster. Remove the dash cluster from the machine. GTH-844 Part No. 1272854...

  • Page 51: Fuel And Hydraulic Tanks

    Open the access door to the engine. Disconnect the battery from the machine. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Part No. 1272854 GTH-844...
  • Page 52 15 Remove the fasteners securing the tank assembly to the chassis. Remove the tank from the machine. Crushing hazard. The tank assembly could become unbalanced and fall if not properly supported when removed from the machine. GTH-844 Part No. 1272854...

  • Page 53: Engines

    Repair procedures and additional engine information is available in the Perkins 1100 Perkins 854 Operation Manual Operation and Maintenance Manual and the Genie part number 218711 Perkins 1104 Service Manual and the Perkins 1100 Perkins 854 Assembly Manual Troubleshooting Manual.

  • Page 54: Engine Fault Codes

    ECM memory. At Dana VDT12000 Service Manual the same time, a colored warning lamp is Genie part number 218706 illuminated and the fault code is shown on the engine diagnostic display, is located on the dashboard in the operator's compartment.

  • Page 55: Transmission

    Section Specifications, Hydraulic Specifications. 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. Part No. 1272854 GTH-844...

  • Page 56: How To Remove The Function Pump

    Do not lower the open end of the case drain hose to below the fluid level of the hydraulic tank until the hose is plugged. GTH-844 Part No. 1272854...

  • Page 57: How To Install The Function

    10 Start the engine and inspect for leaks. 11 Turn the machine off. 12 Adjust the pump pressure. Refer to Repair Procedures, How to Adjust the Function Pump Standby Pressure and How to Adjust the Function Pump Pressure Pressure Compensator. Part No. 1272854 GTH-844...

  • Page 58: How To Adjust The Function Pump Standby Pressure

    Turn the engine off and remove the pressure adjustment screw. gauge. 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. GTH-844 Part No. 1272854...

  • Page 59: How To Adjust The Function Pump Pressure Compensator

    Turn the engine off and remove the pressure gauge. 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. Part No. 1272854 GTH-844...

  • Page 60: Manifolds

    Boom down circuit 20 ft-lbs / 17.6 Nm Check valve, 5 psi / 0.3 bar Tilt down circuit 20 ft-lbs / 27.1 Nm Check valve, 5 psi / 0.3 bar Tilt up circuit 20 ft-lbs / 27.1 Nm GTH-844 Part No. 1272854...
  • Page 61 April 2017 Service and Repair Manual Manifolds Part No. 1272854 GTH-844...
  • Page 62 Solenoid valve, 2 position 4 way Function select -boom down 19-21 ft-lbs / 25.8-28.6 Nm and fork tilt down Solenoid valve, 2 position 2 way Function select - sway circuit 40 ft-lbs / 54 Nm GTH-844 Part No. 1272854...
  • Page 63 April 2017 Service and Repair Manual Manifolds Part No. 1272854 GTH-844...

  • Page 64: Primary Function Manifold Components - Models With Dual Joysticks

    Solenoid valve, 2 pos, 2 way Function select- sway 20 ft-lbs / 27.1 Nm circuit Flow control valve, 2.0 gpm Fork up/down circuit 20 ft-lbs / 27.1 Nm Directional valve, proportional Sway function select 50 ft-lbs / 68 Nm GTH-844 Part No. 1272854...
  • Page 65 April 2017 Service and Repair Manual Manifolds Part No. 1272854 GTH-844...

  • Page 66: Secondary Function Manifold Components

    Brake warning switch Pressure switch Parking brake switch Solenoid valve, 2 position 3 way Rear lock up select 19-21 ft-lbs / 25.8-28.6 Nm Solenoid valve, 2 position 3 way Differential lock up 19-21 ft-lbs / 25.8-28.6 Nm select GTH-844 Part No. 1272854...
  • Page 67 April 2017 Service and Repair Manual Manifolds Part No. 1272854 GTH-844...

  • Page 68: Auxiliary Manifold (Option) And Brake Manifold Components

    13 ft-lbs / 17.6 Nm Pressure switch, 450 psi / 31 bar Clutch cut-off pressure 11 ft-lbs / 14.9 Nm Pressure switch, 50 psi / 3.4 bar Brake light pressure (option) 11 ft-lbs / 14.9 Nm GTH-844 Part No. 1272854...

  • Page 69: Valve Adjustments - Secondary Function Manifold

    Install a 0 to 3500 psi / 0 to 250 bar pressure gauge into test port 'TS' at the top of the secondary function manifold. Refer to Secondary Function Manifold Components. Part No. 1272854 GTH-844...

  • Page 70: How To Set The Parking Brake System Pressure

    Install a 0 to 1000 psi / 0 to 100 bar pressure gauge into test port 'TPB' at the top of the secondary function manifold, Refer to Secondary Function Manifold Components. GTH-844 Part No. 1272854...

  • Page 71: How To Set The Differential Lock/Joystick System Pressure

    Do not allow oil to squirt or spray. Install a 0 to 1000 psi / 0 to 100 bar pressure gauge into test port 'TJ' at the top of the secondary function manifold, Refer to Secondary Function Manifold Components. Part No. 1272854 GTH-844...

  • Page 72: How To Set The Rear Lock-Up System Pressure

    Install a 0 to 500 psi / 0 to 50 bar pressure gauge into test port 'TR' at the top of the secondary function manifold, Refer to Secondary Function Manifold Components. GTH-844 Part No. 1272854...

  • Page 73: Valve Coils

    Tag and disconnect the wiring from the coil to be tested. Test the coil resistance. Result: The resistance should be within specification, plus or minus 30%. Result: If the resistance is not within specification, plus or minus 30%, replace the coil. Part No. 1272854 GTH-844...
  • Page 74 6. Resistor 10Ω Set a multimeter to read DC current. Genie part number 27287 Note: The multimeter, when set to read DC current, Note: The battery should read 9V DC or more when should be capable of reading up to 800 mA.

  • Page 75: Axle

    Do not allow oil to squirt or spray. Loosen the lug nuts of both wheels on the axle to be removed. Do not remove the lug nuts. Part No. 1272854 GTH-844...

  • Page 76: Fault Codes

    Note: Two persons will be required to safely • Machine parked on a firm, level surface perform some troubleshooting procedures. • Boom in the stowed position • Key switch in the off position with the key removed • Wheels chocked GTH-844 Part No. 1272854...

  • Page 77: Diagnostic Display

    ECM has detected. These fault codes may be recalled by service personnel at a later time even if the condition which caused the engine fault has ceased to exist. Note: Additional hardware will be necessary to access stored codes. Part No. 1272854 GTH-844...

  • Page 78: Deutz Tcd3.6 Engine Fault Codes

    Sensor error charged air pressure; signal range check high Sensor error charged air pressure; signal range check low Charged air cooler temperature; system reaction initiated Sensor error charged air temperature; signal range check high Sensor error charged air temperature; signal range check low GTH-844 Part No. 1272854...
  • Page 79 Sensor error intake air; signal range check high Sensor error intake air sensor; signal range check low Sensor ambient air temperature; plausibility error High Low fuel temperature; shut off threshold exceeded High low fuel temperature; warning threshold exceeded Part No. 1272854 GTH-844...
  • Page 80 Break lever mainswitch and break lever redundancyswitch status not plausible SVS lamp; short circuit to battery SVS lamp; short circuit to ground SVS lamp; open load SVS lamp; powerstage over temperature Access error EEPROM CAN-Bus 0 "BusOff-Status" GTH-844 Part No. 1272854...
  • Page 81 Starter relay; short circuit Starter relay; no load error Starter relay; powerstage over temperature Engine running lamp; short circuit to battery Engine running lamp; short circuit to ground Engine running lamp; open load Engine running lamp; powerstage over temperature Part No. 1272854 GTH-844...
  • Page 82 Sensor error exhaust gas temperature upstream turbine; signal range check low Sensor exhaust gas temperature upstream turbine; plausibility error Exhaust gas temperature upstream turbine; out of range, system reaction initiated Exhaust gas temperature upstream turbine; out of range, system reaction initiated GTH-844 Part No. 1272854...
  • Page 83 Physical range check low for EGR exhaust gas mass flow AGS sensor temperature exhaust gas mass flow; plausibility error Exhaust gas recirculation; AGS sensor has "burn off" not performed Exhaust gas recirculation AGS sensor; plausibility error Part No. 1272854 GTH-844...
  • Page 84 NOx Sensor; CAN DLC error NOx Sensor; CAN Timeout Nox Sensor downstream of SCR Catalysator; plausibility error "stuk in range" 3241 Sensor SCR catalyst upstream temperature too high; plausibility error Sensor SCR catalyst upstream temperature too low; plausibility error GTH-844 Part No. 1272854...
  • Page 85 DPF differential pressure sensor and a further sensor or actuator CRT system defective Maximum stand-still-duration reached; oil exchange required Temperature sensor us. and ds. DOC simultaneously defect 3711 Regeneration temperature (PFltRgn LigtOff) not reached; regeneration aborted 3936 Standstill request ignored too long Part No. 1272854 GTH-844...
  • Page 86 SCR Tank heating valve; short circuit to ground SCR main relay (secondary side): open load SCR-heater relay urea tank powerstage output; over temperature SCR main relay; short circuit SCR Tank heating valve; open load 4374 Pressure stabilisation error dosing valve (SCR) GTH-844 Part No. 1272854...
  • Page 87 Actuator EGR-Valve (2.9; 3.6); Open load on ECU output is detected Actuator error EGR-Valve; signal range check high Actuator position for EGR-Valve (2.9; 3.6) Power stage over temperature due to high current 20521 Actuator error EGR-Valve (2.9;3.6) Signal range check low Part No. 1272854 GTH-844...
  • Page 88 Multiple Stage Switch engine speed control parameter; short circuit to ground 23452 64700 2 Multiple Stage Switch engine torque limitation curve; plausibility error Multiple Stage Switch engine torque limitation curve; short circuit to battery Multiple Stage Switch engine torque limitation curve; short circuit to ground GTH-844 Part No. 1272854...
  • Page 89 Pressure overload of SCR-System Pressure build-up error SCR-System Metering control is not performed in time error Pump pressure SCR metering unit too high Pump pressure SCR metering unit too low 23633 64881 11 Nox conversion rate insufficient Part No. 1272854 GTH-844...
  • Page 90 Urea supply module heater temperature; signal disrupted 23721 64969 2 Urea supply module heater temperature; plausibility error Urea supply module temperature; signal disrupted Urea supply module temperature measurement not available 23722 64970 8 Urea supply module PWM signal; signal disrupted GTH-844 Part No. 1272854...
  • Page 91 23910 65158 0 Air Pump; internal error Air Pump; over current Air pump; CAN communication interrupted no purge function available Air Pump; CAN communication lost Air Pump; internal error Air pump doesn´t achieve air mass flow setpoint Part No. 1272854 GTH-844...
  • Page 92 Physical range check low for HCI dosing valve (DV1) downstream pressure; shut off regeneration Sensor HCI dosing valve (DV1) downstream pressure; plausibility error Sensor error HCI dosing valve (DV1) downstream pressure; signal range check high Sensor error HCI dosing valve (DV1) downstream pressure; signal range check low GTH-844 Part No. 1272854...
  • Page 93 23922 65170 3 Burner shut of valve; short circuit to battery Burner shut of valve; short circuit to ground Burner shut off valve; open load Shut off valve: blocked Over temperature error on burner shut of valve Part No. 1272854 GTH-844...
  • Page 94 Sensorcalibration for NOX Sensor (SCR-system downstream cat; DPF- system downstream cat) 23942 65190 9 Timeout Error (BAM to BAM) for CAN-Receive-Frame AT1OGCVol2 information; factors & Sensorcalibration for NOX Sensor (SCR-system downstream cat; DPF- system downstream cat) GTH-844 Part No. 1272854...
  • Page 95 Urea tank level; derating timer below limit 2 23980 65228 14 Bad quality of reduction agent detected 23981 65229 11 Urea-tank without heating function (heating phase) 23982 65230 0 Powerstage diagnosis disabled; high battery voltage Powerstage diagnosis disabled; low battery voltage Part No. 1272854 GTH-844...
  • Page 96 High side to low side short circuit in the injector 8 (in firing order) Injector 8 (in firing order); interruption of electric connection 24004 65252 12 Too many recognized misfires in cylinder 7 (in firing order) 24005 65253 12 Too many recognized misfires in cylinder 8 (in firing order) GTH-844 Part No. 1272854...
  • Page 97 EGR actuator; status message "EGRCust" is missing 24033 65281 7 EGR actuator; due to overload in Save Mode 24034 65282 3 Disc separator; short circuit to battery Disc separator; short circuit to ground Disc Separator; open load Disc Separator; powerstage over temperature Part No. 1272854 GTH-844...
  • Page 98 SCR or SCR relay for suction line not connected or SCR heater supply module; open load or SCR heater tank; open loac DEF supply module, time for defrosting too long or DEF tank, time for defrosting too long GTH-844 Part No. 1272854...
  • Page 99 NOx sensor upstream SCR-CAT, lambda value above upper physical threshold 24081 NOx sensor upstream SCR-CAT, lambda value below lower physical threshold 24083 NOx sensor downstream SCR-CAT, NOx value below minimum value 24085 NOx sensor upstream SCR-CAT, NOx value below lower physical threshold Part No. 1272854 GTH-844...
  • Page 100 24111 65359 9 Timeout error of CAN-Receive-Frame ComRxETVActr 24112 65360 9 Timeout ComITVActr 24113 65361 9 Timeout error of CAN-Receive-Frame ComRxITVActr 24114 65362 9 Timeout error of CAN-Transmit-Frame A1DOC 24115 65363 9 Timeout error of CAN-Transmit-Frame AT1S GTH-844 Part No. 1272854...
  • Page 101 The standstill-regeneration mode time exceeds the short limit threshold; Vehicle was too long or too often within a short time in standstill mode; Change oil and reset counter 24195 Standstill request due to crystalization ignored too long Part No. 1272854 GTH-844...

  • Page 102: Perkins 1104 Engine Fault Codes

    Cylinder #1 injector short battery positive (+) Cylinder #1 injector not responding Engine coolant temperature short to ground Cylinder #2 injector data incorrect Cylinder #2 injector open circuit Cylinder #2 injector short Cylinder #2 injector not responding GTH-844 Part No. 1272854...
  • Page 103 2882 Mode selector switch: data erratic/intermittent or incorrect 3509 5V DC power supply sensor short to battery positive (+) 5V DC power supply sensor short to ground Perkins 1100 Troubleshooting Manual Genie part number 123583 Part No. 1272854 GTH-844...

  • Page 104: Schematics

     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 equipment are available and ready for use. GTH-844 Part No. 1272854...

  • Page 105: Fuse Panel Layout (To 20629)

    CB1- Telehandler Control System Power CB2- Engine Power / ECM CB3- Glow Plugs CB1 and CB3 on all engines CB2: 30A Deutz T3, T4i and Perkins T3 50A Perkins T4i Fuse Board located in the Cab Part No. 1272854 GTH-844...

  • Page 106: Fuse Panel Layout (From 20630 To 21535)

    Deutz T3 (from SN 21536) Deutz T4F (from SN 21536) CB1 50A-EAT Power CB2 50A- ECM Power CB3 50A-Control System Power CB4 60A-Glow Plugs Fuse Board located in the Cab Circuit Breakers located on the Battery Tray GTH-844 Part No. 1272854...

  • Page 107: Deutz Tcd3.6 T4F Module (From 21536, 16E-10000)

    April 2017 Service and Repair Manual Deutz TCD3.6 T4F Module (from 21536, 16E-10000) Deutz TCD3.6 T4F Engine only Part No. 1272854 GTH-844...

  • Page 108: Electrical Component & Wire Color Abbreviation Legend

    1 Amp - Boom Angle Monitor CR12 Sway Left/Right Enable 5 Amp - HVAC Control Panel CR13 Tilt Up/Down Enable CR14 Boom Angle Monitor CR15 HVAC Blower L CR16 HVAC Blower M CR17 HVAC Blower H GTH-844 Part No. 1272854...
  • Page 109 Road / Work Light Switch Parking Brake Release OFF Brake Pressure Warning Switch Brake Light Power ON Transmission Oil Pressure Switch Hazard Power ON Transmission Oil Temp. Switch Not Used Throttle Pedal Motor Turn Signal Shifter Resistor Part No. 1272854 GTH-844...
  • Page 110 RD/WH Red/White Transmission Forward Orange Transmission Reverse OR/BK Orange/Black YD1A 4Wheel Steer SVD1A OR/RD Orange/Red YD1B Crab Steer SVD1B White Left Stabilizer Down WH/BK White/Black Left Stabilizer Up WH/RD White/Red Right Stabilizer Down Right Stabilizer Up GTH-844 Part No. 1272854...

  • Page 111: Telematics Connector Pin Legend

    April 2017 Service and Repair Manual Telematics Connector Pin Legend Genie installed Telematics connector is wired with an Active High digital input. Circuit Type Circuit Properties Genie Machine Function(s) Telematics Use Case System Power 12 VDC Battery Positive – constant power Supply power to device 5 Amp Max.
  • Page 112 Telematics with Active High input Telematics with Active Low input Wireless Certifications Telematic device(s) should comply with specific wireless carrier certifications where applicable and comply with the following: N. America – PTCRB, FCC/IC Europe – CE, R&TTE GTH-844 Part No. 1272854...

  • Page 113: Electrical Symbol Legend

    Battery separator Gauge sending unit open normally closed Oil temperature switch Coolant temperature Oil pressure switch Control relay contact Diode starting aid, glow normally open switch - normally open normally closed normally open plug or flame ignitor Part No. 1272854 GTH-844...

  • Page 114: Hydraulic Symbols Legend

    (mechanically activated) 3 way shuttle valve valve Solenoid operated Solenoid operated Counterbalance valve with 3 position, 4 way Solenoid valve, 2 position 3 position 4 way directional pressure and pilot ratio proportional directional 2 way valve valve GTH-844 Part No. 1272854...

  • Page 115: Electrical Schematics - Harness Maps

    April 2017 Service and Repair Manual Harness Map - Control System Power Single Joystick (to 15-20661)

  • Page 116: Harness Map - Control System Power Single Joystick (To 15-20661)

    Service and Repair Manual April 2017 Harness Map - Control System Power Single Joystick (to 15-20661) GTH-844 Part No. 1272854...

  • Page 117: Harness Map - Control System Ground Single Joystick (To 15-20661)

    April 2017 Service and Repair Manual Harness Map - Control System Ground Single Joystick (to 15-20661) Part No. 1272854 GTH-844...
  • Page 118 Service and Repair Manual April 2017 Harness Map - Control System Ground Single Joystick (to 15-20661)
  • Page 119 April 2017 Service and Repair Manual Harness Map - Control System Power Single Joystick (from 15-20662 to 21535)

  • Page 120: Harness Map - Control System Power Single Joystick (From 15-20662 To 21535)

    Service and Repair Manual April 2017 Harness Map - Control System Power Single Joystick (from 15-20662 to 21535) GTH-844 Part No. 1272854...

  • Page 121: Harness Map - Control System Ground Single Joystick (From 15-20662 To 21535)

    April 2017 Service and Repair Manual Harness Map - Control System Ground Single Joystick (from 15-20662 to 21535) Part No. 1272854 GTH-844...
  • Page 122 Service and Repair Manual April 2017 Harness Map - Control System Ground Single Joystick (from 15-20662 to 21535)
  • Page 123 April 2017 Service and Repair Manual Harness Map - Control System Power Single Joystick (from 15-21536, 16E-10000)

  • Page 124: Harness Map - Control System Power Single Joystick (From 15-21536, 16E-10000)

    Service and Repair Manual April 2017 Harness Map - Control System Power Single Joystick (from 15-21536, 16E-10000) GTH-844 Part No. 1272854...

  • Page 125: Harness Map - Control System Ground Single Joystick (From 15-21536, 16E-10000)

    April 2017 Service and Repair Manual Harness Map - Control System Ground Single Joystick (from 15-21536, 16E-10000) Part No. 1272854 GTH-844...
  • Page 126 Service and Repair Manual April 2017 Harness Map - Control System Ground Single Joystick (from 15-21536, 16E-10000)
  • Page 127 April 2017 Service and Repair Manual Harness Map - Control System Power Dual Joystick (to 15-20661)

  • Page 128: Harness Map - Control System Power Dual Joystick (To 15-20661)

    Service and Repair Manual April 2017 Harness Map - Control System Power Dual Joystick (to 15-20661) GTH-844 Part No. 1272854...

  • Page 129: Harness Map - Control System Ground Dual Joystick (To 15-20661)

    April 2017 Service and Repair Manual Harness Map - Control System Ground Dual Joystick (to 15-20661) Part No. 1272854 GTH-844...
  • Page 130 Service and Repair Manual April 2017 Harness Map - Control System Ground Dual Joystick (to 15-20661)
  • Page 131 April 2017 Service and Repair Manual Harness Map - Control System Power Dual Joystick (from 15-20662 to 21535)

  • Page 132: Harness Map - Control System Power Dual Joystick (From 15-20662 To 21535)

    Service and Repair Manual April 2017 Harness Map - Control System Power Dual Joystick (from 15-20662 to 21535) GTH-844 Part No. 1272854...

  • Page 133: Harness Map - Control System Ground Dual Joystick (From 15-20662 To 21535)

    April 2017 Service and Repair Manual Harness Map - Control System Ground Dual Joystick (from 15-20662 to 21535) Part No. 1272854 GTH-844...
  • Page 134 Service and Repair Manual April 2017 Harness Map - Control System Ground Dual Joystick (from 15-20662 to 21535)
  • Page 135 April 2017 Service and Repair Manual Harness Map - Control System Power Dual Joystick (from 15-21536, 16E-10000)

  • Page 136: Harness Map - Control System Power Dual Joystick (From 15-21536, 16E-10000)

    Service and Repair Manual April 2017 Harness Map - Control System Power Dual Joystick (from 15-21536, 16E-10000) GTH-844 Part No. 1272854...

  • Page 137: Harness Map - Control System Ground Dual Joystick (From 15-21536, 16E-10000)

    April 2017 Service and Repair Manual Harness Map - Control System Ground Dual Joystick (from 15-21536, 16E-10000) Part No. 1272854 GTH-844...
  • Page 138 Service and Repair Manual April 2017 Harness Map - Control System Ground Dual Joystick (from 15-21536, 16E-10000)
  • Page 139 April 2017 Service and Repair Manual Harness Map - Deutz TCD3.6 T3_T4i Engine Battery Power and Ground...

  • Page 140: Harness Map - Deutz Tcd3.6 T3_T4I Engine Battery Power And Ground

    Service and Repair Manual April 2017 Harness Map - Deutz TCD3.6 T3_T4i Engine Battery Power and Ground GTH-844 Part No. 1272854...

  • Page 141: Harness Map - Deutz Tcd3.6 T4F Engine Battery Power And Ground

    April 2017 Service and Repair Manual Harness Map - Deutz TCD3.6 T4F Engine Battery Power and Ground Part No. 1272854 GTH-844...
  • Page 142 Service and Repair Manual April 2017 Harness Map - Deutz TCD3.6 T4F Engine Battery Power and Ground...
  • Page 143 April 2017 Service and Repair Manual Harness Map - Perkins 1104D Engine Battery Power and Ground...

  • Page 144: Harness Map - Perkins 1104D Engine Battery Power And Ground

    Service and Repair Manual April 2017 Harness Map - Perkins 1104D Engine Battery Power and Ground GTH-844 Part No. 1272854...

  • Page 145: Harness Map - Perkins 854E T4I Engine Battery Power And Ground

    April 2017 Service and Repair Manual Harness Map - Perkins 854E T4i Engine Battery Power and Ground Part No. 1272854 GTH-844...
  • Page 146 Service and Repair Manual April 2017 Harness Map - Perkins 854 T4i Engine Battery Power and Ground...
  • Page 147 April 2017 Service and Repair Manual Harness Map - Perkins 854E T4F Engine Battery Power and Ground...

  • Page 148: Harness Map - Perkins 854E T4I Engine Battery Power And Ground

    Service and Repair Manual April 2017 Harness Map - Perkins 854E T4F Engine Battery Power and Ground GTH-844 Part No. 1272854...

  • Page 149: Harness Map - Options Auxiliary Hydraulics, Beacon And 3Rd Gear Lockout

    April 2017 Service and Repair Manual Harness Map - Options Auxiliary Hydraulics, Beacon and 3rd Gear Lockout Part No. 1272854 GTH-844...
  • Page 150 Service and Repair Manual April 2017 Harness Map - Options Auxiliary Hydraulics, Beacon and 3rd Gear Lockout...
  • Page 151 April 2017 Service and Repair Manual Harness Map - Options Work Lights (to 15-21456)

  • Page 152: Harness Map - Options Work Lights (To 15-21456)

    Service and Repair Manual April 2017 Harness Map - Options Work Lights (to 15-21456) GTH-844 Part No. 1272854...

  • Page 153: Harness Map - Options Work Lights (From 15-21457, 16E-10000)

    April 2017 Service and Repair Manual Harness Map - Options Work Lights (from 15-21457, 16E-10000) Part No. 1272854 GTH-844...
  • Page 154 Service and Repair Manual April 2017 Harness Map - Options Work Lights (from 15-21456, 16E-10000)
  • Page 155 April 2017 Service and Repair Manual Harness Map - Options Road Lights (to 15-21456)

  • Page 156: Harness Map - Options Road Lights (To 15-20456)

    Service and Repair Manual April 2017 Harness Map - Options Road Lights (to 15-21456) GTH-844 Part No. 1272854...

  • Page 157: Harness Map - Options Road Lights (From 15-21457, 16E-10000)

    April 2017 Service and Repair Manual Harness Map - Options Road Lights (from 15-21457, 16E-10000) Part No. 1272854 GTH-844...
  • Page 158 Service and Repair Manual April 2017 Harness Map - Options Road Lights (from 15-21457, 16E-10000)
  • Page 159 April 2017 Service and Repair Manual Harness Map - Options Enclosed Cab with Heater...

  • Page 160: Harness Map - Options Enclosed Cab With Heater

    Service and Repair Manual April 2017 Harness Map - Options Enclosed Cab with Heater GTH-844 Part No. 1272854...

  • Page 161: Harness Map - Options Enclosed Cab With Hvac

    April 2017 Service and Repair Manual Harness Map - Options Enclosed Cab with HVAC Part No. 1272854 GTH-844...
  • Page 162 Service and Repair Manual April 2017 Harness Map - Options Enclosed Cab with HVAC...

  • Page 163: Electrical Schematics

    April 2017 Service and Repair Manual Electrical Schematic - View 1 (to 15-20661)

  • Page 164: Electrical Schematic - View 1 (To 15-20661)

    Service and Repair Manual April 2017 Electrical Schematic - View 1 (to 15-20661) GTH-844 Part No. 1272854...

  • Page 165: Electrical Schematic - View 2 (To 15-20661)

    April 2017 Service and Repair Manual Electrical Schematic - View 2 (to 15-20661) Part No. 1272854 GTH-844...
  • Page 166 Service and Repair Manual April 2017 Electrical Schematic - View 2 (to 15-20661)
  • Page 167 April 2017 Service and Repair Manual Electrical Schematic - View 1 (from 15-20662 to 21456)

  • Page 168: Electrical Schematic - View 1 (From 15-20662 To 21456)

    Service and Repair Manual April 2017 Electrical Schematic - View 1 (from 15-20662 to 21456) GTH-844 Part No. 1272854...

  • Page 169: Electrical Schematic - View 2 (From 15-20662 To 21456)

    April 2017 Service and Repair Manual Electrical Schematic - View 2 (from 15-20662 to 21456) Part No. 1272854 GTH-844...
  • Page 170 Service and Repair Manual April 2017 Electrical Schematic - View 2 (from 15-20662 to 21456)
  • Page 171 April 2017 Service and Repair Manual Electrical Schematic - View 1 (from 15-21457 to 21535)

  • Page 172: Electrical Schematic - View 1 (From 15-21457 To 21535)

    Service and Repair Manual April 2017 Electrical Schematic - View 1 (from 15-21457 to 21535) GTH-844 Part No. 1272854...

  • Page 173: Electrical Schematic - View 2 (From 21457 To 21535)

    April 2017 Service and Repair Manual Electrical Schematic - View 2 (from 15-21457 to 21535) Part No. 1272854 GTH-844...
  • Page 174 Service and Repair Manual April 2017 Electrical Schematic - View 2 (from 15-21457 to 21535)
  • Page 175 April 2017 Service and Repair Manual Electrical Schematic - View 1 (from 15-21536, 16E-10000)

  • Page 176: Electrical Schematic - View 1 (From 15-21536, 16E-10000)

    Service and Repair Manual April 2017 Electrical Schematic - View 1 (from 15-21536, 16E-10000) GTH-844 Part No. 1272854...

  • Page 177: Electrical Schematic - View 2 (From 21536, 16E-10000)

    April 2017 Service and Repair Manual Electrical Schematic - View 2 (from 15-21536, 16E-10000) Part No. 1272854 GTH-844...
  • Page 178 Service and Repair Manual April 2017 Electrical Schematic - View 2 (from 15-21536, 16E-10000)

  • Page 179: Hydraulic Schematics

    April 2017 Service and Repair Manual Hydraulic Schematic - Single Joystick (to 19528)

  • Page 180: Hydraulic Schematic - Single Joystick (To 19528)

    Service and Repair Manual April 2017 Hydraulic Schematic - Single Joystick (to 19528) GTH-844 Part No. 1272854...

  • Page 181: Hydraulic Schematic - Single Joystick (From 19529, 16E-10000)

    April 2017 Service and Repair Manual Hydraulic Schematic - Single Joystick (from 19529, 16E-10000) Part No. 1272854 GTH-844...
  • Page 182 Service and Repair Manual April 2017 Hydraulic Schematic - Single Joystick (from 19529, 16E-10000)
  • Page 183 April 2017 Service and Repair Manual Hydraulic Schematic - Dual Joystick (to 19528)

  • Page 184: Hydraulic Schematic - Dual Joystick (To 19528)

    Service and Repair Manual April 2017 Hydraulic Schematic - Dual Joystick (to 19528) GTH-844 Part No. 1272854...

  • Page 185: Hydraulic Schematic - Dual Joystick (From 19529, 16E-10000)

    April 2017 Service and Repair Manual Hydraulic Schematic - Dual Joystick (from 19529, 16E-10000) Part No. 1272854 GTH-844...
  • Page 186 Service and Repair Manual April 2017 Hydraulic Schematic - Single Joystick (from 19529, 16E-10000) GTH-844 Part No. 1272854 Ser vic e and R epair M anual April 2017...
  • Page 187 California Proposition 65 WARNING Operating, servicing and maintaining this equipment, passenger vehicle or off-highway motor vehicle can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm.

This manual is also suitable for:

Gth-636

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