This Manual Includes: Repair Procedures Fault Codes Electrical and Hydraulic Schematics

Service and Repair Manual
Serial Number Range
GTH™-636 from GTH06E-11750

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. 1287209GT

Rev A
April 2018
Service and Repair Manual April 2018
Introduction
Intr oducti on Intr oducti on
Important Technical Publications

Read, understand and obey the safety rules and Genie has endeavored to deliver the highest
operating instructions in the appropriate Operator's degree of accuracy possible. However, continuous
Manual on your machine before attempting any improvement of our products is a Genie policy.
procedure. Therefore, product specifications are subject to
change without notice.
This manual provides troubleshooting and repair
procedures for qualified service professionals. Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
Basic mechanical, hydraulic and electrical skills are communications will be carefully considered for
required to perform most procedures. However, future printings of this and all other manuals.
several procedures require specialized skills, tools,
lifting equipment and a suitable workshop. In these Find a Manual for this Model
instances, we strongly recommend that
maintenance and repair be performed at an Go to http://www.genielift.com
authorized Genie dealer service center.
Use the links to locate Service Manuals,
Maintenance Manuals, Service and Repair
Compliance Manuals, Parts Manuals and Operator's Manuals.
Machine Design Life

Unrestricted with proper operation, inspection and
scheduled maintenance.
Copyright © 2016 by Terex Corporation

1287209GT Rev A, April 2018
Second 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.
ii GTH-636 Part No. 1287209GT

April 2018 Service and Repair Manual
Introduction
Revision History
Revision Date Section Procedure / Page / Description
A 4/2018 Initial Release
Reference Examples:
Section – Repair Procedure, 4-2 Electronic Version
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. 1287209GT GTH-636 iii

Introduction
Serial Number Legend

To August 31, 2016
1 Model 1 Serial label (located inside riser, cab side)

2 Model year 2 Serial number (stamped on chassis)
3 Facility code 3 Serial label (inside fork frame)
4 Sequence number
From September 1, 2016
1 Model 1 Serial label (located inside riser, cab side)

2 Facility code 2 Serial number (stamped on chassis)
3 Sequence number 3 Serial label (located inside fork frame)
iv GTH-636 Part No. 1287209GT

Safety Rules
Section 1 Safety R ules
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.
Part No. 1287209GT GTH-636 v

Safety Rules
Personal Safety Workplace Safety

Any person working on or around a machine must Any person working on or around a machine must
be aware of all known safety hazards. Personal be aware of all known safety hazards. Personal
safety and the continued safe operation of the safety and the continued safe operation of the
machine should be your top priority. machine should be your top priority.
Read each procedure thoroughly. This Be sure to keep sparks, flames and
manual and the decals on the machine, lighted tobacco away from flammable and
use signal words to identify the following: combustible materials like battery gases
and engine fuels. Always have an
Safety alert symbol—used to alert approved fire extinguisher within easy
personnel to potential personal reach.
injury hazards. Obey all safety
messages that follow this symbol Be sure that all tools and working areas
to avoid possible injury or death. are properly maintained and ready for
use. Keep work surfaces clean and free of
Indicates a imminently hazardous debris that could get into machine
situation which, if not avoided, will components and cause damage.
result in death or serious injury.
Be sure any forklift, overhead crane or
Indicates a potentially hazardous other lifting or supporting device is fully
situation which, if not avoided, capable of supporting and stabilizing the
could result in death or serious weight to be lifted. Use only chains or
injury. straps that are in good condition and of
ample capacity.
Indicates a potentially hazardous
situation which, if not avoided, Be sure that fasteners intended for one
may cause minor or moderate time use (i.e., cotter pins and self-locking
injury. nuts) are not reused. These components
may fail if they are used a second time.
situation which, if not avoided, Be sure to properly dispose of old oil or
may result in property damage. other fluids. Use an approved container.
Please be environmentally safe.
Be sure to wear protective eye wear and
other protective clothing if the situation 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.
vi GTH-636 Part No. 1287209GT

April 2018
Table of Contents
Introduction Introduction........................................................................................................... ii
Important Information ............................................................................................. ii
Find a Manual for this Model .................................................................................. ii
Serial Number Legend .......................................................................................... iv
Section 1 Safety Rules .......................................................................................................... v

General Safety Rules ............................................................................................. v
Section 2 Specifications ....................................................................................................... 1

Machine Specifications ........................................................................................... 1
Performance Specifications .................................................................................... 1
Hydraulic Oil Specifications .................................................................................... 2
Hydraulic Component Specifications...................................................................... 5
Manifold Component Specifications ....................................................................... 5
Air Conditioner Refrigerant Specifications ............................................................. 5
Deutz TD 2.9 Engine Specifications ....................................................................... 6
Dana VDT12000 Transmission Specifications ....................................................... 7
Dana 212 Drive Axle .............................................................................................. 7
Hydraulic Hose and Fitting Torque Specifications ................................................. 8
Torque Procedure .................................................................................................. 9
Section 3 Repair Procedures ............................................................................................. 11

Introduction ........................................................................................................... 11
Boom Components ............................................................................................ 13

1-1 Boom .............................................................................................................. 13
How to Replace the Boom Wear Pads ........................................................... 13
How to Use the Quick Attachment .................................................................. 13
How to Replace the Retraction Chain ............................................................. 14
How to Replace the Extension Chains ............................................................ 16
How to Remove the Boom .............................................................................. 18
How to Disassemble the Boom ....................................................................... 20
Part No. 1287209GT GTH-636 vii

April 2018
Table of Contents
1-2 Boom Lift Cylinder ..........................................................................................21

1-3 Boom Extension Cylinder ...............................................................................22
1-4 Fork Level Cylinder ........................................................................................23
1-5 Hydraulic Hoses .............................................................................................24
How to Adjust the Fork Level Cylinder and/or Auxiliary Hose .........................24
How to Replace the Fork Level Cylinder and/or Auxiliary Hoses....................25
Operator's Compartment ...................................................................................27

2-1 Operator's Compartment ................................................................................27
2-2 Machine Controls ...........................................................................................28
How to Remove the Steering Column .............................................................28
How to Remove the Steering Wheel ...............................................................29
How to Remove the Steer Orbitral ..................................................................29
How to Remove the Joystick - Models with Electronic Joystick ......................30
How to Remove the Brake Pedal Assembly ...................................................30
How to Remove the Gauge Cluster Assembly ................................................31
Fuel and Hydraulic Tanks ..................................................................................32

3-1 Fuel and Hydraulic Tanks...............................................................................32
Engines ................................................................................................................34
4-1 Engines...........................................................................................................34
4-2 Engine Fault Codes ........................................................................................34
Transmission ......................................................................................................35
5-1 Transmission ..................................................................................................35
Hydraulic Pump ..................................................................................................36

6-1 Hydraulic Pump ..............................................................................................36
How to Test the Function Pump ......................................................................36
How to Remove the Function Pump ...............................................................37
How to Install the Function ..............................................................................38
How to Prime the Function Pump ...................................................................38
How to Adjust the Function Pump Standby Pressure .....................................39
How to Adjust the Function Pump Pressure Compensator .............................40
viii GTH-636 Part No. 1287209GT

April 2018
Table of Contents
Manifolds ............................................................................................................. 41
7-1 PVG Manifold Components - Electronic Joystick........................................... 41
7-2 Secondary Function Manifold Components ................................................... 42
7-3 Brake Manifold Components .......................................................................... 45
7-4 Valve Adjustments - Secondary Function Manifold ....................................... 46
How to Set the Parking Brake System Pressure ............................................ 46
How to Set the Differential Lock System Pressure ......................................... 47
7-5 Valve Coils ..................................................................................................... 48
Axle ...................................................................................................................... 50
8-1 Axles ............................................................................................................... 50
Section 4 Fault Codes ......................................................................................................... 51

Introduction ........................................................................................................... 51
Diagnostic Display ............................................................................................. 52

Diagnostic Display ................................................................................................ 52
Deutz TD 2.9 L4 Engine Fault Codes ................................................................ 53
Section 5 Schematics.......................................................................................................... 67
Introduction ........................................................................................................... 67
Fuse Panel Layout ............................................................................................... 68
Electrical Component & Wire Color Abbreviation Legend ................................... 69
Telematics Connector Pin Legend ....................................................................... 72
Electrical Symbol Legend ..................................................................................... 74
Hydraulic Symbols Legend ................................................................................... 75
Harness Map Legend ........................................................................................... 76
Part No. 1287209GT GTH-636 ix

April 2018
Table of Contents
Electrical Schematics - Harness Maps .............................................................77

Harness Map - Control System Power Electronic Joystick ..................................78
Harness Map - Deutz TD2.9 Engine Battery Power and Ground .........................80
Harness Map - Options Auxiliary Hydraulics, Beacon and 3rd Gear Lockout ......81
Harness Map - Options Work Lights ....................................................................84
Harness Map - Options Road Lights ....................................................................85
Harness Map - Options Enclosed Cab with Heater ..............................................88
Harness Map - Options Enclosed Cab with HVAC...............................................89
Electrical Schematics .........................................................................................91

Electrical Schematic - View 1 ...............................................................................92
Electrical Schematic - View 2 ...............................................................................93
Electrical Schematic - Deutz T4F Eng Harness ...................................................96
Hydraulic Schematic .............................................................................................97
Hydraulic Schematics ........................................................................................99
x GTH-636 Part No. 1287209GT

Specifications
Section 2 Specific ati ons
Machine Specifications Performance Specifications

Tires and wheels Drive speed, maximum
Tire size 13.00 x 28 Deutz TD2.9 Engines 18 mph
Tire ply rating 12 29.0 km/h
Draw bar pull 15,100 lbs
Weight, rough terrain tire 335 lbs
(air filled) 151.9 kg 6849 kg
Weight, rough terrain tire 780 +50/-20 lbs Lift capacity, maximum 6000 lbs
(foam filled) 353 +23/-9 kg 2722 kg
Tire pressure 58 psi Boom function speeds, maximum

(models with air-filled tires) 4.3 bar Boom up 10 to 12 seconds
Lug nut torque 465 ft-lbs Boom down 8 to 10 seconds
630 Nm
Boom extend 11 to 13 seconds
Lug Pattern 8 x 10.826
Boom retract 9 to 11 seconds
Wheel diameter 28 in
71.12 cm Fork rotate 3 to 6 seconds
Wheel width 10 in Fork tilt up 6 to 8 seconds

25.4 cm Fork tilt down 5 to 7 seconds
Fluid capacities
Fuel tank 27 gallons

102.2 liters
Hydraulic tank 19 gallons
71.9 liters
Hydraulic system 31.5 gallons
(including tank) 119.2 liters
Part No. 1287209GT GTH-636 1

Specifications
Hydraulic Oil Specifications Do not top off with incompatible

hydraulic fluids. Hydraulic fluids
Hydraulic Fluid Specifications may be incompatible due to the
Genie specifications require hydraulic oils which are differences in base additive
designed to give maximum protection to hydraulic chemistry. When incompatible
systems, have the ability to perform over a wide fluids are mixed, insoluble
temperature range, and the viscosity index should materials may form and deposit
exceed 140. They should provide excellent antiwear, in the hydraulic system,
oxidation prevention, corrosion inhibition, seal plugging hydraulic lines, filters,
conditioning, and foam and aeration suppression control valves and may result in
properties.
component damage.
Cleanliness level, ISO 15/13
minimum Note: Do not operate the machine when the
Water content, 250 ppm ambient air temperature is consistently above
maximum 120°F / 49°C.
Recommended Hydraulic Fluid
Hydraulic oil type Chevron Rando HD Premium Hydraulic Fluid Temperature
Viscosity grade 32 Range
Viscosity index 200
Optional Hydraulic Fluids
Mineral based Shell Tellus S2 V 32
Shell Tellus S2 V 46
Shell Tellus S4 VX 32 Shell
Shell Donax TG (Dexron III)
Chevron 5606A
Biodegradable Petro Canada Environ MV 46
Fire resistant UCON Hydrolube HP-5046
Note: Genie specifications require additional
equipment and special installation instructions for Ambient air temperature
the approved optional fluids. Consult Genie
Product Support before use. 1 Chevron hydraulic oil 5606A
2 Petro-Canada Environ MV 46
Optional fluids may not have 3 UCON Hydrolube HP-5046D
the same hydraulic lifespan and 4 Chevron Rando HD premium oil MV
may result in component
damage.
Note: Extended machine operation can cause the

hydraulic fluid temperature to increase beyond it's
maximum allowable range. If the hydraulic fluid
temperature consistently exceeds 200°F / 90°C an
optional oil cooler may be required.
2 GTH-636 Part No. 1287209GT

Specifications
Chevron Rando HD Premium Oil Chevron 5606A Hydraulic Oil

MV Fluid Properties Fluid Properties
ISO Grade 32 ISO Grade 15
Viscosity index 200 Viscosity index 300
Kinematic Viscosity Kinematic Viscosity
cSt @ 200°F / 100°C 7.5 cSt @ 200°F / 100°C 5.5
cSt @ 104°F / 40°C 33.5 cSt @ 104°F / 40°C 15.0
cSt @ -40°F / -40°C 510
Brookfield Viscosity
cP @ -4°F / -20°C 1040 Flash point 180°F / 82°C
cP @ -22°F / -30°C 3310
Pour point -81°F / -63°C
Flash point 375°F / 190°C
Maximum continuous operating 124°F / 51°C
Pour point -58°F / -50°C temperature
Maximum continuous operating 171°F / 77°C Note: Use of Chevron 5606A hydraulic fluid, or
temperature equivalent, is required when ambient temperatures
Note: A hydraulic oil heating system is are consistently below 0°F / -17°C unless an oil
recommended when the ambient temperature is heating system is used.
consistently below 0°F / -18°C.
Continued use of Chevron
Note: Do not operate the machine when the 5606A hydraulic fluid, or
ambient temperature is below -20°F / -29°C with equivalent, when ambient
Rando HD Premium MV. temperatures are consistently
above 32°F / 0°C may result in
component damage
Part No. 1287209GT GTH-636 3

Specifications
Petro-Canada Environ MV 46
Fluid Properties UCON Hydrolube HP-5046 Fluid
ISO Grade 46 Properties
Viscosity index 154 ISO Grade 46
Kinematic Viscosity Viscosity index 192
cSt @ 200°F / 100°C 8.0
Kinematic Viscosity
cSt @ 104°F / 40°C 44.4
cSt @ 149°F / 65°C 22
Flash point 482°F / 250°C cSt @ 104°F / 40°C 46
Pour point -49°F / -45°C cSt @ 0°F / -18°C 1300
Maximum continuous operating 180°F / 82°C Flash point None

temperature Pour point -81°F / -63°C
temperature
Shell Tellus S4 VX Fluid
Properties
ISO Grade 32
Viscosity index 300
Kinematic Viscosity
cSt @ 200°F / 100°C 9
cSt @ 104°F / 40°C 33.8
Brookfield Viscosity
cSt @ -4°F / -20°C 481
cSt @ -13°F / -25°C 702.4
cSt @ -40°F / -40°C 2624
Flash point >100
Pour point -76°F / -60°C
temperature
4 GTH-636 Part No. 1287209GT

Specifications
Hydraulic Component Manifold Component

Specifications Specifications
Function pump Plug torque
Type: variable displacement piston pump SAE No. 2 50 in-lbs / 6 Nm
Displacement 2.3 cu in SAE No. 4 13 ft-lbs / 18 Nm
0 to 38 cc
SAE No. 5 15 ft lbs / 20 Nm
Flow rate @ 2600 rpm 26 gpm
SAE No. 6 18 ft-lbs / 24 Nm
99 L/min
SAE No. 8 50 ft-lbs / 68 Nm
Pump pressure, maximum 3190 psi
220 bar SAE No. 10 55 ft-lbs / 75 Nm
Pressure compensator 3190 psi SAE No. 12 75 ft-lbs / 102 Nm
220 bar
Air Conditioner Refrigerant
Standby pressure 650 psi
44.8 bar Specifications
Primary Function Manifold System Full Charge
System relief valve pressure, maximum 3200 psi R134a
(measured at test port TP) 221 bar
Fork tilt relief valve pressure, maximum 3500 psi
241 bar
Flow regulator, Sway circuit 2 gpm
7.5 L/min
Secondary Function Manifold
Steer relief valve pressure, maximum 2650 psi
(measured at test port TS) 182.7 bar
Parking brake relief valve pressure, 350 psi
maximum 24.1 bar
(measured at test port TPB)
Joystick relief valve pressure, maximum 400 psi
(measured at test port TJ) 27.5 bar
Part No. 1287209GT GTH-636 5

Specifications
Deutz TD 2.9 L4 Engine Oil temperature switch

Installation torque 8 - 18 ft-lbs
Displacement 177 cu. in 11 - 24 Nm
2.9 liters
Temperature switch point 275°F
Number of cylinders 4 135°C
Bore and Stroke 3.6 x 4.3 inches Oil Pressure switch
92 x 110 mm
Installation torque 8 - 18 ft-lbs
Horsepower net intermittent @ 74.2 hp 11 - 24 Nm
2600 rpm 55 kW
Pressure switch point 20 psi
Firing order 1-3-4-2 1.4 bar
Standby idle 1000 rpm Fuel injection system Bosch
Low idle 950 rpm Injection pump pressure, maximum 23200 psi
High idle 2600 rpm 1600 bar
Compression ratio 17.4:1 Injector opening pressure 3046 psi

210 bar
Compression pressure pressure (psi or bar) of the
Fuel requirement
lowest cylinder must be at least 75% of the highest
cylinder For fuel requirements, refer to the engine Operator
Manual for your engine.
Governor electronic
Starter motor
Lubrication system
Current draw, normal load 400A
Oil pressure, hot (@ 2000 rpm) 40 to 60 psi
2.8 to 4.1 bar Battery – Engine starting and control system
Oil capacity (including filter) 9.4 quarts Type 12V DC
8.9 liters Quantity 1
Oil viscosity requirements Battery capacity, maximum 1000A
-22°F to 86°F / -30°C to 30°C 5W-30 Reserve capacity @ 25A rate 200 Minutes
(synthetic)
Alternator output 95A @ 12V DC
-4°F to 104°F / -20°C to 40°C 10W-40
Fan belt deflection 3/8 to 1/2 inch
Above 5°F / -15°C 15W-40 9 to 12 mm
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.
6 GTH-636 Part No. 1287209GT

Specifications
Dana VDT12000 Transmission Dana 212 Drive Axle

Specifications Specifications
Transmission Type 3 speed powershift converter Steering Integrated steer cylinder
Speeds, Forward 3 Joints Heavy duty double U-joints
Speeds, Reverse 3 Steering angle, maximum 45°
Torque Converter Front Axle Lubrication
Maximum input 3100 rpm Front differential 7.4 quarts
7 liters
Size 12 inches
Lubrication Axle planetary end (each) 0.8 quarts
0.8 liters
Oil capacity, transmission 14.3 quarts
Rear Axle Lubrication
13.5 liters
Oil capacity, drop box 1.1 quart Rear differential 8.0 quarts
7.6 liters
1 liter
Oil viscosity requirements Axle planetary end (each) 0.8 quarts
0.8 liters
Units ship with Chevron Ursa Hydraulic 10W.
Oil viscosity requirements
Extreme operating temperatures may require the
use of alternative transmission oils. For oil Differential Chevron Supreme 85W90 (API GL5)
requirements, refer to the Dana VDT12000 Service
Planetary Chevron Supreme 85W90 (API GL5)
Manual. ends
Dana VDT12000 Service Manual
For additional axle information, refer to the
Genie part number 218706 Dana 212 Axle Service Manual.
Dana 212 Axle Service Manual
Genie part number 1259569
Part No. 1287209GT GTH-636 7

Specifications
Hydraulic Hose and Fitting

Torque Specifications SAE O-ring Boss Port
Your machine is equipped with Parker Seal-Lok™ (tube fitting - installed into Aluminum)
(all types)
ORFS or 37° JIC fittings and hose ends. Genie
specifications require that fittings and hose ends be SAE Dash Size Torque
torqued to specification when they are removed -4 14 ft-lbs / 19 Nm
and installed or when new hoses or fittings are -6 23 ft-lbs / 31.2 Nm
installed.
-8 36 ft-lbs / 54.2 Nm
-10 62 ft-lbs / 84 Nm
Seal-Lok™ Fittings -12 84 ft-lbs / 114 Nm
(hose end - ORFS)
-16 125 ft-lbs / 169.5 Nm
SAE Dash Size Torque
-20 151 ft-lbs / 204.7 Nm
-4 10 ft-lbs / 13.6 Nm
-24 184 ft-lbs / 249.5 Nm
-6 30 ft-lbs / 40.7 Nm
-8 40 ft-lbs / 54.2 Nm
-10 60 ft-lbs / 81.3 Nm
-12 85 ft-lbs / 115 Nm
-16 110 ft-lbs / 150 Nm
-20 140 ft-lbs / 190 Nm
-24 180 ft-lbs / 245 Nm
Adjustable Fitting Non-adjustable fitting
1 jam nut
JIC 37° Fittings
(swivel nut or hose connection)
SAE Dash Size Thread Size Flats
SAE O-ring Boss Port
-4 7/16-20 2
(tube fitting - installed into Steel)
-6 9/16-18 1¼
SAE Dash Size Torque
-8 3/4-16 1
-4 ORFS / 37° (Adj) 15 ft-lbs / 20.3 Nm
-10 7/8-14 1 ORFS (Non-adj) 26 ft-lbs / 35.3 Nm
-12 1 1/16-12 1 37° (Non-adj) 22 ft-lbs / 30 Nm
-16 1 5/16-12 1 -5 ORFS (Adj / Non adj) 32 ft lbs / 43.4 Nm
-20 1 5/8-12 1 -6 ORFS (Adj / Non-adj) 35 ft-lbs / 47.5 Nm

37° (Adj / Non-adj) 29 ft-lbs / 39.3 Nm
-24 1 7/8-12 1
-8 ORFS (Adj / Non-adj) 60 ft-lbs / 81.3 Nm
-10 ORFS (Adj / Non-adj) 100 ft-lbs / 135.6 Nm
-12 (All types) 135 ft-lbs / 183 Nm
-16 (All types) 200 ft-lbs / 271.2 Nm
-20 (All types) 250 ft-lbs / 339 Nm
-24 (All types) 305 ft-lbs / 413.5 Nm
8 GTH-636 Part No. 1287209GT

Specifications
Torque Procedure
JIC 37° fittings
Seal-Lok™ fittings 1 Align the tube flare (hex nut) against the nose
of the fitting body (body hex fitting) and tighten
1 Replace the O-ring. The O-ring must be
the hex nut to the body hex fitting to hand tight,
replaced anytime the seal has been broken.
approximately 30 in-lbs / 3.4 Nm.
The O-ring cannot be re-used if the fitting or
hose end has been tightened beyond finger 2 Using a permanent ink marker, make a
tight. reference mark on one the flats of the hex nut
Note: The O-ring in Parker Seal Lok™ fittings and and continue the mark onto the body of the
hose end are custom-size O-rings. They are not hex fitting. Refer to Illustration 1.
standard size O-rings. They are available in the
O-ring field service kit (Genie part number 49612).
2 Lubricate the O-ring before installation.

3 Be sure the O-ring face seal is seated and
retained properly.
4 Position the tube and nut squarely on the face
seal end of the fitting, and tighten the nut
finger tight.
Illustration 1
5 Tighten the nut or fitting to the appropriate
torque. Refer to the appropriate torque chart in 1 hex nut
this section. 2 reference mark
3 body hex fitting
6 Operate all machine functions and inspect the
hose, fittings and related components to
confirm there are no leaks.
Part No. 1287209GT GTH-636 9

Specifications
3 Working clockwise on the body hex fitting,

make a second mark with a permanent ink
marker to indicate the proper tightening
position. Refer to Illustration 2.
Note: Use the JIC 37° Fitting table in this section to
determine the correct number of flats, for the
proper tightening position.
Note: The marks indicate the correct tightening
positions have been determined. Use the second
mark on the body hex fitting to properly tighten the
joint after it has been loosened.
Illustration 2
1 body hex fitting
2 reference mark
3 second mark
4 Tighten the hex nut until the mark on the hex

nut is aligned with the second mark on the
body hex fitting.
5 Operate all machine functions and inspect the
hose, fittings and related components to
confirm there are no leaks.
10 GTH-636 Part No. 1287209GT

Repair Procedures
Machine Configuration:
Section 3 Repair Pr oc edures
 Unless otherwise specified, perform each

repair procedure with the machine in the
following configuration:
• Machine parked on a firm, level surface
• Boom in the stowed position
Observe and Obey:
• Key switch in the off position with the key
 Repair procedures shall be completed by a removed
person trained and qualified on the repair of
this machine. • Wheels chocked
 Immediately tag and remove from service a

damaged or malfunctioning machine.
 Repair any machine damage or malfunction
before operating the machine.
Before Repairs Start:

 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 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.
Part No. 1287209GT GTH-636 11

Repair Procedures
About This Section

Most of the procedures in this section should only
be performed by trained service professional in a
suitably equipped workshop. Select the appropriate
repair procedure after troubleshooting the problem.
Perform disassembly procedures to the point
where repairs can be completed. Then to
re-assemble, perform the disassembly steps in
reverse order.
Symbols Legend
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 a imminently hazardous

situation which, if not avoided, will
result in death or serious injury.

situation which, if not avoided,
could result in death or serious
injury.

may cause minor or moderate
injury.

may result in property damage.
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.
12 GTH-636 Part No. 1287209GT

Boom Components
How to Use the Quick Attachment

How to Us e the Quic k Attac hment
1-1
Boom 1 Remove the quick attach lock pin. Tilt the forks
forward to pivot the quick attach connector
How to Replace the Boom Wear
How to R eplac e the Boom W ear Pads
back.
Pads
1 Lower wear pads: Using a lifting strap from
an overhead crane or a fork lift of sufficient
capacity, lift the boom tube just enough to
remove the weight from the pads.
2 Remove the wear pad retainer plates and
remove the wear pads from the boom.
3 Lubricate the wear surface of the new pads.
Refer to Maintenance Procedure, Lubricate
the Boom.
Note: Do not lubricate the side wear pads.
4 Install the wear pads. Install and securely 1 Quick attach pin
tighten the retainer plates. Do not over tighten. 2 Quick attach lock pin
3 Quick attach lock lever
4 Quick attach connector
5 Attachment hooks
2 Position the boom so that the quick attach pin

on the boom is below and centered between
the hooks on the attachment. Raise the boom
until the pin is secured n the hooks on the
attachment.
Part No. 1287209GT GTH-636 13

Boom Components
How to Replace the Retraction

How to R eplac e the R etraction C hain
3 Tilt the forks back to pivot the quick attach into

the attachment. Chain
Note: Perform this procedure on a firm, level
surface with the boom in the stowed position and
the wheels chocked.
1 Start the engine and allow the engine to idle.

2 Raise the boom to a horizontal position.
4 Insert the quick attach lock pin all the way 3 Fully retract the boom.
through the attachment and be sure the quick
attach lock lever is secured in the notch on the 4 Extend the boom approximately 1 inch / 2.5
pin. cm to insure retract chain is slack. It may be
necessary to loosen the extend chain adjuster.
5 Turn the machine off and remove the key from
the key switch.
6 Working under the boom, remove the
fasteners securing the single-chain tensioner
to the bottom of boom tube number 1.
Note: When installing the new chain, the chain
tensioner should be mounted in the two most
rearward holes.
7 Remove the inspection cover from the pivot

end of the boom. Remove the extension
cylinder. Refer to How to Remove the
Extension Cylinder in the Repair section.
8 Remove the retaining clip from the retaining
pin and then drive the pin securing the chain
anchor to the boom.
9 Working at the pivot end of the boom, pull the
chain out of the boom.
14 GTH-636 Part No. 1287209GT

Boom Components
10 Remove the chain anchors from each end of 13 Now pull the chain carefully toward the pivot
the chain and install them on the new chain. end until the mounting holes of the chain
anchor line up with the holes on the boom
Note: Always use new cotter pins when installing a
tube. Install the fasteners securing the chain to
chain.
the bottom of the boom tube.
14 Working at the pivot end of the boom, route
the chain over the roller and install the chain
onto the boom assembly using the pivot pin
and retaining clip removed in step 8.
15 Install the extension cylinder removed in step
7.
16 Check the tension on the extension chains.
Refer to Maintenance Procedure, Adjust the
Boom Sequencing Chains.
Component damage hazard.
Chains can be damaged if the
boom is used while the chains
are out of adjustment. Do not
return the machine to use until
the chains have been correctly
adjusted.
1 Extension chain anchors
2 Retract chain anchor
11 Feed an electrical 'fish tape' through the boom

from the front and attach it to the new chain.
Also attach a short rope to the pivot end of the
chain.
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.
1 Retract chain anchor bolts
Part No. 1287209GT GTH-636 15

Boom Components
How to Replace the Extension

How to R eplac e the Extension C hai ns
5 Working at the fork end of the boom, loosen

Chains the fasteners securing the single-chain
tensioners to the top of boom tube number 1.
Note: Perform this procedure on a firm, level After noting the orientation and assembly
surface with the boom in the stowed position and order of the components, remove the
the wheels chocked. fasteners and pull the tensioners free of the
boom.
1 Start the engine and allow the engine to idle.
3 Fully retract the boom.
4 Turn the machine off and remove the key from
the key switch.
1 boom tube number 1

4 extension chains
5 single-chain tensioner
6 Select a chain tensioner. Remove the bow tie

clip securing the chain anchor pin to the chain
assembly. Remove the chain anchor pin from
the assembly and remove the chain anchor
from the tensioner assembly.
16 GTH-636 Part No. 1287209GT

Boom Components
7 Repeat this procedure, beginning with step 6, 12 Working at the pivot end of the boom, pull the
for the other chain. chain out of the boom.
8 Working at the fork end of the boom, select a Note: Rope coming loose from the chain during
chain. Securely connect a 30 foot / 10 m removal may result in a difficult reassembly. Be
length of rope to the end of the chain. Securely sure the rope is securely attached to the chain and
tie off the other end of the rope to the boom boom structure before pulling the chain out of the
structure. boom.
9 Remove the inspection cover from the pivot 13 On a workbench, remove the bow tie clip
end of the boom. Remove the extension securing the chain anchor pin to the chain
cylinder. Refer to How to Remove the assembly. Remove the pin and chain anchor
Extension Cylinder in the Repair section. pin from the assembly.
10 Locate the chain anchors of the extension 14 Install the chain anchors, pins and clips onto
chains at the top of boom tube 3. the new chain using new cotter pins.
15 Remove the rope from the end of the old chain
and securely attach the rope to the new chain.
16 Working at the fork end of the boom, use the
rope to carefully pull the chain through the
boom just until the end of the chain is
accessible.
17 Working at the pivot end of the boom and
using the fasteners removed in step 5, install
the chain anchor onto the boom tube.
Securely tighten the fasteners. Do not over
tighten.
18 Remove the rope from the chain and install the
chain into the chain anchor of the tensioner
assembly. Secure the chain to the chain
anchor using the pin and clip removed in step
6.
1 Extension chain anchors

19 Repeat this procedure, beginning with step 5,
for the other chains.
2 Retract chain anchor
11 Remove the fasteners securing the extension

chain anchors to the boom tubes.
Part No. 1287209GT GTH-636 17

Boom Components
How to Remove the Boom

How to R emove the Boom
20 Install the inspection cover, removed in step 9,

onto the boom. Install and securely tighten the
fasteners. Do not over tighten. Bodily injury hazard. This
procedure requires specific repair
21 Install the chain tensioners into the tensioner skills, lifting equipment and a
mount at the fork end of boom tube number 1. suitable workshop. Attempting
Install the mounting components, removed in this procedure without these skills
step 6. Evenly tighten the chain tensioners to and tools could result in death or
the top of the boom tube until they are serious injury and significant
securely tightened. component damage. Dealer
22 Adjust the chains. Refer to Maintenance service is strongly recommended.
Procedure, Adjust the Boom Sequencing
Note: When removing a hose assembly or fitting,
Chains.
the O-ring (if equipped) on the fitting and/or hose
Component damage hazard. end must be replaced. All connections must be
Chains can be damaged if the torqued to specification during installation. Refer to
boom is used while the chains Specifications, Hydraulic Hose and Fitting Torque
are out of adjustment. Do not Specifications.
return the machine to use until
1 Remove the lifting fork and frame. See the
the chains have been correctly
Repair procedure, How to Remove the Lifting
adjusted.
Fork Frame.
2 Attach a lifting strap from an overhead 10 ton /
10,000 kg crane to the fork end of the boom.
Support the boom. Do not apply any lifting
pressure.
3 Select a fork level cylinder. Remove the
fasteners securing the fork level cylinder
rod-end pivot pin to the boom.
4 Using a lifting strap from another overhead
crane, support the rod-end of the fork level
cylinder. Do not apply any lifting pressure.
18 GTH-636 Part No. 1287209GT

Boom Components
5 Use a soft metal drift to remove the fork level 14 Using a suitable tool, remove the boom pivot
cylinder pivot pin. pin.
6 Lower the fork level cylinder onto the chassis. Crushing hazard. The boom will
fall if not properly supported
Crushing hazard. Keep hands when the pivot pin is removed
clear of the cylinder manifold from the machine.
when lowering the cylinder.
15 Carefully remove the boom assembly from the
7 Identify the hydraulic hoses from the lift
machine and place it on a structure capable of
cylinder. Tag, disconnect and plug the hoses supporting it.
at the lift cylinder manifold. Cap the fittings on
the cylinder manifold. Crushing hazard. The boom
could become unbalanced and
8 Remove the fasteners securing the lift cylinder
fall if not properly supported
barrel-end pivot pin to the chassis.
when removed from the
9 Support and secure the barrel end of the lift machine.
cylinder to the boom.
10 Use a soft metal drift to remove the lift cylinder
The weight of the boom
pivot pin.
assembly may crush the
11 Tag, disconnect and plug the hydraulic hoses hydraulic hard lines under the
at the hydraulic hard line connections at the boom. Use caution when placing
pivot end of the boom. Cap the fittings. the boom assembly onto a
structure capable of supporting
12 Using the overhead crane, raise the boom to a it.
horizontal position.
Crushing hazard. The lift cylinder
will fall if not properly supported
when the boom is raised.
13 Remove the fasteners securing the boom

pivot pin to the chassis.
Part No. 1287209GT GTH-636 19

Boom Components
How to Disassemble the Boom

How to Dis ass embl e the Boom
7 Working at the pivot end of the boom, remove

the fasteners securing the hose roller
Bodily injury hazard. This assembly to boom tube number 2. Remove
procedure requires specific repair the hose roller assembly from the boom.
skills, lifting equipment and a
suitable workshop. Attempting 8 Working at the fork end of the boom, loosen
this procedure without these skills evenly, then remove, the fastener securing the
and tools could result in death or chain tensioners to the top of boom tube
serious injury and significant number 1.
component damage. Dealer 9 Working at the fork end of the boom, remove
service is strongly recommended. the fasteners securing the extension chain
rollers to the top of boom tube number 2.
Remove the chain rollers from the boom.
end must be replaced. All connections must be 10 Working at the pivot end of the boom, remove
torqued to specification during installation. Refer to the fasteners securing the retraction chain
Specifications, Hydraulic Hose and Fitting Torque block pivot pin to boom tube number 3.
Specifications. Remove the pins and pivot pin. Remove the
chain from the roller.
1 Remove the extension cylinder. See the
Repair procedure, How to Remove the 11 Working at the pivot end of the boom, remove
Extension Cylinder. the clips securing the retraction chain roller to
boom tube number 2. Remove the chain roller
2 Remove the boom. See the Repair procedure, from the boom.
How to Remove the Boom.
12 Working at the fork end of the boom, remove
3 Remove the hose sheave covers from the the wear pads from boom tube number 2.
hose roller assembly.
13 Working at the pivot end, removed the
Note: The hose covers ensure that the hoses do retainers securing the wearpads, but leave the
not jump off the hose rollers. wearpads in place. This will insure the boom
4 Working at the pivot end of the boom, remove will slide out smoothly.
the clamps securing the hoses to the inside of 14 Support and slide boom tube number 3 out of
boom tube number 3. boom tube number 2. Place boom tube
5 Working at the fork end of the boom, remove number 3 on a structure capable of supporting
the clamps securing the hoses to the inside of it.
boom tube number 3. Crushing hazard. Boom tube
6 Working at the pivot end of the boom, pull the number 3 could become
fork level hydraulic hoses from the boom and unbalanced and fall when
lay them to the side. removed from the boom tube
number 2 if not properly
supported and attached to the
overhead crane.
20 GTH-636 Part No. 1287209GT

Boom Components
Note: During removal, the overhead crane strap will 1-2
need to be adjusted for proper balancing.
Boom Lift Cylinder
How to Remove the Lift Cylinder

end must be replaced. All connections must be
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
Specifications.
1 Attach a lifting strap from an overhead 10 ton /

10,000 kg crane to the fork end of the boom.
Support the boom. Do not apply any lifting
pressure.
2 Tag, disconnect and plug the hydraulic hoses
at the lift cylinder manifold. Cap the fittings.
Bodily injury hazard. Spraying
1 Extension chain anchors hydraulic oil can penetrate and
2 Retract chain anchor burn skin. Loosen hydraulic
connections very slowly to allow
15 Working at the fork end of the boom, remove the oil pressure to dissipate
the wear pads from boom tube number 1. gradually. Do not allow oil to
squirt or spray.
16 Support and slide boom tube number 2 out of
boom tube number 1. Place boom tube Component damage hazard.
number 2 on a structure capable of supporting Hoses can be damaged if they
it. are kinked or pinched.
Crushing hazard. Boom tube Attach a lifting strap from an overhead crane to the
number 2 could become rod end of the lift cylinder. Support the cylinder. Do
unbalanced and fall when not apply any lifting pressure.
removed from the boom tube
number 1 if not properly 3 Remove the fasteners securing the lift cylinder
supported and attached to the barrel-end pivot pin to the chassis.
overhead crane.
Note: During removal, the overhead crane strap will

need to be adjusted for proper balancing.
Part No. 1287209GT GTH-636 21

Boom Components
4 Use a soft metal drift to remove the pivot pin. 1-3

5 Remove the fasteners securing the lift cylinder Boom Extension Cylinder
rod-end pivot pin to the boom.
6 Use a soft metal drift to remove the pivot pin. How to Remove the Extension
Crushing hazard. The boom will Cylinder
fall if not properly supported Note: When removing a hose assembly or fitting,
when the pivot pin is removed the O-ring (if equipped) on the fitting and/or hose
from the machine. end must be replaced. All connections must be
7 Using the overhead crane, raise the boom to a Specifications, Hydraulic Hose and Fitting Torque
horizontal position. Remove the cylinder from Specifications.
the machine.
Crushing hazard. The cylinder
will fall if not properly supported 2 Remove the access covers on the number 1
when removed from the boom.
machine.
at the boom extension cylinder. Cap the
fittings.
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.

Hoses can be damaged if they
are kinked or pinched.
4 Remove the hose sheave covers.

5 Remove the extend cylinder retaining clips
from the #1 and #2 booms.
22 GTH-636 Part No. 1287209GT

Boom Components
6 Support the extension cylinder with a suitable 1-4

lifting device and begin removing from the Fork Level Cylinder
boom assembly.
7 Before the cylinder can be removed from the
boom assembly, loosen the upper wearpad How to Remove the Fork Level
mount retaining fastener. This will allow the Cylinder
mount to lower onto the lower wear pad
mount. Note: When removing a hose assembly or fitting,
8 Remove the cylinder from the boom assembly. end must be replaced. All connections must be
Note: During removal, the overhead crane strap will
need to be adjusted for proper balancing. Specifications, Hydraulic Hose and Fitting Torque
Specifications.
1 Remove the lifting fork frame. See 1-2, How to

Remove the Lifting Fork Frame.
2 Remove the fastener securing the fork level
cylinder rod-end pivot pin to the fork frame
mount.
3 Use a soft metal drift to remove the pivot pin.
4 Attach a lifting strap from an overhead crane
to the barrel end of the fork level cylinder.
Support the cylinder. Do not apply any lifting
pressure.
1 Upper mount retaining fastener
Part No. 1287209GT GTH-636 23

Boom Components
5 Tag, disconnect and plug the fork level 1-5

cylinder hoses from the cylinder manifolds. Hydraulic Hoses
Cap the fittings.
How to Adjust the Fork Level
How to Adj ust the Fork Lev el Cylinder and/or Auxiliary H os e

hydraulic oil can penetrate and Cylinder and/or Auxiliary Hose
connections very slowly to allow 1 Fully retract the boom.
gradually. Do not allow oil to 2 Fully lower the tips of the lifting forks.
squirt or spray. 3 Remove the cover from the fork end of the
boom.
Hoses can be damaged if they 4 Loosen the hose clamp securing the fork level
are kinked or pinched. cylinder or auxiliary hoses.
5 Pull each hose until it is equally tensioned and
6 Remove the fasteners securing the fork level not touching the boom tube.
cylinder barrel-end pivot pin to the boom.
6 Tighten the clamp bolt to secure the hoses in
7 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.
24 GTH-636 Part No. 1287209GT

Boom Components
How to Replace the Fork Level

How to R eplac e the F ork Lev el Cyli nder and/or Auxili ary H oses
5 Disconnect and plug the fork level cylinder

Cylinder and/or Auxiliary Hoses supply hoses at the cylinder manifold or the
auxiliary supply hoses at the quick connect
Note: When removing a hose assembly or fitting, fittings. Cap the fittings.
end must be replaced. All connections must be Bodily injury hazard. Spraying
torqued to specification during installation. Refer to hydraulic oil can penetrate and
Specifications, Hydraulic Hose and Fitting Torque burn skin. Loosen hydraulic
Specifications. connections very slowly to allow
1 Fully retract the boom. gradually. Do not allow oil to
squirt or spray.
2 Fully lower the tips of the lifting forks.
3 Remove the cover from the fork end of the Component damage hazard.
boom. Hoses can be damaged if they
are kinked or pinched.
4 Attach a lifting strap from an overhead crane
to the top of the lifting fork frame. Support the
frame. Do not apply any lifting pressure.
1 chain adjustment bolt

2 hose clamp bolt
6 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. 1287209GT GTH-636 25

Boom Components
7 Securely connect a 30 feet / 10 m length of 13 Install the new hose assembly into the boom in
rope to each end of the hoses disconnected in the same manner the hose was removed.
steps 5 and 6. Securely tie off the other end of Using the rope, carefully pull the hose through
each section of rope to the boom structure. the boom until each end is accessible.
8 Remove the hose clamp at the fork end of the 14 Install both ends of the hose assembly onto
boom by loosening the hose clamp bolt the correct connection points. Torque to
located on the top of the boom. specification. Refer to Section 2,
Specifications.
9 Remove the cover from the pivot end of the
boom and remove the hose sheave cover.
1 hose tension clamp
10 Pull the hose out of the boom. 1 Cover retaining bolts

2 hose sheave cover
Note: Rope coming loose from either end of the
hose or the boom during hose removal may result 15 Repeat this procedure for the remaining hose
in a difficult reassembly. Be sure each section of to be replaced, beginning with step 8.
rope is securely attached to both the hose and the
boom structure before pulling the hose out of the 16 Tension the hoses using the Repair
boom. procedure, "How to Adjust the Fork Level and
Auxiliary Hydraulic Hoses".
11 Remove the rope from each end of the hose.
Discard the hose. 17 Repeat this procedure for the auxiliary
hydraulic hoses beginning with step 5.
12 Securely install a section of rope onto each
end of the new hose assembly. 18 Remove the lifting strap from the fork frame.
Note: Tag each hose before assembly. 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.
26 GTH-636 Part No. 1287209GT

Operator's Compartment
2-1 4 Working under the dashboard, locate the

hydraulic hose at port L of the steering orbitral.
5 Working at the front axle, locate the hydraulic
hose connected to the front axle steer cylinder
How to Remove the Operator's at the operator's compartment side of the
Compartment machine. Tag, disconnect and plug the
hydraulic hose. Cap the fitting.
The operator's compartment is used to activate
machine functions while sitting in the operator's 6 Tag, disconnect and plug the hydraulic hoses
drivers seat. at ports SUP, SUR and SUT of the secondary
function manifold. Cap the fitting.
Within the operator's compartment there is a
transmission column shifter, steering selector, Bodily injury hazard. Spraying
4-way controller, accelerator pedal, brake pedal hydraulic oil can penetrate and
and a differential lock switch. All of these burn skin. Loosen hydraulic
components are replaceable. connections very slowly to allow
For further information or assistance, consult the gradually. Do not allow oil to
Genie Product Support. squirt or spray.
Bodily injury hazard. This 7 Tag, disconnect and plug the hydraulic hose at
procedure requires specific repair port JP of the secondary function manifold.
skills, lifting equipment and a Cap the fitting.
suitable workshop. Attempting
this procedure without these skills Bodily injury hazard. Spraying
and tools could result in death or hydraulic oil can penetrate and
serious injury and significant burn skin. Loosen hydraulic
component damage. Dealer connections very slowly to allow
service is strongly recommended. the oil pressure to dissipate
1 Disconnect the battery from the machine. squirt or spray.
Electrocution/burn hazard. 8 Remove the fasteners securing the joystick

Contact with electrically charged mount to the operator's compartment.
circuits could result in death or Disconnect the joystick harness and the
serious injury. Remove all rings, remove the joystick assembly.
watches and other jewelry.
9 Working inside the chassis, tag and
2 Locate the secondary function manifold under disconnect the wire harnesses at the
the manifold inspection cover. Tag, disconnect connectors next to the operator's
and plug the hydraulic hoses at ports BP and compartment.
BT of the secondary function manifold. Cap
the fittings.
3 Locate the brake manifold under the manifold
inspection cover. Tag, disconnect and plug the
hydraulic hose at the underside of the brake
manifold. Cap the fitting.
Part No. 1287209GT GTH-636 27

10 Support and secure the operator's 2-2

compartment to an adjustable table capable of Machine Controls
supporting the weight and that will allow the
operator's compartment to remain in an
How to Remove the Steering
How to R emove the Steering Col um n
upright and stable position.

Column
Wrapping a strap around the cab 1 Disconnect the battery from the machine.
and lifting using an overhead
crane can put excessive Electrocution/burn hazard.
pressure on the glass windows Contact with electrically charged
of the cab, causing the windows circuits could result in death or
to break. Do not lift the cab using serious injury. Remove all rings,
a strap from an overhead crane if watches and other jewelry.
the strap contacts the windows.
2 Remove the fasteners securing the
Note: Placing a wedge between the operator's transmission control lever and turn signal
compartment and the adjustable table may be shifter, if equipped, to the column. Carefully
required to keep the operator's compartment separate the lever from the column.
stable.
3 Remove the nut securing the key switch to the
11 Remove the lower fasteners securing the dash panel. Gently push the key switch
operator's compartment to the chassis. through the opening.
12 Remove the upper fasteners securing the 4 Remove the fasteners securing the dash
operator's compartment to the chassis. panel to the dashboard.
Crushing hazard. The operator's 5 Carefully pull the dash panel towards the seat
compartment will fall if not of the operator's compartment.
properly supported when the 6 Tag and disconnect the wire harness from the
fasteners are removed from the componments of the dash panel. Remove the
machine. dash panel from the machine.
13 Slowly move the operator's compartment 7 Loosen the two lower fasteners securing the
away from the chassis while feeding all loose dash frame to the operator's compartment.
hoses, cables and wires through the opening 8 Remove the two upper fasteners securing the
of the chassis. dash frame to the operator's compartment.
Component damage hazard. 9 Rotate the dash frame towards the seat of the
Hoses, cables and wires can be operator's compartment.Remove the
damaged if they are kinked or dashboard from the machine.
pinched.
10 Tag and disconnect the ground wire of the
Bolt torque specification steer column.
Operator's cab mounting bolts 750 ft-lbs 11 Support and secure the steer orbitral to the
1017 Nm 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.
28 GTH-636 Part No. 1287209GT

How to Remove the Steering How to Remove the Steer Orbitral

How to R emove the Steering Wheel How to R emove the Steer Or bitral
Wheel 1 Remove the steering column. Refer to Repair

1 Open the access door above the hydraulic Procedure, How to Remove the Steering
tank. Column.
2 Disconnect the battery from the machine. 2 Working under the dashboard, locate the
hydraulic hose at port L of the steering orbitral.
Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
3 Remove the horn button from the steering

wheel. Remove the nut securing the steering
wheel to the column and remove the steering
wheel. 3 Follow the hydraulic hose from port L of the
steer orbitral to its connection at the front axle
of the machine. Tag, disconnect and plug the
hydraulic hose at the front axle. Cap the fitting.
at ports SUP, SUR and SUT of the secondary
function manifold. Cap the fitting.
squirt or spray.
5 Tag, disconnect and plug the hydraulic hose at

port SULS of the primary function manifold.
Cap the fitting.
6 Slowly move the steer orbitral away from the
dash frame while feeding all loose hoses
through the opening of the chassis.
Part No. 1287209GT GTH-636 29

How to Remove the Joystick - How to Remove the Brake Pedal

How to R emove the Joy stick - Models with El ectr onic J oystick How to R emove the Brake Pedal Ass embly
Models with Electronic Joystick Assembly

1 Disconnect the battery from the machine. 1 Disconnect the battery from the machine.
Electrocution/burn hazard. Electrocution/burn hazard.
Contact with electrically charged Contact with electrically charged
circuits could result in death or circuits could result in death or
serious injury. Remove all rings, serious injury. Remove all rings,
watches and other jewelry. watches and other jewelry.
2 Remove the side access panel. 2 Fully press and release the brake pedal a
minimum of 10 times to release the hydraulic
3 Tag and disconnect the joystick wire harness pressure in the brake system.
from the machine.
4 Remove the fasteners securing the joystick at ports BP and BT of the secondary hydraulic
mount panel to the side console. manifold. Cap the fittings.
5 Remove the fasteners securing the joystick to
the mount panel. Remove the joystick.
squirt or spray.
4 Follow the hydraulic hose from port A of the

brake pedal manifold to the brake manifold.
Tag, disconnect and plug this hydraulic hose
at the brake manifold. Cap the fitting.
5 Remove the fasteners securing the brake
pedal assembly to the dash frame.
6 Gently rotate the brake pedal in an upwards
direction and slowly move the brake pedal
assembly away from the dash frame while
feeding all loose hoses through the opening of
the chassis.
30 GTH-636 Part No. 1287209GT

How to Remove the Gauge

How to R emove the Gauge Clus ter Ass em bly
Cluster Assembly
1 Disconnect the battery from the machine.
2 Remove the fasteners securing the

transmission control lever to the column.
Carefully separate the lever from the column.
3 Grasp the edge of the dash cluster and pull
the cluster through the opening in the
dashboard.
4 Tag and disconnect the wire harness from the
dash cluster. Remove the dash cluster from
the machine.
Part No. 1287209GT GTH-636 31

Fuel and Hydraulic Tanks
3-1 3 Tag and disconnect the wire harness from the

fuel level terminals.
4 Remove the filler cap from the fuel tank.
How to Remove the Fuel and 5 Using an approved hand-operated pump,

drain the fuel tank into a container of suitable
Hydraulic Tank Assembly capacity. Refer to Specifications, Machine
Explosion and fire hazard. Specifications.
Engine fuels are combustible. Explosion and fire hazard. When
Remove the fuel tank in an transferring fuel, connect a
open, well-ventilated area away grounding wire between the
from heaters, sparks, flames machine and pump or container.
and lighted tobacco. Always
have an approved fire Note: Be sure to only use a hand operated pump
extinguisher within easy reach. suitable for use with gasoline and/or diesel fuel.
Explosion and fire hazard. 6 Tag, disconnect and plug the fuel supply and
Never drain or store fuel in an return hoses. Cap the fittings.
open container due to the 7 Remove the clamps holding the vent hose so
possibility of fire. the vent and hose can be removed with the
tank.
Explosion and fire hazard. When
transferring fuel, connect a 8 Remove the fastener securing the fuel tank
grounding wire between the straps, unhook and remove. and remove the
machine and pump or container. tank from the chassis.

FUEL TANK
2 Remove the access cover above the fuel tank

and the access door above the filler cap.
32 GTH-636 Part No. 1287209GT

HYDRAULIC TANK
Note: The fuel tank must be removed before
removing the hydraulic tank.
9 Remove the access cover to the hydraulic

tank.
10 Remove the filler cap from the hydraulic tank.
11 Place a drain pan or other suitable container
under the hydraulic tank. Refer Specifications,
Machine Specifications.
12 Remove the drain plug from the hydraulic tank
and completely drain the tank.
Bodily injury hazard. Beware of
hot oil. Contact with hot oil may
cause severe burns.
13 Tag, disconnect and plug the supply and

return hoses from the hydraulic tank. Cap the
fittings.
14 Support and secure the tank assembly to an
appropriate lifting device.
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.
Part No. 1287209GT GTH-636 33

Engines
4-1 4-2
Engines Engine Fault Codes
How to Repair the Deutz TD 2.9 L4 How to Retrieve Engine Fault

Engine Codes
Maintenance procedures and additional engine When the engine Electronic Control Module (ECM)
information is available in the Deutz TD 2.9 detects an abnormal operating condition, a fault
Workshop Manual. code is immediately stored in the ECM memory. At
the same time, a colored warning lamp is
Deutz TD2.9 Workshop Manual illuminated.
To view the fault code, push and hold the
diagnostic button for 5 seconds. The fault code will
be displayed on the screen, if present. If more than
one code is present, quickly push the diagnostic
button to cycle through the codes. Push and hold
the diagnostic button for 5 seconds to return to the
operation screen.
To learn the specifics of and how to use the fault
codes, refer to, Fault Codes Section.
34 GTH-636 Part No. 1287209GT

Transmission
5-1
Transmission
How to Repair the Transmission

Repair procedures and additional transmission
information is available in the Dana VDT12000
Service Manual.
Dana VDT12000 Service Manual

Part No. 1287209GT GTH-636 35

Hydraulic Pump
6-1 2 Start the engine and fully retract the boom.

Continue to hold the joystick in the boom
Hydraulic Pump retract position and observe the pressure
gauge.
How to Test the Function Pump
How to T est the Func tion Pum p
Result: If the pressure gauge reads 3200 psi /

Note: When removing a hose assembly or fitting, 220 bar, immediately stop. The pump is good.
end must be replaced. All connections must be Result: If the pressure fails to reach 3200 psi /
torqued to specification during installation. Refer to 220 bar, the pump needs to be adjusted OR or
Specifications, Hydraulic Hose and Fitting Torque the pump or pump coupling is faulty and will
Specifications. need to be serviced or replaced.
There is no relief valve in the
hydraulic pump and the pump
can be damaged if the pressure
is allowed to exceed
specification. When testing the
pump, crank the engine in one
squirt or spray.
second intervals until the
correct pressure is confirmed.
1 Connect a 0 to 5000 psi / 0 to 350 bar
Do not over-pressurize the
pressure gauge to port TP on the secondary
pump.
function manifold.
3 Remove the pressure gauge and install plug
onto port TP. Torque to specification. Refer to
Section Specifications, Hydraulic
Specifications.
squirt or spray.
36 GTH-636 Part No. 1287209GT

Hydraulic Pump
How to Remove the Function

How to R emove the Functi on Pum p
4 Tag, disconnect and plug the large hydraulic

Pump pump supply hose at the pump. Cap the fitting
on the pump.
Bodily injury hazard. This Note: Placing the open end of the pump supply
procedure requires specific repair hose below the fluid level in the hydraulic tank will
skills, lifting equipment and a result in excessive hydraulic fluid leaking from the
suitable workshop. Attempting hose. Do not lower the open end of the pump
this procedure without these skills supply hose to below the fluid level of the hydraulic
and tools could result in death or tank until the hose is plugged.
serious injury and significant
component damage. Dealer 5 Tag, disconnect and plug the high pressure
service is strongly recommended. hose at the pump. Cap the fitting on the pump.
Note: When removing a hose assembly or fitting, Bodily injury hazard. Spraying
the O-ring (if equipped) on the fitting and/or hose hydraulic oil can penetrate and
end must be replaced. All connections must be burn skin. Loosen hydraulic
torqued to specification during installation. Refer to connections very slowly to allow
Specifications, Hydraulic Hose and Fitting Torque the oil pressure to dissipate
Specifications. gradually. Do not allow oil to
squirt or spray.
Note: Perform this procedure with the engine off
and cool. 6 Remove the fasteners securing the pump to
the transmission. Remove the pump from the
1 Open the engine cover.
machine.
3 Tag and disconnect the case drain hose at the

top of the pump. Cap the fitting on the pump.
Note: Placing the open end of the case drain hose
below the hydraulic oil level in the hydraulic tank
will result in excessive hydraulic fluid leaking from
the hose. 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.
Part No. 1287209GT GTH-636 37

Hydraulic Pump
How to Install the Function Pump How to Prime the Function Pump
How to Ins tall the F uncti on How to Prime the F uncti on Pump
1 Carefully install the hydraulic pump onto the Note: When removing a hose assembly or fitting,
transmission. Install the fasteners and tighten the O-ring (if equipped) on the fitting and/or hose
to finger tight. end must be replaced. All connections must be
2 Torque the fasteners evenly to 85 ft-lbs / 115 Specifications, Hydraulic Hose and Fitting Torque
Nm. Specifications.
3 Install the smaller high pressure hose onto the
1 Install all hoses onto the hydraulic pump.
pump outlet. Torque the fasteners to 27-37
Torque to specification. Refer to
ft-lbs / 37-50 Nm.
Specifications, Hydraulic Hose and Fitting
4 Install the larger low pressure hose onto the Torque Specifications.
pump outlet. Install the hose retaining rings
and fasteners. Torque the fasteners to 55-66 2 Locate the case drain filler plug at the side of
the function pump.
ft-lbs / 74-90 Nm.
3 Remove the plug and slowly fill the case drain
5 Working at the case drain at the top of the
port of the pump with hydraulic fluid until the
pump, fill the pump with hydraulic fluid until the
oil level is even with the bottom of the hole.
fluid is at the top of the case drain fitting.
Install the plug and torque to 40 ft-lbs / 54 Nm.
6 Install the case drain hose onto the pump and
4 Start the engine, allow the engine to run at low
torque to specification. Refer to Specifications,
idle for 15 seconds then shut off the engine.
Hydraulic Specifications.
Wait 15 seconds, then start the engine again.
7 Securely install the wire harness onto the Allow the engine to run at low idle for 15
pump. seconds and then shut off the engine.
8 Check the level of the hydraulic fluid in the 5 Check for hydraulic leaks and clean up any oil
hydraulic tank. Add fluid if needed. that may have spilled.
9 Prime the pump. Refer to Repair Procedure,
How to Prime the Function Pump.
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.
38 GTH-636 Part No. 1287209GT

Hydraulic Pump
How to Adjust the Function Pump

How to Adj ust the Functi on Pum p Standby Pr ess ure
5 Adjust the function pump standby pressure.

Standby Pressure Turn the adjustment screw clockwise to
increase the pressure or counterclockwise to
1 Connect a 0 to 1000 psi / 0 to 100 bar decrease the pressure. Tighten the set screw.
pressure gauge to test port 'TP' on the primary
function manifold. See 7-1 or 7-2, Primary
Function Manifold Components.
2 Start the engine and allow the engine to run at
low idle.
3 Observe the pressure reading on the pressure
gauge.
Result: The pressure gauge reads 650 ±20 psi
/ 44.8 ±1.4 bar. The pump is functioning
correctly. Proceed to step 6.
Result: The pressure gauge fails to read 650
±20 psi / 44.8 ±1.4 bar. The pressure setting
needs to be adjusted. Proceed to step 4. 1 Standby Pressure Adjustment set screw
2 Standby pressure adjustment
4 Loosen the set screw for the standby pressure
3 Pressure compensator adjustment
adjustment screw.
4 Pressure compensator adjustment set
screw
6 Turn the engine off and remove the pressure

gauge.
squirt or spray.
Part No. 1287209GT GTH-636 39

Hydraulic Pump
How to Adjust the Function Pump

How to Adj ust the Functi on Pum p Press ure Com pens ator
5 Loosen the set screw for the pressure

Standby Pressure compensator adjustment screw.
Note: Two people will be required to perform this

procedure.
1 Connect a 0 to 5000 psi / 0 to 350 bar

pressure gauge to port 'M1' on the function
pump.
2 Start the engine and allow the engine to run at
low idle.
3 Fully retract the boom.
4 Continue to activate the boom retract function
and observe the pressure reading on the
pressure gauge.
1 Standby Pressure Adjustment set screw
Result: The pressure gauge reads 3200±150 2 Standby pressure adjustment
psi / 220±10.3 bar. The pump is functioning 3 Pressure compensator adjustment
correctly. Proceed to step 7.
4 Pressure compensator adjustment set
Result: The pressure gauge fails to read screw
3200±150 psi / 220±10.3 bar. The pressure
setting needs to be adjusted. Proceed to step 6 Adjust the pressure compensator pressure.
5. Turn the adjustment screw clockwise to
increase the pressure or counterclockwise to
decrease the pressure. Tighten the set screw.
Do not adjust the pressure
compensator higher than
specified.
7 Turn the engine off and remove the pressure

gauge.
squirt or spray.
40 GTH-636 Part No. 1287209GT

Manifolds
7-1
PVG Manifold Components - Electronic Joystick
The PVG manifold is located under the manifold inspection cover.
Index
Description Function
No.
1 Assembly, lift Controls boom up/down
2 Assembly, auxiliary Controls auxiliary functions
3 Assembly, tilt Fork tilt function
4 Assembly, extend/retract Controls boom extend/retract
5 Assembly, sway Controls sway function
Part No. 1287209GT GTH-636 41

Manifolds
7-2
Secondary Function Manifold Components
The secondary function manifold is located under the manifold inspection cover.
Index Schematic
Description Function Torque
No. Item
1 DO3 valve, 3 position 4 way SVD1 Steer left/right 60 in-lbs / 6.8 Nm
2 Pressure reducing/relief valve, PR2 Differential lock-up circuit 50 ft-lbs / 68 Nm
400 psi / 27.5 bar
3 Pressure reducing/relief valve, PR1 Parking brake circuit 25-30 ft-lbs / 34-41 Nm
350 psi / 24.8 bar
4 Check valve, 5 psi / 0.35 bar CV1 Steering circuit 20 ft-lbs / 27.1 Nm
5 Solenoid valve, 2 position 3 way SV1 Differential lock up select 19-21 ft-lbs /
25.8-28.6 Nm
6 Solenoid valve, 2 position 3 way SV2 Rear lock up select 19-21 ft-lbs / 25.8-28.6
Nm
42 GTH-636 Part No. 1287209GT

Manifolds
Part No. 1287209GT GTH-636 43

Manifolds
44 GTH-636 Part No. 1287209GT

Manifolds
7-3
Brake Manifold Components
The auxiliary manifold is located under the transmission inspection cover.
Index Schematic
Description Function Torque
No. Item
1 Pressure switch, 450 psi / 31 bar S6 Clutch cut-off pressure 11 ft-lbs / 14.9 Nm
2 Pressure switch, 50 psi / 3.4 bar S16 Brake light pressure (option) 11 ft-lbs / 14.9 Nm
Part No. 1287209GT GTH-636 45

Manifolds
7-4 How to Set the Parking Brake

How to Set the Parki ng Br ake Sy stem Pr ess ure
Valve Adjustments - Secondary System Pressure

Function Manifold Note: Be sure that the hydraulic oil level is visible in
the inspection glass of the hydraulic tank.
1 Install a 0 to 1000 psi / 0 to 100 bar pressure

gauge into test port 'TP' at the top of the
primary function manifold, Refer to Primary
Function Manifold Components.
2 Start the engine. Allow the engine to idle after
warming the engine to operating temperature.
3 Without operating any machine controls,
observe the reading on the pressure gauge.
correctly.
needs to be adjusted. Refer to Repair
Procedure, How to Adjust the Function Pump
Pressure.
4 Turn the machine off. Remove the pressure
gauge from the test port.
squirt or spray.
5 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.
46 GTH-636 Part No. 1287209GT

Manifolds
How to Set the Differential Lock

How to Set the Differ enti al Lock System Press ure
6 Start the engine. Allow the engine to idle.

Result: The pressure gauge reads 350 psi / System Pressure
24.1. The pressure setting is correct. Proceed
Note: Be sure that the hydraulic oil level is visible in
to step 11.
the inspection glass of the hydraulic tank.
psi / 24.1. The pressure setting needs to be 1 Install a 0 to 1000 psi / 0 to 100 bar pressure
adjusted. Proceed to step 7. gauge into test port 'TP' at the top of the
primary function manifold, Refer to Primary
7 Turn the machine off. Hold the brake pressure Function Manifold Components.
reducing/relief valve with a wrench and
remove the cap (schematic item PR4). 2 Start the engine. Allow the engine to idle after
warming the engine to operating temperature.
8 Adjust the internal hex socket. Turn it
clockwise to increase the pressure or 3 Without operating any machine controls,
counterclockwise to decrease the pressure. observe the reading on the pressure gauge.
Component damage hazard. Do
not adjust the relief valve
correctly.
pressures higher than
specifications. Result: The pressure gauge fails to read 650
9 Install the relief valve cap. needs to be adjusted. Refer to Repair
Procedure, How to Adjust the Function Pump
10 Repeat this procedure beginning with step 6.
Pressure.
squirt or spray.
squirt or spray.
Part No. 1287209GT GTH-636 47

Manifolds
7-5 Valve Coil Resistance

Valve Coils Specification
Note: The following coil resistance specifications
How to Test a Coil are at an ambient temperature of 68°F / 20°C. As
valve coil resistance is sensitive to changes in air
A properly functioning coil provides an temperature, the coil resistance will typically
electromotive force which operates the solenoid increase or decrease by 4% for each 18°F / 10°C
valve. Critical to normal operation is continuity that your air temperature increases or decreases
within the coil that provides this force field. from 68°F / 20°C.
Since coil resistance is sensitive to temperature, Valve Coil Resistance Specification
resistance values outside specification can
Description Specification
produce erratic operation. When coil resistance
decreases below specification, amperage DO3 valve, 3 position 4 way 5.6Ω
increases. As resistance rises above specification, 12V DC with diode
voltage increases. (schematic items SVD1)
Solenoid valve, 2 position 2 way 8.8Ω
While valves may operate when coil resistance is 12V DC with diode
outside specification, maintaining coils within (schematic items SV9)
specification will help ensure proper valve function Solenoid valve, 2 position 3 way 8.8Ω
over a wide range of operating temperatures. 12V DC with diode
(schematic items SV5, SV7, SV6)
Solenoid valve, 2 position 4 way 12V DC 8.8Ω
with diode
circuits could result in death or (schematic items SV1, SV2, SV3, SV4)
1 Tag and disconnect the wiring from the coil to

be tested.
2 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.
48 GTH-636 Part No. 1287209GT

Manifolds
How to Test a Coil Diode

Properly functioning coil diodes protect the
electrical circuit by suppressing voltage spikes.
Voltage spikes naturally occur within a function
circuit following the interruption of electrical current
to a coil. Faulty diodes can fail to protect the
electrical system, resulting in a tripped circuit
breaker or component damage.
1 Test the coil for resistance. Refer to Repair 1 multimeter

Procedure, How to Test a Coil. 2 9v DC battery
3 10Ω resistor
2 Connect a 10W resistor to the negative
4 coil
terminal of a known good 9V DC battery.
Connect the other end of the resistor to a Note: Dotted lines in illustration indicate a reversed
terminal on the coil. connection as specified in step 6.
Resistor 10Ω 3 Set a multimeter to read DC current.
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.
measured across the terminals.
4 Connect the negative lead to the other
terminal on the coil.
5 Momentarily connect the positive lead from
the multimeter to the positive terminal on the
9V DC battery. Note and record the current
reading.
6 At the battery or coil terminals, reverse the
connections. Note and record the current
reading.
Result: Both current readings are greater than
0 mA and are different by a minimum of 20%.
The coil is good.
Result: If one or both of the current readings
are 0 mA, or if the two current readings do not
differ by a minimum of 20%, the coil and/or its
internal diode are faulty and the coil should be
replaced.
Part No. 1287209GT GTH-636 49

Axle
8-1 6 Raise the end of the machine until the tires are
off the ground. Place blocks under the chassis
Axles for support.
Crushing hazard. The chassis
How to Remove the Axle will fall if not properly supported.
Bodily injury hazard. This
procedure requires specific repair 7 Remove the lug nuts. Remove the tire and
skills, lifting equipment and a wheel assembly from both ends of the axle.
suitable workshop. Attempting 8 Support and secure the axle to an appropriate
this procedure without these skills lifting device.
and tools could result in death or
serious injury and significant 9 Remove the fasteners securing the sway
component damage. Dealer cylinder rod-end pivot pin to the chassis.
service is strongly recommended. 10 Use a soft metal drift to remove the pivot pin.
1 Chock the wheels. 11 Remove the fasteners securing the axle to the
chassis. Remove the axle from the machine.
2 Remove the fasteners securing the driveshaft
to the transmission. Lower the end of the Crushing hazard. The axle will
driveshaft to the ground. fall if not properly supported
when the fasteners are removed
3 Remove the fasteners securing the driveshaft from the machine.
to the axle. remove the driveshaft from the
machine.
4 Tag and remove the hydraulic hoses from the Bolt torque specification
axle. Axle mounting bolts 380 ft-lbs
515 Nm
squirt or spray.
5 Loosen the lug nuts of both wheels on the axle

to be removed. Do not remove the lug nuts.
50 GTH-636 Part No. 1287209GT

Fault Codes
Before Troubleshooting:
Section 4 Faul t Codes
 Read, understand and obey the safety rules

 Be sure that all necessary tools and test
equipment are available and ready for use.
Observe and Obey:  Read each appropriate fault code thoroughly.
 Troubleshooting and repair procedures shall Attempting short cuts may produce hazardous
be completed by a person trained and qualified conditions.
on the repair of this machine  Be aware of the following hazards and follow
 Immediately tag and remove from service a generally accepted safe workshop practices.
damaged or malfunctioning machine. Electrocution/burn hazard.
 Repair any machine damage or malfunction Contact with electrically charged
before operating the machine. circuits could result in death or
 Unless otherwise specified, perform each watches and other jewelry.
procedure with the machine in the following
configuration: Note: Two persons will be required to safely
perform some troubleshooting procedures.
• Machine parked on a firm, level surface
• Boom in the stowed position
• Key switch in the off position with the key
removed
• Wheels chocked
Part No. 1287209GT GTH-636 51

Diagnostic Display
When the engine Electronic Control Module (ECM) Decoding Fault Codes
detects an abnormal operating condition, a fault
code is immediately stored in the ECM memory. The Suspect Parameter Number (SPN) and the
Failure Mode Identifier (FMI), when combined, are
The fault code is displayed on the LCD display the basis for an engine fault code. The SPN
which is located on the gauge cluster in the number indicates the affected component; the FMI
operator's compartment. number reveals the type of failure that has
occurred. Comparing the combination of numbers
The gauge cluster also includes two warning lights. to the fault code chart on the following pages will
They are an amber colored light which signals an help to determine the exact engine fault and a
abnormal engine condition which should be corrective course of action. For additional
corrected as soon as possible and a red colored information, refer to the engine operator's manual
light which signals an engine condition which which came with your machine.
requires the operator to shut down the engine as
soon as possible.
The ECM will, in some cases, automatically shut
down the engine when the red light is displayed.
Active Fault Codes
Active Fault Codes will be displayed on the gauge
cluster when the diagnostic button is pressed for 5
seconds, if present. If multiple fault codes are
detected, scroll through them using the diagnostic
button.
Active Codes vs Stored Codes 1 Diagnostic button
2 LCD screen
Active fault codes, indicating an engine condition or
conditions which have not been corrected, are
displayed at the moment the fault is detected.
Stored fault codes are the cumulative history of
fault codes which the 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.
52 GTH-636 Part No. 1287209GT

Deutz TD 2.9 L4 Engine Fault Codes
SPN FMI Description

SPN = Suspect Parameter Number
51 6 Actuator error EGR-Valve; signal range
FMI = Failure Mode Identifier check high
SPN FMI Description
51 6 Actuator EGR-Valve; over current
51 3 EGR-Valve, short circuit to battery 51 6 Actuator error EGR-Valve; Overload by
51 3 Position sensor error of actuator short-circuit
EGR-Valve; signal range check high 51 7 Actuator position for EGR-Valve not
51 3 EGR-Valve; short circuit to battery (A02) plausible
51 3 EGR-Valve; short circuit to battery (A67) 51 11 Actuator error EGR-Valve; Power stage
over temp due to high current
51 4 EGR-Valve; short circuit to ground
51 12 Actuator EGR-Valve; powerstage over
51 4 Position sensor error actuator EGR-Valve;
temperature
signal range check low
51 12 Mechanical actuator defect EGR-Valve
51 4 EGR-Valve; short circuit to ground (A02)
51 12 Actuator EGR-Valve; over temperature
51 4 EGR-Valve; short circuit to ground (A67)
94 1 Low fuel pressure; warning threshold
1 4 Actuator error EGR-Valve; Voltage below
exceeded
threshold
94 1 Low fuel pressure; shut off threshold
exceeded
check low
94 3 Sensor error low fuel pressure; signal
51 5 Actuator EGR-Valve; open load
range check high
94 4 Sensor error low fuel pressure; signal
check low
range check low
51 5 Actuator EGR-Valve; open load
97 3 Sensor error water in fuel; signal range
51 6 Actuator error EGR-Valve; signal range check high
check high
97 4 Sensor error water in fuel; signal range
check low
97 12 Water in fuel level prefilter; maximum
value exceeded
Part No. 1287209GT GTH-636 53

SPN = Suspect Parameter Number SPN FMI Description

FMI = Failure Mode Identifier 108 3 Sensor error ambient air press.; signal
SPN FMI Description range check high
100 0 High oil pressure; warning threshold 108 4 Sensor error ambient air press.; signal
exceeded range check low
100 0 High oil pressure; shut off threshold 110 0 High coolant temperature; warning
exceeded threshold exceeded
100 1 Low oil pressure; warning threshold 110 0 High coolant temperature; shut off
exceeded threshold exceeded
100 1 Low oil pressure; shut off threshold 110 3 Sensor error coolant temp.; signal range
exceeded check high
100 3 Sensor error oil pressure; signal range 110 4 Sensor error coolant temp.; signal range
check high check low
100 4 Sensor error oil pressure sensor; signal 111 1 Coolant level too low
range check low 132 11 Air flow sensor load correction factor
102 2 Charged air pressure above warning exceeding the maximum drift limit;
threshold plausibility error
102 2 Charged air pressure above shut off 132 11 Air flow sensor load correction factor
threshold exceeding drift limit; plausibility error
102 4 Sensor error charged air press.; signal 132 11 Air flow sensor low idle correction factor
range check low exceeding the maximum drift limit
105 0 High charged air cooler temperature; 132 11 Air flow sensor load correction factor
warning threshold exceeded exceeding the maximum drift limit
105 0 High charged air cooler temperature; shut 157 3 Sesnor error rail pressure; signal range
off threshold exceeded check high
105 3 Sensor error charged air temperature; 157 4 Sensor error rail pressure; signal range
signal range check high check low
105 4 Sensor error charged air temperature;
signal range check low
54 GTH-636 Part No. 1287209GT


FMI = Failure Mode Identifier 174 0 High low fuel temperature; warning
SPN FMI Description threshold exceeded
168 0 Physical range check high for battery 174 0 High Low fuel temperature; shut off
voltage threshold exceeded
168 1 Physical range check low for battery 175 0 Physical range check high for oil
voltage temperature
168 2 High battery voltage; warning threshold 175 0 High oil temperature; warning threshold
exceeded exceeded
168 2 Low battery voltage; warning threshold 175 0 High oil temperature; shut off threshold
exceeded exceeded
168 3 Sensor error battery voltage; signal range 175 1 Physical range check low for oil
check high temperature
168 4 Sensor error battery voltage; signal range 175 2 Sensor oil temperature; plausibility error
check low 175 2 Sensor oil temperature; plausibility error
171 3 Sensor error environment temperature; oil temperature too high
signal range check high 175 3 Sensor error oil temperature; signal range
171 4 Sensor error environment temperature; check high
signal range check low 175 4 Sensor error oil temperature; signal range
172 0 Physical range check high for intake air check low
temperature 190 0 Engine speed above warning threshold
172 1 Physical range check low for intake air (FOC-Level 1)
temperature 190 2 Offset angle between crank- and camshaft
172 2 Sensor ambient air temperature; sensor is too large
plausibility error 190 8 Sensor camshaft speed; disturbed signal
172 2 Intake air sensor; plausibility error
172 3 Sensor error intake air; signal range check
high
172 4 Sensor error intake air sensor; signal
range check low
Part No. 1287209GT GTH-636 55


FMI = Failure Mode Identifier 412 3 Sensor error EGR cooler downstream
SPN FMI Description temperature; signal range check high
190 8 Sensor crankshaft speed; disturbed signal 412 4 Sensor error EGR cooler downstream
temperature; signal range check low
190 11 Engine speed above warning threshold
(FOC-Level 2) 520 9 Timeout Error of CAN-Receive-Frame
TSC1TR; Setpoint
190 12 Sensor camshaft speed; no signal
597 2 Break lever mainswitch and break lever
190 12 Sensor crankshaft speed; no signal redundancy switch status not plausible
190 14 Engine speed above warning threshold 624 3 SVS lamp; short circuit to batt.
(Overrun Mode)
624 4 SVS lamp; short circuit to grd.
190 14 Camshaft- and Crankshaft speed sensor
signal not available on CAN 624 5 SVS lamp; open load
411 0 Physical range check high for differential 624 12 SVS lamp; powerstage over temperature
pressure Venturiunit (EGR) 630 12 Access error EEPROM memory (delete)
411 1 Physical range check low for differential 630 12 Access error EEPROM memory (read)
pressure Venturiunit (EGR)
630 12 Access error EEPROM memory (write)
411 3 Sensor error differential pressure
Venturiunit (EGR); signal range check 639 14 CAN-Bus 0 "BusOff-Status"
high 651 3 Injector 1 (in firing order); short circuit
411 4 Physical range check low for EGR 651 4 High side to low side short circuit in the
differential pressure injector 1 (in firing order)
411 4 Sensor error differential pressure
Venturiunit (EGR); signal range check low
56 GTH-636 Part No. 1287209GT


FMI = Failure Mode Identifier 677 3 Starter relay high side; short circuit to
SPN FMI Description battery
651 5 Injector 1 (in firing order); interruption of 677 3 Starter relay low side; short circuit to
electric connection battery
652 3 Injector 2 (in firing order); short circuit 677 4 Starter relay high side; short circuit to
ground
652 4 High side to low side short circuit in the
injector 2 (in firing order) 677 4 Starter relay low side; short circuit to
ground
652 5 Injector 2 (in firing order); interruption of
electric connection 677 5 Starter relay; no load error
653 3 Injector 3 (in firing order); short circuit 677 12 Starter relay; powerstage over
temperature
injector 3 (in firing order) 703 3 Engine running lamp; short circuit to
battery
electric connection 703 4 Engine running lamp; short circuit to
ground
654 3 Injector 4 (in firing order); short circuit
703 5 Engine running lamp; open load
injector 4 (in firing order) 703 12 Engine running lamp; powerstage over
temperature
electric connection 729 5 Cold start aid relay open load
676 11 Cold start aid relay error. 729 12 Cold start aid relay; over temperature error
676 11 Cold start aid relay open load 898 9 Timeout Error of CAN-Receive-Frame
TSC1TE; Setpoint
1079 13 Sensor supply voltage monitor 1 error
(ECU)
(ECU)
Part No. 1287209GT GTH-636 57


FMI = Failure Mode Identifier 1180 1 Exhaust gas temperature upstream
SPN FMI Description turbine; shut off threshold exceeded
1109 2 Engine shut off demand ignored 1180 3 Sensor error exhaust gas temperature
upstream turbine; signal range check high
1136 0 Physikal range check high for ECU
temperature 1180 11 Sensor exhaust gas temperature
upstream turbine; plausibility error
1136 1 Physikal range check low for ECU
temperature 1188 2 Wastegate; status message from ECU
missing
1136 3 Sensor error ECU temperature; signal
range check high 1188 7 Wastegate actuator; blocked
1136 4 Sensor error ECU temperature; signal 1188 11 Wastegate actuator; internal error
range check low 1188 11 Wastegate actuator; EOL calibration not
1176 3 Sensor error pressure sensor upstream performed correctly
turbine; signal range check high 1188 11 Wastegate actuator; over temperature (>
1176 4 Sensor error pressure sensor downstream 145øC)
turbine; signal range check high 1188 11 Wastegate actuator; over temperature (>
1180 0 Physical range check high for exhaust gas 135øC)
temperature upstream turbine 1188 11 Wastegate actuator; operating voltage
1180 0 Turbocharger Wastegate CAN feedback; error
warning threshold exceeded 1188 13 Wastegate actuator calibration deviation
1180 0 Exhaust gas temperature upstream too large, recalibration required
turbine; warning threshold exceeded 1231 14 CAN-Bus 1 "BusOff-Status"
1180 1 Physical range check low for exhaust gas 1235 14 CAN-Bus 2 "BusOff-Status"
temperature upstream turbine
1180 1 Turbocharger Wastegate CAN feedback;
shut off threshold exceeded
58 GTH-636 Part No. 1287209GT


FMI = Failure Mode Identifier 2798 4 Injector diagnostics; timeout error of
SPN FMI Description short circuit to ground measurement
cyl. Bank 1
1237 2 Override switch; plausibility error
2798 4 Injector diagnostics; short circuit to
1322 12 Too many recognized misfires in more ground monitoring Test in Cyl. Bank 0
than one cylinder
2798 4 Injector diagnostics; short circuit to
1323 12 Too many recognized misfires in cylinder ground monitoring Test in Cyl. Bank 1
1 (in firing order)
3224 2 DLC Error of CAN-Receive-Frame
1324 12 Too many recognized misfires in cylinder AT1IG1 NOX Sensor (SCR-system
2 (in firing order) upstream cat; DPF-system downstream
1325 12 Too many recognized misfires in cylinder cat); length of frame incorrect
3 (in firing order) 3224 9 Timeout Error of CAN-Receive-Frame
1326 12 Too many recognized misfires in cylinder AT1IG1; NOX sensor upstream
4 (in firing order) 3248 4 Sensor error particle filter downstream
2659 0 Physical range check high for EGR temperature; signal range check low
exhaust gas mass flow 3699 2 DPF differential pressure sensor and a
2659 1 Physical range check low for EGR exhaust further sensor or actuator CRT system
gas mass flow defective
2659 2 Exhaust gas recirculation AGS sensor; 3699 2 Temperature sensor us. and ds. DOC
plausibility error simultaneously defect
2659 2 AGS sensor temperature exhaust gas 3699 14 Maximum stand-still-duration reached;
mass flow; plausibility error oil exchange required
2659 12 Exhaust gas recirculation; AGS sensor 4765 0 Physical range check high for exhaust
has "burn off" not performed gas temperature upstream (DOC)
2797 4 Injector diagnostics; timeout error of short 4765 1 Physical range check low for exhaust
circuit to ground measurement cyl. Bank 0 gas temperature upstream (DOC)
Part No. 1287209GT GTH-636 59


FMI = Failure Mode Identifier 23008 2 Timeout error in Manipulation control
SPN FMI Description 23009 9 Pressure Relief Valve (PRV) reached
4766 0 Physical range check high for exhaust maximun allowed opening count
gas temperature downstream (DOC) 23009 10 Pressure relief valve (PRV) reached
4766 1 Physical range check low for exhaust maximun allowed open time
gas temperature downstream (DOC) 23212 9 Timeout Error of CAN-Receive-Frame
4768 2 Sensor exhaust gas temperature ComEngPrt; Engine Protection
upstream (DOC); plausibility error 23216 9 Timeout Error of CAN-Receive-Frame
4768 3 Sensor error exhaust gas temperature PrHtEnCmd; pre-heat command,
upstream (DOC); signal range check engine command
high 23240 9 Timeout CAN-message FunModCtl;
4768 4 Sensor error exhaust gas temperature Function Mode Control
upstream (DOC) signal range check low 23350 4 Injector cylinder-bank 1; short circuit
4769 2 Sensor exhaust gas temperature 23352 4 Injector cylinder-bank 2; short circuit
downstream (DOC); plausibility error
23354 12 Injector powerstage output defect
4769 3 Sensor error exhaust gas temperature
downstream (DOC); signal range check 23470 2 Pressure Relief Valve (PRV) forced to
high open; performed by pressure increase
4769 4 Sensor error exhaust gas temperature 23470 2 Pressure Relief Valve (PRV) forced to
downstream (DOC); signal range check open; performed by pressure shock
low
23006 3 Controller mode switch; short circuit to
battery
23006 4 Controller mode switch; short circuit to
ground
23008 1 Manipulation control was triggered
60 GTH-636 Part No. 1287209GT


FMI = Failure Mode Identifier
23612 12 Internal ECU monitoring detection
SPN FMI Description reported error
23470 7 Maximum rail pressure in limp home 23612 12 Internal ECU monitoring detection
mode exceeded (PRV) reported error
23470 11 The PRV can not be opened at this 23612 12 Internal ECU monitoring detection
operating point with a pressure shock reported error
23470 11 Rail pressure out of tolerance range 23612 12 Internal ECU monitoring detection
23470 12 Open Pressure Relief Valve (PRV); shut reported error
off condition 23612 12 Internal ECU monitoring detection
23470 12 Open Pressure Relief Valve (PRV); reported error
warning condition 23612 12 Internal ECU monitoring detection
23470 14 Pressure Relief Valve (PRV) is open reported error
23550 12 T50 start switch active for too long 23612 12 Internal ECU monitoring detection
reported error
(ECU) 23612 12 Internal ECU monitoring detection
reported error
23603 9 Timeout Error of CAN-Receive-Frame
AMB; Ambient Temperature Sensor 23612 12 Internal ECU monitoring detection
reported error
TSC1AE; Traction Control 23612 12 Internal ECU monitoring detection
reported error
TSC1AR; Retarder 23612 12 Internal ECU monitoring detection
reported error
23612 12 Internal software error ECU; injection
cut off 23612 12 Internal ECU monitoring detection
reported error
reported error 23612 12 Internal ECU monitoring detection
reported error
reported error
Part No. 1287209GT GTH-636 61


23615 3 Metering unit (Fuel-System); short
SPN FMI Description circuit to battery low side
23612 12 Internal ECU monitoring detection 23615 4 Metering unit (Fuel-System); short
reported error circuit to ground high side
23612 12 Internal software error ECU 23615 4 Metering Unit (Fuel-System); short
23612 14 Softwarereset CPU SWReset_0 circuit to ground low side
23612 14 Softwarereset CPU SWReset_1 23615 5 Metering unit (Fuel-System); open load
23612 14 Softwarereset CPU SWReset_2 23615 12 Metering unit (Fuel-System);

powerstage over temperature
23613 0 Maximum positive deviation of rail
pressure exceeded (RailMeUn0) 23619 2 Physical range check high for exhaust
gas temperature upstrem (SCR-CAT)
23613 0 Maximum positive deviation of rail
pressure in metering unit exceeded 23698 11 Shut off request from supervisory
(RailMeUn1) monitoring function
23613 0 Railsystem leakage detected 23717 12 Timeout Error of CAN-Transmit-Frame

(RailMeUn10) AmbCon; Weather environments
23613 0 Maximum negative deviation of rail 23718 3 SCR mainrelay; short circuit to battery
pressure in metering unit exceeded (only CV56B)
(RailMeUn2) 23718 4 SCR mainrelay; short circuit to ground
23613 0 Negative deviation of rail pressure (only CV56B)
second stage (RailMeUn22) 23718 5 SCR mainrelay; open load (only
23613 0 Maximum rail pressure exceeded CV56B)
(RailMeUn4) 23718 12 SCR mainrelay; powerstage over
23613 1 Minimum rail pressure exceeded temperature (only CV56B)
(RailMeUn3) 23766 9 Timeout Error of CAN-Receive-Frame
23613 2 Setpoint of metering unit in overrun Active TSC1AE
mode not plausible 23767 9 Timeout Error of CAN-Receive-Frame
23615 3 Metering unit (Fuel-System); short Passive TSC1AE
circuit to battery highside
62 GTH-636 Part No. 1287209GT


FMI = Failure Mode Identifier 23897 13 check of missing injector adjustment
SPN FMI Description value programming (IMA) injector 3 (in
firing order)
Active TSC1AR 23898 13 check of missing injector adjustment
value programming (IMA) injector 4 (in
23769 9 Timeout Error of CAN-Receive-Frame firing order)
Passive TSC1AR
23910 6 Air Pump; over current
Passive TSC1DE 23913 3 Sensor error glow plug control
diagnostic line voltage; signal range
23776 9 Timeout Error of CAN-Receive-Frame check high
TSC1TE - active
23913 4 Sensor error glow plug control
23777 9 Passive Timeout Error of diagnostic line voltage; signal range
CAN-Receive-Frame TSC1TE; Setpoint check low
23778 9 Active Timeout Errorof 23914 3 Glow plug control; short circuit to battery
CAN-Receive-Frame TSC1TR
23914 4 Glow plug control; short circuit to ground
23779 9 Passive Timeout Error of
CAN-Receive-Frame TSC1TR 23914 5 Glow plug control; open load
23788 12 Timeout Error of CAN-Transmit-Frame 23914 5 Glow plug control release line; short
TrbCH; Status Wastegate circuit error
23793 9 Timeout Error of CAN-Receive-Frame 23914 11 Glow plug control; internal error
UAA10; AGS sensor service message 23914 12 Glow plug control; powerstage over
23794 9 Timeout Error of CAN-Receive-Frame temperature
UAA11; AGS sensor data 23919 2 Sensor air pump airpressure; plausibility
23895 13 Check of missing injector adjustment error
value programming (IMA) injector 1 (in 23920 2 Sensor exhaust gas back pressure
firing order) burner; plausibility error
23896 13 check of missing injector adjustment
value programming (IMA) injector 2 (in
firing order)
Part No. 1287209GT GTH-636 63


23936 12 Timeout Error of CAN-Transmit-Frame
SPN FMI Description EEC3VOL2; Engine send messages
23922 7 Burner Shut Off Valve; blocked closed 23946 0 Zerofuel calibration injector 1 (in firing
23922 7 Burner Shut Off Valve; blocked closed order); maximum value exceeded
23929 0 Fuel Balance Control integrator injector 23946 1 Zerofuel calibration injector 1 (in firing
1 (in firing order); maximum value order); minimum value exceeded
exceeded 23947 0 Zerofuel calibration injector 2 (in firing
23929 1 Fuel Balance Control integrator injector order); maximum value exceeded
1 (in firing order); minimum value 23947 1 Zerofuel calibration injector 2 (in firing
exceeded order); minimum value exceeded
23930 0 Fuel Balance Control integrator injector 23948 0 Zerofuel calibration injector 3 (in firing
2 (in firing order); maximum value order); maximum value exceeded
exceeded
23948 1 Zerofuel calibration injector 3 (in firing
23930 1 Fuel Balance Control integrator injector order); minimum value exceeded
2 (in firing order); minimum value
exceeded
order); maximum value exceeded
23931 0 Fuel Balance Control integrator injector
3 (in firing order); maximum value
order); minimum value exceeded
exceeded
23960 0 Physical range check high for EGR
cooler downstream temp.
exceeded
4 (in firing order); maximum value
exceeded
exceeded
23935 12 Timeout Error of CAN-Transmit-Frame
EEC3VOL1; Engine send messages
64 GTH-636 Part No. 1287209GT


24016 2 Amount of air is not plausible to pump
SPN FMI Description speed
23960 0 High exhaust gas temperature EGR 24016 2 Calculated amount of air is not plausible
cooler downstream; warning threshold to HFM reading
exceeded
24016 11 HFM sensor; electrical fault
23960 1 Physical range check low for EGR
24021 11 Burner fuel line pipe leak behind Shut
cooler downstream temp.
Off Valve
23960 1 High exhaust gas temperature EGR
24024 11 Deviation of the exhaust gas temp.
cooler downstream; shut off threshold
setpoint to actual value downstream
exceeded
(DOC) too high
23980 14 Bad quality of reduction agent detected
24028 2 CAN message PROEGRActr;
23981 11 Urea-tank without heating function plausibility error
(heating phase)
23982 0 Powerstage diagnosis disabled; high ComEGRActr - exhaust gas
battery voltage recirculation positioner
23982 1 Powerstage diagnosis disabled; low 24030 7 EGR actuator; internal error
battery voltage
24031 13 EGR actuator; calibration error
23988 3 Charging lamp; short circuit to battery
24032 2 EGR actuator; status message
23988 4 Charging lamp; short circuit to ground EGRCust is missing
23988 5 Charging lamp; open load 24033 7 EGR actuator; due to overload in Save
23988 12 Charging lamp; over temp. Mode
23998 4 Injector cylinder bank 2 slave; short 24034 3 Disc separator; short circuit to battery
circuit 24034 4 Disc separator; short circuit to ground
23999 12 Injector powerstage output Slave defect 24034 5 Disc Separator; open load
24014 1 Air pressure glow plug flush line; below 24034 12 Disc Separator; powerstage over
limit temperature
Part No. 1287209GT GTH-636 65


24108 9 Timeout error of CAN-Transmit-Frame
SPN FMI Description ComEGRTVActr
24035 12 Injector diagnostics; time out error in the 24109 9 Timeout error of CAN-Receive-Frame
SPI communication ComRxEGRTVActr
24057 2 Electric fuel pump; fuel pressure build 24110 9 Timeout error of CAN-Transmit-Frame
up error ComETVActr
24097 9 Timeout error of CAN-Transmit-Frame 24111 9 Timeout error of CAN-Receive-Frame
DPFBrnAirPmpCtl ComRxETVActr
24098 9 Timeout error of CAN-Transmit-Frame 24112 9 Timeout ComITVActr
ComDPFBrnPT
24113 9 Timeout error of CAN-Receive-Frame
24099 9 Timeout error of CAN-Transmit-Frame ComRxITVActr
ComDPFC1
24100 9 Timeout error of CAN-Transmit-Frame A1DOC
ComDPFHisDat
24101 9 Timeout error of CAN-Transmit-Frame AT1S
ComDPFTstMon
24102 9 Timeout error of CAN-Receive-Frame SCR2
ComRxDPFBrnAirPmpCtl
24103 9 Timeout error of CAN-Receive-Frame SCR3
ComRxDPFBrnAirPmp
24104 9 Timeout error of CAN-Receive-Frame ComRxCM1
ComRxDPFCtl
24105 9 Timeout error of CAN-Transmit-Frame ComRxCustSCR3
ComEGRMsFlw
24106 9 Timeout error of CAN-Receive-Frame ComRxSCRHtDiag
ComRxEGRMsFlw1
24107 9 Timeout error of CAN-Receive-Frame ComRxTrbChActr
ComRxEGRMsFlw2
ComRxUQSens
ComSCRHtCtl
ComTxAT1IMG
ComTxTrbChActr
66 GTH-636 Part No. 1287209GT

Schematics
About This Section

Section 5 Schem atics
There are two groups of schematics in this section.
Electrical Schematics
Observe and Obey: circuits could result in death or
 Troubleshooting and repair procedures shall watches and other jewelry.
be completed by a person trained and qualified
on the repair of this machine
Hydraulic Schematics
 Immediately tag and remove from service a
damaged or malfunctioning machine. Bodily injury hazard. Spraying
 Repair any machine damage or malfunction burn skin. Loosen hydraulic
before operating the machine.
Before Troubleshooting: the oil pressure to dissipate
 Read, understand and obey the safety rules squirt or spray.
 Be sure that all necessary tools and test
equipment are available and ready for use.
Part No. 1287209GT GTH-636 67

Fuse Panel Layout
Circuit Breakers located on the

Battery Tray
CB1- Telehandler Control System

Power
CB2- Engine Power / ECM
CB3- Glow Plugs
Fuse Board located in the Cab
68 GTH-636 Part No. 1287209GT

Electrical Component & Wire Color Abbreviation Legend

Item Description Item Description
ALT Alternator D Diode
B Battery EMS Engine Management System
B1 Main Battery F Fuse
CB Circuit Breaker F1 15 Amp - Break/Shift
CB1 50 Amp Circuit Breaker F2 10 Amp - Aux Hydraulics
CB2 30 Amp or 50 Amp Circuit Breaker F3 10 Amp – Rear Axle Oscillate
CB3 60 AMP Circuit Breaker F4 10 Amp – Sway/Tilt
CB4 20 Amp or 50 Amp Circuit Breaker F5 5 Amp - Horn
C Capacitor F6 5 Amp - Steer/Differential Switch
C1 4700 uf F7 5 Amp - Gauge Cluster Power
CR Control Relay F8 5 Amp - Dome/Beacon Light
CR1 Main Power F9 25 Amp – HVAC
CR2 Options Power F10 15 Amp – Windshield Wiper/Washer
CR3 Service Horn F11 10 Amp – Defrost Fan
CR4 Flasher F12 20 Amp – Lights
CR5 Lights Option F13 15 Amp – Ignition
CR6 Sway Enable F14 10 Amp – Power Port
CR7 Boom Angle F15 1 Amp - Switch Power
CR8 Boom Extend F16 1 Amp – Gauge Cluster ECU
CR9 Forward Enable F17 Not Used
CR10 Reverse Enable F18 Not Used
CR11 Parking Brake Latch F19 5 Amp - Telematics
CR12 Sway Left/Right Enable F20 1 Amp - Boom Angle Monitor
CR13 Tilt Up/Down Enable F21 5 Amp - HVAC Control Panel
CR14 Boom Angle Monitor
CR15 HVAC Blower L
CR16 HVAC Blower M
CR17 HVAC Blower H
Part No. 1287209GT GTH-636 69

Item Description Item Description

L LED Light S Switch
L1 Ignition Power ON S1 Key Start Switch
L2 Options Power Relay ON S4 Boom Extend Switch
L3 Horn Relay ON S5 Parking Brake Pressure Switch
L4 Turn Signal ON S6 Service Brake Pressure Switch
L5 Road Lights, Work Lights ON S7 Sway Enable Pressure Switch
L6 Sway Enable Coil Power ON S8 Sway Enable Switch
L9 Brake Pressure ON S9 Tilt Enable Switch
L10 Backup Light, Alarm ON S10 Steer Select Switch
L11 Parking Brake Latch ON S11 Left Stabilizer Switch
L12 Sway Enable ON S12 Right Stabilizer Switch
L13 Tilt Circuit Power ON S13 Differential Lock Switch
L14 Horn Power ON S14 Auxiliary Cont. Switch
L15 Cab, Tail Light Power ON S15 Horn Switch
L16 Rear Axle Float Coil Power ON S16 Brake Light Pressure Switch
L18 Parking Brake Power ON S17 Windshield Wiper Motor Switch
L19 Forward Coil Power ON S17 Windshield Washer Switch
L20 Reverse Coil Power ON S18 Windshield Wiper Motor Switch
L21 PB Release Coil Power ON S18 Windshield Washer Switch
L22 Sway L/R Enable Coil Power ON S19 Dome Light Switch
L23 Tilt U/D Enable Coil Power ON S21 Enclosed Cab Fan Switch
L24 Forward Shift ON S22 Road / Work Light Switch
L25 Parking Brake Release OFF S23 Brake Pressure Warning Switch
L26 Brake Light Power ON S24 Transmission Oil Pressure Switch
L27 Hazard Power ON S25 Transmission Oil Temp. Switch
L28 Not Used S26 EAT Standstill Switch
M Motor TP Throttle Pedal
R Resistor TSS Turn Signal Shifter
70 GTH-636 Part No. 1287209GT

Item Description Wire Color Legend

Y Valve Coil BL Blue
Y1 Sway Left Enable SV1 BL/BK Blue/Black
Y2 Tilt Up Enable SV2 BL/RD Blue/Red
Y3 Sway Right Enable SV3 BL/WH Blue/White
Y4 Tilt Down Enable SV4 BK Black
Y5 Parking Brake Release SV5 BK/RD Black/Red
Y6 Differential Lock SV6 BK/WH Black/White
Y7 Rear Axle Float SV7 BK/YL Black/Yellow
Y8 Rear Axle Fast SV8 BR Brown
Y9 Sway Enable SV9 GR Green
YA Auxiliary A GR/BK Green/Black
YB Auxiliary B GR/WH Green/White
YD D Transmission RD Red
YE E Transmission RD/BK Red/Black
YF Transmission Forward RD/WH Red/White
YR Transmission Reverse OR Orange
YD1A 4Wheel Steer SVD1A OR/BK Orange/Black
YD1B Crab Steer SVD1B OR/RD Orange/Red
YLD Left Stabilizer Down WH White
YLU Left Stabilizer Up WH/BK White/Black
YRD Right Stabilizer Down WH/RD White/Red
YRU Right Stabilizer Up YL Yellow
OR/WH Orange/White
Part No. 1287209GT GTH-636 71

Telematics Connector Pin Legend
Genie installed Telematics connector is wired with an Active High digital input.
Pin Circuit Type Circuit Properties Genie Machine Function(s) Telematics Use Case
1 System Power 12 VDC Battery Positive – constant power Supply power to device
5 Amp Max. allowed
draw
2 System Ground 0 VDC Battery Negative Device Ground
3 Digital Output 1 12 VDC Engine Run Hour Meter Monitor Engine Hours
12V = engine run, 0V = engine off
4* Digital Output 2 12 VDC Boom Angle Status Monitor Machine Utilization
12V = boom >55°, 0V <55°
5 Digital Output 3 12 VDC Parking Brake Monitor Machine Utilization
12V = active, 0V = inactive
6 Digital Input 1 12 VDC (standard) Remote Disable Engine Start Remotely Prevent Engine
or Ground (optional) Start
7 CAN HIGH J1939 Databus HIGH J1939 Receive J1939 Engine Data
8 CAN LOW J1939 Databus LOW J1939 Receive J1939 Engine Data
* Not available on GTH-636
72 GTH-636 Part No. 1287209GT

Telematics Connector Pin Legend
Remote Disable Engine Start Relay Configuration
Telematics Active High - Schematic Telematics Active Low - Schematic

(standard wiring) (optional wiring)
1 Ignition Start Input

2 Relay
3 Telematics with Active High input
4 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
Part No. 1287209GT GTH-636 73

Electrical Symbol Legend
Battery Coil, solenoid or relay Horn or alarm Flashing beacon Gauge
Diode Hour meter LED Fuse with amperage Foot switch
T-circuits connect Limit Switch Power relay Coil with suppression Fuel or RPM solenoid
T-circuits connect at Circuits crossing no Quick disconnect Circuit breaker with

Connection - no terminal
terminal connection terminal amperage
Key switch Toggle Switch DPDT Toggle Switch SPDT Pump or Motor Tilt sensor
Horn button - normally Emergency Stop button

Resistor with ohm value 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
74 GTH-636 Part No. 1287209GT

Hydraulic Symbols Legend
Orifice with size Check valve Shut off valve Brake
Pump, bi-directional Motor, 2 speed

Pump, fixed displacement Motor, bi-directional
variable displacement bi-directional
Pump, prime mover (engine Shuttle valve. 2 position, 3

Cylinder, double acting Differential sensing valve
or motor) way
Filter with bypass relief Relief valve with pressure Solenoid operated
Priority flow regulator valve
valve setting proportional valve
Solenoid operated 2
Directional valve Pilot operated 3 position, 3
Flow divider/combiner valve position, 3 way directional
(mechanically activated) way shuttle valve
valve
Solenoid operated 3 Solenoid operated 3

Counterbalance valve with Solenoid valve, 2 position 2
position 4 way directional position, 4 way proportional
pressure and pilot ratio way
valve directional valve
Part No. 1287209GT GTH-636 75

Harness Map Legend
Base Harnesses Work Light Option Harnesses

(included In all models)
Item Part Description
20 1258527 Harness, Light, Led, Clear, 5" Round
1 1283065 Harness, Dashboard
21 1258775 Harness Cab Light Power
2 1282182 Harness, Secondary Manifold
22 1256520 Harness, Boom Light Power
3 1256744 Harness, Telematics
23 237934 Harness, Backup Light
4 826149 Harness, Transmission
24 1258528 Harness, Work Lights
5 1258119 Harness, Throttle Pedal
Road Light Option Harnesses
6 231257 Cable, Battery Black 2/0
7 237933 Harness, Pcb Ground
20 1258527 Harness, Light, Led, Clear, 5" Round
8 161444 Assembly, Ground Buss
21 1258775 Harness Cab Light Power
9 824612 Plate, Buss Bar
22 1256520 Harness, Boom Light Power
10 219457 Harness, Backup Alarm
23 237934 Harness, Backup Light
11 161524 Assembly, Power Buss
25 1255589 Harness, Road Lights
12 1283713 Harness, Primary PVG
26 229677 Harness, Taillight Led
13 1283942 Harness, CAN Interface Jumper
27 1253241 Harness,light,drive,clear,3led
Engine Options Harnesses
28 1255647 Harness, Light, Turn Signal,ambr
29 1258919 Harness, Front Lights Power
14 823005 Harness, Engine ECU, TD2.9
Enclosed Cab With HVAC Option Harnesses
15 823349 Harness, Engine Base, TD2.9
16 1251991 Cable, Battery, Red 2/0
30 1257913 Harness, Enclosed Cab
17 1283272 Harness, Diagnostic Plug Ext
31 234859 Harness, Cab Fan
18 219337 Harness,Fuel Pressure Switch
32 233940 Harness, Power, Dome Light
Beacon Light Option Harnesses
33 123817 Dome Light With Connector
35 238126 Harness, Cab A/C
38 229683 Harness Beacon Light
36 1258956 Harness, A/C GTH636
39 229682 Harness, Power, Beacon Light
37 1260044 Fan Assy, Condenser 12V 18A
3rd Gear Lockout Option Harness
Enclosed Cab With Heat Option Harnesses
19 162281 Harness, 3rd Gear Bypass
30 1257913 Harness, Enclosed Cab
31 234859 Harness, Cab Fan
32 233940 Harness, Power, Dome Light
33 123817 Dome Light With Connector
34 234861 Harness, Cab Heater
Rear Proximity Alarm Option
40 1257991 Harness,Rear Prox Alarm,GTH
76 GTH-636 Part No. 1287209GT

Harness Map - Control System

Electronic Joystick
77
Harness Map - Control System Electronic Joystick
78 GTH-636 Part No. 1287209GT

Harness Map - Deutz TD2.9 Engine

Battery Power and Ground
79
Harness Map - Deutz TD2.9 Engine Battery Power and Ground
80 GTH-636 Part No. 1287209GT

Harness Map - Options Auxiliary Hydraulics, Beacon and 3rd Gear Lockout
Part No. 1287209GT GTH-636 81

Harness Map - Options Auxiliary Hydraulics, Beacon and 3rd Gear Lockout
82
Harness Map - Options

Work Lights
83

Work Lights
84 GTH-636 Part No. 1287209GT


Road Lights
Part No. 1287209GT GTH-636 85

Harness Map - Options Road Lights
86

Enclosed Cab with Heater
87

Enclosed Cab with Heater
88 GTH-636 Part No. 1287209GT


Enclosed Cab with HVAC
Part No. 1287209GT GTH-636 89


Enclosed Cab with HVAC
90
Electrical Schematic - View 1
91
92 GTH-636 Part No. 1287209GT

Part No. 1287209GT GTH-636 93

94
Electrical Schematic - Deutz T4F Eng Harness
95
Electrical Schematic - Deutz T4F Eng Harness
96 GTH-636 Part No. 1287209GT

Hydraulic Schematic
Part No. 1287209GT GTH-636 97

Hydraulic Schematic
98
GTH-636 Part No. 1287209GT Servic e and R epair M anual April 2018

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Service and Repair Manual

Serial Number Range

GTH™-636 from GTH06E-11750

For detailed maintenance

Part No. 1287209GT

Important Technical Publications

Machine Design Life

Copyright © 2016 by Terex Corporation

Second Edition, First Printing

"GTH" is a trademark of Terex South Dakota, Inc.

ii GTH-636 Part No. 1287209GT

Part No. 1287209GT GTH-636 iii

Serial Number Legend

1 Model 1 Serial label (located inside riser, cab side)

1 Model 1 Serial label (located inside riser, cab side)

iv GTH-636 Part No. 1287209GT

Do Not Perform Maintenance

Part No. 1287209GT GTH-636 v

Personal Safety Workplace Safety

vi GTH-636 Part No. 1287209GT

Section 1 Safety Rules .......................................................................................................... v

Section 2 Specifications ....................................................................................................... 1

Section 3 Repair Procedures ............................................................................................. 11

Boom Components ............................................................................................ 13

Part No. 1287209GT GTH-636 vii

1-2 Boom Lift Cylinder ..........................................................................................21

Operator's Compartment ...................................................................................27

Fuel and Hydraulic Tanks ..................................................................................32

Hydraulic Pump ..................................................................................................36

viii GTH-636 Part No. 1287209GT

Section 4 Fault Codes ......................................................................................................... 51

Diagnostic Display ............................................................................................. 52

Deutz TD 2.9 L4 Engine Fault Codes ................................................................ 53

Part No. 1287209GT GTH-636 ix

Electrical Schematics - Harness Maps .............................................................77

Electrical Schematics .........................................................................................91

Hydraulic Schematics ........................................................................................99

x GTH-636 Part No. 1287209GT

Machine Specifications Performance Specifications

Tire pressure 58 psi Boom function speeds, maximum

Wheel width 10 in Fork tilt up 6 to 8 seconds

Fuel tank 27 gallons

Part No. 1287209GT GTH-636 1

Hydraulic Oil Specifications Do not top off with incompatible

Note: Extended machine operation can cause the

2 GTH-636 Part No. 1287209GT

Chevron Rando HD Premium Oil Chevron 5606A Hydraulic Oil

Part No. 1287209GT GTH-636 3

Maximum continuous operating 180°F / 82°C Flash point None

4 GTH-636 Part No. 1287209GT

Hydraulic Component Manifold Component

Part No. 1287209GT GTH-636 5

Deutz TD 2.9 L4 Engine Oil temperature switch

Compression ratio 17.4:1 Injector opening pressure 3046 psi

6 GTH-636 Part No. 1287209GT

Dana VDT12000 Transmission Dana 212 Drive Axle

Part No. 1287209GT GTH-636 7

Hydraulic Hose and Fitting

-16 1 5/16-12 1 -5 ORFS (Adj / Non adj) 32 ft lbs / 43.4 Nm