Parts Manual Service Manual: Serial Number Range Serial Number Range

Parts Manual
Service Manual
Serial
Serial
Number
Number
Range
Range
from GTH0813-16606
GTH-844
TM
Part No. 218230

Rev B4
September 2015
September 2015
Introduction
Important Serial Number Information

Read, understand and obey the safety rules and Genie offers the following Service Manuals for
operating instructions in the appropriate operator's these models:
manual before attempting any maintenance or
repair procedure. Title Part No.
This manual provides detailed scheduled GTH-844A

maintenance information for the machine owner and (from serial number 8418 to 16605) .................... 97487
user. It also provides troubleshooting fault codes GTH-844B
and repair procedures for qualified service (from serial number 6946 to 16605) .................... 97487
professionals.
Basic mechanical, hydraulic and electrical skills are
required to perform most procedures. However,
several procedures require specialized skills, tools,
lifting equipment and a suitable workshop. In these
instances, we strongly recommend that
maintenance and repair be performed at an
authorized dealer service center.
Compliance
Machine Design Life
Unrestricted with proper operation, inspection and
scheduled maintenance.
Technical Publications
Genie has endeavored to deliver the highest degree
of accuracy possible. However, continuous
improvement of our products is a Genie policy.
Therefore, product specifications are subject to
change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All Copyright © 2012 by Terex Industries
communications will be carefully considered for
218230 Rev B May 2014
future printings of this and all other manuals. Second Edition, Second Printing
"Genie" is a registered trademark of Terex

Contact Us: South Dakota, Inc. in the USA and many other
countries. "GTH" is a trademark of Terex South
www.genielift.com Dakota, Inc.
e-mail: awp.techpub@terex.com
Printed on recycled paper
Printed in U.S.A.
ii GTH-844 Part No. 218230

September 2015
Revision History
Revision Date Section Procedure / Schematic Page / Description
A 11/2012 New Release
A1 03/13 3 3-19
B 05/14 Specifications Hydraulic Oil
Maintenance B-10 Fork Level and Auxiliary hose tension

Repair 1-6 Fork Level and Auxiliary hydraulic hoses
Schematics Telematics connector legend; electrical schematic;

hydraulic schematic- single and dual joysticks
Harness Maps
B1 09/14 Fault Codes Display Gauge; Deutz Fault Codes

B2 01/15 Schematics electrical schematic, harness maps- options
B3 05/15 Fault Codes Deutz Fault Codes
Schematics Fuse Panel Legend

B4 09/15 Schematics Hydraulic Schematics
REFERENCE EXAMPLES:
Kubota Engine_Section 2_Specifications. Electronic Version

A-6,B-3,C-7_Section 3_Maintenance Procedure.
3-2, 6-4, 9-1_Section 4_Repair Procedure. Click on any procedure or page number
Fault Codes_Section 5. highlighted in blue to view the update.
6-35, 6-56, 6-104_Section 6_Schematic Page #.
Part No. 218230 GTH-844 iii

September 2015
REVISION HISTORY, CONTINUED
Revision Date Section Procedure / Schematic Page / Description
REFERENCE EXAMPLES:
Kubota Engine_Section 2_Specifications. Electronic Version

A-6,B-3,C-7_Section 3_Maintenance Procedure.
3-2, 6-4, 9-1_Section 4_Repair Procedure. Click on any procedure or page number
Fault Codes_Section 5. highlighted in blue to view the update.
6-35, 6-56, 6-104_Section 6_Schematic Page #.
iv GTH-844 Part No. 218230

September 2015
INTRODUCTION
Serial Number Legend
A TEREX BRAND
MODEL: GTH844
SERIAL NUMBER:GTH0810-12101
ATTACHMENT:
MANUFACTURE DATE:04/12/10
TOTAL TRUCK WEIGHT(LBS): 22,600lbs / 10252kg
MAX LIFT CAPACITY(LBS):
8000 LBS
LIFT CAPACITY(LBS)
AT MAX LIFT HEIGHT: 6000 LBS
GTH08 10 - 12101
OUTRIGGERS UP: N/A
OUTRIGGERS DOWN: N/A Model Sequence
COUNTRY OF MANUFACTURE: United States number
MANUFACTURER: Year of
Terex South Dakota, Inc. manufacture
500 Oakwood Road
Watertown, SD 57201 Facility code
United States
THIS FORKLIFT TRUCK COMPLIES

WITH:
ANSI/ITSDF B56.6-2011
CSA B335-04
Serial label
(located inside chassis frame plate on cab side)
Serial label
Serial number (located inside fork frame)
(stamped on chassis) (models with quick attach frame)
Part No. 218230 GTH-844 v

September 2015
This page intentionally left blank.
vi GTH-844 Part No. 218230

September 2015 Section 1 • Safety Rules
Safety Rules
Personal Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Read each procedure thoroughly. This

manual and the decals on the machine,
Danger use signal words to identify the following:
Failure to obey the instructions and safety rules Safety alert symbol—used to alert
in this manual and the appropriate operator's personnel to potential personal
manual on your machine will result in death or injury hazards. Obey all safety
serious injury. messages that follow this symbol
to avoid possible injury or death.
Many of the hazards identified in the
Indicates an imminently hazardous
operator’s manual are also safety hazards
situation which, if not avoided, will
when maintenance and repair procedures
result in death or serious injury.
are performed.
Indicates a potentially hazardous
Do Not Perform Maintenance situation which, if not avoided,
Unless: could result in death or serious
injury.
You are trained and qualified to perform
maintenance on this machine.
situation which, if not avoided,
You read, understand and obey: may cause minor or moderate
- manufacturer’s instructions and safety rules injury.
- employer’s safety rules and worksite
regulations
- applicable governmental regulations
may result in property damage.
You have the appropriate tools, lifting Be sure to wear protective eye wear and
equipment and a suitable workshop. other protective clothing if the situation
warrants it.
Be aware of potential crushing hazards

such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved
steel-toed shoes.
Part No. 218230 GTH-844 vii

Section 1 • Safety Rules September 2015
SAFETY RULES
Workplace Safety
Be sure to keep sparks, flames and
lighted tobacco away from flammable and
combustible materials like battery gases
and engine fuels. Always have an
approved fire extinguisher within easy
reach.
Be sure that all tools and working areas

are properly maintained and ready for
use. Keep work surfaces clean and free of
debris that could get into machine
components and cause damage.
Be sure any forklift, overhead crane or
other lifting or supporting device is fully
capable of supporting and stabilizing the
weight to be lifted. Use only chains or
straps that are in good condition and of
ample capacity.
Be sure that fasteners intended for one

time use (i.e., cotter pins and self-locking
nuts) are not reused. These components
may fail if they are used a second time.
Be sure to properly dispose of old oil or
other fluids. Use an approved container.
Please be environmentally safe.
Be sure that your workshop or work area

is properly ventilated and well lit.
viii GTH-844 Part No. 218230

September 2015
Table of Contents
Introduction
Important Information ......................................................................................... ii
Serial Number Legend ....................................................................................... iii
Section 1 Safety Rules

General Safety Rules ........................................................................................ v
Section 2 Specifications
Machine Specifications ................................................................................ 2 - 1
Performance Specifications ......................................................................... 2 - 2
Hydraulic Specifications ............................................................................... 2 - 3
Hydraulic Component Specifications ............................................................ 2 - 4
Manifold Component Specifications ............................................................. 2 - 5
Air Conditoner Refrigerant Specification ....................................................... 2 - 5
Deutz TCD3.6 Engine ................................................................................... 2 - 6
Perkins 1104D-E44TA Engine ...................................................................... 2 - 7
Perkins 854-E34TA Engine .......................................................................... 2 - 8
Dana VDT12000 Transmission ..................................................................... 2 - 9
Carraro 26.27M Drive Axle ........................................................................... 2 - 9
Hydraulic Hose and Fitting Torque Specifications ....................................... 2 - 10
SAE and Metric Fasteners Torque Charts .................................................. 2 - 11
Section 3 Scheduled Maintenance Procedures

Introduction .................................................................................................. 3 - 1
Pre-delivery Preparation Report .................................................................... 3 - 3
Maintenance Inspection Report .................................................................... 3 - 5
Part No. 218230 GTH-844 ix

September 2015
TABLE OF CONTENTS
Section 3 Scheduled Maintenance Procedures, continued

Checklist A Procedures
A-1 Inspect the Manuals and Decals ......................................................... 3 - 5
A-2 Perform Pre-operation Inspection ........................................................ 3 - 6
A-3 Perform Function Tests ...................................................................... 3 - 6
A-4 Lubricate the Boom ............................................................................. 3 - 6
A-5 Perform Engine Maintenance - All Models ........................................... 3 - 7
A-6 Perform Transmission Maintenance .................................................... 3 - 8
A-7 Perform 30 Day Service ...................................................................... 3 - 8
A-8 Perform Axle Maintenance .................................................................. 3 - 9
A-9 Perform Transmission Maintenance .................................................... 3 - 9
A-10 Perform Axle Maintenance .................................................................. 3 - 9
Checklist B Procedures
B-1 Inspect the Battery ........................................................................... 3 - 10
B-2 Inspect the Electrical Wiring ............................................................. 3 - 11
B-3 Check the Exhaust System .............................................................. 3 - 12
B-4 Inspect the Engine Air Filter .............................................................. 3 - 13
B-5 Inspect the Tires, Wheels and Lug Nut Torque .................................. 3 - 13
B-6 Perform Hydraulic Oil Analysis ......................................................... 3 - 14
B-7 Inspect the Fuel and Hydraulic Tank Cap Venting Systems .............. 3 - 14
B-8 Perform Engine Maintenance - Deutz Models ................................... 3 - 15
B-9 Check the Boom Wear Pads ............................................................. 3 - 16
B-10 Inspect the Fork Level and Auxiliary Hoses ...................................... 3 - 17
B-11 Perform Axle Maintenance ................................................................ 3 - 17
x GTH-844 Part No. 218230

September 2015
TABLE OF CONTENTS
Section 3 Scheduled Maintenance Procedures, continued

Checklist C Procedures
C-1 Perform Engine Maintenance - Deutz Models ................................... 3 - 18
C-2 Perform Engine Maintenance - Perkins Models ................................. 3 - 18
C-3 Perform Engine Maintenance - Perkins Models ................................. 3 - 19
C-4 Inspect and Lubricate the Sequencing Chains ................................... 3 - 19
Checklist D Procedures
D-1 Inspect the Forks .............................................................................. 3 - 21
D-2 Adjust the Boom Sequencing Chains ................................................ 3 - 21
D-3 Replace the Hydraulic Tank Return Filter Element ............................ 3 - 22
D-4 Perform Transmission Maintenance .................................................. 3 - 23
D-5 Perform Engine Maintenance - Deutz Models ................................... 3 - 23
D-6 Perform Engine Maintenance - Perkins Models ................................. 3 - 24
D-7 Perform Axle Maintenance ................................................................ 3 - 24
D-8 Perform Engine Maintenance - Perkins Models ................................. 3 - 25
Checklist E Procedures
E-1 Test or Replace the Hydraulic Oil ...................................................... 3 - 26
E-2 Perform Engine Maintenance - Perkins Models ................................. 3 - 27
E-4 Perform Engine Maintenance - Deutz Models ................................... 3 - 28
E-6 Perform Engine Maintenance - Deutz Models ................................... 3 - 29
Part No. 218230 GTH-844 xi

September 2015
TABLE OF CONTENTS
Section 4 Repair Procedures

Introduction .................................................................................................. 4 - 1
Boom Components
1-1 Boom Proximity Switches ................................................................... 4 - 2
How to Test a Proximity Switch
How to Adjust the Boom Angle Proximity Switch
1-2 Boom .................................................................................................. 4 - 3
How to Replace the Boom Wear Pads
How to Remove the Lifting Fork Frame
How to Replace the Retraction Chain
How to Replace the Extension Chains
How to Remove the Boom
How to Disassemble the Boom
1-3 Boom Lift Cylinder ............................................................................ 4 - 10
How to Remove the Lift Cylinder
1-4 Boom Extension Cylinder ................................................................. 4 - 12
How to Remove the Extension Cylinder
1-5 Fork Level Cylinder ........................................................................... 4 - 12
How to Remove the Fork Level Cylinder
1-6 Hydraulic Hoses ............................................................................... 4 - 13
How to Adjust the Fork Level and/or Auxiliary Hoses
How to Replace the Fork Level and/or Auxiliary Hoses
Operator's Compartment
2-1 Operator's Compartment ................................................................... 4 - 16
How to Remove the Operator's Compartment
xii GTH-844 Part No. 218230

September 2015
TABLE OF CONTENTS
Section 4 Repair Procedures, continued

2-2 Machine Controls .............................................................................. 4 - 18
How to Remove the Steering Column
How to Remove the Steering Wheel
How to Remove the Steer Orbitral
How to Remove the Joystick - Single Joystick
How to Remove the Joystick - Dual Joysticks
How to Remove the Brake Pedal Assembly
How to Remove the Gauge Cluster Assembly
Fuel and Hydraulic Tanks
3-1 Fuel and Hydraulic Tanks ................................................................. 4 - 22
How to Remove the Fuel and Hydraulic Tank Assembly
Engines
4-1 Engines ............................................................................................ 4 - 23
How to Repair the Perkins 1104D-E44TA Engine
How to Repair the Perkins 854E-34TA Engine
How to Repair the Deutz TCD3.6 Engine
4-2 Engine Fault Codes .......................................................................... 4 - 32
How to Retrieve Engine Fault Codes
Transmission
5-1 Transmission .................................................................................... 4 - 24
How to Repair the Transmission
Hydraulic Pumps
6-1 Hydraulic Pump ................................................................................ 4 - 26
How to Test the Function Pump
How to Remove the Function Pump
How to Install the Function Pump
How to Prime the Function Pump
How to Adjust the Function Pump Standby Pressure
How to Adjust the Function Pump Pressure Compensator
Part No. 218230 GTH-844 xiii

September 2015
TABLE OF CONTENTS
Section 4 Repair Procedures, continued

Manifolds
7-1 Primary Function Manifold Components -
Models with Single Joystick ............................................................. 4 - 30
7-2 Primary Function Manifold Components -
Models with Dual Joysticks .............................................................. 4 - 34
7-3 Secondary Function Manifold Components ....................................... 4 - 38
7-4 Auxiliary Manifold (option) and Brake Manifold Components ............. 4 - 40
7-5 Valve Adjustments - Secondary Function Manifold ........................... 4 - 41
How to Set the Steer System Pressure
How to Set the Parking Brake System Pressure
How to Set the Differential Lock/Joystick Pressure
How to Set the Rear Lock-up System Pressure
7-6 Valve Coils ....................................................................................... 4 - 45
How to Test a Coil
Valve Coil Resistance Specification
How to Test a Coil Diode
Axle Components
8-1 Axles ................................................................................................ 4 - 47
How to Remove the Axle
xiv GTH-844 Part No. 218230

September 2015
TABLE OF CONTENTS
Section 5 Fault Codes

Introduction .................................................................................................. 5 - 1
Diagnostic Display ....................................................................................... 5 - 2
Engine Fault Codes - Deutz Models ............................................................. 5 - 3
Engine Fault Codes - Perkins 1104D Models .............................................. 5 - 21
Section 6 Schematics
Introduction .................................................................................................. 6 - 1
Fuse Panel Layout (before SN GTH0815-20630) .......................................... 6 - 2
Fuse Panel Layout (from SN GTH0815-20630) ............................................. 6 - 3
Electrical Component & Wire Color Legend .................................................. 6 - 4
Telematics Connector Legend ...................................................................... 6 - 5
Electrical and Hydraulic Symbols Legends ................................................... 6 - 7
Harness Map - Control System Power_SJ .................................................. 6 - 10
(before SN GTH0815-20662)
Harness Map - Control System Power_SJ .................................................. 6 - 11
Harness Map - Control System Ground_SJ ................................................ 6 - 14
(from SN GTH0815-20662)
Harness Map - Control System Ground_SJ ................................................ 6 - 15
(from SN GTH0815-20662)
Harness Map - Control System Power_DJ .................................................. 6 - 18
Harness Map - Control System Power_DJ .................................................. 6 - 19
Harness Map - Control System Ground_DJ ................................................ 6 - 22
(from SN GTH0815-20662)
Harness Map - Control System Ground_DJ ................................................ 6 - 23
(from SN GTH0815-20662)
Part No. 218230 GTH-844 xv

September 2015
Section 6 Schematics, continued
Harness Map - Deutz TCD3.6 Engine

Battery Power & Ground ............................................................................. 6 - 26
Harness Map - Perkins 1104D Engine
Harness Map - Perkins 854E Engine
Harness Map - Options
Aux Hydraulics, Beacon & 3rd Gear Lockout .............................................. 6 - 31
Work Lights ................................................................................................ 6 - 34
Road Lights ................................................................................................ 6 - 35
Enclosed Cab with Heater .......................................................................... 6 - 38
Enclosed Cab with HVAC ........................................................................... 6 - 39
Electrical Schematic - View 1 ..................................................................... 6 - 42
Electrical Schematic - View 2 ..................................................................... 6 - 43
Hydraulic Schematic - Single Joystick ....................................................... 6 - 46
(before serial number 19529)
Hydraulic Schematic - Single Joystick ....................................................... 6 - 47
(from serial number 19529)
Hydraulic Schematic - Dual Joysticks ........................................................ 6 - 50
Hydraulic Schematic - Dual Joysticks ........................................................ 6 - 51
xvi GTH-844 Part No. 218230

May 2014 Section 2 • Specifications
Specifications
Machine Specifications Tires and wheels
Tire size 13.00 x 24

Fluid capacities
Tire ply rating 12
Fuel tank 35 gallons
132.5 liters Weight, rough terrain tire 315 lbs
Hydraulic tank 40 gallons (air filled) 142.9 kg
151.4 liters Weight, rough terrain tire 967 ±35 lbs
Hydraulic system 55 gallons (foam filled) 439 ±16 kg
(including tank) 208.2 liters
Tire pressure 62 psi
(models with air-filled tires) 4.3 bar
Lug nut torque 295 ft-lbs

For operational specifications, refer to the 400 Nm
Operator's Manual.
Lug pattern 8 x 10.826
Wheel diameter 24 in
60.1 cm
Wheel width 9 in
22.9 cm
Continuous improvement of our products is a

Genie policy. Product specifications are
subject to change without notice.
Part No. 218230 GTH-844 2-1

Section 2 • Specifications May 2014
SPECIFICATIONS
Performance Specifications Boom function speeds, maximum
Drive speed, maximum Boom up 12 to 14 seconds

Deutz 3.6 TCD Engines 15 mph Boom down 9 to 11 seconds
24.1 km/h
Perkins 1104D Engine 14 mph Boom extend 13 to 15 seconds
22.5 km/h
Perkins 854 Engine 16 mph Boom retract 8 to 10 seconds
25.7 mph
Fork rotate 3 to 6 seconds
Draw bar pull 21,000 lbs
9525 kg Fork tilt up 6 to 8 seconds
Lift capacity, maximum 8000 lbs Fork tilt down 5 to 7 seconds

3629 kg

2-2 GTH-844 Part No. 218230

SPECIFICATIONS
Hydraulic Specifications Do not top off with incompatible

hydraulic fluids. Hydraulic fluids
Hydraulic Fluid Specifications may be imcompatible due to the
differences in base additive
Genie specifications require hydraulic oils which are chemistry. When incompatible
designed to give maximum protection to hydraulic fluids are mixed, insoluble
systems, have the ability to perform over a wide materials may form and deposit in
temperature range, and the viscosity index should the hydraulic system, plugging
exceed 140. They should provide excellent antiwear,
hydraulic lines, filters, control
oxidation, corrosion inhibition, seal conditioning, and
foam and aeration suppression properties.
valves and may result in
component damage.
Cleanliness level, minimum 15/13
Note: Do not operate the machine when the
Water content, maximum 250 ppm ambient air temperature is consistently above
120°F / 49°C.
Recommended Hydraulic Fluid
Hydraulic oil type Chevron Rando HD Premium MV Hydraulic Fluid Temperature Range
Viscosity grade 32
Viscosity index 200
Optional fluids 1
Biodegradable Petro Canada Environ MV 46 2
Fire resistant UCON Hydrolube HP-5046 3
Mineral based Shell Tellus S2 V 32 4

Shell Tellus S2 V 46
Chevron Hydraulic Oil 5606A
-40 -22 -4 14 32 50 68 86 104 122 F
-40 -30 -20 -10 -0 10 20 30 40 50 C
Note: Genie specifications require additional

1 Chevron hydraulic oil 5606A
equipment and special installation instructions for 2 Petro-Canada Environ MV 46
the approved optional fluids. Consult the Genie 3 UCON Hydrolube HP-5046D
Service Department before use. 4 Chevron Rando HD Premium MV
Optional fluids may not have the

same hydraulic lifespan and 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. Continuous improvement of our products is a
Genie policy. Product specifications are subject
to change without notice.
Part No. 218230 GTH-844 2-3

Chevron Rando HD Premium MV oil Chevron 5606A hydraulic oil fluid

fluid properties 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 Brookfield Viscosity
cP @ -22°F / -30°C 3310 cP @ -4°F / -20°C 1040
cP @ -22°F / -30°C 3310
Flash Point 375°F / 190°C
Pour Point -58°F / -50°C
Maximum continuous operating 171°F / 77°C
temperature Maximum continuous operating 124°F / 51°C
temperature
Note: An hydraulic oil heating system is

recommended when the ambient termperature is Note: Use of Chevron 5606A hydraulic fluid, or
consistently below 0°F / -18°C. equivalent, is required when ambient termperatures
are consistently below 0°F / -18°C unless an oil
Note: Do not operate the machine when the heating system is used.
ambient temperature is below -20°F / -29°C with
Rando HD Premium MV. Continued use of Chevron 5606A
hydraulic fluid, or equivalent, when
ambient temperatures are
consistently above 32°F / 0°C may
result in component damage.

2-4 GTH-844 Part No. 218230

Petro-Canada Environ MV 46 oil fluid

properties
ISO grade 46
Viscosity index 154
Kinematic Viscosity
cSt @ 200°F / 100°C 8
cSt @ 104°F / 40°C 44.4

temperature
UCON Hydrolube HP-5046 hydraulic oil

fluid properties
ISO grade 46
Viscosity index 192
Kinematic Viscosity
cSt @ 200°F / 100°C 22
cSt @ 104°F / 40°C 46
cSt @ -40°F / -40°C 1300
Flash Point None

temperature

Part No. 218230 GTH-844 2-5

SPECIFICATIONS
Hydraulic Components Primary Function Manifold

Specifications System relief valve pressure, maximum 35000 psi
(measured at test port TP) 241 bar
Function Pump
Fork tilt relief valve pressure, maximum 3500 psi
Type: variable displacement piston pump 241 bar
Displacement 0 to 3.1 cu in Flow regulator, 2 gpm

0 to 51 cc Sway circuit 7.5 L/min
Flow rate @ 2500 rpm 34 gpm Secondary Function Manifold

128 L/min
Steer relief valve pressure, maximum 2650 psi
Pump pressure, maximum 3190 psi (measured at test port TS) 182.7 bar
220 bar
Parking brake relief valve pressure, maximum 350 psi
Pressure compensator 3190 psi (measured at test port TPB) 24.1 bar
220 bar
Diff lock relief valve pressure, maximum 400 psi
Standby pressure 450 psi (measured at test port TJ) 27.5 bar
31 bar
Rear lock-up relief valve pressure, maximum 50 psi
(measured at test port TR) 3.4 bar

2-6 GTH-844 Part No. 218230

SPECIFICATIONS
Manifold Component
Specifications
Plug torque
SAE No. 2 50 in-lbs / 6 Nm
SAE No. 4 13 ft-lbs / 18 Nm
Air Conditioner Refrigerant

Specifications
System Full Charge
R134a 1 lb 14 oz

Part No. 218230 GTH-844 2-7

SPECIFICATIONS
Deutz TCD3.6 L4 Engine Fuel requirement
Displacement 221 cu in For fuel requirements, refer to the engine Operator's

3.62 liters Manual on your machine.
Number of cylinders 4 Fuel injection pressure, maximum 23200 psi

1600 bar
Bore & stroke 3.86 x 4.72 inches
98 x 120 mm Engine coolant
Horsepower 99 @ 2300 rpm Capacity 4.5 gallons

73.8 kw @ 2300 rpm 17 liters
Peak Torque 288 lb-ft @ 1600 rpm Type Extended Life

390 Nm @ 1600 rpm Alternator
Firing order 1-3-4-2 Output 95 A, 12V DC
Compression ratio 17.2:1 Starter Motor
Combustion Direct injection Normal load 300-400 A
Governor Electronic Relay max 60 A
Low idle 1000 rpm Relay continuous 12 A
Frequency 200 Hz
Cranking speed >100 rpm
High idle 2400 rpm
Frequency 500 Hz Glow Plugs
Lubrication system Initial load (0-6 sec) 80 amps
Minimum oil pressure 23.5 psi Continuous load (>6 sec) <40 amps
(warm, at low idle) 1.6 bar
Battery
Oil capacity 9.5 quarts
(including filter) 9 liters Type 12V DC
Oil viscosity requirements Group C31
Units ship with 15W-40 API CJ4 low ash oil. Quantity 1
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the Cold cranking ampere @ 0°F 1000A
Engine Operator's Manual on your machine. Reserve capacity @ 25A rate 200 minutes

2-8 GTH-844 Part No. 218230

SPECIFICATIONS
Perkins 1104D-E44TA Engine Fuel requirement
Displacement 269 cu in For fuel requirements, refer to the engine Operation

Number of cylinders 4 Fuel injection pressure 23700 psi

1635 bar
Bore and stroke 4.13 x 5 inches

73.8 kW @ 2200 rpm 17.4 liters

Compression ratio 16.2:1 Starter Motor
Combustion E-TVCS Normal load 68 A
Governor Electronic Relay max 50 A
Low idle 1000 rpm Relay continuous 20 A
Frequency 200 Hz
Cranking speed 130 - 200 rpm
High idle 2500 rpm
Frequency 500 Hz Glow Plugs
Lubrication system Initial load (0-4 sec) 20 A (EA)
Oil pressure (hot @ 2300 rpm) 43-58 psi Continuous load (>4 sec) 15 A (EA)
2.96-4 bar
Minimum pressure 7.1 psi Battery
Oil capacity 10 quarts Type 12V DC

(including filter) 9.6 liters
Group C31
Oil viscosity requirements
Quantity 1
Units ship with 15W-40.
Extreme operating temperatures may require the use of Cold cranking ampere @ 0°F 1000A
alternative engine oils. For oil requirements, refer to the Reserve capacity @ 25A rate 200 minutes
Engine Operation and Maintenance Manual on your
machine.

Part No. 218230 GTH-844 2-9

SPECIFICATIONS
Perkins 854E-E34TA Engine Fuel requirement
Displacement 207 cu in For fuel requirements, refer to the engine Operation

Number of cylinders 4 Fuel Injection Pressure 23000 psi

1585 bar
Bore and stroke 3.9 x 4.3 inches

73.8 kW @ 2500 rpm 18.5 liters

Compression ratio 17:1 Starter Motor
Governor Electronic Normal load 68 A
Low idle 1000 rpm Relay max 50 A
Frequency 100 Hz
Relay continuous 20 A
High idle 2700 rpm
Frequency 270 Hz Cranking speed 130 - 200 rpm
Lubrication system Glow Plugs
Minimum oil pressure 12 psi Initial load (0-10 sec) 80 amps
0.83 bar
Continuous load (>10 sec) 40 amps
Maximum oil capacity 8.8 quarts
(including filter) 8.3 liters Battery
Oil viscosity requirements Type 12V DC
Units ship with 15W-40 API CJ4 low ash oil. Group C31
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the Quantity 1
Engine Operation and Maintenance Manual on your Cold cranking ampere @ 0°F 1000A
machine.
Reserve capacity @ 25A rate 200 minutes

2 - 10 GTH-844 Part No. 218230

SPECIFICATIONS
Dana VDT12000 Transmission Carraro 26.27M Drive Axle

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
Axle planetary end (each) 0.8 quarts
Lubrication 0.8 liters
Oil capacity, transmission 14.3 quarts Rear Axle Lubrication
13.5 liters
Oil capacity, drop box 1.1 quart Rear differential 7.9 quarts
1 liter 7.5 liters
Oil viscosity requirements Axle planetary end (each) 0.8 quarts

0.8 liters
Units ship with Chevron Ursa Hydraulic 10W.
Extreme operating temperatures may require the use Oil viscosity requirements
of alternative transmission oils. For oil requirements,
refer to the Dana VDT12000 Service Manual Differential Chevron Supreme 80W90 LS
(Dana part number TSM-0022).
Planetary ends Chevron Supreme 80W90 LS
Dana VDT12000 Service Manual
For additional axle information, refer to the Carraro
Genie part number 218706
26.27M Axle Maintenance and Repair Manual.
Carraro 26.27M Axle Maintenance and Repair

Instructions

Part No. 218230 GTH-844 2 - 11

SPECIFICATIONS
Hydraulic Hose and Fitting Seal-Lok® fittings

Torque Specifications 1 Replace the O-ring. The O-ring must be
replaced anytime the seal has been broken.
Your machine is equipped with Parker Seal-Lok® The O-ring cannot be re-used if the fitting or
fittings and hose ends. Genie specifications require hose end has been tightened beyond finger
that fittings and hose ends be torqued to tight.
specification when they are removed and installed
or when new hoses or fittings are installed. Note: The O-rings used in the Parker Seal Lok®
fittings and hose ends are custom-size O-rings.
They are not standard SAE size O-rings. They are
SAE O-ring Boss Port available in the O-ring field service kit (Genie part
(tube fitting - installed into Aluminum) number 49612).
SAE Dash size Torque 2 Lubricate the O-ring before installation.

-4 11 ft-lbs / 14.9 Nm 3 Be sure that the face seal O-ring is seated and
retained properly.
-6 23 ft-lbs / 31.2 Nm
4 Position the tube and nut squarely on the face
-8 40 ft-lbs / 54.2 Nm seal end of the fitting and tighten the nut finger
-10 69 ft-lbs / 93.6 Nm
tight.
5 Tighten the nut or fitting to the appropriate
-12 93 ft-lbs / 126.1 Nm
torque per given size as shown in the table.
-16 139 ft-lbs / 188.5 Nm
6 Operate all machine functions and inspect the
-20 172 ft-lbs / 233.2 Nm hoses and fittings and related components to
confirm that there are no leaks.
-24 208 ft-lbs / 282 Nm
SAE O-ring Boss Port Seal-Lok Fittings

®
(tube fitting - installed into Steel) (hose end)
SAE Dash size Torque SAE Dash size Torque
-4 16 ft-lbs / 21.7 Nm -4 18 ft-lbs / 24.4 Nm
-6 35 ft-lbs / 47.5 Nm -6 27 ft-lbs / 36.6 Nm
-8 60 ft-lbs / 81.3 Nm -8 40 ft-lbs / 54.2 Nm
-10 105 ft-lbs / 142.4 Nm -10 63 ft-lbs / 85.4 Nm
-12 140 ft-lbs / 190 Nm -12 90 ft-lbs / 122 Nm
-16 210 ft-lbs / 284.7 Nm -16 120 ft-lbs / 162.7 Nm
-20 260 ft-lbs / 352.5 Nm -20 140 ft-lbs / 190 Nm
-24 315 ft-lbs / 427.1 Nm -24 165 ft-lbs / 223.7 Nm
2 - 12 GTH-844 Part No. 218230

SPECIFICATIONS
SAE FASTENER TORQUE CHART

• This chart is to be used as a guide only unless noted elsewhere in this manual •
A574 High Strength
SIZE THREAD Grade 5 Grade 8
Black Oxide Bolts
LUBED DRY LUBED DRY LUBED
in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm
1/4 20 80 9 100 11.3 110 12.4 140 15.8 130 14.7

28 90 10.1 120 13.5 120 13.5 160 18 140 15.8
LUBED DRY LUBED DRY LUBED
f t - lbs Nm f t - lbs Nm f t - lbs Nm f t - lbs Nm f t - lbs Nm
5/16 18 13 17.6 17 23 18 24 25 33.9 21 28.4

24 14 19 19 25.7 20 27.1 27 36.6 24 32.5
3/8 16 23 31.2 31 42 33 44.7 44 59.6 38 51.5
24 26 35.2 35 47.4 37 50.1 49 66.4 43 58.3
7/16 14 37 50.1 49 66.4 50 67.8 70 94.7 61 82.7
20 41 55.5 55 74.5 60 81.3 80 108.4 68 92.1
1/2 13 57 77.3 75 101.6 80 108.4 110 149 93 126
20 64 86.7 85 115 90 122 120 162 105 142
9/16 12 80 108.4 110 149 120 162 150 203 130 176
18 90 122 120 162 130 176 170 230 140 189
5/8 11 110 149 150 203 160 217 210 284 180 244
18 130 176 170 230 180 244 240 325 200 271
3/4 10 200 271 270 366 280 379 380 515 320 433
16 220 298 300 406 310 420 420 569 350 474
7/8 9 320 433 430 583 450 610 610 827 510 691
14 350 474 470 637 500 678 670 908 560 759
8 480 650 640 867 680 922 910 1233 770 1044
1
12 530 718 710 962 750 1016 990 1342 840 1139
7 590 800 790 1071 970 1315 1290 1749 1090 1477
1 1/8
12 670 908 890 1206 1080 1464 1440 1952 1220 1654
7 840 1138 1120 1518 1360 1844 1820 2467 1530 2074
1 1/4
12 930 1260 1240 1681 1510 2047 2010 2725 1700 2304
6 1460 1979 1950 2643 2370 3213 3160 4284 2670 3620
1 1/2
12 1640 2223 2190 2969 2670 3620 3560 4826 3000 4067
METRIC FASTENER TORQUE CHART

• This chart is to be used as a guide only unless noted elsewhere in this manual •
Size Class 4.6 4.6 Class 8.8 8.8 Class 10.9 10.9 Class 12.9 12.9
(m m ) LUBED DRY LUBED DRY LUBED DRY LUBED DRY

in- lbs Nm in-lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm
5 16 1.8 21 2.4 41 4.63 54 6.18 58 6.63 78 8.84 68 7.75 91 10.3
6 19 3.05 36 4.07 69 7.87 93 10.5 100 11.3 132 15 116 13.2 155 17.6
7 45 5.12 60 6.83 116 13.2 155 17.6 167 18.9 223 25.2 1.95 22.1 260 29.4
LUBED DRY LUBED DRY LUBED DRY LUBED DRY
f t - lbs Nm f t -lbs Nm f t - lbs Nm f t - lbs Nm f t - lbs Nm ft - lbs Nm f t - lbs Nm f t - lbs Nm
8 5.4 7.41 7.2 9.88 14 19.1 18.8 25.5 20.1 27.3 26.9 36.5 23.6 32 31.4 42.6
10 10.8 14.7 14.4 19.6 27.9 37.8 37.2 50.5 39.9 54.1 53.2 72.2 46.7 63.3 62.3 84.4
12 18.9 25.6 25.1 34.1 48.6 66 64.9 88 69.7 94.5 92.2 125 81 110 108 147
14 30.1 40.8 40 54.3 77.4 105 103 140 110 150 147 200 129 175 172 234
16 46.9 63.6 62.5 84.8 125 170 166 226 173 235 230 313 202 274 269 365
18 64.5 87.5 86.2 117 171 233 229 311 238 323 317 430 278 377 371 503
20 91 124 121 165 243 330 325 441 337 458 450 610 394 535 525 713
22 124 169 166 225 331 450 442 600 458 622 612 830 536 727 715 970
24 157 214 210 285 420 570 562 762 583 791 778 1055 682 925 909 1233
Part No. 218230 GTH-844 2 - 13

2 - 14 GTH-844 Part No. 218230

May 2014 Section 3 • Scheduled Maintenance Procedures
Scheduled Maintenance Procedures

About This Section
This section contains detailed procedures for each
scheduled maintenance inspection.
Each procedure includes a description, safety

warnings and step-by-step instructions.
Observe and Obey: Read each procedure thoroughly. This
manual and the decals on the machine,
Maintenance inspections shall be completed by use signal words to identify the following:
a person trained and qualified on the
maintenance of this machine. Symbols Legend
Scheduled maintenance inspections shall be Safety alert symbol—used to alert

completed daily, quarterly, semi-annually, personnel to potential personal
annually and every 2 years as specified on the injury hazards. Obey all safety
Maintenance Inspection Report. The frequency messages that follow this symbol
and extent of periodical examinations and tests to avoid possible injury or death.
may also depend on national regulations. Indicates an imminently hazardous
situation which, if not avoided, will
Failure to perform each procedure
as presented and scheduled could Indicates a potentially hazardous
result in death, serious injury or situation which, if not avoided,
substantial damage. could result in death or serious
injury.
Immediately tag and remove from service a
damaged or malfunctioning machine. Indicates a potentially hazardous
Repair any machine damage or malfunction may cause minor or moderate
before operating the machine. injury.
Use only Genie approved replacement parts. Indicates a potentially hazardous
Machines that have been out of service for a may result in property damage.
period longer than 3 months must complete the
quarterly inspection. Indicates that a specific result is expected after
performing a series of steps.
Unless otherwise specified, perform each
maintenance procedure with the machine in the Indicates that an incorrect result has occurred
following configuration: after performing a series of steps.
· 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. 218230 GTH-844 3-1

Section 3 • Scheduled Maintenance Procedures May 2014
SCHEDULED MAINTENANCE PROCEDURES
Maintenance Symbols Legend Pre-delivery Preparation Report

Note: The following symbols have been used in The pre-delivery preparation report contains
this manual to help communicate the intent of the checklists for each type of scheduled inspection.
instructions. When one or more of the symbols
appear at the beginning of a maintenance Make copies of the Pre-delivery Preparation report
procedure, it conveys the meaning below. to use for each inspection. Store completed forms
as required.
Maintenance Schedule
Indicates that tools will be required to
perform this procedure. There are five types of maintenance inspections
that must be performed according to a schedule—
daily, quarterly, semi-annually, annually, and
two year. The Scheduled Maintenance Procedures
Indicates that new parts will be required
Section and the Maintenance Inspection Report
to perform this procedure.
have been divided into five subsections—A, B, C,
D, and E. Use the following chart to determine
which group(s) of procedures are required to
Indicates that a cold engine will be perform a scheduled inspection.
required to perform this procedure.
Inspection Checklist
Indicates that a warm engine will be Daily or every 8 hours A

required to perform this procedure.
Quarterly or every 250 hours A+B
Semi-annually or every 500 hours A+B+C

Indicates that dealer service will be
required to perform this procedure. Annually or every 1000 hours A+B+C+D
Two year or every 2000 hours A+B+C+D+E
Maintenance Inspection Report
The maintenance inspection report contains

checklists for each type of scheduled inspection.
Make copies of the Maintenance Inspection Report
to use for each inspection. Store completed forms
for three years.
3 - LM
2 GTH-844 Part No. 218230
Pre-Deliver
Pre-Deliveryy Preparation
Fundamentals Instructions
It is the responsibility of the dealer to perform the Use the operator’s manual on your machine.
Pre-delivery Preparation.
The Pre-delivery Preparation consists of completing
The Pre-delivery Preparation is performed prior to each the Pre-operation Inspection, the Maintenance items
delivery. The inspection is designed to discover if and the Function Tests.
anything is apparently wrong with a machine before it is
put into service. Use this form to record the results. Place a check in
the appropriate box after each part is completed.
A damaged or modified machine must never be used. Follow the instructions in the operator’s manual.
If damage or any variation from factory delivered
condition is discovered, the machine must be tagged If any inspection receives an N, remove the machine
and removed from service. from service, repair and reinspect it. After repair, place
a check in the R box.
Repairs to the machine may only be made by a
qualified service technician, according to the Legend
manufacturer's specifications. Y = yes, completed
Scheduled maintenance inspections shall be performed N = no, unable to complete
by qualified service technicians, according to the R = repaired
manufacturer's specifications and the requirements Comments
listed in the responsibilities manual.
Pre-Delivery Preparation Y N R
Pre-operation inspection
completed
Maintenance items completed
Function tests completed
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Terex South Dakota, Inc USA Genie UK

500 Oak Wood Road The Maltings, Wharf Road
PO Box 1150 Grantham, Lincolnshire
Watertown, SD 57201-6150 NG31- 6BH England
(605) 882-4000 (44) 1476-584333
Copyright © 2011 Terex Corporation. Genie® is a registered trademark of Terex South
Dakota, Inc. 218230 Rev A
Section 3 • Scheduled Maintenance Procedures November
May 2014
2012
Maintenance Inspection Report

Model Checklist A - 8 hours Y N R Checklist C - 500 hours* Y N R
A-1 Manuals and decals C-1 Engine maintenance -
Serial number Perkins models
A-2 Pre-operation inspect
Date A-3 Function tests C-2 Engine maintenance -
Perkins models
A-4 Lubricate boom
Hour meter C-3 Inspect and lubricate
A-5 Engine maintenance - sequencing chains
All models
Machine owner Checklist D - 1000 hours* Y N R
A-6 Transmission
maintenance D-1 Forks
Inspected by (print)
Perform after 40 hours: D-2 Sequencing chains
Inspector signature A-7 30 day service D-3 Hydraulic return filter
Perform after 50 hours: D-4 Transmission

Inspector title D-5 Engine maintenance -
A-8 Axle maintenance
Deutz models
Inspector company Perform after 100 hours:
D-6 Engine maintenance -
A-9 Transmission Perkins models
Instructions
Perform after 150 hours: Perform every 1500 hours:
· Make copies of this report to use for
each inspection. A-10 Axle maintenance D-7 Axle maintenance
Checklist B - 250 hours* Y N R D-8 Engine maintenance -
· Select the appropriate checklist(s) for
the type of inspection to be B-1 Battery Perkins models
performed. B-2 Electrical wiring Checklist E - 2000 hours* Y N R
B-3 Exhaust system E-1 Hydraulic oil
Daily or 8 hour
Inspection: A B-4 Engine air filter E-2 Engine maintenance -
B-5 Tires and wheels Perkins models
Quarterly or 250 hour
Inspection: A+B B-6 Hydraulic oil Perform every 3000 hours:
Semi-annually or 500 hour B-7 Tank venting systems E-3 Engine maintenance -
Inspection: A+B+C Perkins models
B-8 Engine maintenance -
Annually or 1000 hour Deutz models E-4 Engine maintenance -
Inspection: A+B+C+D Deutz models
B-9 Boom wear pads
Perform every 4000 hours:
2 Year or 2000 hour B-10 Inspect hose tension
Inspection: A+B+C+D+E E-5 Engine maintenance -
Perkins models
· Place a check in the appropriate box B-11 Axle maintenance
after each inspection procedure is
E-6 Engine maintenance -
completed. * procedures may also include a Deutz models
· Use the step-by-step procedures in time interval
this section to learn how to perform Perform every 12,000 hours:
these inspections. E-7 Engine maintenance -
· If any inspection receives an “N”, tag Perkins models
and remove the machine from service,
repair and re-inspect it. After repair, Comments
place a check in the “R” box.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
3-4 GTH-844 Part No. 218230

Checklist A Procedures
A-1 3 Open the operator's manual to the decals
inspection section. Carefully and thoroughly
Inspect the Manuals and Decals inspect all decals on the machine for legibility
Note: Genie specifications require that this and damage.
procedure be performed every 8 hours or daily, Result: The machine is equipped with all
whichever comes first. required decals, and all decals are legible and
Maintaining the operator’s and safety manuals in in good condition.
good condition is essential to safe machine Result: The machine is not equipped with all
operation. Manuals are included with each required decals, or one or more decals are
machine and should be stored in the container illegible or in poor condition. Remove the
provided in the operator's compartment. An machine from service until the decals are
illegible or missing manual will not provide safety replaced.
and operational information necessary for a safe
operating condition. 4 Always return the manuals to the storage
container after use.
In addition, maintaining all of the safety and
instructional decals in good condition is mandatory Note: Contact your authorized Genie distributor or
for safe machine operation. Decals alert operators Genie if replacement manuals or decals are
and personnel to the many possible hazards needed.
associated with using this machine. They also
provide users with operation and maintenance
information. An illegible decal will fail to alert
personnel of a procedure or hazard and could
result in unsafe operating conditions.
1 Check to make sure that the operator's and

safety manuals are present and complete in the
storage container in the operator's
compartment.
2 Examine the pages of each manual to be sure
that they are legible and in good condition.
Result: The operator's manual is appropriate for
the machine and all manuals are legible and in
good condition.
Result: The operator's manual is not
appropriate for the machine or all manuals are
not in good condition or is illegible. Remove the
machine from service until the manual is
replaced.
Part No. 218230 GTH-844 3-5

CHECKLIST A PROCEDURES
A-2 A-4
Perform Pre-operation Inspection Lubricate the Boom
Note: Genie specifications require that this
procedure be performed every 8 hours or daily,
whichever comes first. Note: Genie specifications require that this
Completing a Pre-operation Inspection is essential procedure be performed every 8 hours or daily,
to safe machine operation. The Pre-operation whichever comes first.
Inspection is a visual inspection performed by the Greasing the specified locations is essential for
operator prior to each work shift. The inspection is good machine performance and service life.
designed to discover if anything is apparently Operating the machine with little or no grease
wrong with a machine before the operator performs may cause the machine to perform poorly and
the function tests. The Pre-operation Inspection continued use may cause component damage.
also serves to determine if routine maintenance
procedures are required. 1 Fully extend and raise the boom, then retract the
boom, checking to insure it operates smoothly.
Complete information to perform this procedure is There should be a light film of lubricant on wear
available in the appropriate operator's manual. pad contact surfaces.
Refer to the Operator's Manual on your machine.
Result: Boom operates smoothly and a thin film
of lubricant is visible. Proceed to step 5.
A-3
Result: Boom does not extend or retract
Perform Function Tests smoothly and no lubricant is visible on wear pad
contact surfaces. Proceed to step 2.
procedure be performed every 8 hours or daily, 2 Apply a thin layer of grease to the underside of
whichever comes first. the number 3 boom tube where it makes contact
with the number 2 boom tube lower wear pads.
Completing the function tests is essential to safe
machine operation. Function tests are designed to
discover any malfunctions before the machine is
put into service. A malfunctioning machine must
never be used. If malfunctions are discovered, the
machine must be tagged and removed from
service.
Complete information to perform this procedure is

available in the appropriate operator's manual.
Refer to the Operator's Manual on your machine.
3-6 GTH-844 Part No. 218230

3 Apply a thin layer of grease to the underside of A-5

the number 2 boom tube where it makes
contact with the number 1 boom tube lower Perform Engine Maintenance -
wear pads. All Models
4 Lubricate the top and side boom tube wear
pads.
5 Return the boom to the stowed position.
Note: Engine specifications require that this
Grease specification whichever comes first.
EP NLGI 2 (lithium based) or equivalent Engine oil level - check
Coolant level - check/add
Lube-A-Boom grease, 7 lb pail (recommended) Fuel system filter/water separator - drain
Genie part number 110147 Engine tightness - check or leaks
Exhaust system - check for leaks
Chevron Ultra-Duty EP 2 grease (alternate)
Required maintenance procedures and additional

engine information is available in the
Perkins 1100D Operation and Maintenance Manual
(Perkins part number SEBU8172-00),
Perkins 854 Operation and Maintenance Manual
(Perkins part number SEBU8726-01),
OR the Deutz TCD3.6 Operation Manual
(Deutz part number 0312 3907).
Perkins 1100D Operation and Maintenance Manual


Deutz TCD3.6 Operation Manual

Part No. 218230 GTH-844 3-7

A-6 A-7
Perform Transmission Perform 30 Day Service
Maintenance
The 30 day maintenance procedure is a one-time

sequence of procedures to be performed after the
Note: Transmission specifications require that this
first 30 days or 40 hours of usage. After this
interval, refer to the maintenance checklists for
whichever comes first.
continued scheduled maintenance.
Transmission oil level - check/add*
1 Perform the following maintenance procedures:
Drop box oil level - check/add*
· B-5 Inspect the Tires, Wheels and
*check oil with engine running at idle and oil at 180- Lug Nut Torque
200° F / 65-93° C
· D-3 Replace the Hydraulic Tank
Required maintenance procedures and additional Return Filter Element
transmission information is available in the · Check belt tension
· Check the engine mounts
· Check hose clamps
3-8 GTH-844 Part No. 218230

A-8 A-9
Perform Axle Maintenance Perform Transmission
Maintenance
Note: Axle specifications require that this procedure

be performed after 50 hours. Note: Manufacturer specifications require that this
Oil level - check/add one-time procedure be performed after 100 hours of
operation.
axle information is available in the Change transmission filter
Carraro 26.27M Axle Maintenance and Repair Required maintenance procedures and additional
Manual axle information is available in the Dana VDT12000
(Carraro part number CA270077). Service Manual
Instructions
A-10
Perform Axle Maintenance
Note: Axle specifications require that this one-time

procedure be performed after 150 hours of
operation.
Change axle oil
Clean magnetic oil plugs
Oil breather - clean
Grease axle (if required)

axle information is available in the Carraro 26.27M
Axle Maintenance and Repair Manual
(Carraro part number CA270077).

Instructions
Part No. 218230 GTH-844 3-9

Checklist B Procedures
B-1 3 Be sure that the battery cable connections are
free of corrosion.
Inspect the Batteries
Note: Adding terminal protectors and a corrosion
preventative sealant will help eliminate corrosion on
the battery terminals and cables.
Note: Genie requires that this procedure be 4 Be sure that the battery retainers and cable
performed every 250 hours or quarterly, whichever connections are tight.
comes first.
5 Be sure that the battery separator wire
Proper battery condition is essential to good engine connections are tight.
performance and operational safety. Improper fluid
6 Fully charge the battery(s) and allow the
levels or damaged cables and connections can
battery(s) to rest at least 6 hours.
result in engine component damage and hazardous
conditions. 7 Remove the battery vent caps and check the
specific gravity of each battery cell with a
Electrocution/burn hazard. Contact
hydrometer. Note the results.
with hot or live circuits could result
in death or serious injury. Remove 8 Check the ambient air temperature and adjust
all rings, watches and other the specific gravity reading for each cell as
jewelry. follows:
Bodily injury hazard. Batteries • Add 0.004 to the reading of each cell for
contain acid. Avoid spilling or every 10° / 5.5° C above 80° F / 26.7° C.
contacting battery acid. Neutralize
• Subtract 0.004 from the reading of each cell for
battery acid spills with baking soda
every 10° / 5.5° C below 80° F / 26.7° C.
and water.
Result: All battery cells display an adjusted
Note: Perform this test after fully charging the
specific gravity of 1.277 or higher. The battery
batteries.
is fully charged. Proceed to step 12.
Note: For a more accurate determination of the
Result: One or more battery cells display a
battery condition, fully charge the batteries and specific gravity of 1.217 or below. Proceed to
allow the batteries to rest 24 hours before step 9.
performing this procedure to allow the battery cells
to equalize.
1 Put on protective clothing and eye wear.

2 Remove the cover from the auxiliary power unit
batteries located at the ground controls side of
the machine.
Note: Perform the remaining steps on the auxiliary
power unit batteries and the engine starting battery.
3 - 10 GTH-844 Part No. 218230

CHECKLIST B PROCEDURES
9 Perform an equalizing charge OR fully charge B-2

the battery(s) and allow the battery(s) to rest at
least 6 hours. Inspect the Electrical Wiring
10 Remove the battery vent caps and check the
specific gravity of each battery cell with a
hydrometer. Note the results.
Note: Genie requires that this procedure be
11 Check the ambient air temperature and adjust performed every 250 hours or quarterly, whichever
the specific gravity reading for each cell as comes first.
follows:
Maintaining electrical wiring in good condition is
• Add 0.004 to the reading of each cell for essential to safe operation and good machine
every 10° / 5.5° C above 80° F / 26.7° C. performance. Failure to find and replace burnt,
• Subtract 0.004 from the reading of each cell for chafed, corroded or pinched wires could result in
every 10° / 5.5° C below 80° F / 26.7° C. unsafe operating conditions and may cause
component damage.
Result: All battery cells display a specific
gravity of 1.277 or greater. The battery is fully Electrocution hazard. Contact with
charged. Proceed to step 12. hot or live circuits could result in
death or serious injury. Remove all
Result: The difference in specific gravity rings, watches and other jewelry.
readings between cells is greater than 0.1 OR
the specific gravity of one or more cells is less 1 Inspect the following areas for burnt, chafed,
than 1.177. Replace the battery. corroded and loose wires:
12 Check the battery acid level. If needed, · Inside of the operator's compartment
replenish with distilled water to 1/8 inch / 3 mm · Underside of the chassis
below the bottom of the battery fill tube. Do not
· Boom assembly
overfill.
2 Inspect for a liberal coating of dielectric grease
13 Install the vent caps and neutralize any in the following locations:
electrolyte that may have spilled.
· All harness connectors
3 Start the engine and raise the boom so there is
enough room to access and remove all the
covers attached to the chassis.
Part No. 218230 GTH-844 3 - 11

4 Attach a lifting strap from an overhead crane to B-3

the boom. Support the boom. Do not apply any
lifting pressure. Check the Exhaust System
5 Remove all engine covers, hydraulic tank covers
and chassis covers.
Crushing hazard. Death or serious Note: Genie requires that this procedure be
injury could result if the boom performed every 250 hours or quarterly, whichever
should unexpectedly fall while comes first.
working underneath the boom. Do
not stand or work beneath a boom Maintaining the exhaust system is essential to
that is not properly supported. good engine performance and service life. Running
the engine with a damaged or leaking exhaust
6 Inspect the following areas for burnt, chafed, system can cause component damage and unsafe
corroded, pinched and loose wires: operating conditions.
· Engine Bodily injury hazard. Do not
· Transmission inspect while the engine is
· Manifolds running. Remove the key to
secure from operation.
· Chassis
Bodily injury hazard. Beware of
7 Inspect for a liberal coating of dielectric grease
hot engine components. Contact
in all connections between the engine,
with hot engine components may
transmission and the operator's compartment.
cause severe burns.
8 Install all covers removed in step 5.
1 Open the engine access cover.
9 Remove the lifting strap from the overhead
2 Be sure that all fasteners are tight.
crane.
3 Inspect all welds for cracks.
10 Start the engine and lower the boom to the
stowed position. Turn the machine off. 4 Inspect for exhaust leaks; i.e., carbon buildup
around seams and joints.
5 Close the engine access cover.
3 - 12 GTH-844 Part No. 218230

B-4 B-5
Inspect the Engine Air Filter Inspect the Tires, Wheels and
Lug Nut Torque

performed every 250 hours or quarterly, whichever Note: Genie requires that this procedure be
comes first. Perform this procedure more often if performed every 250 hours or quarterly, whichever
dusty conditions exist. comes first.
Maintaining the engine air filter in good condition is Maintaining the tires and wheels in good
essential to good engine performance and service condition, including proper wheel fastener torque,
life. Failure to perform this procedure can lead to is essential to safe operation and good
poor engine performance and component damage. performance. Tire and/or wheel failure could result
Note: Perform this procedure with the engine off. in a machine tip-over. Component damage may
also result if problems are not discovered and
1 Release the latches on the front cover of the air repaired in a timely fashion.
cleaner assembly. Remove the cover.
Bodily injury hazard. An
2 Gently twist and pull out the external or primary overinflated tire can explode and
filter element. could result in death or serious
3 Remove the inner or secondary filter element. injury.
4 Clean the inside of the canister and the gasket Tip over hazard. Do not use
with a damp cloth. temporary flat tire repair products.
5 Inspect the primary and secondary air filter Note: The tires on some machines are foam filled
elements. If needed, blow from the inside and do not need air added to them.
out using low pressure dry compressed air, 1 Check all tire treads and sidewalls for cuts,
or carefully tap out dust. cracks, punctures and unusual wear.
6 Install the secondary filter element first, then 2 Check each wheel for damage, bends and
install the primary filter element. cracks.
7 Install the front cover onto the air cleaner 3 Check each lug nut for proper torque. Refer to
assembly and secure the latches. Section 2, Specifications.
4 Check the air pressure in each tire. Refer to
Section 2, Specifications.
Part No. 218230 GTH-844 3 - 13

B-6 B-7
Perform Hydraulic Oil Analysis Inspect the Fuel and Hydraulic
Tank Cap Venting Systems

performed every 250 hours or quarterly, whichever Note: Genie requires that this procedure be
comes first. performed every 250 hours or quarterly, whichever
Replacement or testing of the hydraulic oil is comes first. Perform this procedure more often if
essential for good machine performance and dusty conditions exist.
service life. Dirty oil may cause the machine to Free-breathing fuel and hydraulic tank caps are
perform poorly and continued use may cause essential for good machine performance and
component damage. Extremely dirty conditions service life. A dirty or clogged tank vent system
may require oil changes to be performed more may cause the machine to perform poorly and
often. Refer to Section 2, Specifications. continued use may cause component damage.
Note: Before replacing the hydraulic oil, the oil may Extremely dirty conditions may require that the vent
be tested by an oil distributor for specific levels of system be inspected more often.
contamination to verify that changing the oil is Explosion and fire hazard. Engine
necessary. If the hydraulic oil is not replaced at fuels are combustible. Perform this
the two year inspection, test the oil quarterly. procedure in an open, well-
Replace the oil when it fails the test. See E-1, ventilated area away from heaters,
Test or Replace the Hydraulic Oil. sparks, flames and lighted
tobacco. Always have an
approved fire extinguisher within
easy reach.
Note: Perform this procedure with the engine off.
1 Identify the vent tube breather from the fuel tank

under the chassis center cover.
2 Check for proper venting.
Result: Air passes through the vent tube.
Proceed to step 4.
Result: If air does not pass through the vent
tube, clean or replace the tube. Proceed to step
3.
Note: When checking for positive tank cap venting,
air should pass freely through the tube.
3 - 14 GTH-844 Part No. 218230

3 Using a mild solvent, carefully wash the tube B-8

venting system. Dry using low pressure
compressed air. Repeat this procedure Perform Engine Maintenance -
beginning with step 2. Deutz Models
4 Install the fuel tank cap onto the fuel tank.
5 Remove the breather cap from the hydraulic
tank.
6 Check for proper venting. The cap is procedure be performed every 250 hours.
pressureized to 3 psi.
Engine oil and filter - change
Result: Air passes through the hydraulic tank
cap. Proceed to step 8. Engines with exhaust after-treatment system
Deutz DQC II LA approved oil
Result: If air does not pass through the cap, API CJ-4 low ash approved oil
clean or replace the cap. Proceed to step 7. Deutz DQC III LA approved oil in extreme conditions.
Note: When checking for positive tank cap venting, Engines without exhaust after-treatment system
air should pass freely through the cap. Deutz DQC II LA approved oil
7 Using a mild solvent, carefully wash the cap API CJ-4 low ash approved oil
venting system. Dry using low pressure Deutz DQC III approved oil in extreme conditions
compressed air. Repeat this procedure Deutz DQC III LA approved oil in extreme conditions
beginning with step 6. Required maintenance procedures and additional
8 Install the breather cap onto the hydraulic tank. engine information is available in the

Part No. 218230 GTH-844 3 - 15

B-9
Check the Boom Wear Pads
upper wear pad groove

procedure be performed every 250 hours of
operation.
1 Extend the boom until the wear pads are

accessible.
Note: It may be necessary to remove the wear pad upper wear pad groove
retainer plates to expose the wear pads.
2 Inspect the end of each upper wear pad.

Result: The wear pad grooves are visible on the
4 Measure each side wear pad.
end of the wear pad.
Result: The grooves on the end of the wear pad Result: The measurement is within
are no longer visible. Replace both wear pads. specification.
Refer to the Repair Procedure, How to Replace Result: The measurement is less than
the Boom Wear Pads. specification. Replace all side wear pads. Refer
3 Repeat the procedure for the lower wear pads. to the Repair Procedure, How to Replace the
Boom Wear Pads.
Boom Wear Pad Specifications,

GTH-844
Side wear pad thickness, minimum 3/8 inch

9.5 mm
3 - 16 GTH-844 Part No. 218230

B-10 B-11
Inspect the Fork Level and Perform Axle Maintenance
Auxiliary Hydraulic Hoses
Tension
Note: Axle specifications requires that this
procedure be performed every 300 hours of
Note: Genie specifications require that this operation.
procedure be performed every 250 hours of Oil level - check/add
operation. Oil breather - clean
1 Fully retract the boom.
2 Fully lower the tips of the lifting forks. Required maintenance procedures and additional
axle information is available in the Carraro 26.27M
3 Remove the cover from the fork end of the Axle Maintenance and Repair Manual
boom. (Carraro part number CA270077).
4 Inspect the fork level and/or auxiliary hydraulic
hoses for proper tension. Each hose should Carraro 26.27M Axle Maintenance and Repair
have the same amount of droop and should not Instructions
rest on the boom tube. Genie part number 218710
Result: The hose/s rest on the boom tube or

have an unequal amount of droop. Refer to the
Repair Procedure, How to Adjust the Fork Level
and Auxiliary Hydraulic Hose Tension.
Part No. 218230 GTH-844 3 - 17

Checklist C Procedures
C-1 C-2
Perform Engine Maintenance - Perform Engine Maintenance -
Perkins Models Perkins Models
Note: Engine specifications require that this Note: Engine specifications require that this
procedure be performed every 500 hours. procedure be performed every 500 hours or
annually.
1104 Engine
V-belts - inspect/adjust/replace 1104 Engine
Engine oil and filter - change
854 Engine API CH-4 or API CI-4 approved oil
Engine oil and filter - change Fuel system primary filter (water separator)
API CJ-4 low ash approved oil element - replace
Fuel system primary filter (water separator) Fuel system secondary filter - replace
element - replace Hoses and clamps - inspect/replace
Fuel system secondary filter - replace Radiator - clean
Fan clearance - check
854 Engine
Required maintenance procedures and additional Radiator - clean
Perkins 1104 Operation and Maintenance Manual Required maintenance procedures and additional
(Perkins part number SEBU7833-01) engine information is available in the
OR the, Perkins 1104 Operation and Maintenance Manual
Perkins 854 Operation and Maintenance Manual (Perkins part number SEBU7833-01)
(Perkins part number SEBU8726-01). OR the,
Perkins 1104 Operation and Maintenance Manual (Perkins part number SEBU8726-01).
Perkins 854 Operation and Maintenance Manual Genie part number 117765
3 - 18 GTH-844 Part No. 218230

March
May 2014
2013 Section 3 • Scheduled Maintenance Procedures
CHECKLIST C PROCEDURES
C-3 The load cycles and environmental conditions

make it impossible to predict chain life. It is
Inspect and Lubricate the therefore necessary to conduct regular inspections.
Sequencing Chains
1 Park the machine on a firm level surface, level
the boom and engage the parking brake.
2 Fully extend the boom.
Genie specifications require that this procedure be 3 Inspect the chains for the following conditions:
performed every 500 hours or semi-annually,
whichever comes first. In extremely dusty or hostile · Elongation
environments, it may be necessary to lubricate the BL666 chain - Measure 16 pitches of the
chains more often. extend chain for machines using BL666 chain.
Maintaining the sequencing chains in good Note: For identification, this chain typically
condition is essential to safe operation and good measures 3/4 inch between pin centers when new.
machine performance. Failure to detect damage to Note: Both the extend and retract chains should be
the chains could result in a hazardous operating measured.
condition.
Note: Measurement should be taken in the area
Environments in which Genie Telehandlers operate where the chain articulates most frequently over the
can vary widely from outdoor moisture and sheaves.
temperature extremes, to mildly corrosive or highly
corrosive industrial atmospheres, in addition to Result: The distance measures 12.36 inches /
abrasive exposures such as sand and grit. 313mm or less. The chain is within
specifications. Continue with inspection.
In addition, dynamic shock loading can impose
abnormal loads above the endurance limit of the Result: If the distance is greater than
chains. Examples of dynamic shock loading are: 12.36 inches / 313mm, the machine shall be
removed from service until the chain is
· High velocity movement of load, followed by
replaced.
sudden abrupt stops.
· Carrying loads in suspension over irregular Note: The boom chain's normal life expectancy can
surfaces and rough terrain. be expressed as a maximum percent of elongation
of 3%.
· Attempting to "inch" loads which are beyond
the rated capacity of the vehicle.
Part No. 218230 GTH-844 3 - 19

· Edge wear
Check the chain for wear on the link plate
edges caused by running back and forth over
the sheave. The maximum reduction of
material should not exceed 5%.
· Cracked plates
Check link side plates for any cracks. These
are generally a sign of chain fatigue.
· Turning pins
Check the pins. The position of the riveting
must be parallel with the top and bottom of the
side plate.
If any of these conditions are discovered during the
inspection, the chain must be replaced.
After inspection and before being returned to

service, the chains must be lubricated with a
quality chain lubricant.
Note: Do not use grease to lubricate chains.

The chain plates should be brushed with a wire
brush prior to lubrication to clear the space between
the plates.
The lubricant must penetrate the chain joint to

prevent wear. Applying lubricant to the external
surfaces will prevent rust, but the chains should be
articulated to make sure the lubricant penetrates to
the working surfaces between the pins and links.
Lubricant may be applied with a brush, sprayed or
poured on, but the chain should be well flooded with
lubricant and the boom should be extended and
retracted to insure that the lubricant penetrates to
the working surfaces. All excess lubricant should
be wiped away from the external surfaces.
Note: Do not use solvents to remove excess

lubricant.
3 - 20 GTH-844 Part No. 218230

Checklist D Procedures
D-1 D-2
Inspect the Forks Adjust the Boom Sequencing
Chains

procedure be performed every 1000 hours or Note: Genie specifications require that this
annually, whichever comes first OR whenever procedure be performed every 1000 hours or
permanent deformation of the forks is suspected. annually, whichever comes first.
Maintaining the lifting forks in good condition is 1 Raise the boom to the horizontal position.
essential to safe operation and good machine
performance. Failure to detect damage to the forks 2 Extend the boom fully, then retract the boom
could result in a hazardous operating condition. approximately 1 inch / 25 mm.
1 Thoroughly clean the lifting forks. 3 On either side of the middle boom section,
estimate the center. Place one end of a
2 Inspect the forks for the following: tape measure on the top surface of the
· Surface cracks boom directly above the estimated center.
· Straightness of the blade and shank 4 Select a reference point on the sequencing
chain. Measure the distance between the chain
· Fork angle at 90 ± 3 degrees
and the top surface of the boom. Note the
· Relative height of fork tips shall not differ measurement (1). Refer to the following
more than 3% of blade length illustrations.
· Excessive wear to the forks, fork mount or
legible markings
2
Result: If any of the above criteria are not met,
the fork shall be removed from service until it is
repaired or replaced. 1
a shank
b blade
Part No. 218230 GTH-844 3 - 21

CHECKLIST D PROCEDURES
5 Move to the fork end of the same boom section D-3

that was just measured.
Replace Hydraulic Tank Return
6 Measure the distance between the top surface
of the boom and the same reference point used
Filter Element
on the sequencing chain in step 4. Note the
measurement (2).
Result: The difference between measurements
1 and 2 is 0.25 to 0.5 inch / 6.35 to 12.7 mm. procedure be performed every 1000 hours or
No adjustment to the chain is necessary. annually, whichever comes first
Proceed to step 10.
Replacing the hydraulic return filter element is
Result: The difference between measurements
essential to good machine performance and service
1 and 2 is less than a 0.25 inch / 6.35 mm OR
life. A dirty or clogged filter element may cause the
is greater than 0.5 inch / 12.7 mm. The chain
machine to perform poorly and continued use may
requires adjustment. Proceed to step 7.
cause component damage. Extremely dirty
Note: The measurements taken in step 4 and step conditions may require that the filter element be
6 must be taken from the same plane on the boom. replaced more often.
7 Working at the fork end of the large boom tube, Bodily injury hazard. Beware of
locate the adjustable chain anchor on the top of hot oil. Contact with hot oil may
boom section. cause severe burns.
Note: Perform this procedure with the engine off.
8 Place an adjustable wrench across the flat part
of the chain, just ahead of the chain anchor. 1 Start the engine. Raise the boom to allow
Tighten the wrench onto the chain. access to the hydraulic tank.
9 Using a 1 7/16 inch wrench, adjust the nut as 2 Remove the access cover to the tank.
required to tighten or loosen the chain. Repeat 3 Release the pressure in the oil reservoir by
this procedure beginning with step 4. loosening the filler/breather cap.
10 The procedure is complete. 4 Unscrew the return filter.
5 Install the new filter element.
6 Tighten the filler/breather cap.
7 Record the hours the filter element was replaced
and keep with your maintenance records.
8 Start the engine.
9 Inspect the filter assembly to be sure that there
are no leaks.
10 Clean up any oil that may have spilled during the
installation procedure.
3 - 22 GTH-844 Part No. 218230

D-4 D-5
Perform Transmission Perform Engine Maintenance -
Maintenance Deutz Models
Note: Transmission specifications require that this Note: Engine specifications require that this
procedure be performed every 1000 hours. procedure be performed every 1000 hours or
annually, whichever comes first.
Transmission - change oil and filter
Drop box - change oil and filter Charge air cooler entry area - drain lube oil/
condensate
Required maintenance procedures and additional Cold starting device - check
transmission information is available in the Engine mounts - check
Dana VDT12000 Service Manual Hose clamps and hoses - check
(Dana part number TSM-0022). V-rib belt and tensioning pulley - check
Fuel filter cartridge - replace
Dana VDT12000 Service Manual Filter insert for fuel pre-filter - replace

A oil drain, drop box

B oil drain, transmission
Part No. 218230 GTH-844 3 - 23

D-6 D-7
Perform Engine Maintenance - Perform Axle Maintenance
Perkins Models
Note: Axle specifications require that this procedure

Note: Engine specifications require that this be performed every 1500 hours of operation.
procedure be performed every 1000 hours. Change axle oil
1104 Engine Clean magnetic oil plugs
Engine valve lash - inspect/adjust
854 Engine Required maintenance procedures and additional

Water pump - inspect axle information is available in the Carraro 26.27M
Axle Maintenance and Repair Manual
Required maintenance procedures and additional (Carraro part number CA270077).
Perkins 1104 Operation and Maintenance Manual Carraro 26.27M Axle Maintenance and Repair
(Perkins part number SEBU7833-01) Instructions
OR the, Genie part number 218710
(Perkins part number SEBU8726-01).


3 - 24 GTH-844 Part No. 218230

D-8
Perform Engine Maintenance -
Perkins Models

procedure be performed every 1500 hours.
854 Engines
Engine crankcase breather element - replace

(Perkins part number SEBU7833-01)
OR the,


Part No. 218230 GTH-844 3 - 25

Checklist E Procedures
E-1 2 Remove oil cap from top of hydraulic tank.
Test or Replace the Hydraulic Oil 3 Using an approved hand-operated pump, drain
the hydraulic tank into a suitable container.
Refer to Section 2, Specifications.
Bodily injury hazard. Beware of hot
Note: Genie specifications require that this oil. Contact with hot oil may cause
procedure be performed every 2000 hours or two severe burns.
years, whichever comes first 4 Remove the drain plug from the rear of the tank.
Replacement or testing of the hydraulic oil is 5 Rinse out the inside of the tank using a mild
essential for good machine performance and solvent.
service life. Dirty oil may cause the machine to
perform poorly and continued use may cause 6 Install the drain plug and securely tighten. Do
component damage. Extremely dirty conditions not over tighten.
may require oil changes to be performed more 7 Fill the tank with hydraulic oil until the fluid level
frequently. Refer to Section 2, Specifications. is in the center of the sight glass at the rear of
Component damage hazard. The the tank.
work area and surfaces where this 8 Clean up any oil that may have spilled.
procedure will be performed must
be clean and free of debris that
could get into the hydraulic
system.
Note: Before replacing the hydraulic oil, the oil may
be tested by an oil distributor for specific levels of
contamination to verify that changing the oil is
necessary. If the hydraulic oil is not replaced at
the two year inspection, test the oil quarterly.
Replace the oil when it fails the test.
1 Lower the boom to the stowed position.
3 - 26 GTH-844 Part No. 218230

CHECKLIST E PROCEDURES
E-2 E-3
Perkins Models Perkins Models
procedure be performed every 2000 hours. procedure be performed every 3000 hours .
1104 Engine 1104 Engine
Aftercooler core - inspect Alternator Belt - Inspect/Adjust/Replace
Alternator - inspect Fuel Injector - test/change
Engine mounts - inspect
Starting Motor - inspect 854 Engine
Turbocharger - inspect Alternator - inspect
Water pump - inspect Alternator and Fan Belts - replace
Diesel Particulate Filter - clean
854 Engine Radiator Pressure Cap - clean/replace
Aftercooler core - inspect
Engine mounts - inspect Required maintenance procedures and additional
Starting motor - inspect engine information is available in the
Turbocharger - inspect Perkins 1104 Operation and Maintenance Manual
Required maintenance procedures and additional OR the,
engine information is available in the Perkins 854 Operation and Maintenance Manual
Perkins 1104 Operation and Maintenance Manual (Perkins part number SEBU8726-01).
OR the, Perkins 1104 Operation and Maintenance Manual

Part No. 218230 GTH-844 3 - 27

E-4 E-5
Deutz Models Perkins Models
procedure be performed every 3000 hours. procedure be performed every 4000 hours.
V-rib belt and tensioning pulley- replace 854 Engine

Aftercooler Core - Clean/Test
engine information is available in the Required maintenance procedures and additional
Deutz TCD3.6 Operation Manual engine information is available in the
(Deutz part number 0312 3907). Perkins 1104 Operation and Maintenance Manual
Deutz TCD3.6 Operation Manual OR the,
Genie part number 218707 Perkins 854 Operation and Maintenance Manual


3 - 28 GTH-844 Part No. 218230

E-6 E-7
Deutz Models Perkins Models
procedure be performed every 5000 hours. procedure be performed every 12,000 hours or
every three years, whichever comes first.
General engine overhaul
1104 and 854 Engines
Required maintenance procedures and additional Cooling System Coolant
engine information is available in the (Extended life coolant) - change
(Deutz part number 0312 3907). Required maintenance procedures and additional
Genie part number 218707 (Perkins part number SEBU7833-01)
OR the,


Part No. 218230 GTH-844 3 - 29

3 - 30 GTH-844 Part No. 218230

May 2014 Section 4 • Repair Procedures
Repair Procedures
About This Section
Most of the procedures in this section should only
be performed by a trained service professional
in a suitably equipped workshop. Select the
appropriate repair procedure after troubleshooting
the problem.
Observe and Obey: Perform disassembly procedures to the point where
repairs can be completed. To re-assemble, perform
Repair procedures shall be completed by a
the disassembly steps in reverse order.
person trained and qualified on the repair of this
machine. Symbols Legend
Immediately tag and remove from service a Safety alert symbol—used to alert
damaged or malfunctioning machine. personnel to potential personal
Repair any machine damage or malfunction injury hazards. Obey all safety
before operating the machine. messages that follow this symbol
to avoid possible injury or death.
Before Repairs Start: Indicates an imminently hazardous
Read, understand and obey the safety rules situation which, if not avoided, will
and operating instructions in the appropriate result in death or serious injury.
operator’s manual on your machine. Indicates a potentially hazardous
Be sure that all necessary tools and parts are situation which, if not avoided,
available and ready for use. could result in death or serious
injury.
Use only Genie approved replacement parts.
Read each procedure completely and adhere situation which, if not avoided,
to the instructions. Attempting shortcuts may may cause minor or moderate
produce hazardous conditions. injury.
Unless otherwise specified, perform each Indicates a potentially hazardous
repair procedure with the machine in the situation which, if not avoided,
following configuration: may result in property damage.
Indicates that a specific result is expected after
· Boom in the stowed position performing a series of steps.
· Key switch in the off position with the key Indicates that an incorrect result has occurred
removed after performing a series of steps.
· Wheels chocked
Part No. 218230 GTH-844 4-1

Section 4 • Repair Procedures May 2014
Boom Components
1-1 How to Test a Proximity Switch
Boom Proximity Switch 1 Remove the switch from the machine. Do not
disconnect the switch wire harness from the
The boom angle switch is a proximity switch. This machine.
switch functions by sensing a change in the
electromagnetic field of the switch, due to the 2 Start the engine.
introduction of metal into the field. A proximity 3 Move the switch away from any ferrous or
switch is, simply, a metal detector. metallic object
The switch generates an electromagnetic field at Result: The light of the limit switch assembly is
the face of the switch. This field senses when steel not illuminated.
has been moved close to the switch as well as
when the steel has been moved away, which is 4 Move the switch close to any ferrous or metallic
how the switch contacts open and close. object
Result: The light of the proximity switch
These switches are of a fail-safe design. Should
assembly turns on. The switch is functioning
the switch or the switch wire circuit be faulty, the
correctly.
machine will not function outside its designed
range of use.
The boom proximity switch is a component of the a
drive circuit and the chassis sway circuit. Both the
drive and the chassis sway functions are disabled
when the boom is raised to 60° or higher.
a boom angle proximity switch (located

on engine side)
4-2 GTH-844 Part No. 218230

BOOM COMPONENTS
How to Adjust the Boom Angle 1-2

Proximity Switch Boom
The boom angle proximity switch is attached to a
mounting bracket, located between the boom and How to Replace the
the chassis directly beneath the boom pivot pin. Boom Wear Pads
The switch location is adjustable.
1 Lower wear pads: Using a lifting strap from an
1 Start the engine. overhead crane or a fork lift of sufficient
capacity, lift the boom tube just enough to
2 Raise the boom to 60°. Confirm with a digital
remove the weight from the pads.
level.
2 Remove the wear pad retainer plates and
3 Working at the pivot end of the boom, locate the
remove the wear pads from the boom.
boom angle proximity switch. Loosen the
fasteners, securing the proximity switch 3 Lubricate the wear surface of the new pads.
assembly to the chassis, just enough to allow Refer to Maintenance Procedure A-4, Lubricate
the bracket to move. the Boom.
4 Move the proximity switch assembly until the Note: Do not lubricate the side wear pads.
light of the proximity switch turns on, then move
the proximity switch assembly until the light of 4 Install the wear pads. Install and securely
the proximity switch just turns off. tighten the retainer plates. Do not over tighten.
5 Securely tighten the fasteners. Do not over How to Remove the Lifting Fork
tighten.
Frame
6 Lower the machine to 55°.
1 With the boom in the stowed position, attach a
Result: The light of the proximity switch lifting strap from an overhead crane to the top
assembly is illuminated. of the lifting fork frame at the front of the boom.
Support the frame. Do not apply any lifting
7 Raise the boom to 60°. Confirm with a digital
pressure.
level.
2 Working from the rear of the frame, lift the
spring-assisted handle of the lock securing the
assembly is not illuminated. The proximity
lower fork frame lock pin to the fork frame
switch is properly calibrated.
mount. Use a soft metal drift to remove the pin.
assembly is illuminated. The proximity switch is
not calibrated correctly. Repeat this procedure
beginning with step 4.
Part No. 218230 GTH-844 4-3

BOOM COMPONENTS
3 Using the overhead crane, lift and remove the

fork frame from the boom.
Crushing hazard. The fork frame
could fall if not properly supported b
when the lock pin is removed from a
the machine.
How to Replace the Retraction

Chain
Note: Perform this procedure on a firm, level c
surface with the boom in the stowed position and
the wheels chocked. d
e
1 Start the engine and allow the engine to idle.
2 Raise the boom to a horizontal position.
3 Fully retract the boom.
4 Extend the boom approximately 1 inch / 2.5 cm.
Illustration 1
5 Turn the machine off and remove the key from a extension chains
the key switch. b single-chain tensioner
c boom tube number 1
6 Working at the fork end of the boom, loosen the d boom tube number 2
fasteners securing the single-chain tensioners e boom tube number 3
to the top of boom tube number 1. After noting
the orientation and assembly order of the
components, remove the fasteners and pull the a
tensioners free of the boom. Refer to Illustration
1.
7 Remove the inspection cover from the pivot end
of the boom. Locate the chain anchor of the
boom retraction chain where it attaches to the
chain anchor mount at the lower side of boom
tube 3. Refer to Illustration 2.
Illustration 2
a chain anchor
4-4 GTH-844 Part No. 218230

BOOM COMPONENTS
8 Remove a cotter pin securing the chain anchor 15 Install the chain tensioners into the tensioner
pivot pin to the anchor mount of the boom tube. mount at the fork end of boom tube number 1.
Remove the pivot pin and pull the chain free of Install the mounting components, removed in
the mount. step 8. Evenly tighten the chain tensioners to
the top of the boom tube until they are securely
9 Working at the fork end of the boom, securely
tightened.
connect a 30 foot / 10 m length of rope to the
end of the chain. Securely tie off the other end 16 Adjust the chains. Refer to Maintenance
of the rope to the boom structure. Procedure D-2, Adjust the Boom Sequencing
Chains.
10 Working at the pivot end of the boom, pull the
chain out of the boom. Component damage hazard.
Chains can be damaged if the
Note: Rope coming loose from the chain during
boom is used while the chains are
removal may result in a difficult reassembly. Be
out of adjustment. Do not return
sure the rope is securely attached to the chain and
the machine to use until the chains
boom structure before pulling the chain out of the
have been correctly adjusted.
boom.
11 Remove the rope from the end of the chain and How to Replace the Extension
securely attach the rope to the new chain. Chains
12 Working at the fork end of the boom, use the Note: Perform this procedure on a firm, level
rope to carefully pull the chain through the boom surface with the boom in the stowed position and
just until the end of the chain is accessible. the wheels chocked.
Remove the rope from the chain.
1 Start the engine and allow the engine to idle.
13 Working at the pivot end of the boom, install the
chain into the chain anchor mount. Secure the 2 Raise the boom to a horizontal position.
chain anchor to the mount using the pivot pin 3 Fully retract the boom.
and cotter pin removed in step 8. Secure the
cotter pin. 4 Turn the machine off and remove the key from
the key switch.
14 Working at the pivot end of the boom, route the
chain over the roller and install the chain onto 5 Working at the fork end of the boom, loosen the
the boom assembly using the pivot pin removed fasteners securing the single-chain tensioners
in step 11. Securely tighten the fasteners. Do to the top of boom tube number 1. After noting
not over tighten. the orientation and assembly order of the
components, remove the fasteners and pull the
tensioners free of the boom. Refer to Illustration
1.
Part No. 218230 GTH-844 4-5

BOOM COMPONENTS
6 Select a chain tensioner. Remove the bow tie 15 Working at the fork end of the boom, use the
clip securing the chain anchor pin to the chain rope to carefully pull the chain through the boom
assembly. Remove the chain anchor pin from just until the end of the chain is accessible.
the assembly and remove the chain anchor from
16 Working at the pivot end of the boom and using
the tensioner assembly.
the fasteners removed in step 5, install the
7 Repeat this procedure, beginning with step 6, for chain anchor onto the boom tube. Securely
the other chains. tighten the fasteners. Do not over tighten.
8 Working at the fork end of the boom, select a 17 Remove the rope from the chain and install the
chain. Securely connect a 30 foot / 10 m length chain into the chain anchor of the tensioner
of rope to the end of the chain. Securely tie off assembly. Secure the chain to the chain anchor
the other end of the rope to the boom structure. using the pin and clip removed in step 6.
9 Remove the inspection cover from the pivot end 18 Repeat this procedure, beginning with step 5, for
of the boom and locate the chain anchors of the the other chains.
extension chains at the top of boom tube 3.
19 Install the inspection cover, removed in step 9,
10 Remove the fasteners securing the extension onto the boom. Install and securely tighten the
chain anchors to the boom tubes. fasteners. Do not over tighten.
11 Working at the pivot end of the boom, pull the 20 Install the chain tensioners into the tensioner
chain out of the boom. mount at the fork end of boom tube number 1.
Install the mounting components, removed in
Note: Rope coming loose from the chain during
step 6. Evenly tighten the chain tensioners to
removal may result in a difficult reassembly. Be
the top of the boom tube until they are securely
sure the rope is securely attached to the chain and
tightened.
boom structure before pulling the chain out of the
boom. 21 Adjust the chains. Refer to Maintenance
Procedure D-2, Adjust the Boom Sequencing
12 On a workbench, remove the bow tie clip Chains.
securing the chain anchor pin to the chain
assembly. Remove the pin and chain anchor pin Component damage hazard.
from the assembly. Chains can be damaged if the
boom is used while the chains are
13 Install the chain anchor, pin and clip onto the out of adjustment. Do not return
new chain. the machine to use until the chains
14 Remove the rope from the end of the old chain have been correctly adjusted.
and securely attach the rope to the new chain.
4-6 GTH-844 Part No. 218230

BOOM COMPONENTS
How to Remove the Boom 1 Remove the lifting fork and frame. See 1-2, How
to Remove the Lifting Fork Frame.
Bodily injury hazard. This
procedure requires specific repair 2 Attach a lifting strap from an overhead
skills, lifting equipment and a 10 ton / 10,000 kg crane to the fork end of the
suitable workshop. Attempting this boom. Support the boom. Do not apply any
procedure without these skills and lifting pressure.
tools could result in death or 3 Select a fork level cylinder. Remove the
serious injury and significant fasteners securing the fork level cylinder
component damage. Dealer rod-end pivot pin to the boom.
service is strongly recommended.
4 Using a lifting strap from another overhead
Note: When removing a hose assembly or fitting, crane, support the rod-end of the fork level
the O-ring on the fitting and/or hose end must be cylinder. Do not apply any lifting pressure.
replaced and then torqued to specification during
installation. Refer to Section 2, Hydraulic Hose and 5 Use a soft metal drift to remove the fork level
Fitting Torque Specifications. cylinder pivot pin.
6 Lower the fork level cylinder onto the chassis.
Crushing hazard. Keep hands clear
of the cylinder manifold when
lowering the cylinder.
7 Repeat this procedure beginning with step 3 for
the other fork level cylinder.
b
8 Identify the hydraulic hoses from the lift
a
cylinder. Tag, disconnect and plug the hoses at
the lift cylinder manifold. Cap the fittings on the
cylinder manifold.
9 Remove the fasteners securing the lift cylinder
barrel-end pivot pin to the chassis.
c 10 Support and secure the barrel end of the lift
cylinder to the boom.
d
e
a extension chains
b single-chain tensioner
c boom tube number 1
d boom tube number 2
e boom tube number 3
Part No. 218230 GTH-844 4-7

BOOM COMPONENTS
11 Use a soft metal drift to remove the lift cylinder How to Disassemble the Boom
pivot pin.
Bodily injury hazard. This
12 Tag, disconnect and plug the hydraulic hoses at procedure requires specific repair
the hydraulic hard line connections at the pivot skills, lifting equipment and a
end of the boom. Cap the fittings. suitable workshop. Attempting this
13 Using the overhead crane, raise the boom to a procedure without these skills and
horizontal position. tools could result in death or
serious injury and significant
Crushing hazard. The lift cylinder component damage. Dealer
will fall if not properly supported service is strongly recommended.
when the boom is raised.
Note: When removing a hose assembly or fitting,
14 Remove the fasteners securing the boom pivot the O-ring on the fitting and/or hose end must be
pin to the chassis. replaced and then torqued to specification during
15 Using a suitable tool, remove the boom pivot installation. Refer to Section 2, Hydraulic Hose and
pin. Fitting Torque Specifications.
Note: This may require a hydraulic power unit. 1 Remove the extension cylinder. See 1-4, How to
Remove the Extension Cylinder.
Crushing hazard. The boom will fall
if not properly supported when the 2 Remove the boom. See 1-2, How to Remove the
pivot pin is removed from the Boom.
machine. 3 Select a lift cylinder. Remove the fasteners
16 Carefully remove the boom assembly from the securing the lift cylinder rod-end pivot pin to the
machine and place it on a structure capable of boom.
supporting it. 4 Using a lifting strap from an overhead crane,
Crushing hazard. The boom could support the lift cylinder. Do not apply any lifting
become unbalanced and fall if not pressure.
properly supported when removed 5 Use a soft metal drift to remove the lift cylinder
from the machine. rod-end pivot pin. Remove the cylinder from the
Component damage hazard. The boom.
weight of the boom assembly may Crushing hazard. The cylinder
crush the hydraulic hard lines could become unbalanced and fall
under the boom. Use caution when if not properly supported when
placing the boom assembly onto a removed from the machine.
structure capable of supporting it.
6 Repeat this procedure beginning with step 3 for
the other lift cylinder.
7 Remove the fastener securing the fork level
cylinder rod-end pivot pin to the fork frame
mount.
4-8 GTH-844 Part No. 218230

BOOM COMPONENTS
8 Use a soft metal drift to remove the rod-end 13 Remove the inspection cover at the pivot end of
pivot pin. the boom.
9 Attach a lifting strap from an overhead crane to 14 Remove the hose keepers from the hose roller
the barrel end of the fork level cylinder. Support assembly.
the cylinder. Do not apply any lifting pressure.
Note: The hose keepers ensure that the hoses do
10 Tag, disconnect and plug the fork level cylinder not jump off the hose rollers.
hoses from the cylinder manifolds. Cap the
fittings. 15 Working at the pivot end of the boom, remove
the clamps securing the hoses to the inside of
Bodily injury hazard. Spraying boom tube number 3.
hydraulic oil can penetrate and
burn skin. Loosen hydraulic 16 Working at the fork end of the boom, remove the
connections very slowly to allow clamps securing the hoses to the inside of
the oil pressure to dissipate boom tube number 3.
gradually. Do not allow oil to 17 Working at the pivot end of the boom, pull the
squirt or spray. fork level hydraulic hoses from the boom and
Component damage hazard. lay them to the side.
Hoses can be damaged if they are 18 Working at the pivot end of the boom, remove
kinked or pinched the fasteners securing the hose roller assembly
11 Remove the fasteners securing the fork level to boom tube number 2. Remove the hose roller
cylinder barrel-end pivot pin to the boom. assembly from the boom.
12 Use a soft metal drift to remove the pivot pin. 19 Working at the fork end of the boom, loosen
Remove the cylinder from the boom. evenly, then remove, the fasteners securing the
chain tensioners to the top of boom tube
Crushing hazard. The cylinder number 1.
could fall if not properly supported
when the pivot pin is removed from 20 Working at the fork end of the boom, remove the
the machine. fasteners securing the extension chain rollers to
the top of boom tube number 2. Remove the
chain rollers from the boom.
Part No. 218230 GTH-844 4-9

BOOM COMPONENTS
21 Working at the pivot end of the boom, remove 1-3

the fasteners securing the retraction chain block
pivot pin to boom tube number 3. Remove the Boom Lift Cylinder
pivot pin. Remove the chain from the roller.
22 Working at the pivot end of the boom, remove
How to Remove the Lift Cylinder
the fasteners securing the retraction chain roller Note: When removing a hose assembly or fitting,
to boom tube number 2. Remove the chain the O-ring on the fitting and/or hose end must be
roller from the boom. replaced and then torqued to specification during
23 Working at the fork end of the boom, remove the installation. Refer to Section 2, Hydraulic Hose and
wear pads from boom tube number 2. Fitting Torque Specifications.
24 Support and slide boom tube number 3 out of 1 Attach a lifting strap from an overhead
boom tube number 2. Place boom tube number 10 ton / 10,000 kg crane to the fork end of the
3 on a structure capable of supporting it. boom. Support the boom. Do not apply any
lifting pressure.
Crushing hazard. Boom tube
number 3 could become 2 Tag, disconnect and plug the hydraulic hoses at
unbalanced and fall when the lift cylinder manifold. Cap the fittings.
removed from the boom tube Bodily injury hazard. Spraying
number 2 if not properly supported hydraulic oil can penetrate and
and attached to the overhead burn skin. Loosen hydraulic
crane. connections very slowly to allow
Note: During removal, the overhead crane strap will the oil pressure to dissipate
need to be adjusted for proper balancing. gradually. Do not allow oil to
squirt or spray.
25 Working at the fork end of the boom, remove the
wear pads from boom tube number 1. Component damage hazard.
Hoses can be damaged if they are
26 Support and slide boom tube number 2 out of kinked or pinched.
boom tube number 1. Place boom tube number
2 on a structure capable of supporting it. 3 Attach a lifting strap from an overhead crane to
the rod end of the lift cylinder. Support the
Crushing hazard. Boom tube cylinder. Do not apply any lifting pressure.
number 2 could become
unbalanced and fall when removed
from the boom tube number 1 if not
properly supported and attached to
the overhead crane.
Note: During removal, the overhead crane strap will
need to be adjusted for proper balancing.
4 - 10 GTH-844 Part No. 218230

BOOM COMPONENTS
4 Remove the fasteners securing the lift cylinder 2 Tag, disconnect and plug the hydraulic hoses at
barrel-end pivot pin to the chassis. the boom extension cylinder manifold. Cap the
fittings.
5 Use a soft metal drift to remove the pivot pin.
Bodily injury hazard. Spraying
6 Remove the fasteners securing the lift cylinder
rod-end pivot pin to the boom.
burn skin. Loosen hydraulic
7 Use a soft metal drift to remove the pivot pin. connections very slowly to allow
the oil pressure to dissipate
Crushing hazard. The boom will fall gradually. Do not allow oil to
if not properly supported when the squirt or spray.
pivot pin is removed from the
machine. Component damage hazard. Hoses
can be damaged if they are kinked
8 Using the overhead crane, raise the boom to a or pinched.
horizontal position. Remove the cylinder from
the machine. 3 Remove the access covers on the number 1
boom and remove the bolts holding the extend
Crushing hazard. The cylinder will cylinder support at the fork end of the machine.
fall if not properly supported when
removed from the machine. 4 At the pivot end of the machine, remove the
retainer plates securing the extension cylinder
to the number 2 and number 3 tubes and lift the
extension cylinder out of the support sockets.
1-4 5 Support the extension cylinder with a suitable
Boom Extension Cylinder lifting device and remove from the boom
assembly.
How to Remove the Extension Note: During removal, the overhead crane strap will
Cylinder need to be adjusted for proper balancing.

the O-ring on the fitting and/or hose end must be
installation. Refer to Section 2, Hydraulic Hose and
Fitting Torque Specifications.
1 Raise the boom to a horizontal position.
Part No. 218230 GTH-844 4 - 11

BOOM COMPONENTS
1-5 7 Use a soft metal drift to remove the pivot pin.

Remove the cylinder from the machine.
Fork Level Cylinder
Crushing hazard. The cylinder
could fall if not properly supported
How to Remove the Fork Level when the pivot pin is removed from
Cylinder the machine.
the O-ring on the fitting and/or hose end must be
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.
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.
5 Tag, disconnect and plug the fork level cylinder
hoses from the cylinder manifolds. Cap the
fittings.
connections very slowly to allow
gradually. Do not allow oil to
squirt or spray.
Component damage hazard. Hoses
can be damaged if they are kinked
or pinched
6 Remove the fasteners securing the fork level
cylinder barrel-end pivot pin to the boom.
4 - 12 GTH-844 Part No. 218230

BOOM COMPONENTS
1-6 How to Replace the Fork Level

Hydraulic Hoses Cylinder and/or Auxiliary Hoses
How to Adjust the Fork Level the O-ring on the fitting and/or hose end must be
Cylinder and/or Auxiliary Hoses replaced and then torqued to specification during
1 Fully retract the boom. Fitting Torque Specifications.
2 Fully lower the tips of the lifting forks. 1 Fully retract the boom.
3 Remove the cover from the fork end of the 2 Fully lower the tips of the lifting forks.
boom.
3 Remove the cover from the fork end of the
4 Loosen the hose clamp securing the fork level boom.
cylinder or auxiliary hoses.
4 Attach a lifting strap from an overhead crane to
5 Pull each hose until it is equally tensioned and the top of the lifting fork frame. Support the
not touching the boom tube. frame. Do not apply any lifting pressure.
6 Tighten the clamp bolt to secure the hoses in
place.
1
2
1 hose clamp
1 front cover
2 hose clamp bolt
Part No. 218230 GTH-844 4 - 13

BOOM COMPONENTS
5 Disconnect and plug the fork level cylinder 10 Select one of the hoses. Pull the hose out of the
supply hoses at the cylinder manifold or the boom.
auxiliary supply hoses at the quick connect
Note: Rope coming loose from either end of the
fittings. Cap the fittings.
hose or the boom during hose removal may result
Bodily injury hazard. Spraying in a difficult reassembly. Be sure each section of
hydraulic oil can penetrate and rope is securely attached to both the hose and the
burn skin. Loosen hydraulic boom structure before pulling the hose out of the
connections very slowly to allow boom.
gradually. Do not allow oil to 11 Remove the rope from each end of the hose.
squirt or spray. Discard the hose.
Component damage hazard. Hoses 12 Securely install a section of rope onto each end
can be damaged if they are kinked of the new hose assembly.
or pinched. Note: Tag each hose before assembly.
6 Working near the center of the boom assembly, 13 Install the new hose assembly into the boom in
tag, disconnect and plug the hydraulic hoses the same manner the hose was removed. Using
from the hydraulic hard lines under boom tube the rope, carefully pull the hose through the
number number 1. Cap the hard lines. boom until each end is accessible.
7 Securely connect a 30 feet / 10 m length of rope
to each end of the hoses disconnected in steps
5 and 6. Securely tie off the other end of each
section of rope to the boom structure.
8 Remove the hose clamp at the fork end of the
boom by loosening the hose clamp bolt located
on the top of the boom.
9 Remove the cover from the pivot end of the
boom and remove the hose sheave cover.
Note: Partial extension of the boom on some
machines may be necessary to access the sheave
cover fasteners.
2
1 hose sheave cover

2 Cover retaining bolts
4 - 14 GTH-844 Part No. 218230

BOOM COMPONENTS
14 Install both ends of the hose assembly onto the

correct connection points. Torque to
specification. Refer to Section 2, Specifications.
13 Repeat this procedure for the remaining hose to
be replaced, beginning with step 8.
14 Tension the hoses using the Repair procedure,
"How to Adjust the Fork Level and Auxiliary
Hydraulic Hoses".
14 Repeat this procedure for the auxiliary hydraulic
hoses beginning with step 5.
14 Remove the lifting strap from the fork frame.
15 Install hose sheave covers removed in step 9.
15 Install the covers onto both ends of the boom.
Install and securely tighten the retaining
fasteners.
Part No. 218230 GTH-844 4 - 15

Operator's Compartment
2-1 3 Locate the secondary function manifold under
the manifold inspection cover. Tag, disconnect
Operator's Compartment and plug the hydraulic hoses at ports BP and
BT of the secondary function manifold. Cap the
How to Remove the Operator's fittings.
Compartment 4 Locate the brake manifold under the manifold
inspection cover. Tag, disconnect and plug the
The operator's compartment is used to activate
hydraulic hose at the underside of the brake
machine functions while sitting in the operator's
manifold. Cap the fitting.
drivers seat.
5 Working under the dashboard, locate the
Within the operator's compartment there is a hydraulic hose at port L of the steering orbitral.
transmission column shifter, steering selector,
4-way controller, accelerator pedal, brake pedal and 6 Working at the front axle, locate the hydraulic
a differential lock switch. All of these components hose connected to the front axle steer cylinder
are replaceable. at the operator's compartment side of the
machine. Tag, disconnect and plug the
For further information or assistance, consult the hydraulic hose. Cap the fitting.
Genie Service Department.
7 Tag, disconnect and plug the hydraulic hoses at
Bodily injury hazard. This ports SUP, SUR and SUT of the secondary
procedure requires specific repair function manifold. Cap the fitting.
skills, lifting equipment and a
suitable workshop. Attempting this Bodily injury hazard. Spraying
procedure without these skills and hydraulic oil can penetrate and
tools could result in death or burn skin. Loosen hydraulic
serious injury and significant connections very slowly to allow
component damage. Dealer the oil pressure to dissipate
service is required. gradually. Do not allow oil to
squirt or spray.
1 Open the access door above the hydraulic tank.
8 Tag, disconnect and plug the hydraulic hose at
2 Disconnect the battery from the machine. port SULS of the primary function manifold.
Cap the fitting.
Electrocution hazard. Contact with
electrically charged circuits could
Remove all rings, watches and
other jewelry.
4 - 16 GTH-844 Part No. 218230

OPERATOR'S COMPARTMENT
9 Tag, disconnect and plug the hydraulic hose at 16 Models with dual joystick: With the tee fitting
port JP of the secondary function manifold. Cap above the top of the hydraulic tank, tag,
the fitting. disconnect and plug the tank return hydraulic
hose from the tee fitting. Cap the fitting.
hydraulic oil can penetrate and Note: Removing the hydraulic hose from the tee
burn skin. Loosen hydraulic fitting with the tee fitting below the hydraulic oil
connections very slowly to allow level in the hydraulic tank will result in excessive
the oil pressure to dissipate hydraulic fluid leaking from the hose. Do not
gradually. Do not allow oil to disconnect the hose from the tee fitting if the tee
squirt or spray. fitting is below the hydraulic oil level in the
hydraulic tank.
ports J1, J2, J3 and J4 of the primary function 17 Working inside the chassis, tag and disconnect
manifold. Cap the fittings. the wire harnesses at the connectors next to
11 Models with dual joystick: Tag, disconnect the operator's compartment.
and plug the hydraulic hoses at ports JT2, JT4, 18 Support and secure the operator's compartment
JS3 and JS1 of the primary function manifold. to an adjustable table capable of supporting the
Cap the fittings. weight and that will allow the operator's
12 Tag, disconnect and plug the hydraulic hoses at compartment to remain in an upright and stable
ports JE1, JE3, JL2and JL4 of the primary position.
function manifold. Cap the fittings. Component damage hazard.
13 Remove the fasteners securing the joystick Wrapping a strap around the cab
mount to the operator's compartment. Remove and lifting using an overhead
the joystick assembly. crane can put excessive pressure
on the glass windows of the cab,
14 Models with single joystick: With the base of causing the windows to break. Do
the joystick above the top of the hydraulic tank, not lift the cab using a strap from
tag disconnect and plug the hydraulic hose at an overhead crane if the strap
port T of the joystick. Cap the fitting. contacts the windows.
Note: Removing the hydraulic hose from port T of Note: Placing a wedge between the operator's
the joystick with the joystick below the hydraulic oil compartment and the adjustable table may be
level in the hydraulic tank will result in excessive required to keep the operator's compartment
hydraulic fluid leaking from the hose. Do not stable.
disconnect the hose from the joystick if the joystick
is below the hydraulic oil level in the hydraulic tank. 19 Remove the lower fasteners securing the
operator's compartment to the chassis.
15 Models with dual joystick: Locate the tee
fitting which joins together the hydraulic hoses
from port T of both joysticks to the tank return
hydraulic hose.
Part No. 218230 GTH-844 4 - 17

20 Remove the upper fasteners securing the 2-2

operator's compartment to the chassis.
Machine Controls
Crushing hazard. The operator's
compartment will fall if not properly
supported when the fasteners are
How to Remove the Steering
removed from the machine. Column
21 Slowly move the operator's compartment away 1 Open the access door above the hydraulic tank.
from the chassis while feeding all loose hoses,
2 Disconnect the battery from the machine.
cables and wires through the opening of the
chassis. Electrocution hazard. Contact with
Component damage hazard.
Hoses, cables and wires can
be damaged if they are kinked
other jewelry.
or pinched.
3 Remove the fasteners securing the transmission
Bolt torque specification control lever to the column. Carefully separate
Operator's cab mounting bolts 750 ft-lbs the lever from the column.
1017 Nm 4 Remove the nut securing the key switch to the
dash panel. Gently push the key switch through
the opening.
5 Remove the fasteners securing the dash panel
to the dashboard.
6 Carefully pull the dash panel towards the seat
of the operator's compartment.
7 Tag and disconnect the wire harness from the
componments of the dash panel. Remove the
dash panel from the machine.
8 Loosen the two lower fasteners securing the
dash frame to the operator's compartment.
9 Remove the two upper fasteners securing the
dash frame to the operator's compartment.
10 Rotate the dash frame towards the seat of the
operator's compartment.Remove the dashboard
from the machine.
4 - 18 GTH-844 Part No. 218230

11 Tag and disconnect the ground wire of the steer 3 Follow the hydraulic hose from port L of the
column. steer orbitral to its connection at the front axle
of the machine. Tag, disconnect and plug the
12 Support and secure the steer orbitral to the dash
hydraulic hose at the front axle. Cap the fitting.
frame.
13 Remove the fasteners securing the steer column
ports SUP, SUR and SUT of the secondary
and steer orbitral to the dash frame.
function manifold. Cap the fitting.
14 Lower the steer orbitral and remove the steer
column from the machine.
How to Remove the Steering burn skin. Loosen hydraulic
Wheel the oil pressure to dissipate
1 Open the access door above the hydraulic tank.
squirt or spray.
5 Tag, disconnect and plug the hydraulic hose at
Electrocution hazard. Contact with port SULS of the primary function manifold.
electrically charged circuits could Cap the fitting.
6 Slowly move the steer orbitral away from the
dash frame while feeding all loose hoses
other jewelry.
through the opening of the chassis.
3 Remove the horn button from the steering wheel.
Remove the nut securing the steering wheel to How to Remove the Joystick -
the column and remove the steering wheel. Models with Single Joystick
How to Remove the Steer 1 Open the access door above the hydraulic tank.
Orbitral 2 Disconnect the battery from the machine.
1 Remove the steering column. See 2-2, How to Electrocution hazard. Contact with
Remove the Steering Column. electrically charged circuits could
2 Working under the dashboard, locate the
hydraulic hose at port L of the steering orbitral.
other jewelry.
3 Remove the fasteners securing the joystick
mount panel to the side console.
LS
L R
T P
Part No. 218230 GTH-844 4 - 19

4 Tag and disconnect the joystick wire harness How to Remove the Joystick -
from the machine.
Models with Dual Joysticks
5 Tag, disconnect and plug the hoses from ports
1, 2, 3, 4, P and T of the joystick. Cap the 1 Open the access door above the hydraulic tank.
fittings. 2 Disconnect the battery from the machine.
Note: Removing the hydraulic hose from port T of Electrocution hazard. Contact with
the joystick with the joystick below the hydraulic oil electrically charged circuits could
level in the hydraulic tank will result in excessive result in death or serious injury.
hydraulic fluid leaking from the hose. Do not Remove all rings, watches and
disconnect the hose from the port if the joystick is other jewelry.
below the hydraulic oil level in the hydraulic tank.
3 Remove the fasteners securing the joystick
6 Remove the fasteners securing the joystick to mount panel to the side console.
the mount panel. Remove the joystick.
4 Tag and disconnect the joystick wire harness
from the machine.
2 T 5 Tag, disconnect and plug the hoses from ports

1, 2, 3, 4 and P of the joystick. Cap the fittings.
3 1 6 Locate the tee fitting which joins together the

hydraulic hoses from port T of both joysticks to
the tank return hydraulic hose.
4
P 7 With the tee fitting above the top of the hydraulic
tank, tag, disconnect and plug the tank return
hydraulic hose from the tee fitting. Cap the
Joystick port orientation fitting.
Note: Removing the hydraulic hose from port T of
the joystick with the joystick below the hydraulic oil
level in the hydraulic tank will result in excessive
hydraulic fluid leaking from the hose. Do not
disconnect the hose from the port if the joystick is
below the hydraulic oil level in the hydraulic tank.
8 Remove the fasteners securing the joystick to

the mount panel. Remove the joystick.
4 - 20 GTH-844 Part No. 218230

How to Remove the Brake Pedal How to Remove the Gauge

Assembly Cluster Assembly
1 Open the access door above the hydraulic tank. 1 Open the engine cover.
2 Disconnect the battery from the machine. 2 Disconnect the battery from the machine.
Electrocution hazard. Contact with Electrocution hazard. Contact with
electrically charged circuits could electrically charged circuits could
result in death or serious injury. result in death or serious injury.
Remove all rings, watches and Remove all rings, watches and
other jewelry. other jewelry.
3 Fully press and release the brake pedal a 3 Remove the fasteners securing the transmission
minimum of 10 times to release the hydraulic control lever to the column. Carefully separate
pressure in the brake system. the lever from the column.
4 Tag, disconnect and plug the hydraulic hoses at 4 Reach under the dashboard and gently push the
ports BP and BT of the secondary hydraulic dash cluster through the opening in the
manifold. Cap the fittings. dashboard.
Bodily injury hazard. Spraying 5 Tag and disconnect the wire harness from the
hydraulic oil can penetrate and dash cluster. Remove the dash cluster from the
burn skin. Loosen hydraulic machine.
squirt or spray.
5 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.
6 Remove the fasteners securing the brake pedal
assembly to the dash frame.
7 Gentley 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.
Part No. 218230 GTH-844 4 - 21

Fuel and Hydraulic Tank

3-1 6 Remove the drain plug from the hydraulic tank
and completely drain the tank.
Fuel and Hydraulic Tank
Bodily injury hazard. Beware of hot
oil. Contact with hot oil may cause
How to Remove the Fuel and severe burns.
Hydraulic Tank Assembly
7 Tag, disconnect and plug the supply and return
Explosion and fire hazard. Engine hoses from the hydraulic tank. Cap the fittings.
fuels are combustible. Remove the
8 Proceed to step 14.
fuel tank in an open, well-
ventilated area away from heaters, FUEL TANK
sparks, flames and lighted
tobacco. Always have an 9 Remove the access cover above the fuel tank
approved fire extinguisher within and the access door above the filler cap.
easy reach. 10 Tag and disconnect the wire harness from the
Explosion and fire hazard. Never fuel level terminals.
drain or store fuel in an open 11 Remove the filler cap from the fuel tank.
container due to the possibility of
fire. 12 Using an approved hand-operated pump, drain
the fuel tank into a container of suitable
Explosion and fire hazard. When capacity. Refer to Section 2, Specifications.
transferring fuel, connect a
grounding wire between the Explosion and fire hazard. When
machine and pump or container. transferring fuel, connect a
grounding wire between the
1 Open the access door to the engine. machine and pump or container.
2 Disconnect the battery from the machine. Note: Be sure to only use a hand operated pump
Electrocution hazard. Contact with suitable for use with gasoline and/or diesel fuel.
electrically charged circuits could 13 Tag, disconnect and plug the fuel supply and
result in death or serious injury. return hoses. Cap the fittings.
other jewelry. 14 Remove the clamps holding the vent hose so
the vent and hose can be removed with the
HYDRAULIC TANK tank.
3 Remove the access cover to the hydraulic tank. 15 Support and secure the tank assembly to an
4 Remove the filler cap from the hydraulic tank. appropriate lifting device.
5 Place a drain pan or other suitable container 16 Remove the fasteners securing the tank
under the hydraulic tank. Refer to Section 2, assembly to the chassis. Remove the tank from
Specifications. the machine.
Crushing hazard. The tank
assembly could become
unbalanced and fall if not properly
supported when removed from the
machine.
4 - 22 GTH-844 Part No. 218230

Engines
4-1 How to Repair the
Engines Deutz TCD3.6 Engine
Maintenance procedures and additional engine
How to Repair the information is available in the
Perkins 1104D-E44TA Engine Deutz TCD3.6 Workshop Manual
Repair procedures and additional engine information
is available in the Deutz TCD3.6 Workshop Manual
(Perkins part number SEBU8172-00) and the
Perkins 1104 Service Manual
(Perkins part number RENR9401) and the
Perkins 1100 Troubleshooting Manual
(Perkins part number SENR9982-01). 4-2
Perkins 1100 Operation and Maintenance Manual Engine Fault Codes
Perkins 1104 Service Manual How to Retrieve Engine Fault

Genie part number 117764 Codes
Perkins 1100 Troubleshooting Manual When the engine Electronic Control Module (ECM)
Genie part number 123583 detects an abnormal operating condition, a fault
code is immediately stored in the ECM memory. At
the same time, a colored warning lamp is
How to Repair the illuminated and the fault code is shown on the
Perkins 854E-34TA Engine engine diagnostic display, is located on the
dashboard in the operator's compartment.
Repair procedures and additional engine information
is available in the To learn the specifics of and how to use the fault
Perkins 854 Systems Operation Testing & Adjusting codes, refer to Section 5, Fault Codes.
(Perkins part number UENR0623) or the
Perkins 854 Disassembly & Assembly
(Perkins part number UENR0624)
Perkins 854 Operation Manual

Perkins 854 Assembly Manual
Part No. 218230 GTH-844 4 - 23

Transmission
5-1
Transmission
How to Repair the Transmission

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

4 - 24 GTH-844 Part No. 218230

TRANSMISSION
Part No. 218230 GTH-844 4 - 25

Hydraulic Pump
6-1 2 Start the engine and fully retract the boom.
Continue to hold the joystick in the boom retract
Hydraulic Pump position and observe the pressure gauge.
Result: If the pressure gauge reads
How to Test the Function Pump 3200 psi / 220 bar, immediately stop. The pump
Note: When removing a hose assembly or fitting, is good.
the fitting and/or hose end must be torqued to Result: If the pressure fails to reach
specification during installation. Refer to Section 2, 3200 psi / 220 bar, the pump needs to be
Hydraulic Hose and Fitting Torque Specifications. adjusted OR or the pump or pump coupling is
Bodily injury hazard. Spraying faulty and will need to be serviced or replaced.
hydraulic oil can penetrate and Component damage hazard. There
burn skin. Loosen hydraulic is no relief valve in the hydraulic
connections very slowly to allow pump and the pump can be
the oil pressure to dissipate damaged if the pressure is allowed
gradually. Do not allow oil to squirt to exceed specification. When
or spray. testing the pump, crank the engine
1 Connect a 0 to 5000 psi / 0 to 350 bar pressure in one second intervals until the
gauge to port TP on the secondary function correct pressure is confirmed. Do
manifold. not over-pressurize the pump.
3 Remove the pressure gauge and install plug
onto port TP. Torque to specification. Refer to
Section 2, Specifications.
gradually. Do not allow oil to squirt
or spray.
4 - 26 GTH-844 Part No. 218230

HYDRAULIC PUMP
How to Remove the Function 5 Tag, disconnect and plug the large hydraulic
pump supply hose at the pump. Cap the fitting
Pump 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 this hose. Do not lower the open end of the pump
procedure without these skills and supply hose to below the fluid level of the hydraulic
tools could result in death or tank until the hose is plugged.
component damage. Dealer 6 Tag, disconnect and plug the high pressure hose
service is strongly recommended. at the pump. Cap the fitting on the pump.
Note: When removing a hose assembly or fitting, Bodily injury hazard. Spraying
the O-ring on the fitting and/or hose end must be hydraulic oil can penetrate and
replaced and then torqued to specification during burn skin. Loosen hydraulic
installation. Refer to Section 2, Hydraulic Hose and connections very slowly to allow
Fitting Torque Specifications. the oil pressure to dissipate
Note: Perform this procedure with the engine off or spray.
and cool.
7 Remove the fasteners securing the pump to the
1 Open the engine cover. transmission. Remove the pump from the
machine.
other jewelry.
4 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. 218230 GTH-844 4 - 27

HYDRAULIC PUMP
How to Install the Function How to Prime the Function

Pump Pump
1 Carefully install the hydraulic pump onto the Note: When removing a hose assembly or fitting,
transmission. Install the fasteners and tighten to the O-ring on the fitting and/or hose end must be
finger tight. replaced and then torqued to specification during
2 Torque the fasteners evenly to
85 ft-lbs / 115 Nm.
3 Install the smaller high pressure hose onto the 1 Install all hoses onto the hydraulic pump.
pump outlet. Torque the fasteners to Torque to specification. Refer to Section 2,
27-37 ft-lbs / 37-50 Nm. Hydraulic Hose and Fitting Torque
Specifications.
4 Install the larger low pressure hose onto the
pump outlet. Install the hose retaining rings and 2 Locate the case drain filler plug at the side of
fasteners. Torque the fasteners to the function pump.
55-66 ft-lbs / 74-90 Nm. 3 Remove the plug and slowly fill the case drain
port of the pump with hydraulic fluid until the oil
5 Working at the case drain at the top of the
level is even with the bottom of the hole. Install
pump, fill the pump with hydraulic fluid until the
the plug and torque to 40 ft-lbs / 54 Nm.
fluid is at the top of the case drain fitting.
4 Start the engine, allow the engine to run at low
6 Install the case drain hose onto the pump and
idle for 15 seconds then shut off the engine.
torque to specification. Refer to Section 2,
Wait 15 seconds, then start the engine again.
Specifications.
Allow the engine to run at low idle for 15
7 Securely install the wire harness onto the 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. See 6-1, How to Prime the
Function Pump.
10 Start the engine and inspect for leaks.
11 Turn the machine off.
12 Adjust the pump pressure. See 6-1, How to
Adjust the Function Pump Standby Pressure
and How to Adjust the Function Pump Pressure
Pressure Compensator.
4 - 28 GTH-844 Part No. 218230

HYDRAULIC PUMP
How to Adjust the Function How to Adjust the Function

Pump Standby Pressure Pump Pressure Compensator
1 Connect a 0 to 1000 psi / 0 to 100 bar pressure Note: Two people will be required to perform this
gauge to test port 'TP' on the primary function procedure.
manifold. See 7-1 or 7-2, Primary Function
Manifold Components. 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. 2 Start the engine and allow the engine to run at
low idle.
3 Observe the pressure reading on the pressure
gauge. 3 Fully retract the boom.
Result: The pressure gauge reads 4 Continue to activate the boom retract function
450 ±25 psi / 31 ±1.7 bar. The pump is and observe the pressure reading on the
functioning correctly. Proceed to step 6. pressure gauge.
Result: The pressure gauge fails to read Result: The pressure gauge reads
450 ±25 psi / 31 ±1.7 bar. The pressure setting 3200±50 psi / 220±3.4 bar. The pump is
needs to be adjusted. Proceed to step 4. functioning correctly. Proceed to step 7.
4 Loosen the set screw for the standby pressure Result: The pressure gauge fails to read
adjustment screw. 3200±50 psi / 220±3.4 bar. The pressure setting
needs to be adjusted. Proceed to step 5.
5 Adjust the function pump standby pressure.
Turn the adjustment screw clockwise to 5 Loosen the set screw for the pressure
increase the pressure or counterclockwise to compensator adjustment screw.
decrease the pressure. Tighten the set screw. 6 Adjust the pressure compensator pressure. Turn
6 Turn the engine off and remove the pressure the adjustment screw clockwise to increase the
gauge. pressure or counterclockwise to decrease the
pressure. Tighten the set screw.
hydraulic oil can penetrate and Component damage hazard. Do
burn skin. Loosen hydraulic not adjust the pressure
connections very slowly to allow compensator higher than specified.
the oil pressure to dissipate 7 Turn the engine off and remove the pressure
gradually. Do not allow oil to squirt gauge.
or spray.
or spray.
Part No. 218230 GTH-844 4 - 29

Manifolds
7-1
Primary Function Manifold Components -
Models with Single Joystick
The primary function manifold is located under the manifold inspection cover.
Index Schematic
No. Description Item Function Torque
1 Solenoid valve, 2 position 4 way ... SV1 ......... Function select -

boom retract and sway right ..................... 2-3 ft-lbs / 3-4 Nm
2 Directional valve,proportional ........ PE1 ......... Boom extend/retract ....................... 65-75 ft-lbs / 88-101 Nm
3 Directional valve, proportional ....... PE2 ......... Boom up/down ............................... 65-75 ft-lbs / 88-101 Nm

boom extend and sway left ....................... 2-3 ft-lbs / 3-4 Nm
5 Directional valve, proportional ....... PE3 ......... Fork tilt up/down ............................... 33-37 ft-lbs / 45-50 Nm
6 Relief valve, 3500 psi / 241 bar ..... RV3 ......... Fork tilt up relief .......................................... 20 ft-lbs / 27 Nm
7 Check valve, pilot operated
100 psi / 6.9 bar .............................. CV9 ......... Fork tilt down circuit .................................... 25 ft-lbs / 34 Nm
100 psi / 6.9 bar .............................. CV8 ......... Fork tilt up circuit ......................................... 25 ft-lbs / 34 Nm
9 Relief valve, 3500 psi / 241 bar ..... RV2 ......... Fork tilt down relief ..................................... 20 ft-lbs / 27 Nm
10 Relief valve, 3500 psi / 241 bar ..... RV1 ......... System relief ............................................... 25 ft-lbs / 34 Nm
11 Check valve, 5 psi / 0.3 bar ............ CV7 ......... Sway right circuit .............................. 12-14 ft-lbs / 16-19 Nm
12 Check valve, 5 psi / 0.3 bar ............ CV1 ......... Boom retract circuit ........................... 12-14 ft-lbs / 16-19 Nm
13 Check valve, 5 psi / 0.3 bar ............ CV3 ......... Boom down circuit ............................ 12-14 ft-lbs / 16-19 Nm
14 Check valve, 5 psi / 0.3 bar ............ CV6 ......... Tilt down circuit ................................. 12-14 ft-lbs / 16-19 Nm
15 Check valve, 5 psi / 0.3 bar ............ CV5 ......... Tilt up circuit ...................................... 12-14 ft-lbs / 16-19 Nm
4 - 30 GTH-844 Part No. 218230

MANIFOLDS
SV1
SV9 1
23
PE1
SV2 2
22
PE2
3
SV3
4
PE3
5
View A
RV3
6
CV9
7
CV8
8
SV4
21
RV2
9
RV1
10
PE4
20 View B
CV7
11
FR1
19
FR2
18
CV2
17 CV1
12
CV3
CV4 13
16
CV6
14
CV5
15
Part No. 218230 GTH-844 4 - 31

MANIFOLDS

Models with Single Joystick, continued
16 Check valve, 5 psi / 0.3 bar ............ CV4 ......... Boom up circuit ................................. 12-14 ft-lbs / 16-19 Nm
17 Check valve, 5 psi / 0.3 bar ............ CV2 ......... Boom extend circuit .......................... 12-14 ft-lbs / 16-19 Nm
18 Flow regulator valve,
0.1 gpm / 0.4 L/min ......................... FR2 ......... Sway left circuit / load sense bleed ............ 20 ft-lbs / 27 Nm
19 Flow control valve, adj.,
2.0 gpm / 7.6 L/min ......................... FR1 ......... Sway left circuit ........................................... 20 ft-lbs / 27 Nm
20 Directional valve, proportional
3 position 4 way, pilot operated ..... PE4 ......... Sway left/right ................................... 33-37 ft-lbs / 45-50 Nm
boom up and fork tilt up ............................ 2-3 ft-lbs / 3-4 Nm
boom down and fork tilt down .................. 2-3 ft-lbs / 3-4 Nm
23 Solenoid valve, 2 position 2 way ... SV9 ......... Function select - sway circuit ...................... 20 ft-lbs / 27 Nm
4 - 32 GTH-844 Part No. 218230

MANIFOLDS
SV1
SV9 1
23
PE1
SV2 2
22
PE2
3
SV3
4
PE3
5
View A
RV3
6
CV9
7
CV8
8
SV4
21
RV2
9
RV1
10
PE4
20 View B
CV7
11
FR1
19
FR2
18
CV2
17 CV1
12
CV3
CV4 13
16
CV6
14
CV5
15
Part No. 218230 GTH-844 4 - 33

MANIFOLDS
7-2
Models with Dual Joysticks
The primary function manifold is located under the manifold inspection cover.
Index Schematic
1 Directional valve, proportional ....... PE1 ......... Boom extend/retract ....................... 65-75 ft-lbs / 88-101 Nm
2 Directional valve, proportional ....... PE2 ......... Boom up/down ............................... 65-75 ft-lbs / 88-101 Nm
3 Directional valve, proportional ....... PE3 ......... Fork tilt up/down ............................... 33-37 ft-lbs / 45-50 Nm
100 psi / 6.9 bar .............................. PC2 ......... Fork tilt down circuit .................................... 25 ft-lbs / 34 Nm
5 Relief valve, 3500 psi / 241 bar ..... RV1 ......... System relief ............................................... 20 ft-lbs / 27 Nm
6 Relief valve, 3500 psi / 241 bar ..... RV3 ......... Fork tilt down circuit .................................... 25 ft-lbs / 34 Nm
100 psi / 6.9 bar .............................. PC1 ......... Fork tilt up circuit ......................................... 25 ft-lbs / 34 Nm
8 Relief valve, 3500 psi / 241 bar ..... RV2 ......... Fork tilt up relief .......................................... 20 ft-lbs / 27 Nm
9 Relief valve, 3500 psi / 241 bar ..... CV7 ......... Sway right check valve ............................... 25 ft-lbs / 34 Nm
10 Shuttle valve .................................... LS1 ......... Function select - sway left/right .................. 20 ft-lbs / 27 Nm
11 Flow regulator valve,
0.1 gpm / .38 L/min ......................... FR2 ......... Sway left circuit / load sense bleed ............ 20 ft-lbs / 27 Nm
12 Check valve, 5 psi / 0.3 bar ............ CV1 ......... Boom retract circuit ........................... 12-14 ft-lbs / 16-19 Nm
13 Check valve, 5 psi / 0.3 bar ............ CV3 ......... Boom down circuit ............................ 12-14 ft-lbs / 16-19 Nm
14 Check valve, 5 psi / 0.3 bar ............ CV2 ......... Boom extend circuit .......................... 12-14 ft-lbs / 16-19 Nm
4 - 34 GTH-844 Part No. 218230

MANIFOLDS
PE1
1
PE4 PE2
20 2
View A PE3
3
FR1
19 PC2
4
RV1
5
RV3
6
SV9 PC1
18 7
RV2
8
CV7
CV5 9
17
CV4
16
CV6
15
CV2 LS1
14 10
CV3
13
Cv1
12
FR2
11
View B
Part No. 218230 GTH-844 4 - 35

MANIFOLDS

Models with Dual Joysticks, continued
15 Check valve, 5 psi / 0.3 bar ............ CV6 ......... Tilt down circuit ................................. 12-14 ft-lbs / 16-19 Nm
16 Check valve, 5 psi / 0.3 bar ............ CV4 ......... Boom up circuit ................................. 12-14 ft-lbs / 16-19 Nm
17 Check valve, 5 psi / 0.3 bar ............ CV5 ......... Tilt up circuit ...................................... 12-14 ft-lbs / 16-19 Nm
18 Solenoid valve, 2 pos, 2 way ......... SV9 ......... Function select- sway circuit ............ 12-14 ft-lbs / 16-19 Nm
19 Flow control valve, 2.0 gpm ........... FR1 ......... Fork up/down circuit ......................... 12-14 ft-lbs / 16-19 Nm
20 Directional valve, proportional ....... PE4 ......... Sway function select ......................... 33-37 ft-lbs / 45-50 Nm
4 - 36 GTH-844 Part No. 218230

MANIFOLDS
PE1
1
PE4 PE2
20 2
View A PE3
3
FR1
19 PC2
4
RV1
5
RV3
6
SV9 PC1
18 7
RV2
8
CV7
CV5 9
17
CV4
16
CV6
15
CV2 LS1
14 10
CV3
13
Cv1
12
FR2
11
View B
Part No. 218230 GTH-844 4 - 37

MANIFOLDS
7-3
Secondary Function Manifold Components
The secondary function manifold is located under the manifold inspection cover.
Index Schematic
1 DO3 valve, 3 position 4 way ......... SVD1 ....... Steer left/right ............................................ 60 in-lbs / 6.8 Nm
2 Pressure reducing/relief valve,
50 psi / 3.4 bar ................................ PR2 ......... Rear lock-up circuit ........................... 25-27 ft-lbs / 34-37 Nm
400 psi / 27.5 bar ........................... PR1 ......... Differential lock-up circuit ................. 25-27 ft-lbs / 34-37 Nm
2650 psi / 183 bar .......................... PR3 ......... Steer circuit ....................................... 25-27 ft-lbs / 34-37 Nm
350 psi / 24.8 bar ........................... PR4 ......... Parking brake circuit ......................... 25-27 ft-lbs / 34-37 Nm
6 Solenoid valve, 2 position 3 way ... SV5 ......... Parking brake release ................................ 20 ft-lbs / 27 Nm
7 Check valve, 5 psi / 0.35 bar .......... CV9 ......... Brake circuit ................................................ 20 ft-lbs / 27 Nm
8 Check valve, 5 psi / 0.35 bar .......... CV8 ......... Steering circuit ............................................ 20 ft-lbs / 27 Nm
9 Pressure switch ............................... S23 ......... Brake warning switch
10 Pressure switch ................................ S5 .......... Parking brake switch
11 Solenoid valve, 2 position 3 way ... SV7 ......... Rear lock up select ................................... 2-3 ft-lbs / 3-4 Nm
12 Solenoid valve, 2 position 3 way ... SV6 ......... Differential lock up select ......................... 2-3 ft-lbs / 3-4 Nm
4 - 38 GTH-844 Part No. 218230

MANIFOLDS
(TR) SVD1
1
(TB)
(TP)
(TPB)
12345
12345
12345
(LS)
12345
View A 12345
(TS) (TJ)
PR2
SV6 2
12
PR1
3
PR3
SV7 4
11
PR4
5
SV5
6
View B
CV9
7
CV8
8
S23
9
S5
10
Part No. 218230 GTH-844 4 - 39

MANIFOLDS
7-4
Auxiliary Manifold (option) and Brake Manifold Components
The auxiliary manifold is located under the transmission inspection cover.
Index Schematic
1 Check valve, 5 psi / 0.3 bar ............ CV2 ......... Auxiliary 'A1' circuit ........................... 12-14 ft-lbs / 16-19 Nm
2 DO3 valve, 3 position 4 way ......... SVD1 ....... Auxiliary function enable .......................... 60 in-lbs / 6.8 Nm
3 Flow regulator valve ....................... NV1 ......... Function speed control ............................... 25 ft-lbs / 34 Nm
4 Check valve, 5 psi / 0.3 bar ............ CV1 ......... Auxiliary 'A2' circuit ........................... 12-14 ft-lbs / 16-19 Nm
5 Pressure switch,
450 psi / 31 bar ................................ S6 .......... Clutch cut-off pressure ............................ 11 ft-lbs / 14.9 Nm
6 Pressure switch,
50 psi / 3.4 bar ................................. S16 ......... Brake light pressure (option) ................... 11 ft-lbs / 14.9 Nm
CV1
4 CV2
1
NV1
3
SVD1
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12345678901234567890123456789012123456789012345678901
2
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12345678901234567890123456789012123456789012345678901
12345678901234567890123456789012123456789012345678901
12345678901234567890123456789012123456789012345678901 S6
12345678901234567890123456789012123456789012345678901
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5
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12345678901234567890123456789012123456789012345678901
12345678901234567890123456789012123456789012345678901
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12345678901234567890123456789012123456789012345678901 S16
12345678901234567890123456789012123456789012345678901 6
12345678901234567890123456789012123456789012345678901
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12345678901234567890123456789012123456789012345678901
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12345678901234567890123456789012123456789012345678901 TO REAR AXLE
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12345678901234567890123456789012123456789012345678901
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12345678901234567890123456789012123456789012345678901
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12345678901234567890123456789012123456789012345678901 TO FRONT AXLE
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4 - 40 GTH-844 Part No. 218230

MANIFOLDS
7-5 5 Install a 0 to 3500 psi / 0 to 250 bar pressure

gauge into test port 'TS' at the top of the
Valve Adjustments - secondary function manifold. See 7-3,
Secondary Function Manifold Secondary Function Manifold Components.
6 Start the engine. Allow the engine to idle.
How to Set the Steer System
7 Fully turn and hold the steering wheel in the left
Pressure direction and allow the wheels to fully turn to
the left. Continue holding the steering while
Note: Be sure that the hydraulic oil level is visible
observing the pressure reading on the pressure
in the inspection glass of the hydraulic tank.
gauge.
1 Install a 0 to 1000 psi / 0 to 100 bar pressure
Result: The pressure gauge reads
gauge into test port 'TP' at the top of the
2650 psi / 183 bar. The pressure setting is
secondary function manifold. See 7-3,
correct. Proceed to step 12.
Secondary Function Manifold Components.
Result: The pressure gauge fails to read
2 Start the engine. Allow the engine to idle after
2650 psi / 183 bar. The pressure setting needs
warming the engine to operating temperature.
to be adjusted. Proceed to step 8.
3 Without operating any machine controls,
8 Turn the machine off. Hold the steer pressure
observe the reading on the pressure gauge.
reducing/relief valve with a wrench and remove
Result: The pressure gauge reads the cap (schematic item PR3).
450 ±25 psi / 31 ±1.7 bar. The pump is
9 Adjust the internal hex socket. Turn it clockwise
functioning correctly.
to increase the pressure or counterclockwise to
Result: The pressure gauge fails to read decrease the pressure.
450 ±25 psi / 31 ±1.7 bar. The pressure setting
Component damage hazard. Do
needs to be adjusted. See Repair Procedure
not adjust the relief valve
6-1, How to Adjust the Function Pump
pressures higher than
Pressure.
specifications.
4 Turn the machine off. Remove the pressure
10 Install the relief valve cap.
gauge from the test port.
11 Repeat this procedure beginning with step 6.
hydraulic oil can penetrate and 12 Turn the machine off. Remove the pressure
burn skin. Loosen hydraulic gauge from the test port.
or spray.
or spray.
Part No. 218230 GTH-844 4 - 41

MANIFOLDS
How to Set the Parking Brake 5 Install a 0 to 1000 psi / 0 to 100 bar pressure
gauge into test port 'TPB' at the top of the
System Pressure secondary function manifold. See 7-3,
Note: Be sure that the hydraulic oil level is visible Secondary Function Manifold Components.
in the inspection glass of the hydraulic tank. 6 Start the engine. Allow the engine to idle.
1 Install a 0 to 1000 psi / 0 to 100 bar pressure Result: The pressure gauge reads
gauge into test port 'TP' at the top of the 350 psi / 24.1. The pressure setting is correct.
primary function manifold. See 7-1 or 7-2, Proceed to step 11.
Primary Function Manifold Components.
2 Start the engine. Allow the engine to idle after 350 psi / 24.1. The pressure setting needs to be
warming the engine to operating temperature. adjusted. Proceed to step 7.
3 Without operating any machine controls, 7 Turn the machine off. Hold the brake pressure
observe the reading on the pressure gauge. reducing/relief valve with a wrench and remove
the cap (schematic item PR4).
450 ±25 psi / 31 ±1.7 bar. The pump is 8 Adjust the internal hex socket. Turn it clockwise
functioning correctly. to increase the pressure or counterclockwise to
decrease the pressure.
450 ±25 psi / 31 ±1.7 bar. The pressure setting Component damage hazard. Do
needs to be adjusted. See Repair Procedure not adjust the relief valve
6-1, How to Adjust the Function Pump pressures higher than
Pressure. specifications.
4 Turn the machine off. Remove the pressure 9 Install the relief valve cap.
connections very slowly to allow Bodily injury hazard. Spraying
the oil pressure to dissipate hydraulic oil can penetrate and
gradually. Do not allow oil to squirt burn skin. Loosen hydraulic
or spray. connections very slowly to allow
or spray.
4 - 42 GTH-844 Part No. 218230

MANIFOLDS
How to Set the Differential 5 Install a 0 to 1000 psi / 0 to 100 bar pressure
gauge into test port 'TJ' at the top of the
Lock/Joystick System Pressure secondary function manifold. See 7-3,
Note: Be sure that the hydraulic oil level is visible Secondary Function Manifold Components.
gauge into test port 'TP' at the top of the 400 psi / 27.5. The pressure setting is correct.
2 Start the engine. Allow the engine to idle after 400 psi / 27.5 bar. The pressure setting needs
warming the engine to operating temperature. to be adjusted. Proceed to step 7.
3 Without operating any machine controls, 7 Turn the machine off. Hold the diff lock/joystick
observe the reading on the pressure gauge. pressure reducing/relief valve with a wrench and
remove the cap (schematic item PR1).
or spray.
Part No. 218230 GTH-844 4 - 43

MANIFOLDS
How to Set the Rear Lock-up 5 Install a 0 to 500 psi / 0 to 50 bar pressure
gauge into test port 'TR' at the top of the
System Pressure secondary function manifold (See 7-3,
Note: Be sure that the hydraulic oil level is visible Secondary Function Manifold Components).
gauge into test port 'TP' at the top of the 50 psi / 3.4 bar. The pressure setting is correct.
2 Start the engine. Allow the engine to idle after 50 psi / 3.4 bar. The pressure setting needs to
warming the engine to operating temperature. be adjusted. Proceed to step 7.
3 Without operating any machine controls, 7 Turn the machine off. Hold the rear lockup
observe the reading on the pressure gauge. pressure reducing/relief valve with a wrench and
remove the cap (schematic item PR2).
or spray.
4 - 44 GTH-844 Part No. 218230

MANIFOLDS
7-6 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
A properly functioning coil provides an valve coil resistance is sensitive to changes in air
electromagnetic force which operates the solenoid temperature, the coil resistance will typically
valve. Critical to normal operation is continuity increase or decrease by 4% for each 18°F / 20°C
within the coil. Zero resistance or infinite resistance that your air temperature increases or decreases
indicates the coil has failed. from 68°F / 20°C.
Since coil resistance is sensitive to temperature, Description Specification

resistance values outside specification can
DO3 valve, 3 position 4 way 5.6Ω
produce erratic operation. When coil resistance
12V DC with diode
decreases below specification, amperage (schematic items SVD1)
increases. As resistance rises above specification,
voltage increases. Solenoid valve, 2 position 2 way 8.8Ω
12V DC with diode
While valves may operate when coil resistance is (schematic items SV9)
outside specification, maintaining coils within
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 8.8Ω
12V DC with diode
result in death or serious injury. (schematic items SV1, SV2, SV3, SV4)
other jewelry.
Note: If the machine has been in operation, allow
the coil to cool at least 3 hours before performing
this test.
1 Tag and disconnect the wiring from the coil to

be tested.
2 Test the coil resistance using a multimeter set
to resistance (Ω). Refer to the Valve Coil
Resistance Specification table.
Result: If the resistance is not within the
adjusted specification, plus or minus 10%,
replace the coil.
Part No. 218230 GTH-844 4 - 45

MANIFOLDS
How to Test a Coil Diode 4 Connect the negative lead to the other terminal
on the coil.
Genie incorporates spike suppressing diodes in all
of its coils. Properly functioning coil diodes protect Note: If testing a single-terminal coil, connect the
the electrical circuit by suppressing voltage spikes. negative lead to the internal metallic ring at either
Voltage spikes naturally occur within a function end of the coil.
circuit following the interruption of electrical current
to a coil. Faulty diodes can fail to protect the
electrical system, resulting in a tripped circuit
COIL
breaker or component damage. a
MULTI
d METER
result in death or serious injury. c -
+
other jewelry. b
10 W 9V
RESISTOR BATTERY
1 Test the coil for resistance. See 7-8, How to
Test a Coil. c
b
+
2 Connect a 10Ω resistor to the negative terminal -
of a known good 9V DC battery. Connect the
other end of the resistor to a terminal on the a multimeter
b 9V DC battery
coil. c 10Ω resistor
d coil
Note: The battery should read 9V DC or more
when measured across the terminals. Note: Dotted lines in illustration indicate a
reversed connection as specified in step 6
Ω
Resistor, 10Ω
5 Momentarily connect the positive lead from the
multimeter to the positive terminal on the 9V
battery. Note and record the current reading.
3 Set a multimeter to read DC amperage. 6 At the battery or coil terminals, reverse the
Note: The multimeter, when set to read DC connections. Note and record the current
amperage, should be capable of reading up to reading.
800 mA. 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.
4 - 46 GTH-844 Part No. 218230

Axle
8-1 5 Loosen the lug nuts of both wheels on the axle
to be removed. Do not remove the lug nuts.
Axles
6 Raise the end of the machine until the tires are
off the ground. Place blocks under the chassis
How to Remove the Axle for support.
Bodily injury hazard. This Crushing hazard. The chassis will
procedure requires specific repair fall if not properly supported.
skills, lifting equipment and a
suitable workshop. Attempting this 7 Remove the lug nuts. Remove the tire and wheel
procedure without these skills and assembly from both ends of the axle.
tools could result in death or
8 Support and secure the axle to an appropriate
lifting device.
component damage. Dealer
service is required. 9 Remove the fasteners securing the sway
cylinder rod-end pivot pin to the chassis.
1 Chock the wheels.
2 Remove the fasteners securing the driveshaft to
the transmission. Lower the end of the 11 Remove the fasteners securing the axle to the
driveshaft to the ground. chassis. Remove the axle from the machine.
3 Remove the fasteners securing the driveshaft to Crushing hazard. The axle will fall
the axle. remove the driveshaft from the if not properly supported when the
machine. fasteners are removed from the
machine.
4 Tag and remove the hydraulic hoses from the
axle. Bolt torque specification
Bodily injury hazard. Spraying Axle mounting bolts 380 ft-lbs
hydraulic oil can penetrate and 515 Nm
or spray.
Part No. 218230 GTH-844 4 - 47

4 - 48 GTH-844 Part No. 218230

May 2015 Section 5 • Fault Codes
Fault Codes
Before Troubleshooting:
Read, understand and obey the safety rules
and operating instructions in the appropriate
operator's manual on your machine.
Be sure that all necessary tools and test
equipment are available and ready for use.
Observe and Obey:
Be aware of the following hazards and follow
Troubleshooting and repair procedures shall be generally accepted safe workshop practices.
completed by a person trained and qualified on
Crushing hazard. When testing
the repair of this machine.
or replacing any hydraulic
Immediately tag and remove from service a component, always support
damaged or malfunctioning machine. the structure and secure it
from movement.
Repair any machine damage or malfunction
before operating the machine. Electrocution hazard. Contact
with electrically charged circuits
Unless otherwise specified, perform each
could result in death or serious
repair procedure with the machine in the injury. Remove all rings, watches
following configuration: and other jewelry.
· Boom in the stowed position hydraulic oil can penetrate and
· Key switch in the off position with the key burn skin. Loosen hydraulic
removed connections very slowly to allow
· Wheels chocked
squirt or spray.
Part No. 218230 GTH-844 5-1

Section 5 • Fault Codes May 2015
DIAGNOSTIC DISPLAY
The fault code is displayed on the LCD display Decoding Fault Codes
which is located on the gauge cluster in the
operator's compartment. The Suspect Parameter Number (SPN) or the
Alternate Suspect Parameter Number (ASPN) and
The gauge cluster also includes two warning lights. the Failure Mode Identifier (FMI), when combined,
are the basis for an engine fault code. The SPN or
They are an amber colored light which signals an ASPN number indicates the affected component;
abnormal engine condition which should be the FMI number reveals the type of failure that has
corrected as soon as possible and a red colored occurred. Comparing the combination of numbers to
light which signals an engine condition which the fault code chart on the following pages will help
requres the operator to shut down the engine as to determine the exact engine fault and a corrective
soon as possible. course of action. For additional information, refer to
The ECM will, in some cases, automatically shut the engine operator's manual which came with your
down the engine when the red light is displayed. machine.
Active Fault Codes
Active Fault Codes will be displayed on the gauge

cluster whenever a fault is detected. If multiple fault
codes are detected, the fault codes will scroll on
the display. 1
Active Codes vs Stored Codes 2
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 4 3

fault codes which the ECM has detected. These
fault codes may be recalled by service personnel at Gauge Cluster
a later time even if the condition which caused the
1 FMI Code
engine fault has ceased to exist. 2 SPN Code or ASPN Code
3 amber warning light
Note: Additional hardware will be necessary to 4 red stop engine light
access stored codes.
5-2 GTH-844 Part No. 218230

Engine Fault Codes -

Models with Deutz Power
SPN = Suspect Parameter Number

ASPN = Alternate Suspect Parameter Number
FMI = Failure Mode Identifier
SPN ASPN FMI Description

29 3 Hand throttle error, short circuit to battery on idle validation switch or
sensor error
4 Hand throttle error, short circuit to ground on idle validation switch or
sensor error
51 3 Temperature to high for power stage of EGR-Valve (2.9;3.6) / Throttle-Valve
(6.1,7.8) or position sensor error
4 Open load actuator EGR-Valve (2.9;3.6) / Throttle-Valve (6.1,7.8) or position
sensor error
5 Target range to low for actuator EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8)
6 Target range to high for actuator EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8)
7 The actuator position for EGR-Valve (2.9,3.6) or Throttle-Valve (6.1,7.8)
is not plausible
12 Open load actuator EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8)
91 3 Target range to high for accelerator pedal sensor
4 Target range to low for accelerator pedal sensor
8 PWM signal accelerator pedal out of target range, to high
11 Plausibility check between APP1 and APP2 or APP1 and idle switch
94 1 Low fuel pressure is out of target range; system reaction generated
3 Target range to high for low fuel pressure sensor
4 Target range to low for low fuel pressure sensor
97 3 Water in Fuel Sensor - Short Circuit to U-Batt
12 Water level in fuel prefilter above maximum value
100 0 High oil pressure; system reaction generated
1 Low oil pressure; system reaction generated
3 Target range to high for oil pressure sensor
4 Target range to low for oil pressure sensor
108 3 Target range to high for ambient air pressure sensor
4 Target range to low for ambient air pressure sensor
110 0 Coolant temperature is out of target range; system reaction generated
3 Target range to high for coolant temperature sensor
4 Target range to low for coolant temperature sensor
Part No. 218230 GTH-844 5-3

ENGINE FAULT CODES -

MODELS WITH DEUTZ POWER


111 1 Coolant level underneath the allowed minimum
157 3 Target range to high for rail pressure sensor
4 Target range to low for rail pressure sensor
168 0 Battery voltage is out of the target range (to high)
1 Battery voltage is out of the target range (to low)
2 Battery voltage is out of the target range; warning condition is generated
3 Target range to high for battery voltage sensor
4 Target range to low for battery voltage sensor
172 2 Ambient air temperature sensor value is not plausible
3 Target range to high for intake air sensor
4 Target range to low for intake air sensor
174 0 Low fuel temperature is out of target range; system reaction generated
175 0 Oil temperature is out of target range; system reaction generated
1 Physical Range Check low for Oil Temperature
2 Oil temperature value is not plausible
3 Target range to high for oil temperature sensor
4 Target range to low for oil temperature sensor
190 0 Engine speed target range exceeded; FOC-range 1
2 Speed sensor of crankshaft and camshaft signals are out of phase
8 Speed sensor signal not plausible
11 Engine speed target range exceeded; FOC-range 2
12 Speed sensor no signal
14 Engine speed target range exceeded; overrun mode
412 0 Differential pressure sensor value (AGR) out of target range, to high
1 Differential pressure sensor value (AGR) out of target range, to low
3 SRC high for EGR cooler downstream temperature sensor
4 SRC low for EGR cooler downstream temperature sensor
520 9 Timeout Error of CAN-Receive-Frame TSC1TR
597 2 Break Lever Main switch and Break Lever Redundancy switch status not plausible
5-4 GTH-844 Part No. 218230




624 3 Short circuit to battery on SVS lamp
4 Short circuit to ground on SVS lamp
5 No load error SVS lamp
12 Temperature to high for power stage of SVS lamp
630 12 Access error EEPROM memory
639 14 CAN-Bus 0 "BusOff"-Status
651 3 General short circuit injector 1
5 Interruption of electric connection injector 1
677 3 Short circuit on high side starter relay
4 Short circuit on low side starter relay
5 No load error starter relay
12 Over load ECU power stage for Starter (overtemp.)
729 5 Air Heater not connected.
1079 13 Sensor supply voltage monitor error
1109 2 Engine off request ignored
Part No. 218230 GTH-844 5-5




1180 3 Target range to high for exhaust gas temperature sensor
4 Target range to low for exhaust gas temperature sensor
11 Exhaust gas temperature value before turbine (upstream) not plausible
1761 1 Urea tank temperature sensor value is out of the target range (to low); warning
condition is generated
3031 0 Urea tank temperature sensor value out of the target range (to high)
1 Urea tank temperature sensor value is out of the target range (to low); warning
condition is generated
3224 1 Plausibility error Min for NOx sensor upstream of SCR Cat
9 Timeout Error of CAN-Receive-Frame AT1IG1Vol; AT1O1; AT1OG1Vol
3234 9 Timeout Error of CAN-Receive-Frame AT1IG1Vol; AT1O1; AT1OG1Vol
11 Nox sensor value downstream not plausible "stuck in range"
3241 1 Target range to low for SCR catalyst upstream temperature sensor
3251 0 Differential pressure sensor value (DPF) out of target range, to high
1 Differential pressure sensor value (DPF) out of target range, to low
3253 2 Differential pressure sensor signal (DPF) not plausible
3 Target range to high for differential pressure sensor (DPF)
4 Target range to low for differential pressure sensor (DPF)
3361 3 Short circuit to battery at powerstage of Urea dosing valve
4 Short circuit to ground at powerstage of Urea dosing valve
7 Dosing valve blocked
3532 3 Target range to high for urea tank level sensor
4 Target range to low for urea tank level sensor
4243 11 Urea heating procedure not successful
4334 0 Target range to high for urea pump module pressure sensor before
pressure build up
1 Physical range check low for urea pump module pressure sensor
4343 11 General pressure check error (SCR)
4345 11 General backflow line plausibility error (SCR)
5-6 GTH-844 Part No. 218230




4360 0 Urea catalyst upstream temperature out of the target range (to high)
1 Urea catalyst upstream temperature out of the target range (to low)
4361 3 Target range to high for urea catalyst exhaust gas temperature sensor upstream
4 Target range to low for urea catalyst exhaust gas temperature sensor upstream
4365 0 Urea tank temperature too high
3 Short circuit to battery error on urea tank sensor
4 Short circuit to ground error on urea tank sensor
4366 5 SCR main relay short circuit or open load
4374 13 Pressure stabilization error dosing valve (SCR)
4375 3 Short circuit to battery on powerstage for urea pump motor
4 Short circuit to ground on powerstage for urea pump motor
5 No load error on powerstage for urea pump motor
4376 3 Short circuit to battery on SCR reversal valve
4 Short circuit to ground on SCR reversal valve
5 No load error SCR reversal valve
4765 0 Exhaust gas temperature sensor value upstream (DOC) out of target range, to high
1 Exhaust gas temperature sensor value upstream (DOC) out of target range, to low
4766 0 Exhaust gas temperature sensor value downstream (DOC) out of target range, to
high
1 Exhaust gas temperature sensor value downstream (DOC) out of target range, to
low
4768 2 Exhaust gas temperature sensor signal upstream (DOC) not plausible
3 Exhaust gas temperature sensor voltage to high
4 Exhaust gas temperature sensor voltage to low
4769 2 Exhaust gas temperature sensor signal downstream (DOC) not plausible
3 Target range to high for exhaust gas temperature sensor downstream (DOC)
4 Target range to low for exhaust gas temperature sensor downstream (DOC)
Part No. 218230 GTH-844 5-7




23006 64254 3 Controller mode switch; short circuit to battery
4 Controller mode switch; short circuit to ground
23008 64256 1 Manipulation control was triggered
2 Timeout error in Manipulation control
23009 64257 9 Pressure Relief Valve (PRV) reached maximun allowed opening count
10 Pressure relief valve (PRV) reached maximun allowed open time
23212 64460 9 Timeout Error of CAN-Receive-Frame ComEngPrt; Engine Protection
23216 64464 9 Timeout Error of CAN-Receive-Frame PrHtEnCmd; pre-heat command, engine
command
23240 64488 9 Timeout CAN-message FunModCtl; Function Mode Control
23330 64578 14 Immobilizer status; fuel blocked
23350 64598 4 Injector cylinder-bank 1; short circuit
23352 64600 4 Injector cylinder-bank 2; short circuit
23354 64602 12 Injector powerstage output defect
23450 64698 2 Multiple Stage Switch constant speed; plausibility error
3 Multiple Stage Switch constant speed; short circuit to battery
4 Multiple Stage Switch constant speed; short circuit to ground
23451 64699 2 Multiple Stage Switch engine speed control parameter; plausibility error
3 Multiple Stage Switch engine speed control parameter; short circuit to battery
4 Multiple Stage Switch engine speed control parameter; short circuit to ground
23452 64700 2 Multiple Stage Switch engine torque limitation curve; plausibility error
3 Multiple Stage Switch engine torque limitation curve; short circuit to battery
4 Multiple Stage Switch engine torque limitation curve; short circuit to ground
23470 64718 2 Pressure Relief Valve (PRV) forced to open
7 Maximum rail pressure in limp home mode exceeded (PRV)
11 Pressure Relief Valve (PRV) error; Rail pressure out of tolerance range
Rail pressure out of tolerance range
12 Pressure Relief Valve (PRV) forced to open; system reaction initiated
14 Pressure Relief Valve (PRV) is open
5-8 GTH-844 Part No. 218230



23550 64798 12 T50 start switch active for too long
23601 64849 13 Sensor supply voltage monitor 3 error (ECU)
23602 64850 0 Fan control; out of range, system reaction initiated
23603 64851 9 Timeout Error of CAN-Receive-Frame AMB; Ambient Temperature Sensor
23605 64853 9 Timeout Error of CAN-Receive-Frame TSC1AE; Traction Control
23606 64854 9 Timeout Error of CAN-Receive-Frame TSC1AR; Retarder
23612 64860 12 ECU reported internal software error
Internal software error ECU
14 Softwarereset CPU
23613 64861 0 Rail pressure disrupted
1 Minimum rail pressure exceeded (RailMeUn3)
2 Setpoint of metering unit in overrun mode not plausible
23615 64863 3 Metering unit (Fuel-System); short circuit to battery
4 Metering unit (Fuel-System); short circuit to ground
5 Metering unit (Fuel-System); open load
12 Metering unit (Fuel-System); powerstage over temperature
23619 64867 2 Physical range check high for exhaust gas temperature upstrem (SCR-CAT)
23632 64880 0 Pressure overload of SCR-System

1 Pressure build-up error SCR-System
2 Metering control is not performed in time error
16 Pump pressure SCR metering unit too high
18 Pump pressure SCR metering unit too low
23633 64881 11 Nox conversion rate insufficient
23698 64946 11 Shut off request from supervisory monitoring function
23717 64965 12 Timeout Error of CAN-Transmit-Frame AmbCon; Weather environments
23718 64966 3 SCR main relay (primary side); short circuit to battery
SCR mainrelay; short circuit to battery (only CV56B)
4 SCR main relay (primary side); short circuit to ground
SCR mainrelay; short circuit to ground (only CV56B)
5 SCR main relay (primary side); open load
SCR mainrelay; open load (only CV56B)
12 SCR mainrelay; powerstage over temperature (only CV56B)
Part No. 218230 GTH-844 5-9




23719 64967 3 SCR heater urea supplymodule; short circuit to battery
4 SCR heater urea supplymodule; short circuit to ground
5 SCR heater relay urea supply module; open load
23720 64968 2 Urea supply module heater temperature; plausibility error
8 Urea supply module heater temperature; signal disrupted
23721 64969 2 Urea supply module heater temperature; plausibility error
8 Urea supply module temperature; signal disrupted
11 Urea supply module temperature measurement not available
23722 64970 8 Urea supply module PWM signal; signal disrupted
23723 64971 11 Detection of AdBlue filled SCR system in Init-State
23766 65014 9 Timeout Error of CAN-Receive-Frame Active TSC1AE
23767 65015 9 Timeout Error of CAN-Receive-Frame Passive TSC1AE
23768 65016 9 Timeout Error of CAN-Receive-Frame Active TSC1AR
23769 65017 9 Timeout Error of CAN-Receive-Frame Passive TSC1AR
23770 65018 9 Timeout Error of CAN-Receive-Frame Passive TSC1DE
23776 65024 9 Timeout Error of CAN-Receive-Frame TSC1TE - active
23777 65025 9 Passive Timeout Error of CAN-Receive-Frame TSC1TE; Setpoint
23778 65026 9 Active Timeout Errorof CAN-Receive-Frame TSC1TR
23779 65027 9 Passive Timeout Error of CAN-Receive-Frame TSC1TR
23788 65036 0 Turbo charger wastegate; CAN Fehler
12 Timeout Error of CAN-Transmit-Frame TrbCH; Status Wastegate
23793 65041 9 Timeout Error of CAN-Receive-Frame UAA10; AGS sensor service message
23794 65042 9 Timeout Error of CAN-Receive-Frame UAA11; AGS sensor data

23803 65051 9 Timeout Error of CAN-Receive-Frame RxEngPres; Status burner airpump
23867 65115 12 Timeout Error of CAN-Transmit-Frame UAA1 on CAN 2; Burner Air Pump Control
23895 65143 13 Check of missing injector adjustment value programming (IMA) injector 1 (in firing
order)
23896 65144 13 check of missing injector adjustment value programming (IMA) injector 2 (in firing order)
5 - 10 GTH-844 Part No. 218230



23906 5 engine shut off due to missing fuel pressure, start function is locked
23910 65158 0 Air Pump; internal error
6 Air Pump; over current
7 Air pump; CAN communication interrupted no purge function available
9 Air Pump; CAN communication lost
12 Air Pump; internal error
14 Air pump doesn´t achieve air mass flow setpoint
23911 65159 0 Burner dosing valve (DV2); overcurrent at the end of the injection phase
3 Burner dosing valve (DV2); short circuit to battery
4 Burner dosing valve (DV2); short circuit to ground
7 Burner dosing valve (DV2); blocked closed
11 Burner dosing valve (DV2); short circuit high side powerstage
12 Burner dosing valve (DV2); powerstage over temperature
23912 65160 0 Physical range check high for burner dosing valve (DV2) downstream pressure;shut off
regeneration
1 Physical range check low for burner dosing valve (DV2) downstream pressure; shut off
regeneration. When burner injector is actuated, the measured pressure does not rise
above ca. 1250mbar abs (expected: ca. 2400mbar).
2 Burner dosing valve (DV2) downstream pressure sensor; plausibility error

3 Sensor error burner dosing valve (DV2) downstream pressure sensor; signal range
check high
4 Sensor error burner dosing valve (DV2) downstream pressure sensor; signal range
check low
23913 65161 3 Sensor error glow plug control diagnostic line voltage; signal range check high
4 Sensor error glow plug control diagnostic line voltage; signal range check low
Part No. 218230 GTH-844 5 - 11



23914 65162 3 Glow plug control; short circuit to battery
4 Glow plug control; short circuit to ground
5 Glow plug control; open load
11 Glow plug control; internal error
12 Glow plug control; powerstage over temperature
23915 65163 0 HCI dosing valve (DV1); overcurrent at the end of the injection phase
3 HCI dosing valve (DV1); short circuit to battery
4 HCI dosing valve (DV1); short circuit to ground
7 HCI dosing valve (DV1); blocked
11 HCI dosing valve (DV1); short circuit high side powerstage
12 HCI dosing valve (DV1); powerstage over temperature
23916 65164 0 Physical range check high for HCI dosing valve (DV1) downstream pressure; shut off
regeneration
1 Physical range check low for HCI dosing valve (DV1) downstream pressure; shut off
regeneration
2 Sensor HCI dosing valve (DV1) downstream pressure; plausibility error
3 Sensor error HCI dosing valve (DV1) downstream pressure; signal range check high
4 Sensor error HCI dosing valve (DV1) downstream pressure; signal range check low
23917 65165 0 Physical range check high for DV1 & DV2 upstream pressure; shut off regeneration
1 Physical range check low for DV1 & DV2 upstream pressure; shut off regeneration
2 Sensor DV1 & DV2 upstream pressure; plausibility error

3 Sensor error DV1 & DV2 upstream pressure; signal range check high
4 Sensor error DV1 & DV2 upstream pressure; signal range check low
23918 65166 0 Physical range check high for DV1 & DV2 upstream temperature; shut off regeneration
1 Physical range check low for DV1 & DV2 upstream temperature; shut off regeneration
2 Sensor DV1 & DV2 upstream temperature; plausibility error

3 Sensor error DV1 & DV2 upstream temperature; signal range check high
4 Sensor error DV1 & DV2 upstream temperature; signal range check low
5 - 12 GTH-844 Part No. 218230



23919 65167 0 Physical range check high for airpump pressure; shut off regeneration
1 Physical range check low for airpump pressure; shut off regeneration
2 Sensor airpump pressure; plausibility error
3 Sensor error airpump pressure; signal range check high
4 Sensor error airpump pressure; signal range check low
23920 65168 0 Physical range check high for exhaustgas back pressure burner; shut off regeneration
1 Physical range check low for exhaustgas back pressure burner; shut off regeneration
2 Sensor exhaustgas back pressure; plausibility error

3 Sensor error exhaustgas back pressure burner; signal range check high
4 Sensor error exhaustgas back pressure burner; signal range check low
23921 65169 0 Physical range check high for burner temperature
1 Physical range check low for burner temperature
2 Sensor burner temperature; plausibility error
3 Sensor error burner temperature; signal range check high
4 Sensor error burner temperature; signal range check low
11 Sensor burner temperature; plausibility error
23922 65170 3 Burner shut of valve; short circuit to battery
4 Burner shut of valve; short circuit to ground
5 Burner shut off valve; open load
7 Shut off valve: blocked
12 Over temperature error on burner shut of valve
23929 65177 0 Fuel Balance Control integrator injector 1 (in firing order); maximum value exceeded
1 Fuel Balance Control integrator injector 1 (in firing order); minimum value exceeded
Part No. 218230 GTH-844 5 - 13



23935 65183 12 Timeout Error of CAN-Transmit-Frame EEC3VOL1; Engine send messages
23936 65184 12 Timeout Error of CAN-Transmit-Frame EEC3VOL2; Engine send messages
23938 65186 9 Timeout Error (BAM to packet) for CAN-Receive-Frame AT1IGCVol1 information;
factors & Sensorcalibration for NOX Sensor (SCR-system upstream cat; DPF- system
downstream cat)
23939 65187 9 Timeout Error (BAM to BAM) for CAN-Receive-Frame AT1IGCVol1 information; factors
& Sensorcalibration for NOX Sensor (SCR-system upstream cat; DPF- system
downstream cat)
23940 65188 9 Timeout Error (PCK2PCK) for CAN-Receive-Frame AT1IGCVol1 information; factors
& Sensorcalibration for NOX Sensor (SCR-system upstream cat; DPF-system
downstream cat)
5 - 14 GTH-844 Part No. 218230



23941 65189 9 Timeout Error (BAM to packet) for CAN-Receive-Frame AT1OGCVol2 information;
factors & Sensorcalibration for NOX Sensor (SCR-system downstream cat; DPF-
system downstream cat)
23942 65190 9 Timeout Error (BAM to BAM) for CAN-Receive-Frame AT1OGCVol2 information; factors
& Sensorcalibration for NOX Sensor (SCR-system downstream cat; DPF- system
downstream cat)
53943 65191 9 Timeout Error (PCK2PCK) for CAN-Receive-Frame AT1OGCVol2 information; factors &
Sensorcalibration for NOX Sensor (SCR-system downstream cat; DPF- system
downstream cat)
23946 65194 0 Zerofuel calibration injector 1 (in firing order); maximum value exceeded
1 Zerofuel calibration injector 1 (in firing order); minimum value exceeded
23960 65208 0 EGR cooler downstream temperature; out of range, system reaction initiated
Exhaust gas temperature EGR downstream; out of range, system reaction initiated
1 EGR cooler downstream temperature; out of range, system reaction initiated

Exhaust gas temperature EGR downstream; out of range, system reaction initiated
23973 65221 14 SCR Tamper detection; derating timer below limit 1

23974 65222 14 SCR Tamper detection; derating timer below limit 2
Part No. 218230 GTH-844 5 - 15



23975 65223 14 Urea quality; derating timer below limit 1
23976 65224 14 Urea qulaity; derating timer below limit 2
23977 65225 14 Urea tank level; derating timer below limit 1
23978 65226 14 Urea tank level; derating timer below limit 2
23980 65228 14 Bad quality of reduction agent detected
23981 65229 11 Urea-tank without heating function (heating phase)
23982 65230 0 Powerstage diagnosis disabled; high battery voltage
1 Powerstage diagnosis disabled; low battery voltage
23988 65236 3 Charging lamp; short circuit to battery
4 Charging lamp; short circuit to ground
5 Charging lamp; open load
12 Charging lamp; over temperature
23992 65240 9 Timeout Error of CAN-Receive-Frame DM19Vol1; NOX sensor upstream

23993 65241 9 Timeout Error of CAN-Receive-Frame DM19Vol2; NOX sensor downstream
5 - 16 GTH-844 Part No. 218230



23998 65246 4 Injector cylinder bank 2 slave; short circuit
23999 65247 12 Injector powerstage output Slave defect
24000 65248 3 Injector 7 (in firing order); short circuit
4 High side to low side short circuit in the injector 7 (in firing order)
5 Injector 7 (in firing order); interruption of electric connection
24001 65249 3 Injector 8 (in firing order); short circuit
4 High side to low side short circuit in the injector 8 (in firing order)
5 Injector 8 (in firing order); interruption of electric connection
24004 65252 12 Too many recognized misfires in cylinder 7 (in firing order)
24005 65253 12 Too many recognized misfires in cylinder 8 (in firing order)
24013 65261 7 Burner operation disturbed
24014 65262 1 Air pressure glow plug flush line; below limit
24016 65264 2 Air Pump; air flow is not plausible
11 HFM sensor; electrical fault
24017 65265 12 Spark plug control unit (SPCU); internal error
24018 65266 14 DPF wasn´t regenerated, power reduction phase 1 (manuell regeneration request)
24019 65267 11 Air Pump; air lines blocked

24020 65268 14 Engine power; Not enough oxygen for regeneration
24021 65269 11 Burner fuel line pipe leak behind Shut Off Valve
24022 65270 14 DPF wasn´t regenerated, power reduction phase 2 (manuell regeneration request)
24023 65271 14 DPF wasn´t regenerated, warning condition (manuell regeneration mode)
24024 65272 11 Deviation of the exhaust gas temperature setpoint to actual value downstream (DOC)
too high
24025 65273 5 DPF system; operating voltage error
14 Particulate filter; regeneration not succesful
24028 65276 2 CAN message PROEGRActr; plausibility error
24029 65277 2 Timeout Error of CAN-Receive-Frame ComEGRActr - exhaust gas recirculation
positioner
Part No. 218230 GTH-844 5 - 17



24030 65278 7 EGR actuator; internal error
24031 65279 13 EGR actuator; calibration error
24032 65280 2 EGR actuator; status message "EGRCust" is missing
24033 65281 7 EGR actuator; due to overload in Save Mode
24034 65282 3 Disc separator; short circuit to battery
4 Disc separator; short circuit to ground
5 Disc Separator; open load
12 Disc Separator; powerstage over temperature
24035 65283 12 Injector diagnostics; time out error in the SPI communication
24036 65284 12 Injector diagnostics Slave; time out error in the SPI communication
24037 65285 3 Ashlamp; short circuit to battery
4 Ashlamp; short circuit to ground
5 Ashlamp; open load
24038 65286 9 Timeout error of CAN-Receive-Frame ComMS_Sys1TO (error memory Slave); Master-
Slave internal CAN message
24044 65292 9 CAN message ComMS_Sys7 not received from slave
5 - 18 GTH-844 Part No. 218230



24045 65293 9 Master-Slave CAN; Message-Counter-Error of CAN-Receive-Frame
ComMSMoFOvR
24046 65294 9 Master-Slave CAN; Checksum-Error of CAN-Receive-Frame ComMSMoFOvR
24047 65295 9 Master-Slave CAN; Messsage-Length-Error of CAN-Receive-Frame

ComMSMoFOvR
24048 65296 9 Timeout error CAN message ComMSMoFOvR1TO error memory Slave
24049 65297 9 Message copy error in the Master / Slave data transfer
24052 65300 11 MS ECU reported internal error
24055 65303 4 Spark Plug Control Unit (SPCU); short circuit to ground
24057 65305 2 Electric fuel pump; fuel pressure build up error
24062 65310 12 EAT-system HMI disrupted
24068 65316 2 Master ECU and Slave ECU have been identified as the same types
24069 65317 9 Timeout Error of CAN-Receive-Frame MSMon_FidFCCTO; Master-Slave CAN
communication faulty
24097 65345 9 Timeout error of CAN-Transmit-Frame DPFBrnAirPmpCtl
24098 65346 9 Timeout error of CAN-Transmit-Frame ComDPFBrnPT
24099 65347 9 Timeout error of CAN-Transmit-Frame ComDPFC0
24100 65348 9 Timeout error of CAN-Transmit-Frame ComDPFHisDat
24101 65349 9 Timeout error of CAN-Transmit-Frame ComDPFTstMon
24102 65350 9 Timeout error of CAN-Receive-Frame ComRxDPFBrnAirPmpCtl
24103 65351 9 Timeout error of CAN-Receive-Frame ComRxDPFBrnAirPmp
24104 65352 9 Timeout error of CAN-Receive-Frame ComRxDPFCtl
Part No. 218230 GTH-844 5 - 19



24105 65353 9 Timeout error of CAN-Transmit-Frame ComEGRMsFlw
24106 65354 9 Timeout error of CAN-Receive-Frame ComRxEGRMsFlw1
24107 65355 9 Timeout error of CAN-Receive-Frame ComRxEGRMsFlw2
24108 65356 9 Timeout error of CAN-Transmit-Frame ComEGRTVActr
24109 65357 9 Timeout error of CAN-Receive-Frame ComRxEGRTVActr
24110 65358 9 Timeout error of CAN-Transmit-Frame ComETVActr
24111 65359 9 Timeout error of CAN-Receive-Frame ComRxETVActr
24112 65360 9 Timeout ComITVActr
24113 65361 9 Timeout error of CAN-Receive-Frame ComRxITVActr
24114 65362 9 Timeout error of CAN-Transmit-Frame A1DOC
24115 65363 9 Timeout error of CAN-Transmit-Frame AT1S
24116 65364 9 Timeout error of CAN-Transmit-Frame SCR2
24117 65365 9 Timeout error of CAN-Transmit-Frame SCR3
24118 65366 9 Timeout error of CAN-Receive-Frame ComRxCM0
24119 65367 9 Timeout error of CAN-Receive-Frame ComRxCustSCR2
24120 65368 9 Timeout error of CAN-Receive-Frame ComRxSCRHtDiag
24121 65369 9 Timeout error of CAN-Receive-Frame ComRxTrbChActr
24122 65370 9 Timeout error of CAN-Receive-Frame ComRxUQSens
24123 65371 9 Timeout error of CAN-Receive-Frame ComSCRHtCtl
24124 65372 9 Timeout error of CAN-Receive-Frame ComTxAT1IMG
24125 65373 9 Timeout error of CAN-Receive-Frame ComTxTrbChActr
5 - 20 GTH-844 Part No. 218230

Engine Fault Codes -

Models with Perkins Power

SPN FMI Description

91 2 Incorrect throttle switch inputs
3 Throttle position sensor: voltage above normal or shorted high
4 Throttle position sensor: voltage below normal or shorted low
8 Throttle position sensor: abnormal frequency, pulse width or period
100 3 Engine oil pressure sensor: voltage above normal or shorted high
4 Engine oil pressure sensor :voltage below normal or shorted low
102 3 Boost pressure sensor voltage: voltage above normal or shorted high
4 Boost pressure sensor voltage: voltage below normal or shorted low
10 No 5V to sender
105 3 Intake manifold temperature sensor: temperature above normal or shorted high
4 Intake manifold temperature sensor: temperature below normal or shorted low
105 3 Intake manifold air temperature open/short to battery positive (+)
4 Intake manifold air temperature short to ground
110 3 Engine coolant temperature open/short to battery positive (+)
4 Engine coolant temperature short to ground
157 3 Fuel rail pressure open/short to battery positive (+)
4 Fuel rail pressure short to ground
168 0 System voltage high
1 System voltage low
2 ECM battery power intermittent/erratic
172 3 Air inlet temperature voltage high
4 Air inlet temperature voltage low
174 2 Fuel temperature sensor: data erratic/intermittent or incorrect
190 8 Engine speed signal abnormal
15 Engine speed: overspeed WARNING
190 0 Engine overspeed
626 5 Ether start aid current low
6 Ether start aid current high
630 2 System parameters incorrect
631 2 Personality module mismatch
637 11 Engine timing calibration invalid
Part No. 218230 GTH-844 5 - 21


MODELS WITH PERKINS POWER

SPN FMI Description
637 139 Engine timing calibration required
639 9 J1939 data link communications
12 J1939 data link malfunction
651 2 Cylinder #1 injector data incorrect
5 Cylinder #1 injector open circuit
6 Cylinder #1 injector short
7 Cylinder #1 injector not responding
678 3 8V DC supply short to battery positive (+)
4 8V DC supply shorted to ground
723 8 Secondary engine speed signal abnormal
1188 5 Turbo wastegate drive current low
1196 9 Machine security system module non-communication
1347 5 Fuel rail pump output current low
6 Fuel rail pump output current high
7 Fuel rail pressure valve solenoid not responding
2882 2 Mode selector switch: data erratic/intermittent or incorrect
3509 3 5V DC power supply sensor short to battery positive (+)
3509 4 5V DC power supply sensor short to ground
For further engine fault code troubleshooting and
diagnostic information, refer to the
(Perkins part number SENR9982-01).

5 - 22 GTH-844 Part No. 218230

May 2015 Section 6 • Schematics
Schematics
About This Section
There are two groups of schematics in this section.
An illustration legend precedes each group of
drawings.
Electrical Schematics
Observe and Obey: Electrocution hazard. Contact with

Troubleshooting and repair procedures shall be result in death or serious injury.
completed by a person trained and qualified on Remove all rings, watches and
the repair of this machine. other jewelry.
Immediately tag and remove from service a Hydraulic Schematics
damaged or malfunctioning machine.
Repair any machine damage or malfunction hydraulic oil can penetrate and
before operating the machine. burn skin. Loosen hydraulic
Before Troubleshooting: the oil pressure to dissipate
Read, understand and obey the safety rules
or spray.
and operating instructions in the appropriate
operator's manual on your machine. General Repair Process
Be sure that all necessary tools and test
equipment are available and ready for use.
Malfunction Identify Troubleshoot
discovered symptoms
problem
still exists
Return to Inspect Perform

service problem and test repair
solved
Part No. 218230 GTH-844 6-1

Section 6 • Schematics May 2015
Fuse Panel Layout

RN1 RN3 RN2
R10
R4
R2
R3
C6 C7
L10
L2
L1
L4
L5
L7
L11
L6
L3
L8
L9
L12
L13
L14
HARNESS
BEACON LT
HARNESS
CAB
ENCLOSED
60 Amp
CB3
50 Amp CB2*
CB1 C8
L23
L24
L22
L25
L27
L28
L15
L21
L26
L16
L17
L20
L19
L18
HARNESS
DOME LT
C5 F15 1A F14 10A F11 10A F8 5A
SWITCH PWR PWR PORT DEFROST FAN DOME/BEACON

HARNESS
DASHBOARD
Circuit Breakers located on the F3 10A F6 5A F17 10A MAX F7 5A

Battery Tray CR14
SPARE
REAR AXLE OSCSTEER/DIFF SW SPARE GAUGE CLS PWR
+
CB1 and CB3 on all engines
F4 10A F1 15A F10 15A F16 1A
D14
CB2 30A C4 BRAKE/SHIFT WIPER/WASHER GAUGE CLS ECU
Deutz T3 or T4i D3
SWAY/TILT
Perkins T3
MANIF. HARNESS
SECONDARY
+
30A F20 10A MAX F2 10A F12 20A F19 10A MAX
D1
+
CB2 50A SPARE AUX HYD LIGHTS SPARE CR4
D2 FLASHER
Perkins T4i
+
F5 5A F18 10A MAX F9 25A F13 15A
CB1- Telehandler Control System Power
CB2- Engine Power / ECM
CB3- Glow Plugs HORN SPARE HVAC IGNITION
C3
MANIF. HARNESS
PRIMARY
CR11 CR12 CR13

P.BRAKE SWAY TILT U/D
LATCH L/R ENBL ENABLE
D11
D6
D12
+ + +
D13
+
D5
+
CR8 CR9 CR10
D4 BOOM FORWARD REVERSE
EXTEND ENABLE ENABLE
C2 +
D8
+ + +
D10
D9
LIGHT HARNESS
ROAD/WORK
CR5 CR6 CR7

LIGHTS SWAY BOOM
OPTION ENABLE ANGLE
D18
+ + +
D19
D7
R1
C1 CR1 CR2 CR3

D17
MAIN OPTIONS SERVICE

POWER POWER HORN
HARNESS
TRANSMISSION
CAP1
+ + +
D15
D16
C9
JOYSTICK
HARNESS
PCB Board Fuse Panel located in the Cab
6-2 GTH-844 Part No. 218230

Fuse Panel Layout

RN1 RN3 RN2
R10
R4
R2
R3
C6 C7
L10
L2
L1
L4
L5
L7
L11
L6
L3
L8
L9
L12
L13
L14
HARNESS
BEACON LT
HARNESS
CAB
ENCLOSED
60 Amp
CB3
50 Amp CB2*
CB1 C8
L23
L24
L22
L25
L27
L28
L15
L21
L26
L16
L17
L20
L19
L18
HARNESS
DOME LT
C5 F15 1A F14 10A F11 10A F8 5A
SWITCH PWR PWR PORT DEFROST FAN DOME/BEACON

HARNESS
DASHBOARD
CR14
Circuit Breakers located on the F3 10A F6 5A F17 10A MAX F7 5A
BOOM
ANGLE
Battery Tray MONITOR
REAR AXLE OSC STEER/DIFF SW SPARE GAUGE CLS PWR
+
CB1 and CB3 on all engines
F4 10A F1 15A F10 15A F16 1A
D14
CB2 30A C4 BRAKE/SHIFT WIPER/WASHER GAUGE CLS ECU
Deutz T3 or T4i D3
SWAY/TILT
Perkins T3
MANIF. HARNESS
SECONDARY
+
30A F20 1A F2 10A F12 20A F19 5A
D1
+
CB2 50A AUX HYD LIGHTS TELEM CR4
D2 ANGLE MONITOR FLASHER
Perkins T4i
+
F5 5A F18 10A MAX F9 25A F13 15A
CB1- Telehandler Control System Power
CB2- Engine Power / ECM
CB3- Glow Plugs HORN SPARE HVAC IGNITION
C3
MANIF. HARNESS
PRIMARY
CR11 CR12 CR13

P.BRAKE SWAY TILT U/D
LATCH L/R ENBL ENABLE
D11
D6
D12
+ + +
+ D13
D5
+
CR8 CR9 CR10
D4 BOOM FORWARD REVERSE
EXTEND ENABLE ENABLE
C2 +
D8
+ + +
D10
D9
LIGHT HARNESS
ROAD/WORK
CR5 CR6 CR7

LIGHTS SWAY BOOM
OPTION ENABLE ANGLE
D18
+ + +
D19
D7
R1
C1 CR1 CR2 CR3

D17
MAIN OPTIONS SERVICE

POWER POWER HORN
HARNESS
TRANSMISSION
CAP1
+ + +
D15
D16
C9
JOYSTICK
HARNESS
B
PCB Board Fuse Panel located in the Cab
Part No. 218230 GTH-844 6-3

Electrical Component Legend
Electrical Component & Wire Color Abbreviation Legend

ALT Alternator L LED Light
B Battery L1 Ignition Power ON
B1 Main Battery L2 Options Power Relay ON
CB Circuit Breaker L3 Horn Relay ON
CB1 50 Amp Circuit Breaker L4 Turn Signal ON
CB2 30 Amp Circuit Breaker L5 Road Lights, Work Lights ON
CB3 60 Amp Circuit Breaker L6 Sway Enable Coil Power ON
C Capacitor L7 Boom Angle ON
C1 4700 uf L8 Boom Extend ON
CR Control Relay L9 Brake Pressure ON
CR1 Main Power L10 Backup Light, Alarm ON
CR2 Options Power L11 Parking Brake Latch ON
CR3 Service Horn L12 Sway Enable ON
CR4 Flasher L13 Tilt Circuit Power ON
CR5 Lights Option L14 Horn Power ON
CR6 Sway Enable L15 Cab, Tail Light Power ON
CR7 Boom Angle L16 Rear Axle Float Coil Power ON
CR8 Boom Extend L17 Rr Ax Fast Power (GTH1056) ON
CR9 Forward Enable L18 Parking Brake Power ON
CR10 Reverse Enable L19 Forward Coil Power ON
CR11 Parking Brake Latch L20 Reverse Coil Power ON
CR12 Sway Left/Right Enable L21 PB Release Coil Power ON
CR13 Tilt Up/Down Enable L22 Sway L/R Enable Coil Power ON
CR15 HVAC Blower L L23 Tilt U/D Enable Coil Power ON
CR16 HVAC Blower M L24 Forward Shift ON
CR17 HVAC Blower H L25 Parking Brake Release OFF
D Diode L26 Brake Light Power ON
EMS Engine Management System L27 Hazard Power ON
F Fuse L28 Not Used
F1 15 Amp - Break/Shift M Motor
F2 10 Amp - Aux Hydraulics R Resistor
F3 10 Amp – Rear Axle Oscillate S Switch
F4 10 Amp – Sway/Tilt S1 Key Start Switch
F5 5 Amp - Horn S2 Parking Brake Switch
F6 5 Amp - Steer/Differential Switch S3 Boom Angle Switch
F7 5 Amp - Gauge Cluster Power S4 Boom Extend Switch
F8 5 Amp - Dome/Beacon Light S5 Parking Brake Pressure Switch
F9 25 Amp – HVAC S6 Service Brake Pressure Switch
F10 15 Amp – Windshield Wiper/Washer S7 Sway Enable Pressure Switch
F11 10 Amp – Defrost Fan S8 Sway Enable Switch
F12 20 Amp – Lights S9 Tilt Enable Switch
F13 15 Amp – Ignition S10 Steer Select Switch
F14 10 Amp – Power Port S11 Left Stabilizer Switch
F15 1 Amp - Switch Power S12 Right Stabilizer Switch
F16 1 Amp – Gauge Cluster ECU S13 Differential Lock Switch
F17 Not Used S14 Auxiliary Cont. Switch
F18 Not Used S15 Horn Switch
F21 HVAC Control Panel S16 Brake Light Pressure Switch
S17A Windshield Wiper Motor Switch
S17B Windshield Washer Switch
S18A Windshield Wiper Motor Switch
S18B Windshield Washer Switch
S19 Dome Light Switch
S21 Enclosed Cab Fan Switch
S22 Road / Work Light Switch
S23 Brake Pressure Warning Switch
S24 Transmission Oil Pressure Switch
S25 Transmission Oil Temp. Switch
6-4 GTH-844 Part No. 218230

Electrical Component Legend
Electrical Component & Wire Color Abbreviation Legend

TP Throttle Pedal Wire Color Legend
TSS Turn Signal Shifter
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
YD D Transmission GR/WH Green/White
YE E Transmission RD Red
YF Transmission Forward RD/BK Red/Black
YR Transmission Reverse RD/WH Red/White
YD1A 4Wheel Steer SVD1A OR Orange
YD1B Crab Steer SVD1B
OR/BK Orange/Black
YLD Left Stabilizer Down
YLU Left Stabilizer Up OR/RD Orange/Red
YRD Right Stabilizer Down WH White
YRU Right Stabilizer Up WH/BK White/Black
WH/RD White/Red
Part No. 218230 GTH-844 6-5

Telematics Connector Legend
Telematics Connector Pin Legend

Genie installed Telematics connector is wired with an Active High digital input
A Deutsch plug p/n DT06-08SA mates with the Genie telematics connector
Pin Circuit Type Circuit Properties Genie Machine Function(s) Telematics Use Case
12 VDC Battery Positive – constant

1 System Power Supply power to device
5 Amp Max. allowed draw power
2 System Ground 0 VDC Battery Negative Device GND
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

0 0
*0V = boom <55 , 12V = boom >55
5 Digital Output 3 12 VDC Parking Brake Monitor machine utilization

*12V = active, 0V = inactive
Remote Machine Disable
6 Digital Input 1 12 VDC ** Configurable Active High or Active Remote Engine Shutdown
Low via wiring at the Disable Relay
7 CAN HIGH J1939 Databus HIGH J1939 Receive J1939 Engine data
8 CAN LOW J1939 Databus LOW J1939 Receive J1939 Engine data
Remote Disable Relay Configuration

Telematic device software should monitor that Pin 3 is at 0V before activating Disable Relay
Wireless Certifications
Telematic device(s) should comply with specific wireless carrier certifications where applicable and comply w ith
the following:
N. America – PTCRB, FCC/IC
Europe – CE, R&TTE
6-6 GTH-844 Part No. 218230

Electrical and Hydraulic Symbols Legend
Electrical Schematic Symbols Hydraulic Schematic Symbols

ACC
BAT
KS1
KEY START M3
STARTER Pressure switch Axle
SWITCH IGN
Hydraulic cylinder
Key switch Engine start
B
86 30
Orifice Adjustable orifice Filter
D1
ALT
85 87 87A
G
Control relay Alternator

Check valve Flow regulator Relief valve
Fuse Circuit breaker
2 position 3 way 2 position 3 way

Horn or Alarm 3 position 4 way solenoid valve directional valve,
Light pilot-operated
solenoid valve
Valve coil with diode Valve coil 2 position 2 way

2 position 4 way
solenoid valve solenoid valve
Diode P
Switch T
1 3 2 4
Joystick
Proximity switch Limit switch
Counterbalance
valve
Temperature switch Fuel level sender
Pressure switch
Battery
Part No. 218230 GTH-844 6-7

6-8 GTH-844 Part No. 218230

Section 6 • Schematics January 2015
Harness Map - Control System Power

Single Joystick (before SN GTH0815-20662)
6 - 10
6-9

HARNESS LEGEND SJ
NUM. PART DESCRIPTION
1 227495 HARNESS, DASHBOARD
2 227496 HARNESS, SECONDARY MANIFOLD
3 219457 HARNESS, BACKUP ALARM
4 227493 HARNESS, TRANSMISSION
5 233941 HARNESS, BOOM ANGLE SW
6 217207 HARNESS, THROTTLE PEDAL
1 7 214443 ASSEMBLY, FOOT SWITCH
11 236979 FORMING, BUSS BAR
12 227944 CONTROLLER, HYD ERGO, 2 SWITCH
13 227497 HARNESS, PRIMARY MANIFOLD SJ
6 - 10 GTH-844 Part No. 218230

January 2015 Section 6 • Schematics
Harness Map - Control System Ground

HARNESS LEGEND GND_SJ

10 161444 ASSEMBLY, GROUND BUSS
13 227497 HARNESS, PRIMARY MANIFOLD SJ
Part No. 218230 GTH-844 6 - 11


6 - 11
6 - 12

Single Joystick (from SN GTH0815-20662)
6 - 14
6 - 13

SINGLE JOYSTICK- CONTROL SYSTEM POWER HARNESSES
823125A
6 - 14 GTH-844 Part No. 218230


SINGLE JOYSTICK- SYSTEM GROUND HARNESSES
823125A
Part No. 218230 GTH-844 6 - 15


6 - 15
6 - 16

Dual Joystick (before SN GTH0815-20662)
6 - 18
6 - 17

HARNESS LEGEND DJ
5 233941 HARNESS, BOOM ANGLE SW
1
6 217207 HARNESS, THROTTLE PEDAL
7 214443 ASSEMBLY, FOOT SWITCH
11 236979 FORMING, BUSS BAR
12 227944 CONTROLLER, HYD ERGO, 2 SWITCH
14 215445 HARNESS, PRIMARY MANIFOLD DJ
6 - 18 GTH-844 Part No. 218230


HARNESS LEGEND GND_DJ

10 161444 ASSEMBLY, GROUND BUSS
14 215445 HARNESS, PRIMARY MANIFOLD DJ
Part No. 218230 GTH-844 6 - 19


6 - 19
6 - 20

Dual Joystick (from SN GTH0815-20662)
6 - 22
6 - 21

DUAL JOYSTICKS- SYSTEM POWER HARNESSES
823125A
6 - 22 GTH-844 Part No. 218230


DUAL JOYSTICK- SYSTEM GROUND HARNESSES
823125A
Part No. 218230 GTH-844 6 - 23


6 - 23
6 - 24
Harness Map - Deutz TCD3.6 Engine

Battery Power and Ground
6 - 26
6 - 25
Harness Map - Deutz 3.6TCD Engine

DEUTZ T3/T4i ENGINE HARNESSES
227493 (before sn GTH0815-20662)

(from sn GTH0815-20662)
823125A
6 - 26 GTH-844 Part No. 218230


PERKINS 1104D-E44TA ENGINE HARNESSES
227493 (before sn GTH0815-20662)

(from sn GTH0815-20662)
823125A
Part No. 218230 GTH-844 6 - 27


6 - 27
6 - 28

6 - 30
6 - 29

PERKINS 854E-E34TA ENGINE HARNESSES
227493 (before sn GTH0815-20662)

(from sn GTH0815-20662)
823125A
6 - 30 GTH-844 Part No. 218230


Auxiliary Hydraulics, Beacon and 3rd Gear Lockout
AUXILIARY, BEACON & 3RD GEAR LOCKOUT HARNESSES
823125A
Part No. 218230 GTH-844 6 - 31


Auxiliary Hydraulics, Beacon and 3rd Gear Lockout
6 - 31
6 - 32

Work Lights
6 - 34
6 - 33

Work Lights
823125A
6 - 34 GTH-844 Part No. 218230


Road Lights
823125A
Part No. 218230 GTH-844 6 - 35


Road Lights
6 - 35
6 - 36

Enclosed Cab with Heater
6 - 38
6 - 37

Enclosed Cab with Heater
823125A
6 - 38 GTH-844 Part No. 218230


Enclosed Cab with HVAC
823125A
Part No. 218230 GTH-844 6 - 39


Enclosed Cab with HVAC
6 - 39
6 - 40
Electrical Schematic - View 1
6 - 42
6 - 41
N
BL/RD
BR
S24 C39-2
BL
OR/BK C39-1 C37-3 BR S24 TRANS.OIL PRESS SW.(N.C.)"TR"

BL/WH C36-1 S23 C36-2
C26-11 BR S23 BRAKE PRESS SW.(N.C.)"SM"
BL C86-1 C86-2 C37-2 BR FUEL SENDER
RD/WH C87-1
S25 TRANS OIL TEMP SW.(N.O.)"TR"
S25
ENGINE COOLANT TEMP
ENGINE OIL PRESSURE
C13-24 OR/BK C10-4
C13-7 RD/WH C10-5

C13-8 BL/WH C11-1
CRAB STEER LIGHT
ES0459E
ENGINE WARNING
LCD/HOURMETER
C13-22 BL C95-1
HEADLIGHTS ON
M
DPF DISABLED
ENGINE STOP
TACHOMETER
TURN SIGNAL
BACKLIGHT
2WS LIGHT
4WS LIGHT
HEST
DPF
C13-6
BR C15-2
GAUGE CLUSTER
120
L10
L16
L21
L9
L7
L1
L4
L5
BL/RD
L19
L17
L20
L8
L2
L6
BL
L
C13-2
GAUGE CLUSTER CPU
C13-3
BR
1 AMP
C13-13
C13-5
C13-21
C13-16
F16
C13-17
C13-1
C13-4
C5-6 RD
C5-5 WH/RD
5 AMP
F7
K
C5-4 WH/RD
SELECT
STEER
C14-4 GR/WH C11-3 GR/WH C34-1 C34-2 BR C26-9

SW.
S10
SVD1B CRAB STEER COIL"SM"

C5-1 GR C14-2
C14-1 GR/BK C11-2 GR/BK C33-1 C33-2 BR C26-8
SVD1A 4WS COIL"SM"
5 AMP
F6
C4-9 OR/RD C28-1 C28-2 OR/BK C32-1 C32-2 BR C26-5

SV6 DIFFERENTIAL LOCK COIL"SM"
LOCK
DIFF.
SW.
S13
J
10 AMP
C55-4 RD C57-1 C57-2 GR

F2
AUX COIL B
C3-12 YL C55-2
C55-1 WH C56-1 C56-2 BK
CONT.
AUX COIL A
AUX.
OPTION
SW.
S14
HYD.
AUX.
10 AMP
F14
C4-10 RD/WH C11-4 RD/WH C91-1 C91-2 BR BR C15-2 12V POWER PORT
POWER
PORT
HORN
SW.
CAN L GR
CAN H YL
12V
S15
L3
I
D17
C10-6 BL C89-1
5 AMP
C1-3 BL
CR3 HORN RELAY"PCB"
F5
CR3
NO
C4-8 BL/BK C88-1 C88-2 BR C26-2

H1 HORN
L14
L13
CR13 TILT FUNCTION

RELAY"PCB"
C9-4
L23
C9-2 BK BL
D13
2
1
ENABLE
TILT
SW.
S9
RED
SINGLE JOYSTICK
C3-6 YL C22-1 C22-2 BR C17-10 SV4 TILT DOWN

ENABLE COIL"PM"
H
CR13
NO
OPTION
C3-5 OR/RDC23-1 C23-2 BR C17-9 SV2 TILT UP

ENABLE
WHITE
ENABLE COIL "PM"

SWAY
SW.
S8
C3-4 BK/WHC20-1 C20-2 BR C17-4 SV3 SWAY RIGHT

11
C9-1 WH
12
ENABLE COIL"PM"
CR12
NO
DUAL JOYSTICK
RD C9-3 C3-3 BK/RD C21-1 C21-2 BR C17-3 SV1 SWAY LEFT

ENABLE
ENABLE COIL"PM"
C27-B
C27-A
SWAY
L22
PS.
OPTION
S7
D19
D12
CR12 SWAY FUNCTION

RELAY"PCB"
CR6 SWAY ENABLE
G
RELAY"PCB"
L12
L18
L6
F4
CR6
10 AMP
NO
C3-7 RD/WHC19-1 C19-2 BR C17-11

SV9 SWAY ENABLE COIL"PM"
D2
S6
S5
10 AMP
C4-6 GR/BK C27-A C27-B GR C29-1 C29-2 WH C4-7 C4-4 BL/BK C31-1 C31-2 BR C26-4 SV7 REAR AXLE FLOAT COIL"SM"
PRESS.SW.
PRESS.SW.
(N.O.)"SM"
(N.C.)"BM"
F3
PARKING
SERVICE
D3
L16
D1
L17
BRAKE
BRAKE
CR7
L9
NO
CR7 BOOM ANGLE RELAY"PCB"

CR14 BOOM ANGLE MONITOR"PCB"
L7
F
C3-10
January 2015
Part No. 218230

GR
D14
C12-2 GR C10-2 C42-1 C42-2 BR C37-6

D7
SV"D" TRANS COIL"TR"

L28
1
CR14
YL C105-2
YL C12-3 YL C10-3 YL C43-1 C43-2 BR C37-7
NO
SV"E" TRANS COIL"TR"

C4-11
D9
F-N-R SHIFTER
C4-1
C105-1 RD/BK
RD/BK CR9 FORWARD ENABLE RELAY"PCB"
3
CR9
NO
S3 BOOM ANGLE SW.
C24-2
BLU
BL/WH C5-2 C1-1 BL C41-1 C41-2 BR C37-5 SV"A" FORWARD COIL"TR"

C12-1
F20 1 AMP
L19
D10
WH/RD C12-8 L24
E
(N.O.)
CR10 REVERSE ENABLE RELAY"PCB"

BRN
B
C24-1
CR10
NO
GR/WH C5-3 C1-2 BL/BK C40-1 C40-2 BR C37-4 SV"B" REVERSE COIL"TR"
C12-7
L20
RD
1 AMP
F15
C3-8
C12-6 C12-5
L10
C3-11 WH C18-1 RD BK C18-2 BR C17-2 BACKUP ALARM"PM"
C5-11
LIGHT OPTION
WORK/ROAD
C2-2 RD/WH C50-1 WH BK C50-2 BR C45-6 BACKUP LIGHT
RD/WH
F1
15 AMP
WH
D
CR1 MAIN POWER RELAY"PCB"

CR1
CR2 OPTIONS POWER RELAY"PCB"

NO
D15
WH/RD
L25
L21
C15-6
C104-4
C15-8
D6
C15-1 BL/WH C5-10 C4-5 BL/WH C30-1 C30-2 BR C26-3
D16
SV5 PARKING BRAKE RELEASE COIL"SM"

CR2
CR11
NO
D5
C15-4 BL/RD C5-12
PARKING BRAKE LATCH RELAY"PCB"
C15-2
BRAKE SW.
4700
C1
µF
S2 PARK
D11
C5-8
L2
C15-9
3RD GEAR LOCKOUT OPTION

L11
L1
GTH-844
R1
0.1
C
BR
CAN L GR
CAN H YL
C107-30 RD/WH
BK
BR C15-3 PARKING BRAKE LIGHT

C5-9
WH
DEUTZ,T3/T4 30AMP
PERKINS T4 50AMP
PERKINS T3 30AMP
C90-4
C104-2
C84
BR
THROTTLE PEDAL
ACC C90-2
C107-87A RD/WH C103-1 RD/WH C44-6 C44-4 OR C38-4 IVS
RD/BK
START IVS
A B C D
VCC C44-3 BL/WH C38-3 VCC
ENGINE MANAGEMENT
START
SWITCH
RD/BK C10-1 RD/BK C44-5 GND C44-2 YL/WH C38-2

S1 KEY
IGN GND
NOTES:
BL/RD
C44-1 GR/WH C38-1 APS
C90-3 C104-1 RD/BK APS
SYSTEM
BAT IGN
C108-1
GND
CR18
NC
RD/BK
D+
C90-1 ALT
B
A
C107-86
4 7 8 1 2 6 3 5
C108-3 BK C107-85
G
B
GLOW PLUG
ALT
15 AMP
ST
B+
ECU PWR
C114 TELEMATICS
S27
BL
F13
CAN H
CAN L
BR
PWR
C5-7 RD
C108-2
STARTER SOLENOID & RELAY
Section 6 • Schematics
C106-B GR CAN L
RD
C106-A YL CAN H STARTER MOTOR
C44-7
C44-8
C1-4 RD C103-2
60 AMP
STARTER
50 AMP
BK/WH
CB.1
CB.2
CB.3
F19
5 AMP
C106-B
C106-A
C106-A
C106-B
BR
PCB BAT+ RD 12 VOLT BATTERY
RED BATTERY CABLE
B1
A
C4-12 BK/WH C11-6 BK/WH C104-3 BK/WH
6 - 42
1
8
N M L K J I H G F E D C B A
ROAD/WORK LIGHT OPTION ROAD LIGHT OPTION BEACON LIGHT OPTION ENCLOSED CAB OPTION
1
F12 F8 F9
20 AMP 5 AMP 25 AMP
LH NR
C6-2
C6-2
C6-1
C6-1
C10-7 BL 2-3
BL 2>7 F11
2 2>4 CAB HVAC OPTION DETAILS F10
CAB HEATER OPTION DETAILS 5 AMP 15 AMP
3-4 3-7 3-2
RD
RD
3>7 A/C DRIER
3 3-5 3-8 3>4
RD
RD
NOTE:
C1-5
C2-3
SWITCH
C2-4 OR/BK
C7-1
C8-1
4-3 CIRCLED NUMBERS
4 4-5 H G CONTROL PANEL 26-1397 A1 A2
PRINTED ON WIRES
L4 5-3 5-6 5-6
5 5-4 5-6 5-8 5-8 C85-1 C85-2 BK 2
RD/BK C49-A
HEAT VALVE A/C SWITCH BLOWER SWITCH
CR4 6-5 6-5 BLOWER SPEED SWITCH INFO: CONTROL PANEL 56-0048 POTENTIOMETER (ON/OFF) SPEED CONTROL
C6-5
C6-3
C6-4
6 6-8 6-5 6-8 6-8 OFF - UNIT OFF HEAT VALVE BLOWER SWITCH
P L - BLOWER LOW SPEED POTENTIOMETER SPEED CONTROL 10KW C77-1
7-3
X L 7 M - BLOWER MEDIUM SPEED
BK C82-1
C48-2
7-8 10KW
H - BLOWER HIGH SPEED
CCW
WH
8-3 8-5 8-5
CW BK
8 8-6 8-7 8-6 8-6
RD
RD
RD
RD
FLASHER
CCW
CW BK
BL
WH
HEATER VALVE POT INFO: RD RD
C65-1
CCW - COOL SETTING C OFF L M H B
BL
WH
S22 S16 TURN SIGNAL SHIFTER CW - HOT SETTING C OFF L M H B
WH
C7-1
RD C63-4
RD C62-4
A/C
BK/WH
BRAKE LIGHT
RD C62-7
RD
RD C63-7
C76-A
C76-B
C76-C
C77-4
C77-3
C78-C
C78-L
C78-M
C78-H
C78-B
ROAD/WORK
LIGHT SW. PS.SW.(N.O.) COMPR.
C76-A
C76-B
C76-C BK
C78-L
C78-M
C78-H
C78-B
WH SOLINOID
L27 C2-1 F21
C49-B RD
C48-4
RD
S19 4 AMP
16
3
WH
L26 C66 INLINE
WH
BL
C2-10 A WH S17 S18
OR
YL
RD
YL
BL/RD BL/RD 2 WINDSHIELD SKYLIGHT
BL K WH
D4
WASHER
WASHER
SWITCH SWITCH
WIPER
WIPER
3
BL/RD C2-5
32 15
RD J WH
4 22
OR/BK BK GND
BK
5 E WH WH
C2-11 C2-12 GY 20
6 BK
GR L 10 X I F B
C7-1
7
GR/BK
8
C62-8
C63-8
C62-2
C62-1
C63-2
C63-1
C65-2
WH C83-1
RD C80-B
WHC80-D
WHC80-E
WHC80-F
OR C80-A
YL C80-C
C61-1
18
L15 NOTE: WH
CR5 31
CIRCLED NUMBERS
NO
L5 PRINTED ON WIRES 22 17 18 25 26 27 5 21 1 S21
D18 FAN 2
BLOWER SPEED SWITCH INFO: SW. 4
WHC80-E
WHC80-B
WHC80-A
WHC80-C
WHC79-B
WHC79-C
WHC80-F
WHC79-A
WHC80-D
RD
RD
OR/WH
OR
BL
GR
BL/WH
GR/WH
L 10 X I F B OFF - UNIT OFF 3 1
L - BLOWER LOW SPEED
BK
ACTUATOR SEALED RED N
BK
R2 M - BLOWER MEDIUM SPEED BK GND
OR
RD
YL
WH
WH
HEATER VALVE 82KW H - BLOWER HIGH SPEED B
C81-A WH
C2-8
C2-9
C2-9
C2-6
C2-6
C2-7
C2-7
IGN HEATER VALVE POT INFO: A/C CORE 13-2537
CCW - COOL SETTING
C60-2
C59-2
C60-3
C59-3
C92-1
C93-1
C60-1
C59-1
SIG C81-D WH CW - HOT SETTING 22 17 18 25 26 27 5 21 1
M 8
RD C75-2
RD C75-2
WH C75-1
WH C75-1
C61-2
WH
WH
WH
WH
WH
GND A/C SWITCH INFO: WH
C81-C WH
OR
OR
RD
RD
BL
BL
7 D M ON - A/C ON WH
OFF - A/C OFF 12
WH
BLOWER 4
HEATER CORE 13-2541 M M M M
OR/BK C52-B RD
GR/BK C51-B RD
WH
10 2 5
RD C46-1
RD C46-1
WH C47-1
WH C47-1
GR C54-1
RD C53-1
OR C51-A
OR C52-A
OR C51-A
BK C51-B
THERMOSTAT
CR16 CR17
BL NO NO
C92-2
C93-2
C60-4
C59-4
BL/RD
COLD CUT-OUT: 23 29 11 30
BK
BK
RD
-3.0ºC±1.0ºC
BK
R2
"PCB" - LOCATION PCB 82K W
ACTUATOR SEALED
WH C51-C BR
WH C52-C BR
WH C51-C BR
BR
BR
BR
BR
BR
"PM" - LOCATION PRIMARY MANIFOLD 28
"SM" - LOCATION SECONDARY MANIFOLD HEATER VALVE
24 3
C46-2 BR
C46-2 BR
C74-2 BK
C74-2 BK
C54-2 BR
4
C53-2 BR
"TM" - LOCATION TRANSMISSION C81-C WH CR15

GND 11
SIG C81-D WH
NO
13
6
M
C58-1
C58-3
C58-2
C58-4
M
C8-2
C6-6
C7-2
C75-4 BR
C75-4 BR
C75-3 BR
C75-3 BR
IGN C81-A WH
BLOWER
C45-2
C45-5
C45-2
C45-4
C45-5
C45-7
C45-7
BR
SKYLIGHT WASHER
CR5 LIGHTS RELAY"PCB"
RIGHT CAB LIGHT
RIGHT CAB LIGHT
HVAC MOTOR
LEFT CAB LIGHT
LEFT CAB LIGHT
SKYLIGHT WIPER
DEFROSTER FAN
DOME LIGHT
HEATER MOTOR
STROBE LIGHT
WINDSHIELD WASHER
RIGHT FRONT BLINKER
WINDSHIELD WIPER
LEFT FRONT BLINKER
LEFT TAILIGHT
RIGHT TAILIGHT
RIGHT TAILIGHT
WORK LIGHTS ROAD LIGHTS
ES0459E
Part No. 218230 GTH-844 6 - 43

6 - 42
6 - 44
Section 6 • Schematics September 2015
Hydraulic Schematic - Single Joystick

6 - 46
6 - 45

A B C D E F G H I J K L M N
T P 4-WAY CONTROL
1
SERVICE BRAKE BRAKE LIGHTS (OPTION) TILT
PRESSURE SWITCH 1 3 2 4
PRESSURE SWITCH 14 / 10 gpm
450 psi 50 psi
31 bar 53 / 37.9 L/min
3.5 bar EXTEND / RETRACT LIFT
FRONT STEER REAR STEER 31 / 14 gpm 31 / 19 gpm SWAY
6 gpm 6 gpm 117.4 / 53 L/min 117.4 / 72 L/min 2.2 gpm
22.8 L/min 22.8 L/min DIFF LOCK 8.4 L/min
REAR LOCK-UP
2 STEERING UNIT PARKING
BRAKE
5 gpm
19 L/min
15.3 cid / 250 cc L R L R SERVICE BRAKE
MANIFOLD
P REAR AXLE FRONT AXLE
L BRAKE PEDAL
STRG. 0-640 psi / 0-44.2 bar
WHL. BRAKE WARNING LIGHT R E
R PRESSURE
SWITCH A E R
T PARKING BRAKE
350 psi PRESSURE SWITCH R E R E AUX HYD
24.1 bar 250 psi / 17.3 bar P
3 LS P T 15 gpm
MASTER 56.8 L/min
SUP TS SUT SULS SUR SRF SLR SRR BS BA TB BP BT TPB PBS PB DL TJ JP TR LU LUP J1 ER EE J3 J2 LD LU J4 TD TU SL SR A1 A2
#6 ALS
CV8 SVD1
b SV5 SV6 ALS
0.1 gpm
CV9 CV8 0.8 L/min
CV1 CV2 CV3 CV4 CV2 CV1
FR2 CV7 SVD1
SV1 SV2 SV3 SV4 CV6 CV5 a b
a
4 PE1 PE2 PE3 PE4
PR2 50 psi
3.5 bar SV7 FR1 NV1
2.0 gpm
PR3 2650 psi 350 psi 7.6 L/min
PR4
183 bar 24.1 bar AUX MANIFOLD AP AT
(OPTION)
PR1 400 psi SV9
28 bar TP
5
CV9
P2 P2
RV1 RV2 RV3 AP
LS2 LS2 3500 psi 3500 psi 3500 psi
241.4 bar 241.4 bar 241.4 bar
6 T2 T2 AT
SECONDARY FUNCTION MANIFOLD MAIN FUNCTION MANIFOLD
LS PLS P T HS0205B
B X
E
BREATHER / FILLER L1
3 psi / 0.3 bar L2
8 L S FUNCTION PUMP
3250/450 PSI PC/LS SETTING
3.11 CID (51 CC)
2370-2580 RPM MAX
RESERVOIR
6 - 46 GTH-844 Part No. 218230

September 2015 Section 6 • Schematics

HS0205F 8
Part No. 218230 GTH-844 6 - 47


from serial number 19529)
6 - 47
6 - 48
Hydraulic Schematic - Dual Joystick

6 - 50
6 - 49

A B C D E F G H I J K L M N
T P 4-WAY CONTROL T P 4-WAY CONTROL

1
SERVICE BRAKE BRAKE LIGHTS (OPTION)
PRESSURE SWITCH PRESSURE SWITCH 1 3 2 4 4 2 1 3
450 psi 50 psi TILT
31 bar 3.5 bar
EXTEND / RETRACT LIFT 14 / 10 gpm
FRONT STEER REAR STEER 31 / 14 gpm 31 / 19 gpm 53 / 37.9 L/min SWAY
6 gpm 6 gpm 117.4 / 53 L/min 117.4 / 72 L/min 2.2 gpm
22.8 L/min 22.8 L/min DIFF LOCK 8.4 L/min
REAR LOCK-UP
2 STEERING UNIT PARKING 5 gpm
15.3 cid / 250 cc L R L R BRAKE 19 L/min
SERVICE BRAKE
MANIFOLD
P REAR AXLE FRONT AXLE
L
STRG. BRAKE PEDAL
WHL. BRAKE WARNING LIGHT 0-640 psi / 0-44.2 bar R E
R PRESSURE A PARKING BRAKE E R
T SWITCH
350 psi PRESSURE SWITCH R E R E AUX HYD
3 LS 24.1 bar P T 250 psi / 17.3 bar P
15 gpm
MASTER
56.8 L/min
SUP TS SUT SULS SUR SRF SLR SRR BS BA TB BP BT TPB PBS PB DL TJ JP TR LU LUP JE1 ER EE JE3 JL2 LD LU JL4 JT4 TD TU JT2 JS1 SL SR JS3 A1 A2
#4
SVD1
CV8 b ALS
SV5 SV6 0.1 gpm ALS
CV1 CV2 CV3 CV4 PC1 PC2 0.8 L/min CV2 CV1
FR2 CV7
SVD1
4 CV5 CV6 a b
a PE1 PE2 PE4
PE3
PR2 50 psi FR1 SWAY ENABLE

3.5 bar SV7 PRESSURE NV1
2.0 gpm
7.6 L/min LS1 SWITCH
PR3 2650 psi PR4 350 psi 50 psi / 3.5 bar
183 bar 24.1 bar AP AT
SV9 SS AUX MANIFOLD
PR1 400 psi (OPTION)
5 28 bar TP
CV9
P2 P2
RV1 RV2 RV3 AP
LS2 LS2 3500 psi 3500 psi 3500 psi
241.4 bar 241.4 bar 241.4 bar
6
T2 T2 AT
SECONDARY FUNCTION MANIFOLD MAIN FUNCTION MANIFOLD
LS PLS P T
HS0206C
B X
E
BREATHER / FILLER L1
3 psi / 0.3 bar L2
8
L S FUNCTION PUMP
3250/450 PSI PC/LS SETTING
3.11 CID (51 CC)
2370-2580 RPM MAX
RESERVOIR
6 - 50 GTH-844 Part No. 218230


HS0206G
Part No. 218230 GTH-844 6 - 51


6 - 51 6 - 52
California Proposition 65
Warning
The exhaust from this product
contains chemicals known to
the State of California to
cause cancer, birth defects
or other reproductive harm.
Genie North America

Phone 425.881.1800
Toll Free USA and Canada
Distributed By:
800.536.1800
Fax 425.883.3475
Genie Australia Pty Ltd.

Phone +61 7 3375 1660
Fax +61 7 3375 1002
Genie Scandinavia
Phone +46 31 575100 Genie China
Fax +46 31 579020 Phone +86 21 53852570
Fax +86 21 53852569
Genie France
Phone +33 (0)2 37 26 09 99 Genie Malaysia
Fax +33 (0)2 37 26 09 98 Phone +65 98 480 775
Fax +65 67 533 544
Genie Iberica
Phone +34 93 579 5042 Genie Japan
Fax +34 93 579 5059 Phone +81 3 3453 6082
Fax +81 3 3453 6083
Genie Germany
Phone 0800 180 9017 Genie Korea
Phone +49 422 149 1818 Phone +82 25 587 267
Fax +49 422 149 1820 Fax +82 25 583 910
Genie U.K. Genie Brasil

Phone +44 (0)1476 584333 Phone +55 11 41 665 755
Fax +44 (0)1476 584334 Fax +55 11 41 665 754
Genie Mexico City Genie Holland

Phone +52 55 5666 5242 Phone +31 183 581 102
Fax +52 55 5666 3241 Fax +31 183 581 566

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Parts Manual

Part No. 218230

Important Serial Number Information

This manual provides detailed scheduled GTH-844A

"Genie" is a registered trademark of Terex

ii GTH-844 Part No. 218230

B 05/14 Specifications Hydraulic Oil

Maintenance B-10 Fork Level and Auxiliary hose tension

Schematics Telematics connector legend; electrical schematic;

B1 09/14 Fault Codes Display Gauge; Deutz Fault Codes

B3 05/15 Fault Codes Deutz Fault Codes

Schematics Fuse Panel Legend

Kubota Engine_Section 2_Specifications. Electronic Version

Part No. 218230 GTH-844 iii

REVISION HISTORY, CONTINUED

Revision Date Section Procedure / Schematic Page / Description

Kubota Engine_Section 2_Specifications. Electronic Version

iv GTH-844 Part No. 218230

Serial Number Legend

THIS FORKLIFT TRUCK COMPLIES

Part No. 218230 GTH-844 v

This page intentionally left blank.

vi GTH-844 Part No. 218230

Read each procedure thoroughly. This

Be aware of potential crushing hazards

Part No. 218230 GTH-844 vii

Be sure that all tools and working areas

Be sure that fasteners intended for one

Be sure that your workshop or work area

viii GTH-844 Part No. 218230

Section 1 Safety Rules

Section 3 Scheduled Maintenance Procedures

Part No. 218230 GTH-844 ix

Section 3 Scheduled Maintenance Procedures, continued

x GTH-844 Part No. 218230

Section 3 Scheduled Maintenance Procedures, continued

Part No. 218230 GTH-844 xi

Section 4 Repair Procedures

xii GTH-844 Part No. 218230

Section 4 Repair Procedures, continued

Part No. 218230 GTH-844 xiii

Section 4 Repair Procedures, continued

xiv GTH-844 Part No. 218230

Section 5 Fault Codes

Part No. 218230 GTH-844 xv

Section 6 Schematics, continued

Harness Map - Deutz TCD3.6 Engine

xvi GTH-844 Part No. 218230

Tire size 13.00 x 24

Lug nut torque 295 ft-lbs

Continuous improvement of our products is a

Part No. 218230 GTH-844 2-1

Performance Specifications Boom function speeds, maximum

Drive speed, maximum Boom up 12 to 14 seconds

Lift capacity, maximum 8000 lbs Fork tilt down 5 to 7 seconds

Continuous improvement of our products is a

2-2 GTH-844 Part No. 218230

Hydraulic Specifications Do not top off with incompatible

Fire resistant UCON Hydrolube HP-5046 3