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GTH-844 from SN GTH0813-16606 (PN 218230)

1. ROADIWORK LIGHT OPTION ROAD LIGHT OPTION BEACON LIGHT OPTION _ ENCLOSED CAB OPTION I F8 F9 12 20AMP SAMP 4 mas o lo BL C107 BL 23 5 T de F10 2 224 CAB HEATER OPTION DETAILS GABHVAG OPTION DETAILS SAMP 15AMP m AIC DRIER Q 23 3 8 3 gt 4 e NOTE 6 5 SWITCH N E q i 9 4145 EN CIRCLED NUMBERS H G CONTROL PANEL 26 1397 AD 2 51225655 PRINTED ON WIRES lt C854 C852 BK 2 9 8 5 5456 5858 CONTROL PANEL 56 0048 e D TENTE UH 1 6 5 CR4 L 6 5 6 5 BLOWER SPEED SWITCH INFO m POTENTIOMETER ON OFF SPEED CONTROL 9 9 B 3 6 6 8 6 5 65 65 OFF UNIT OFF BLOWER SWITCH 5
2. A B C D E F G H L M 4 WAY CONTROL 1 SERVICE BRAKE BRAKE LIGHTS OPTION 1 PRESSURE SWITCH PRESSURE SWITCH S UE T T M n qup a 53 37 9 L min Lo O35 bar EXTEND RETRACT E SW FRONTSTEER REAR STEER 31 14 gpm E gpm 6 gpm 6 gpm 117 4 53 L min 117 4 72 L min 2 2 22 8 Limin 22 8 L min 1 REAR LOCK UP 8 4 L min 2 STEERINGUNIT pO PARKING 5 gpm 15 3cid 250cc L JR L R SERVICE BRAKE BRAKE 19 L min MANIFOLD T E REAR AXLE FRONT AXLE x E BRAKE PEDA IGHT 640 psi 0 44 2 bar SWITCH PARKING BRAKE 350 psi PRESSURE SWITCH E AUX HYD 24 bar 20 3 15 NT wr 56 8 L min SUP 15 SUT SULS S
3. RN1 RN3 RN2 PCBA 237363 ef gt 5 elele z C6 rg o gt amp gt gt 00000000000000 28 92 E D n gp 00000000000000 CF fF ee EE EE T ae eS Ig C5 F15 1 F14 10A F11 10A F8 5A 29 ca zm 1 10 mo wo Ig SWITCH PWR PWRPORT DEFROSTFAN DOME BEACON 20 CR14 28 10 F6 5A 17 10 F75A 89 ANGLE 8 10 5 wo 5 REAR AXLE OSC STEER DIFFSW SPARE GAUGE CLS PWR pex 4 10 1 15 10 15 F161A NE C0 15 uou 1 5 SWAY TILT WIPER WASHER GAUGE CLS ECU P Sh 28 a F201A F2 10 F12 20A F19 D m9 5 zo 2 1 10 LOJ GO 25 gt ANGLEMONIToR AUX HYD LIGHTS TELEM Eu OR en di u e F5 5 F1810AMAX F925A 1 15 5 wm 5 HORN SPARE HVAC IGNITION 53 zz CR11 CR12 CR13 gt PBRAKE SWAY TILT U D x LATCH UR ENBL 5 ENABLE 2 D6 5 T 5 02 o a o D5 CR9 De BOOM FORWARD REVERSE co FR EXTEND E
4. Circuit Breakers located on the Battery Tray CB1 and on all engines CB2 30A Deutz T3 or T4i Perkins 30A CB2 50A Perkins T4i CB1 Telehandler Control System Power CB2 Engine Power ECM CB3 Glow Plugs PCBA 237363 RN1 RN3 RN2 R10 R2 M R4 gt y 06 zg D gt 555 00000000000000 28 92 o n og 00000000000000 r P Li pz r r _ 68 5 15 1 14 10 11 10 F8 59 zm 1 coc uoc ae zg SWITCHPWR PWRPORT DEFROSTFAN DOME BEACON 22 20 F3 10A F6 217 10 F75A CR14 Cio 5 foo 5 DN SPARE REAR AXLE OSCSTEER DIFF SW SPARE GAUGE CLS PWR p d r F4 10A F1 15A F10 15A F16 1A Ne E C4 10 15 Go 2 SWAY TILT BRAKE SHIFT WIPER WASHER GAUGE CLS ECU o 5 PN gt m za F20 10A MAX F2 10A F12 20A F19 10A MAX 19 Di Eu zb 4 qm 0090 Go 0000 55 S
5. 60 in Ibs 6 8 Nm 2 Pressure reducing relief valve 50 psi 3 4 bar 2 Rear lock up circuit 25 27 ft lbs 34 37 Nm 3 Pressure reducing relief valve 400 psi 27 5 bar PR1 Differential lock up circuit 25 27 ft lbs 34 37 Nm 4 Pressure reducing relief valve 2650 psi 183 Steer circuit 25 27 ft lbs 34 37 Nm 5 Pressure reducing relief valve 350 psi 24 8 bar PRA Parking brake circuit 25 27 ft lbs 34 37 Nm 6 Solenoid valve 2 position 3 way SV5 Parking brake release 20 ft Ibs 27 Nm 7 Check valve 5 psi 0 35 bar 9 Brake circuit oit eritque 20 ft lbs 27 Nm 8 Check valve 5 psi 0 35 bar 8 Steering circuit 20 ft Ibs 27 Nm 9 Pressure switch S23 Brake warning switch 10 Pressure switch S5 ius Parking brake switch 11 Solenoid valve 2 position way SV7 Rear lock up 2 3 ft lbs 3 4 Nm 12 Solenoid valve 2 position way SV6 Differential lock up s
6. 3 17 Genie 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 3 19 Checklist D Procedures 0 1 Inspect the Forks us 3 21 D 2 Adjust the Boom Sequencing Chains 3 21 D 3 Replace the Hydraulic Tank Return Filter Element 3 22 0 4 Perform Transmission Maintenance 3 23 0 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 1 Testor Replace the Hydraulic 3 26 E 2 Perform Engine Maintenance Perkins Models 3 27 E 3 Perform Engine Maintenance Perkins Models 3 27 E 4 Perform Engine Maintenance Deutz Models
7. 3 28 E 5 Perform Engine Maintenance Perkins Models 3 28 E 6 Perform Engine Maintenance Deutz Models 3 29 E 7 Perform Engine Maintenance Perkins Models 3 29 Genie Part No 218230 GTH 844 Xi September 2015 TABLE OF CONTENTS Section 4 Repair Procedures E 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 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 u a a i 4 10 How to Remove the Lift Cylinder 1 4 Boom Extension Cylinder 42200 0 10000 4 12 How to Remove the Extension Cylinder 1 5 Fork Level Cylinder 4 12 How to Remove the Fork Level Cylinder 1 6 HydrauliGHOSes s iere d xc eee eee eate 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 TEREX COMPANY Xii GTH 844 Part No 218230 September 2015 TABLE CONTENTS Sec
8. Ct0 4 5 C39 1 OIL PRESS S24 caso c10 5 S51C87 1 OIL 525 44 855 CAN H iE CMM J ACAN esl SECONDARY MANIFOLD c4 5 x C30 1 SV5 P BRAKE RELEASE C24 C4 4 C31 1 SV7 REAR AXLE FLOAT 28 2 C32 1 SV6 DIFF LOCK C11 335 C34 1 SVD1B CRAB STEER C11 235 C33 1 SVDIA 4WS 11 5 C36 2 S23 BRAKE PRESSURE PRIMARY MANIFOLD C4 6 por S5 PARKING BRAKE PwR H 29 SV9 SWAY ENABLE c19 1 kec3 7 un 2 51 SWAY LEFT 21 1 x C3 3 QUORN PWR 88 TR SV3 SWAY RIGHT 20 1 Ee SV2 TILT UP C23 1 Exe C3 5 SV4 TILT DOWN C22 1 lt C3 6 BACKUP BRAKE MANIFOLD ALARM 2 1 JOYSTICK TRAPS 4 1 0 H 2 sal 5 af IRGND 4 38 2 C38 AT TR VCC C84BCEXK C38 3 c10 E 5 59 Iu TR IVS1 4 C38 4 Gy C95 en OS C5 9 C104 1 24 at 9 3 10 1 LEFT 59 5 C90 1 3 C5 7 ous NOTE 29 amp gt lacc pwr cgo 2F c5 8 ie da a BASE UNIT UL START c90 4 15 6 abe SIN C10 6 2 C1 3 SIS RET SINGLE JOYSTICK OPTION 4 PwR POR PORT Leon 4 2 Ei uere eire MEE CONTROL SYSTEM POWER o C12 8 a CONNECTORS DETAILS SILIT sw SWPWR Cis 2Hhz c5 n C21 1 51C3 3 SVI PWR PCB C11 C38 BRAKE SV 15 1 4 amp 5 10 C20 1 2 C3 4 SVS PWR Avo X STA
9. 3 ie i 400 Psi L F 50205 Genie PartNo 218230 GTH 844 6 47 September 2015 Section 6 Schematics Hydraulic Schematic Single Joystick from serial number 19529 48 49 Section 6 Schematics September 2015 p Hydraulic Schematic Dual Joystick before serial number 19529 Section 6 Schematics September 2015 Hydraulic Schematic Dual Joystick before serial number 19529 A B C D E F G H J K L M N 1 WAY CONTR
10. SCHEDULED MAINTENANCE PROCEDURES Pre delivery Preparation Report The pre delivery preparation report contains checklists for each type of scheduled inspection Make copies of the Pre delivery Preparation report to use for each inspection Store completed forms as required Maintenance Schedule 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 Section and the Maintenance Inspection Report 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 perform a scheduled inspection Inspection Checklist Daily or every 8 hours A Quarterly or every 250 hours A B Semi annually or every 500 hours A B C 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 Part No 218230 Pre Delivery Preparation Fundamentals It is the responsibility of the dealer to perform the Pre delivery Preparation The Pre delivery Preparation is performed prior to each delivery The inspection is designed to discover if anything is apparently wrong w
11. 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 23897 65145 13 check of missing injector adjustment value programming IMA injector 3 in firing order Genie 5 10 GTH 844 Part No 218230 2015 Section 5 Fault Codes T ENGINE FAULT CODES MODELS WITH DEUTZ POWER SPN Suspect Parameter Number ASPN Alternate Suspect Parameter Number FMI Failure Mode Identifier SPN ASPN FMI Description 23898 65146 13 check of missing injector adjustment value programming IMA injector 4 in firing order 23899 65147 13 check of missing injector adjustment value programming IMA injector 5 in firing order 23900 65148 13 check of missing injector adjustment value programming IMA injector 6 in firing order 23906 23910 65158 engine shut off due to missing fuel pressure start function is locked Air Pump internal error Air Pump over current Air pump CAN communication interrupted no purge function available Air Pump CAN communication lost Air Pump internal error 14 Air pump doesn t achieve air mass flow setpo
12. C63 4 ZGC59 1 EZ w wewr 63 7156 06 4 LL LWASH PWR 63 8 65 823125 Genie 6 38 GTH 844 Part No 218230 FRONT RIGHT LEFT January 2015 Section 6 Schematics A C SOLENOID 85 2 1 82 1 A C PWR sl WINDSHIELD WASHER PUMP _ WASH PWR C92 113 c62 8 LWASH GND C92 2 4 C58 5 SKYLIGHT WASHER PUMP WASH PWR C93 1L c63 8 LWASH GND C93 2 FK C58 6 A C DRIER SW c83 122 c85 1 A C PWRI 6821 56852 _A C PWR es WINDSHIELD_WIPER WIPE PWR C60 1 x C62 4 VIPERET C60 2 C62 2 WPE ON 60 3 62 1 WPE GND ce0 4 c58 1 HEATER 58 Dome 519 CONTROL PANEL GROUND STUDS 58 3 LIGHT Bower sw 4 Power 78 8 21 C77 4 SW HI 78 80 79 SKYLIGHT_WIPER c63 4 c56 1 WIPE PWR 663 253 659 2 WIPE RET C63 1 1C59 3 WIPE ON L M ce SW MED 78 lt lt 80 SW LOW C78 L X amp C80 D 58 ose C78 C X C77 1 F21 C83 1 lt C78 lt C78 H X GND LUG K C77 3 T i E 2 9 BUSS CONNECTOR DIST JEZI A C SWITCH 60 4 5 58 1 WIPE GND os E ui A C SW PWR C77 1E amp C78 C C59 4 35 c58 2 WIPE GND 223353 2 al C77 3 3 C80 B LUG GND3jc58 3 LUG GND 24258888 555 EET GROUND C77 4 X LUG GND 68 LUG GND 351C58 4 LUG GND 114 07 92 2 1 58 5
13. 11 ft Ibs 14 9 Nm c c CV1 5 c 9 dE O NV1 L y i SVD1 S6 5 516 6 TO FRONT AXLE TO REAR AXLE Genie 4 40 GTH 844 Part No 218230 2014 Section 4 Repair Procedures 7 5 Valve Adjustments Secondary Function Manifold How to Set the Steer System Pressure Note Be sure that the hydraulic oil level is visible in the inspection glass of the hydraulic tank 1 Install a 0 to 1000 psi to 100 bar pressure gauge into test port at the top of the secondary function manifold See 7 3 Secondary Function Manifold Components 2 Startthe engine Allow the engine to idle after warming the engine to operating temperature 3 Without operating any machine controls observe the reading on the pressure gauge Result The pressure gauge reads 450 25 psi 31 1 7 bar The pump is functioning correctly Result The pressure gauge fails to read 450 25 psi 31 1 7 bar The pressure setting needs to be adjusted See Repair Procedure 6 1 How to Adjust the Function Pump Pressure 4 Turn the machine off Remove the pressure gauge from the test port AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray PartNo 218230 Genie GTH 844 MANIFOLDS 5 Install a 0 to 3500 psi
14. 65 O1 CO ol Al O1 CO O O1 CO zx A A T NI A a E c B 3 lt c 0 le ER ER c 1 c 1 5 o O NI PSN SJA iol ol PR Ay N T P E eo E m lt e zv SIND RINI Cyn Copco ojoj o AININ RO OF CO o Tu i On On 0 oj A Oo 52 NI wo N S O AIN n ge 49 cO 29 5 ojo FI 8 NI oye OI On Ke S O1 CO o DIN lt Alo NI wN 65 h5 C2 O1 Po N A A Section 2 Specifications May 2014 m rm This page intentionally left blank Genie 2 14 GTH 844 Part No 218230 2014 Section 3 Scheduled Maintenance Procedures Scheduled Maintenance Procedures Observe and Obey Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machin
15. 75 1 562 7 CAB LT R C52 A32 02 8 TAILLTL C51 A X C2 9 TAILLT R C66 2 1c2 10 SHFTR 2 C49 B X C2 1 SI6 RET 666 6 55 2 12 SHFTR 6 L 823125 Harness Map Options Road Lights C2 9 551 A TAIL LT R ces ese ATAL ELR 1 645 455 C TAILR GND 51 C50 C C ROAD LIGHT OPTION HARNESSES c2 2 gt 3 BACK PWR D BAckuPl C45 632 2 BACK GNO C52 2 8 2 A TAILLLT L th 8 E LEFT C66 52 TAIL BL L TAILLIGHT 45 35 C TAIL L GND J NOTE ROAD LIGHTS OPTION Part No 218230 233989 HARNESS CAB LIGHT 214334 HARNESS CAB LIGHT POWER 229677 HARNESS TAILLIGHT LED 123929 ROAD LIGHT BLINKER 229679 HARNESS ROAD LIGHTS 237934 HARNESS BACKUP LIGHT Genie GTH 844 January 2015 Section 6 Schematics Harness Map Options Road Lights 35 36 Section 6 Schematics January 2015 _ Harness Options Enclosed Cab with Heater Section 6 Schematics January 2015 Harness Map Options Enclosed Cab with Heater RIGHT WINDSHIELD WASHER PUMP_ WASH PWR C92 1L lt Cc62 8 LWASH GND C92 2 4 C58 5 SKYLIGHT WASHER PUMP WASH PWR C93 1L3 C63 8 LWASH GND C93 2 X C58 6 a WINDSHIELD WIPER 63 SKYLIGHT WIPE PWR C60 1 x C62 4 63 4 5 56 1 WIPE PWR WPER
16. s L 5 CR12 SWAY FUNCTION RELAY PCB CR6 SWAY ENABLE RELAY PCB i go I 2 5 C3 7 RDIWHC19 1 3 19 2 BR C17 11 8 bz 8 a C4 6 gt GR BK C27 A J I 027 8 GRC29 1 Te 0292 WH NC C4 4 C31 1 5031 2 BR C264 SV REAR AXLE FLOAT COIL SM ds o es Zuo a 2 c Zsa 5 amp 258 a 4 NR CRT BOOM ANGLE RELAY PCB E CR14 BOOM ANGLE MONITOR PCB i oa 5422 E B UE 12 2 GR 10 2 GR C42 1 0 0422 BR 037 6 4 SV D TRANS 8 z te YL d 12 YL C103 YL 2 BR c37 7 4 SV E TRANS COLL TR 3 a a 4 105 RDIBKS E RD BI CR9 FORWARD ENABLE RELAY PCB qa 5 52 C1 1 BL 5 5 gt 2 41 1 41 2 BR C37 5 4 SV A FORWARD COIL TR E C12 1 EIS 5 WH RDC12 8 INC 88 8 CR10 REVERSE ENABLE RELAY PCB 236 V a 9 J ke Wi 99 S 01 2 BUBK 4041 11 40 2 BR 37 4 4 SV B REVERSE 12 7 8 4 s gt Le B 12 6 PUN C12 5 sd 4 4 Sh C3 11 WH 18 1 RD 8 amp 5 C182 BR 017 24 4 BACKUP ALARM PM _ 1 att t gt u 02 2 RDWH C50 1 WH N 182 C50 j WH BK C502 BRC45 6 BACKUP 85 L 2 E CR1 MAIN POWER RELAY PCB 9 CR2 OPTIONS POWER RELAY PCB a
17. 11 4 1 4 10 PWR PORT HARNESS LEGEND DJ wae C84 D 4 5 TR VST K C44 4 CAN H C13 2 X C10 10 NUM PART DESCRIPTION C12 5 43 START C44 6 3 CAN L Ci3 3 amp C10 112 9559595 C44 O SVDIA PWR C13 4 ANNAN C14 2 3105 1 S10 PWR 1 227495 HARNESS DASHBOARD C12 3 4 3 SvE PWR I C43 1 MALES GC PWR C13 5 MMMMMMM C12 1 392 C5 2 SVA PWR 2 227496 HARNESS SECONDARY MANIFOLD 13 24 4 4 E C39 1 1 C38 1 4 1 TR APS l ENGINE 9 25 1 7 Tae C12 7 5 C5 3 SVB PWR 3 219457 HARNESS BACKUP ALARM C13 7 4 5 S25 RET CB7 1 38 2 4 2 0 S23 RET C13 8 did dd dd C13 21 gt C5 4 GC BK LT 4 227493 HARNESS TRANSMISSION 90 3 lt 6 44 5 38 3 4 5 SVD1B PWR C13 13 0555555 C13 5 2 C5 5 GC PWR 5 233941 HARNESS BOOM ANGLE SW 13 16 4 7 1 5 38 5 4 4 1 51 INDIC PWR C13 16 vevo 13 1 1 5 6 CPU PWR 6 217207 HARNESS THROTTLE PEDAL C89 1 4 8 S15 RET C1 3 C10 6 4 5 IGNITION K ENGINE GC BK LT C13 21 C90 1 2 C5 7 BAT 214443 ASSEMBLE FOOT SWITCH C13 22 XF9 FUEL RET K C86 1 10 1 lt 6 5 lt FUEL RET 13 221 lt 10 9 d EXE C90 2 1C5 8 13 2 910 H CC44 8 C10 11 lt 7 CAN L K ENGINE S24 RET C13 24 X C10 4 C90 3 2 C5 9 IGN 11 236979 FORMING
18. sw sales tos 116 o 4 D speen 528286 256 EFR B segs 9 2 ACTUATOR SEALED REDIN R2 lt x lo M BLOWER MEDIUM SPEED Be GAD 2 HEATER VALVE 8 H BLOWER HIGH SPEED E bp o D n gt 8 59 x C81 A_ WH gt Q Q R R R R R R IGN l HEATER VALVE POT INFO AIC CORE 13 2537 gt 56 gt A CCW COOL SETTING gigig g egg B x u se C81 D WH 0 081 GW HOT SETTING 6247486966 DAA y 888 R sig 5 bb 5 2 8 x 6 GND EXIT AIC SWITCH INFO 5 WH 2 gt lo gt m lo AIC ON S 5 6 9 a 9 DO Qe WH ao P PU N LA at 4 9 HEATER CORE 13 2541 BLOWER KM 5 2 3 3 2 Q 2 3 16 2 8 9 L THERMOSTAT o 0 o lo CR16 CRIT BL g 5 eos 8 9 m 8 8 IE No No X X A US X gt n Je n ds D BURD v z COLD CUT OUT eo G 20 S 8 2 m x 3 0 1 0 IN f A e X Py gt Z VAY Pad 22 OO x A T R2 EN Z PON PEN CCS S CS Z PCB LOCATION PCB ACTUATOR SEALED 82kw g g g g M LOCATION PRIMARY MANIFOLD HEATER VALJE 08 a a a a SM LOCATION SECONDARY MANIFOLD HEATERVALE __ 3 S 8 9 9 o 9 9 TM LOCATION TRANSMISSION GN 1 WH g CR15 19 5 5 5 P NO
19. 1 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to port TP on the secondary function manifold Genie GTH 844 2 Start the engine and fully retract the boom Continue to hold the joystick in the boom retract position and observe the pressure gauge Result If the pressure gauge reads 3200 psi 220 bar immediately stop The pump is good Result If the pressure fails to reach 3200 psi 220 bar the pump needs to be adjusted OR or the pump or pump coupling is faulty and will need to be serviced or replaced Component damage hazard There is no relief valve in the hydraulic pump and the pump can be damaged if the pressure is allowed to exceed specification When testing the pump crank the engine in one second intervals until the correct pressure is confirmed Do not over pressurize the pump 3 Remove the pressure gauge and install plug onto port TP Torque to specification Refer to Section 2 Specifications AWARNING au injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray PartNo 218230 2014 Section 4 Repair Procedures How to Remove the Function Pump AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could resu
20. as tadalicii eite 6 34 Harness Map Options Ahaha cents uae dee ele 6 35 Harness Map Options Enclosed Cab with Heater is 6 38 Harness Map Options Enclosed Cab with HVAC issues eee mene eee n 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 before serial number 19529 Hydraulic Schematic Dual Joysticks 6 51 from serial number 19529 xvi GTH 844 Part No 218230 2014 Section 2 Specifications Machine Specifications Fluid capacities Fuel tank 35 gallons 132 5 liters Hydraulic tank 40 gallons 151 4 liters Hydraulic system 55 gallons including tank 208 2 liters For operational specifications refer to the Operator s Manual Part No 218230 Genie Specifications Tires and wheels Tire size 13 00 x 24 Tire ply rating 12 Weight rough terrain tire 315 16 air filled 142 9 kg Weight rough terrain tire 967 35 lbs foam filled 439 16 kg Tire pressure 62 psi models with air filled tires 4 3 bar Lug nut torque 295 ft lbs 400 Nm Lug pattern 8 x 10 826 Wheel diameter 24 in 60 1 cm Wheel width 9 in 22 9 cm Continuous improvement of our pro
21. 4 Select a reference point on the sequencing chain Measure the distance between the chain and the top surface of the boom Note the measurement 1 Refer to the following illustrations Section 3 Scheduled Maintenance Procedures May 2014 CHECKLIST D PROCEDURES 5 Move to the fork end of the same boom section that was just measured 6 Measure the distance between the top surface of the boom and the same reference point used 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 No adjustment to the chain is necessary Proceed to step 10 Result The difference between measurements 1 and 2 is less than a 0 25 inch 6 35 mm OR is greater than 0 5 inch 12 7 mm The chain requires adjustment Proceed to step 7 Note The measurements taken in step 4 and step 6 must be taken from the same plane on the boom 7 Working at the fork end of the large boom tube locate the adjustable chain anchor on the top of boom section 8 Place an adjustable wrench across the flat part of the chain just ahead of the chain anchor Tighten the wrench onto the chain 9 Using a1 7 16 inch wrench adjust the nut as required to tighten or loosen the chain Repeat this procedure beginning with step 4 10 The procedure is complete TEREX GTH 844 D 3 Replace Hydraulic Tank Return Filter Element
22. Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 61 7 3375 1002 Genie China Phone 86 21 53852570 Fax 86 21 53852569 Genie Malaysia Phone 65 98 480 775 Fax 65 67 533 544 Genie Japan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie Korea Phone 82 25 587 267 Fax 82 25 583 910 Genie U K Phone 44 0 1476 584333 Fax 44 0 1476 584334 Genie Brasil Phone 55 11 41 665 755 Fax 55 11 41 665 754 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566 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
23. N optional oil cooler may be required PartNo 218230 Continuous improvement of our products isa Genie policy Product specifications are subject to change without notice Genie GTH 844 2 3 Section 2 Specifications May 2014 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 4 F 20 C 1040 Brookfield Viscosity 22 F 30 C 3310 4 F 20 C 1040 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 Note An hydraulic oil heating system is recommended when the ambient termperature is consistently below 0 F 18 C Note Do not operate the machine when the ambient temperature is below 20 F 29 C with Rando HD Premium MV Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie GTH 844 Flash Point 180 F 82 C Pour Point 81 F 63 C Maximum continuous operating 124 F 51 C temperature Note Use of Chevron 5606A hydraulic fluid or equivalen
24. Note Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Replacing the hydraulic return filter element is essential to good machine performance and service life A dirty or clogged filter element may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filter element be replaced more often Bodily injury hazard Beware of ACAUTION hot oil Contact with hot oil may cause severe burns Note Perform this procedure with the engine off 1 Start the engine Raise the boom to allow access to the hydraulic tank Remove the access cover to the tank Release the pressure in the reservoir by loosening the filler oreather cap Unscrew the return filter Install the new filter element Tighten the filler breather cap Record the hours the filter element was replaced and keep with your maintenance records 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 Part No 218230 2014 Section 3 Scheduled Maintenance Procedures D 4 Perform Transmission Maintenance Note Transmission specifications require that this procedure be performed every 1000 hours Transmission change oil and filter Drop box change oil and filter
25. Telematic device s should comply with specific wirelesg carrier certifications where applicable and comply with the following N America PTCRB FCC IC Europe CE R amp TTE Genie 6 6 GTH 844 PartNo 218230 2015 Section 6 Schematics Electrical and Hydraulic Symbols Legend Electrical Schematic Symbols Key switch EA 85 87 87A Control relay Horn or Alarm E Valve coil with diode Pie Switch 9 Proximity switch Ti Temperature switch Battery Engine start B ALT G Alternator 1 g Circuit breaker Valve coil Diode pA Limit switch 07 Fuel level sender DZ Pressure switch Hydraulic Schematic Symbols m Pressure switch Orifice Check valve All 3 position 4 way solenoid valve ua 2 position 4 way solenoid valve T xu aX re 1 BE Hydraulic cylinder gt e Axle Adjustable orifice Filter ma X Ae Flow regulator Relief valve 127 2 position 3 way directional valve pilot operated
26. 48 Z c132 cts HALSNTO aonv l ae VW UT w P e e 2 2 5 a C56 RD 9 5 5 5 5 5 WH RD z nt ES 1 5 654 WHIRD gs 14 4 GRIWH 11 3 GR WH cs BR c26 9 SE WE CRH yee 4 1 Ls 034 2 BR C269 4 SVD1B CRAB STEER COIL SM 653651 GR 142 Bie 2 04 GRIBK 0042 GRIBK 033 2 BR c26 8 EI 25 m C49 ORRD C28 1 0282 OR BK C321 1 5yC32 2 BR C26 5 4 SV6 DIFFERENTIAL LOCK COIL SM D i 5695 g 1 p as _ 055 RD 657 17 057 2 GR P AUXCOLB 4 c3 12 YL C552 2 1 2 zi IHE 09 WH cse D cse 2 lauxcow amp a xat L Daoa 2 5 5 4 C40 RDMH _ C114 RD WH g y 5 91 2 BR BR C152 _ 12V POWER PORT g zc a p 858 255 5 55 AE C13 BL C06 BL 891 HORN RELAY PCB D 5 C88 1 C88 2 BR C26 2 SATHORN e 5 4 CR13 TILT FUNCTION 9 2 BK F se C94 2 8 RELACPCB HER s 5 amp D g C96 YL C224 A C222 BR C17 10 4 SV4 TILT DOWN 2i ENABLE 8 E ug o 3 5 ORIRDC23 1 3 2 BR 17 9 SV2 TILT UP SE x H ENABLE COIL PM z2z 8666 _ pE 2 3 4 BKIWHC20 1 A C202 BR C174 4 SV3 SWAY RIGHT Slo ENABLE 2 RD C9 3 C3 3 BK RDC21 1 A C21 2 BR 17 3 4 SV1 SWAY LEFT 5 ENABLE COIL PM Sl 8 251 m
27. 6 oO m 4 E Pi g E E 2 2 Ix m BG WH O M 5 E E 9 g 8 9 9 9 9 9 AS IGN ij t S A b b gt Y 3 3 2 3 BLOWER 4 8 R g a z 5 BR 4 4 4 4 t 4 4 5 r 2 9 Rm g 2 h 58 E 8 i m 2 7 3 8 31 8 3 8 1 8 5 8 g 9 g gt 3 Q m 5 9 g 2 t Q E E 2 9 d m m E 3 2005 s 8 os 5 5 4 E 2 9 9 gt E 9 5 9 5 e 4 5 5 5 Bg i 89 8 B p 3 8 3 gt 5 2 2 3 8 5 8 WORK LIGHTS ROAD LIGHTS a L 1 Genie Part No 218230 GTH 844 6 43 January 2015 Section 6 Schematics E Electrical Schematic View 2 45 Section 6 Schematics September 2015 s E Hydraulic Schematic Single Joystick before serial number 19529 6 46 Section 6 Schematics September 2015 Hydraulic Schematic Single Joystick before serial number 19529
28. 6 Tag disconnect and plug the high pressure hose at the pump Cap the fitting on the pump AWARNING injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 7 Remove the fasteners securing the pump to the transmission Remove the pump from the machine Section 4 Repair Procedures May 2014 HYDRAULIC PUMP How to Install the Function Pump 1 Carefully install the hydraulic pump onto the transmission Install the fasteners and tighten to finger tight 2 Torque the fasteners evenly to 85 ft Ibs 115 Nm 3 Install the smaller high pressure hose onto the pump outlet Torque the fasteners to 27 37 ft lbs 37 50 Nm 4 Install the larger low pressure hose onto the pump outlet Install the hose retaining rings and fasteners Torque the fasteners to 55 66 ft Ibs 74 90 Nm 5 Working at the case drain at the top of the pump fill the pump with hydraulic fluid until the fluid is at the top of the case drain fitting 6 Install the case drain hose onto the pump and torque to specification Refer to Section 2 Specifications 7 Securely install the wire harness onto the pump 8 Checkthe level of the hydraulic fluid in the hydraulic tank Add fluid if needed 9 Prime the pump See 6 1 How to Prime the Function Pump 10 Start the engine and inspect for leaks 11 Turn the
29. C15 8 X C12 6 AUX HYDRAULICS 14 POWER CONNECTED HARNESS x C24 22205 10 S3 RET 229681 WHEN AUX HYDRAULICS OPTION INSTALLED C11 C4 9 4 1 S13 PWR l s13 B ILC s 15 4 C18 1 gt C3 11 B ALRM SWAY PWR C9 1 X S8 11 C32 1 2 S13 RET J S13 b 5 SVDTAPWR 14 cu 2 KR cs55 232 C3 12 S14 PWR TILT PWR 9 2 lt s9 d cc13 8 431 S23 RET k c36 22 Qu SIO PWR C14 2 C5 1 SWAY RET C9 3 58 12 C14 1 4 2 SVD1A PWR C33 1 pjiSVDIB PWR C14 4 X amp C11 3 C31 1 C4 4 SV7 PWR OTT RET 89 2 C14 4 3 SVD1B PWR C34 1 C38 R C13 13 Em CSI I Q4 PWRPORICKC4 102 ccB4 A 4 1 RAPS kc4 1 7 S S SRET 9 1 10 8 629 2 3 64 7 SERET HARNESS LEGEND SJ 3 SP CPU PWR 1 1 lt t 88 1 1 4 8 HORN PWR NUM PART DESCRIPTION C10 9209476 EL COPUSEWR CIS 7I C25 1171774 C28 1 2 C4 9 SV13 PWR C84 D cm TR VS1 I C44 4 D CAN 13 2 10 10 DodCwwaw 11 4 55364 10 PWR PORT 1 227495 HARNESS DASHBOARD C12 5 d1 START C44 6 j L Ci3 3 C10 117 9550595 i 2 227496 HARNESS SECONDARY MANIFOLD IRSE A st E 13 24 4 4 524 39 1 38 1 4 1 5 9 sos RET 13 7 6 10 5 C12 1 gt C5 2 SVA PWR 4 227493 HARNESS TRANSMISSION C13 der 5 S25 RET EC 1 LE 53 2 TR GND K ENGINE S23 RET Cl3 8 X C
30. CHECKLIST B PROCEDURES B 6 Perform Hydraulic Oil Analysis Note Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more often Refer to Section 2 Specifications 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 See E 1 Test or Replace the Hydraulic Oil TEREX GTH 844 MPANY B 7 Inspect the Fuel and Hydraulic Tank Cap Venting Systems Note Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Perform this procedure more often if dusty conditions exist Free breathing fuel and hydraulic tank caps are essential for good machine performance and service life A dirty or clogged tank vent system may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the vent system be inspected more often ADANGER Explosion and fire hazard Engine
31. F 26 7 C e Subtract 0 004 from the reading of each cell for every 10 5 5 C below 80 F 26 7 O Result All battery cells display a specific gravity of 1 277 or greater The battery is fully charged Proceed to step 12 Result The difference in specific gravity readings between cells is greater than 0 1 OR the specific gravity of one or more cells is less than 1 177 Replace the battery 12 Check the battery acid level If needed replenish with distilled water to 1 8 inch 3 mm below the bottom of the battery fill tube Do not overfill 13 Install the vent caps and neutralize any electrolyte that may have spilled Part No 218230 TEREX CON GTH 844 3 11 CHECKLIST PROCEDURES B 2 Inspect the Electrical Wiring Note Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining electrical wiring in good condition is essential to safe operation and good machine performance Failure to find and replace burnt chafed corroded or pinched wires could result in unsafe operating conditions and may cause component damage Electrocution hazard Contact with AWARNING hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Inspect the following areas for burnt chafed corroded and loose wires Inside of the operator s compartment Underside of the chassis Boom assembly
32. GC BK LT 1 21 lt lt 5 4 FUEL RET 13 22 95 1 24 _ 13 24 10 4 aaa 50 513 F N R SHIFTER DIFFERENTIAL Lock SWITCH A TEREX WG GTH 844 Part No 218230 ENGINE _ C44 122 TR APS C44 222 TR GND 44 3 5 TR VCC 44 4 1 TR IVS1 C44 S 25 IGN PWR C44 6 3 START PWR 44 7 5 C44 872 21 SECONDARY MANIFOLD C31 1 SV7 REAR AXLE FLOAT 32 1 SV6 DIFF LOCK 34 1 SVD1B CRAB STEER C33 1 SVD1A 4WS 36 2 S23 BRAKE PRESSURE 27 5 PARKING BRAKE PUR a 105 41 1 1 SVA PWR 7 C40 151C1 2 SVB PWR C10 6 2 C1 3 S15 RET 103 2 1 4 TELM PWR i cto 7 c1 5 INDIC PWR PCB cig 1 21c3 7 svo PWR C24 1 2 C3 8 S3 PWR C105 235 C3 10 BM LOW C18 1 2 C3 11 B ALRM lt Jecss 2 gt jJc3 12 S14 PWR ct05 122 c4 1 S3 RET 31 1 564 4 SV7 PWR C30 1 gt 4 5 SV5 PWR C27 A c4 6 S5 PWR C29 2 C4 7 S6 RET 24 C88 1 21c4 8 HORN PWR lg C28 1 2 C4 9 SVI3 PWR C11 4 c4 10 PWR PORT C105 235 04 1 BMLOW C11 622 64 12 BOOM ANG Cl4 2 3 c5 1 SIO PWR C12 1 S51C5 2 SVA PWR c12 7 c5 3 sv amp PWR 13 21 65 4 GC BK LT 6135 5655 ccPwR C5 6 CPU PWR 5 7 BAT PWR 5 8 ACC PWR 90 3 565 9 IGN PWR 15 1 51 5 10 BRAKE SV 15 2 5 11 SW PWR 15 4 265 12 BRAKE CR C13 1 X C90 1 X C90 2 X
33. Genie A TEREX BRAND Serial Number Range GTH 644 from GTH0813 16606 Part No 218230 Rev B4 September 2015 September 2015 Introduction Important Read understand and obey the safety rules and operating instructions in the appropriate operator s manual before attempting any maintenance or repair procedure This manual provides detailed scheduled maintenance information for the machine owner and user It also provides troubleshooting fault codes andrepair procedures for qualified service professionals Basic mechanical hydraulic and electrical skills are required to perform most procedures However several procedures require specialized skills tools lifting equipment and a suitable workshop In these instances we strongly recommend that maintenance and repair be performed at an authorized dealer service center 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 communications will be carefully considered for future printings of this and all other manuals Contact Us www genielift com e mail awp
34. 0 8 liters Oil viscosity requirements Differential Chevron Supreme 80W90 LS Planetary ends Chevron Supreme 80W90 LS For additional axle information refer to the Carraro 26 27M Axle Maintenance and Repair Manual Carraro 26 27M Axle Maintenance and Repair Instructions Genie part number 218710 Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Section 2 Specifications May 2014 SPECIFICATIONS Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with Parker Seal Lok fittings and hose ends Genie specifications require that fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed SAE O ring Boss Port tube fitting installed into Aluminum SAE Dash size Torque 4 11 ft lbs 14 9 Nm 6 23 ft lbs 31 2 Nm 8 40 ft Ibs 54 2 Nm 10 69 ft lbs 93 6 Nm 12 93 ft lbs 126 1 Nm 16 139 ft Ibs 188 5 Nm 20 172 ft lbs 233 2 Nm 24 208 ft lbs 282 Nm SAE O ring Boss Port Seal Lok fittings 1 Replace the O ring The O ring must be replaced anytime the seal has been broken The O ring cannot be re used if the fitting or hose end has been tightened beyond finger tight Note The O rings used in the Parker Seal Lok fittings and hose ends are custom size O rings They are not standard SAE si
35. 2 Inspectfor a liberal coating of dielectric grease in the following locations All harness connectors 3 Startthe engine and raise the boom so there is enough room to access and remove all the covers attached to the chassis Section 3 Scheduled Maintenance Procedures May 2014 CHECKLIST B PROCEDURES 4 Attach a lifting strap from an overhead crane to the boom Support the boom Do not apply any lifting pressure 5 Remove all engine covers hydraulic tank covers and chassis covers ADANGER Crushing hazard Death or serious injury could result if the boom should unexpectedly fall while working underneath the boom Do not stand or work beneath a boom that is not properly supported 6 Inspect the following areas for burnt chafed corroded pinched and loose wires Engine Transmission Manifolds Chassis 7 Inspect for a liberal coating of dielectric grease in all connections between the engine transmission and the operator s compartment 8 Install all covers removed in step 5 9 Remove the lifting strap from the overhead crane 10 Start the engine and lower the boom to the stowed position Turn the machine off TEREX GTH 844 B 3 Check the Exhaust System Note Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the exhaust system is essential to good engine performance and service life Running the engine w
36. 823125A S7 PWR co 1 xcc74 A S7 RET C9 3 C74 B PRIMARY MANIFOLD 5 SWAY ENABLE C19 1 BACKUP ALARM NOTE BASE UNIT DUAL JOYSTICK OPTION CONTROL SYSTEM POWER lt AUX HYDRAULICS S14 POWER CONNECTED TO AUX HYDRAULICS HARNESS 229681 WHEN AUX HYDRAULICS OPTION IS INSTALLED DUAL JOYSTICKS SYSTEM POWER HARNESSES ITEMIPART DESCRIPTION 1 1256695 HARNESS DASHBOARD 2 11260180 HARNESS SECONDARY MANIFOLD 3 11256744 HARNESS TELEMATICS 4 11260181 HARNESS TRANSMISSION 5 233941 HARNESS BOOM ANGLE SW 6 11258119 HARNESS THROTTLE PEDAL 7 214443 ASSEMBLY FOOT SWITCH 12 219457 HARNESS BACKUP ALARM 15 1260183 HARNESS PRIMARY MANIFOLD DJ January 2015 Section 6 Schematics Harness Map Control System Ground Dual Joystick from SN GTH0815 20662 RIGHT TRANSMISSION C37 5 1C41 2 SVA FORWARD 37 4 40 2 SVB REVERSE 37 6 1 42 2 SVD GEAR C37 7 gt 1C43 2 SVE GEAR SECONDARY MANIFOLD C26 3 39 30 2 SVS P BRAKE RELEASE C26 4 C31 2 SV7 REAR AXLE FLOAT C26 5 3 C32 2 SV6 DIFF LOCK C26 9 h 34 2 SVD1B CRAB STEER 26 8 C33 2 SVDIA 4WS THORN GND C88 2 c26 2 BACKUP LUG GND X ea GROUND_STUDS 3 3 DEP H 16 1 LUG GND NOTE UNIT DUA
37. Repair Procedures 8 Use a soft metal drift to remove the rod end pivot pin 9 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 10 Tag disconnect and plug the fork level cylinder hoses from the cylinder manifolds Cap the fittings AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Component damage hazard Hoses can be damaged if they are kinked or pinched 11 Remove the fasteners securing the fork level cylinder barrel end pivot pin to the boom 12 Use a soft metal drift to remove the pivot pin Remove the cylinder from the boom AWARNING Crushing hazard The cylinder could fall if not properly supported when the pivot pin is removed from the machine PartNo 218230 Genie GTH 844 4 9 BOOM COMPONENTS 13 Remove the inspection cover at the pivot end of the boom 14 Remove the hose keepers from the hose roller assembly Note The hose keepers ensure that the hoses do not jump off the hose rollers 15 Working at the pivot end of the boom remove the clamps securing the hoses to the inside of boom tube number 3 16 Working at the fork end of the boom remove the clamps securing the hoses to the inside of boom tube number 3 17 Working at the pivot
38. SERVICE BRAKE S5 RET C29 1 3 C27 B xs SERVICE BRAKE S6 RET C29 2 4 7 1 14 C19 2 A 3 M 18 2 GROUND STUDS 7 2 C26 6 YQ 5 we e 1 9 LUG GND 1 237 8 POWER PORT _ NOTE HARNESS PWR PORT 91 21 16 4 LUG GND22 C37 1 LUG GND 1 11 WA mese C86 2 S 51C37 2 FUELGND UNIT C39 2 3 037 3 524040 DUAL JOYSTICK OPTION PARKING SE CONTROL SYSTEM GROUND BRAKE S2 C41 2 gt 1037 5 SVA GND 9 9 D C42 2 5 C37 6 SVD GND S2 GND c15 9 16 1 C43 2 S51C37 7 SVE GND 9 LUG GND221C37 8 LUG GND 2 O C88 2 52 1C26 2 HORN GND C30 2 92 C26 3 SV5 CND 15 C31 2 35 626 4 Sv7 GND 5 GAUGE CLUSTER C322 2 26 5 SV6 GND 5 ROWE LUG GND 2 C26 6 LUG GND 61 CPU PWR ci3 eE c16 2 LUG GND 551C26 7 LUG GND 918 C32 2 5 C26 8 SVDIA GND 34 2 5 26 9 SVDIB GND 19 ea ee HARNESS LEGEND GND_DJ NUM PART DESCRIPTION 1 52 5 1 227495 HARNESS DASHBOARD 2 227496 HARNESS SECONDARY MANIFOLD C91 2 351c16 4 GND PorT 9 3 219457 HARNESS BACKUP ALARM m 4 227493 HARNESS TRANSMISSION 10 161444 ASSEMBLY GROUND BUSS 14 215445 HARNESS PRIMARY MANIFOLD DJ Genie Part No 218230 GTH 844 6 19 January 2015 Section 6 Schematics Harness Map Control System Ground Dual Joystick before SN GTH0815 20662 20 21 Section 6 Schematics January 2015 E Harnes
39. procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or 3 serious injury and significant component damage Dealer service is strongly recommended 4 Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and 5 Fitting Torque Specifications 6 BOOM COMPONENTS Remove the lifting fork and frame See 1 2 How to Remove the Lifting Fork Frame Attach a lifting strap from an overhead 10 ton 10 000 kg crane to the fork end of the boom Support the boom Do not apply any lifting pressure Select a fork level cylinder Remove the fasteners securing the fork level cylinder rod end pivot pin to the boom Using a lifting strap from another overhead crane support the rod end of the fork level cylinder Do not apply any lifting pressure Use a soft metal drift to remove the fork level cylinder pivot pin Lower the fork level cylinder onto the chassis hingh 1 AWARNING Crushing hazard Keep hands clear 7 8 9 10 a extension chains b single chain tensioner boom tube number 1 d tube number 2 e boom tube number 3 Genie PartNo 218230 GTH 844 of the cylinder manifold when lowering the cylinder Repeat this procedure beginning with step 3 for the
40. 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 4 4 GTH 844 Genie Illustration 1 extension chains single chain tensioner boom tube number 1 boom tube number 2 boom tube number 3 O O o o o Illustration 2 a chain anchor PartNo 218230 2014 Section 4 Repair Procedures 8 Remove a cotter pin securing the chain anchor pivot pin to the anchor mount of the boom tube Remove the pivot pin and pull the chain free of the mount 9 Working at the fork end of the boom securely connect a 30 foot 10 m length of rope to the end of the chain Securely tie off the other end of the rope to the boom structure 10 Working at the pivot end of the boom pull the chain out of the boom Note Rope coming loose from the chain during removal may result in a difficult reassembly Be sure the rope is securely attached to the chain and boom structure before pulling the chain out of the boom 11 Remove the rope from the end of the chain and securely attach the rope to the new chain 12 Working at the fork end of the boom use the rope to carefully pull the chain through the boom just until the end of the chain is accessible Remove the rope from the chain 13 Working at the pivot end
41. 0 to 250 bar pressure gauge into test port TS at the top of the secondary function manifold See 7 3 Secondary Function Manifold Components 6 Startthe engine Allow the engine to idle 7 Fully turn and hold the steering wheel in the left direction and allow the wheels to fully turn to the left Continue holding the steering while observing the pressure reading on the pressure gauge O Result The pressure gauge reads 2650 psi 183 bar The pressure setting is correct Proceed to step 12 W Result The pressure gauge fails to read 2650 psi 183 bar The pressure setting needs to be adjusted Proceed to step 8 8 Turn the machine off Hold the steer pressure reducing relief valve with a wrench and remove the cap schematic item PR3 9 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure CAUTION Component damage hazard Do not adjust the relief valve pressures higher than specifications 10 Install the relief valve cap 11 Repeat this procedure beginning with step 6 12 Turn the machine off Remove the pressure gauge from the test port AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Section 4 Repair Procedures May 2014 MANIFOLDS How to Set the Parking Brake System Pres
42. 1 Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the appropriate operator s manual on your machine will result in death or serious injury Many of the hazards identified in the operator s manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless M You are trained and qualified to perform maintenance on this machine You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulations You have the appropriate tools lifting equipment and a suitable workshop PartNo 218230 Genie GTH 844 vii 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 messages that follow this symbol to avoid possible injury or death Indicates an imminently hazardous ADANGER situation which if not avoided will result in death or serious injury Read each procedure thoroughly This manual and the decals on the machine use signal words to identify the following Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety AWARNING Indicates a potentially hazardous situation which if not avoided could result
43. 2 position 2 way SV9 Function select sway circuit 20 ft lbs 27 Nm Genie 4 32 GTH 844 Part No 218230 Section 4 Repair Procedures May 2014 MANIFOLDS G GTH 844 33 PartNo 218230 Section 4 Repair Procedures May 2014 SSS MANIFOLDS 7 2 Primary Function Manifold Components Models with Dual Joysticks The primary function manifold is located under the manifold inspection cover Index Schematic No Description Item Function Torque 1 Directional valve proportional Boom extend retract 65 75 ft lbs 88 101 Nm 2 Directional valve proportional Boom up down 65 75 ft lbs 88 101 Nm 3 Directional valve proportional 2 2 Fork tilt up down 33 37 ft lbs 45 50 Nm 4 Check valve pilot operated 100 psi 6 9 2 Fork tilt down circuit 25 ft lbs 34 Nm 5 Relief valve 3500 psi 241 bar RV1 System relief 20 ft Ibs 27 Nm 6 Relief valve 3500 psi 241 bar RV3 Fork tilt down circuit 25 ft lbs 34 Nm 7 Check valv
44. 229678 HARNESS BACKUP LIGHT LED 29 229680 HARNESS WORK LIGHTS FRONT fFRONT 1 BLINKER LRIGHT _ TFRONT 1 BLINKE ut R LEFT i 16 667 2 BL R GND FK LUG GND 1 BUL PWR E c66 4 j 2 BL L GND FR LUG GND HEAD LT LRICH T HEAD LT LEFT BRAKE_MANIF OLD C C47 1 44 CAB LTR c2 7 C46 1 4 2 CAB LT L amp C2 6 C47 620 2 1 2 62 35 2 LT R 6ND GAUGE CLUSTER S22RET 15 17 4 4 CAB LTL Re c75 2 ID TX C75 4 27 99 46 LIGHTS S22 _ s22 PwR c48 2lx c2 4 LS22RET amp 17 2 5 Le C47 1 4 3 LT R GND k C45 7 C46 1 4 4 LT L GND K C45 2 5 z D 2 9 m m E 1 s 2992 2 999 Z1 Z99549 999 9 14 5 992 Z WLJH 8 262 5 992 WIE Tvl 9902 uM d 118 999 ulL3HSI u 220 1 2 9 10 58 01 295 1 62 January 2015 Section 6 Schematics GROUND_ STUDS C53 2 C54 2 C45 1 LUG GND C45 8 BUSS CONNECTOR LuG cND2z c45 1 LUG GND 75 4 1 45 2 LT L GND 52 1 45 3 TAIL L GND 51 45 4 TAIL R GND C50 2 9 C45 6 BACK GND C75 3 391C45 7 LT R GND LUG GND22 C45 8 LUG GND F PCB C66 3 C2 1 SHFTR 3 50 1 3531 2 2 BACK PWR 649 562 3 SIG PUR 648 2 5 2 4 S22 PWR C48 4 5 c2 5 s22RET 75 2 2462 6
45. 4365 Urea tank temperature too high Short circuit to battery error on urea tank sensor Short circuit to ground error on urea tank sensor 4366 a OO O SCR main relay short circuit or open load 4374 Pressure stabilization error dosing valve SCR 4375 Short circuit to battery on powerstage for urea pump motor Short circuit to ground on powerstage for urea pump motor No load error on powerstage for urea pump motor 4376 Short circuit to battery on SCR reversal valve Short circuit to ground on SCR reversal valve No load error SCR reversal valve 4765 Exhaust gas temperature sensor value upstream DOC out of target range to high Exhaust gas temperature sensor value upstream DOC out of target range to low 4766 O O O O O k Exhaust gas temperature sensor value downstream DOC out of target range to high Exhaust gas temperature sensor value downstream DOC out of target range to low 4768 Exhaust gas temperature sensor signal upstream DOC not plausible Exhaust gas temperature sensor voltage to high Exhaust gas temperature sensor voltage to low 4769 N Exhaust gas temperature sensor signal downstream DOC not plausible Target range to high for exhaust gas temperature sensor downstream DOC Target range to low for exhaust gas temperature sensor downstream DOC Part No 218230 Genie GTH 844 5 7 Section 5 F
46. 5 Cylinder 1 injector open circuit 6 Cylinder 1 injector short 7 Cylinder 1 injector not responding 652 2 Cylinder 2 injector data incorrect 5 Cylinder 2 injector open circuit 6 Cylinder 2 injector short 7 Cylinder 2 injector not responding 653 2 Cylinder 3 injector data incorrect 5 Cylinder 3 injector open circuit 6 Cylinder 3 injector short 7 Cylinder 3 injector not responding 654 2 Cylinder 4 injector data incorrect 5 Cylinder 4 injector open circuit 6 Cylinder 4 injector short 7 Cylinder 4 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 1100 Troubleshooting Manual Perkins part number SENR9982 01 Perkins 1100 Troubleshooting Manual Genie part number 123583 Genie 5 22 GTH 844 Part No 218230 2015 Section 6 Schematics Observe and Obey Troubleshooting and repair procedures shall be completed by a perso
47. 61 16 2 C22 2 5 c17 10 Sva cnD mon C19 2 51C17 11 SV9 GND LUG GND 551C17 12 LUG GND nn HARNESS LEGEND GND_SJ C88 2 351C26 2 HORN GND C30 2 C26 3 SV5 GND eee ean NUM PART DESCRIPTION 032 2 3 c28 5 SVG GND 1 227495 HARNESS DASHBOARD LUG GND3 1C26 6 LUG GND 2 227496 HARNESS SECONDARY MANIFOLD LUG GND331C26 7 LUG GND 3 219457 HARNESS BACKUP ALARM 2 2 921026 8 SVDIA GND 4 227493 HARNESS TRANSMISSION 10 161444 ASSEMBLY GROUND BUSS C36 1 721C26 11 S23 GND 13 227497 HARNESS PRIMARY MANIFOLD SJ c15 9 35 C16 1 52 0 0 13 6 16 2 GC GND LUG GND 51C16 3 LUG GND O 91 2 6 4 GND PORT BUSS CONNECTOR BUSS CONN Genie Part No 218230 GTH 844 6 11 January 2015 Section 6 Schematics r Harness Map Control System Ground Single Joystick before SN GTH0815 20662 12 13 Section 6 Schematics January2015 s Harness Map Control System Power Single Joystick from SN GTH0815 20662 Section 6 Schematics January 2015 Harness Control System Power Single Joystick from SN GTH0815 20662 C44 ENGINE HARNESS RIGHT ENGINE _ ies J 2 2 644 1954 TR APS C1 1 3 pm 1 SVA FORWARD OS AYKA C1 2 35 C40 1 SVB REVERSE C10 2 S51C42 1 SVD GEAR Puce M C10 3 95 C43 1 SVE GEAR
48. AXLE FLOAT 7 oo 7 C26 9 V C34 2 SVD1B CRAB STEER FUEL TANK 26 8 C33 2 SVDIA 4WS 26 5 gt gt 32 2 SV6 DIFF LOCK 26 11 36 1 S23 BRAKE PRESSURE PRIMARY MANIFOLD 5 HON _ _ FUELRET C86 2 lt CC37 2 SWAY ENABLE 19 2 17 11 amp HORN GND C88 2 X C26 2 LES 6 svi SWAY LEFT 21 2 17 3 lege ee SV3 SWAY RIGHT C20 2 17 4 SV2 TITL UP C23 2 x C17 9 SV4 TILT DOWN C22 2 lt 6 17 10 C18 O n T C pe m BACKUP BRAKE MANIFOLD SERVICE BRAKE S5 RET C29 1L C27 B SERMCE BRAKE S6 RET 29 2 FK C4 7 Y 2 5 1 2 B ALRM GND 1 9 1 serai Susie s dM GROUND STUDS 3 Lo JL AL G GND N T POWER PORT _ D 0242 NOTE HARNESS MAP PWR PORT 91 2 Ke c16 4 8 LUG GND2 C37 1 LUG GND L BASE UNIT ter e C86 2 931C37 2 FUEL GND SINGLE JOYSTICK OPTION C39 2 351037 3 S24 GND C40 2 C37 4 SVB GND BRAKE 52 eq 2 2 c37 5 SVA GND CONTROL SYSTEM GROUND mp aeri C42 6 SVD 52 0 0 c15 9 16 1 C43 2 51C37 7 SVE GND LUG GND221C37 8 LUG GND C37 BUSS CONNECTOR BUSS CONNECTOR LUG GND3 C17 1 LUG GND C18 2 35 C17 2 B ALRM 21 2 35 C17 3 SVI GND C20 2 35 C17 4 SV3 GND GAUGE CLUSTER C23 2 51c17 9 SV2 GND CPU PWR 13
49. BUSS BAR C13 3 4 11 CAN_L K c44 7 10 10 4 8 AnD 15 1 5 10 BRAKE SV 12 227944 CONTROLLER HYD ERGO 2 SWITCH 513 F N R SHIFTER C15 2 c5 11 SW PWR 14 215445 HARNESS PRIMARY MANIFOLD DJ DIFFERENTIAL C15 4 92 C5 12 BRAKE CR LOCK SWITCH Genie 6 18 GTH 844 Part No 218230 RIGHT January 2015 Section 6 Schematics Harness Control System Ground Dual Joystick before SN GTH0815 20662 TRANSMISSION Se 37 5 5 41 2 SVA FORWARD C37 4 640 2 SVB REVERSE C42 2 SVD GEAR 37 7 51 43 2 SVE GEAR 37 3 39 2 OIL PRESS S24 SECONDARY MANIFOLD C26 3 j C30 2 SV5 P BRAKE RELEASE C26 4 S C31 2 SV7 REAR AXLE FLOAT C26 5 35 32 2 SV6 DIFF LOCK 26 9 C34 2 SVD1B CRAB STEER FUEL TANK 26 8 33 2 SVD1A 4WS 26 11 C36 1 S23 BRAKE PRESSURE PRIMARY MANIFOLD FUEL SENDER J HORN FUELRET 86 2 lt 37 2 SV9 SWAY ENABLE 19 2 FK LUG eND amp THORN GND 2 26 2 4 C18 e 4 BACKUP 2 LUG GND22 2 B ALRM GND 3 LAR BRAKE ALARM
50. C37 BUSS CONNECTOR 52 0 0 c15 9 c16 5 43 2 1 37 7 SVE GND g 106 04 54637 8 LUG GND _ 18 2 32 6172 ALR GMD C21 2 51C17 3 SVI CND 20 2 551 17 4 SV3 GND GND35 C17 6 LUG GND CAUCE CLUSTER LUS GND 177 LUG OND CPU PWR Ci3 elx 21508 16 2 23 2 93 C17 9 SV2 GND DESCRIPTION C22 2 S51C17 10 SV4 GND Gy Seso 256695 HARNESS DASHBOARD 2 51 26 2 HORN GND 1260180 ARNESS SECONDARY MANIFOLD era E ca 1256744 HARNESS TELEMATICS 1260181 ARNESS TRANSMISSION C31 2 321C26 4 SV7 GND 219457 ARNESS BACKUP ALARM TELM GND C108 L TELM GND C114 L SINGLE JOYSTICK SYSTEM GROUND HARNESSES BUSS CONNECTOR C32 2 C26 5 SV6 GND LUG GND2 C26 6 LUG GND LUG GND221C26 7 LUG GND 9 C32 2 gt 1 C26 8 SVDIA GND C34 2 32 C26 9 SVD1B GND C36 1 392 C26 11 S23 GND 1 26 BUSS CONN BUSS CONNECTOR LUG cND221c16 1 LUG GND C13 6 3 c16 2 GC GND C15 9 3 5 C16 3 S2 GND 5 91 2 51616 4 GND PORT 823125 Genie Part No 218230 GTH 844 6 15 January 2015 Section 6 Schematics Harness Control System Power Single Joystick from SN GTH0815 20662 16 17 Section 6 Schematics January 2015 Harness Control System Power Dual Joystick before SN GTH0815 20662 Section 6 Schematics January 2015 Harnes
51. Ground Section 6 Schematics January 2015 Harness Map Deutz 3 6TCD Engine Battery Power and Ground RIGHT aig amp E FUEL GLOW amp cel PLucs amp RELAY REAY BLACK BAT CABLE ENGINE LECU I 4 GROUND STUDS GROUND NOTE DEUTZ T3 T4i ENGINE LEFT BATTERY POWER AND GROUND DISTRIBUTION DEUTZ T3 T4i ENGINE HARNESSES PART DESCRIP TION 227493 HARNESS TRANSMISSION before sn GTH0815 20662 1260181 HARNESS TRANSMISSION from sn GTH0815 20662 231257 CABLE BATTERY BLACK 2 0 237933 HARNESS PCB GROUND 161444 ASSEMBLY GROUND BUSS 236979 FORMING BUSS BAR 219388 HARNESS ENGINE ECM TCD3 6 8K 219334 HARNESS ENGINE TCD 5 6 231260 CABLE BATTERY RED 2 0 823125A Genie 6 26 844 Part No 218230 RIGHT LEFT January 2015 Section 6 Schematics ENGINE Perkins 11040 75 2 12V BATTERY BLACK BAT CABLE GROUND_ STUDS GROUND PART Harness Map Perkins 1104D Engine Battery Power and Ground NOTE PERKINS T3 ENGINE BATTERY POWER AND GROUND DISTRIBUTION PERKINS 1104D E44TA ENGINE HARNESSES DESCRIPTION 227493 HARNESS TRANSMISSION before sn GTH0815 20662 1260181 251257 HARN
52. Joysticks 4 934 7 3 Secondary Function ManifoldComponents 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 ee 4 45 How to Test Valve Coil Resistance Specification How to Test a Coil Diode Axle Components 8 1 AXIS e uitis 4 47 How to Remove the Axle TEREX COMPANY GTH 844 Part No 218230 September 2015 TABLE OF CONTENTS Section 5 Fault Codes 5 1 Diagnostic DIS play ceti mec c dos 5 2 Engine Fault Codes Deutz Models 5 3 Engine Fault Codes Perkins 11040 Models 5 21 Section 6 Schematics Introduction m REL nies ade etie e Ee 6 1 Fuse Panel Layout before SN GTH0815 20630 6 2 Fuse Panel Layout from SN 815 20630 6 3 Electrical Component amp Wire Color Legend 6 4 Telematics Connector Legend 6 5 Electrical an
53. Loh 2 position 2 way solenoid valve 2 position 3 way solenoid valve 1 Counterbalance valve Part No 218230 7 i Joystick Genie GTH 844 Section 6 Schematics May 2015 This page intentionally left blank Genie 6 8 GTH 844 PartNo 218230 Section 6 Schematics January 2015 mw sa a ss iz u a K sAa Harness Map Control System Power Single Joystick before SN GTH0815 20662 Section 6 Schematics January 2015 Harness Map Control System Power SN 15 20662 Single Joystick before C44 gt ENGINE HARNESS RIGHT ENGINE TRANSMISSION aac maps 41 1 SVA FORWARD 40 1 SVB REVERSE 4 5 TRIVS 1 E EAR C44 555 IGN PWR m C44 622 START PWR C39 1 OIL PRESS S24 644_7 55 2 C87 1 OIL TEMP S25 644 5 SI CANE l SECONDARY MANIFOLD L 8 638 BOOM ANG S3 SRET 2 F amp C3 10 C4 5 3 1 30 1 SV5
54. Manual Genie part number 117765 Perkins 854 Operation and Maintenance Manual Genie part number 218708 CHECKLIST D PROCEDURES TEREX COMPANY Part No 218230 GTH 844 Section 3 Scheduled Maintenance Procedures May 2014 Checklist E Procedures E 1 Test or Replace the Hydraulic Oil Note Genie specifications require that this procedure be performed every 2000 hours or two years whichever comes first Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more frequently Refer to Section 2 Specifications Component damage hazard The work area and surfaces where this 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 TEREX GTH 844 MPANY 2 Remove cap from top of hydraulic tank 3 Usinganapprovedhand operated pump drain the hydraulic tank into a suitable container Refer to Secti
55. Manual Genie part number 117765 Perkins 854 Operation and Maintenance Manual Genie part number 218708 Part No 218230 GTH 844 3 29 Section 3 Scheduled Maintenance Procedures May 2014 pe This page intentionally left blank 3 30 GTH 844 Part No 218230 2014 Section 4 Repair Procedures Observe and Obey Repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Repairs Start Read understand and obey the safety rules and operating instructions in the appropriate operators manual on your machine Be sure that all necessary tools and parts are available and ready for use Use only Genie approved replacement parts Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a firm level surface Boomin the stowed position Key switch in the off position with the key removed Wheels chocked PartNo 218230 Genie GTH 844 4 1 Repair Procedures About This Section Most of the procedures in this section should o
56. May 2014 This page intentionally left blank Genie 4 48 GTH 844 Part No 218230 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 the repair of this machine ADANGER Crushing testing or replacing any hydraulic Immediately tag and remove from service 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 AWARNING with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a firm level surface Bodilv iniurv h ds AWARNING injury hazard Spraying Boom in the stowed position hydraulic oil can penetrate and Key switch in the off position with the key burn skin Loosen hydra
57. Required maintenance procedures and additional transmission information is available in the Dana VDT12000 Service Manual Dana partnumber TSM 0022 Dana VDT12000 Service Manual Genie part number 218706 CHECKLIST D PROCEDURES D 5 Perform Engine Maintenance Deutz Models Note Engine specifications require that this procedure be performed every 1000 hours or annually whichever comes first Charge air cooler entry area drain lube oil condensate Cold starting device check Engine mounts check Hose clamps and hoses check V rib belt and tensioning pulley check Fuel filter cartridge replace Filter insert for fuel pre filter replace Required maintenance procedures and additional engine information is available in the Deutz TCD3 6 Operation Manual Deutz part number 0312 3907 Deutz TCD3 6 Operation Manual Genie part number 218707 LEFT VIEW A oildrain drop box oil drain transmission Part No 218230 GTH 844 3 23 Section 3 Scheduled Maintenance Procedures May 2014 CHECKLIST D PROCEDURES D 6 Perform Engine Maintenance Perkins Models Note Engine specifications require that this procedure be performed every 1000 hours 1104 Engine Engine valve lash inspect adjust 854 Engine Water pump insp
58. Tilt up circuit 12 14 ft Ibs 16 19 Nm Genie 4 30 GTH 844 Part No 218230 Section 4 Repair Procedures May 2014 MANIFOLDS 31 Genie GTH 844 PartNo 218230 Section 4 Repair Procedures May 2014 SS MANIFOLDS Primary Function Manifold Components Models with Single Joystick continued 16 Check valve 5 psi 0 3 bar CVA 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 Ibs 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 Sway left circuit 20 ft lbs 27 Nm 20 Directional valve proportional 3 position 4 way pilot operated Sway left right 33 37 ft lbs 45 50 Nm 21 Solenoid valve 2 position 4 way SVA Function select boom and fork tilt up 2 3 ft lbs 3 4 Nm 22 Solenoid valve 2 position 4 way SV2 Function select boom down and fork tilt down 2 3 ft lbs 3 4 Nm 23 Solenoid valve
59. Transmit Frame AT1S 24116 65364 Timeout error of CAN Transmit Frame SCR2 24117 65365 Timeout error of CAN Transmit Frame SCR3 24118 65366 Timeout error of CAN Receive Frame ComRxCMO 24119 65367 Timeout error of CAN Receive Frame ComRxCustSCR2 24120 65368 Timeout error of CAN Receive Frame ComRxSCRHtDiag 24121 65369 Timeout error of CAN Receive Frame ComRxTrbChActr 24122 65370 Timeout error of CAN Receive Frame ComRxUQSens 24123 65371 Timeout error of CAN Receive Frame ComSCRHiCil 24124 65372 Timeout error of CAN Receive Frame ComTxAT1IMG 24125 65373 Timeout error of CAN Receive Frame ComTxTrbChActr o o cO Of co CO CO OF CO Genie 5 20 GTH 844 Part No 218230 2015 Section 5 Fault Codes Engine Fault Codes Models with Perkins Power SPN Suspect Parameter Number FMI Failure Mode Identifier 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
60. WASH GND lt 595432 855 LT VALVE CONTROL 53 WASH GNDI 55294 853 La POWER C76 A X F21 zl 74 VAL RET C76 B X Cc80 B C76 A Jod _ GROUND C76 Cj K LUG GND 21525 79 B C61 L OOME PUR 1 eces 6 H ERA T See 53 DoME cND 2 lt 65 2 E FAM GND 2 X c6 6 F21 4 AMP 66 1 6 2 HVAC PWR C79 C 517 WINDSHIELD W W WINDSHIELD E 6 3 W W PWR 69 F WIPE ON C62 1kec60 3 252 15 C6 4 WAYNE WIPE RET C62 2 Eee 61 1 1 6 5 FAN PWR WIPE PWR C62 4 C60 1 x W W PWR 62 7 C6 3 C61 2 2166 6 FAN GND a LWASH PWR_C62 8 XC WIN WP 12214 S18_SKYLIGHT_W W amp C63 1Exec59 3 I5 WIPE RET C63 2 Z C59 2 JE MPEPUR C63 4 E C59 1 iz w wpw ces 7 Ex ce 4 LWASH PWR_C63 8 FKSKY WP 823125 Harness Options Enclosed Cab with HVAC NOTE ENCLOSED CAB WITH HVAC OPTION ENCLOSED CAB WITH HVAC OPTION HARNESSES 33 233812 HARNESS ENCLOSED CAB 34 234859 HARNESS CAB FAN 35 233940 HARNESS POWER DOME LIGHT 123817 _ DOM E LIGHT WITH CONNECTOR Part No 218230 38 238126 ARNESS 39 216083 ARNESS A C GTH844 Genie GTH 844 January 2015 Section 6 Schematics Harness Map Options Enclosed Cab with HVAC 40 Section 6 Schematics January 2015 ih vCC Electrical Sch
61. WITH DEUTZ POWER SPN Suspect Parameter Number ASPN Alternate Suspect Parameter Number FMI Failure Mode Identifier SPN ASPN FMI Description 111 1 Coolant level underneath the allowed minimum 157 Target range to high for rail pressure sensor Target range to low for rail pressure sensor 168 Battery voltage is out of the target range to high Battery voltage is out of the target range to low Battery voltage is out of the target range warning condition is generated Target range to high for battery voltage sensor Target range to low for battery voltage sensor 172 Ambient air temperature sensor value is not plausible Target range to high for intake air sensor Target range to low for intake air sensor 174 175 Low fuel temperature is out of target range system reaction generated Oil temperature is out of target range system reaction generated Physical Range Check low for Oil Temperature Oil temperature value is not plausible Target range to high for oil temperature sensor Target range to low for oil temperature sensor 190 Engine speed target range exceeded FOC range 1 Speed sensor of crankshaft and camshaft signals are out of phase 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 OO DOI RON ND D HOW 412 0 Differential pressure sensor value AG
62. a i i os m 501044 BUWH C5 10 30 1 C30 2 BR C26 3 g 2 W KELL e802 BR C263 5 5 PARKING BRAKE RELEASE COIL SM mE C512 PARKING BRAKE LATCH RELAY PCB E w 5120 BINE C15 9 z Hr SS AP 5 ols NC t og x EN a BR_C15 3 PARKING BRAKE LIGHT E C59 E oo 8 5 3 1 amp g 8 555 5 8 5 6107 87 RD WHZS C103 1 C44 C44 4 OR C38 4 daws 18 288 8 4 F a 8 n te 8 lt a fdsranT 4 3 BLIWH TES 5 ovce 5 FRE 2 ae g amp l RD BK C10 1 RD BK C44 5 Jin GND 99 5 rz 5 2 4 ApS CC44 1 GRIWH C38 9 8 SSN C90 3 C104 1 RD BK a a 9 g 2 lo 22 enol Domi E 8 5 AL lt a C108 3 BK C107 85 C107 86 E e og 35 5 BL a 8 2r BR ME t 8 Sg e STARTER SOLENOID amp RELAY 5 106 GR L LE C106 A YL s STARTER MOTOR 1 C1 4 RD C103 2 7 5 C C a S5 2 55 55 8 SINE PCB RD C 12 VOLT BATTERY C4 12 C11 6 BK WH C104 3 BKWH 1 li e LO A TEREX Un GTH 844 Part No 218230 6 42 January 2015 Section 6 Schematics n MN Electrical Schematic View 2 N M L K J H G F E D B A
63. assembly onto a structure capable of supporting it Genie 4 8 GTH 844 How to Disassemble the Boom AWARNING P dily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the extension cylinder See 1 4 How to Remove the Extension Cylinder 2 Remove the boom See 1 2 How to Remove the Boom 3 Select a lift cylinder Remove the fasteners securing the lift cylinder rod end pivot pin to the boom 4 Using a lifting strap from an overhead crane support the lift cylinder Do not apply any lifting pressure 5 Use soft metal drift to remove the lift cylinder rod end pivot pin Remove the cylinder from the boom Crushing hazard The cylinder AWARNING could become unbalanced and fall if not properly supported when removed from the machine 6 Repeat this procedure beginning with step for the other lift cylinder 7 Remove the fastener securing the fork level cylinder rod end pivot pin to the fork frame mount Part No 218230 2014 Section 4
64. burner temperature plausibility error Sensor error burner temperature signal range check high Sensor error burner temperature signal range check low Sensor burner temperature plausibility error Burner shut of valve short circuit to battery Burner shut of valve short circuit to ground Burner shut off valve open load Shut off valve blocked Over temperature error on burner shut of valve Fuel Balance Control integrator injector 1 in firing order maximum value exceeded 23921 65169 23922 65170 A BOND O WO N 23929 65177 Fuel Balance Control integrator injector 1 in firing order minimum value exceeded 23930 65178 Fuel Balance Control integrator injector 2 in firing order maximum value exceeded 1 Fuel Balance Control integrator injector 2 in firing order minimum value exceeded Genie Part No 218230 GTH 844 5 13 Section 5 Fault Codes May 2015 ENGINE FAULT CODES MODELS WITH DEUTZ POWER SPN Suspect Parameter Number ASPN Alternate Suspect Parameter Number FMI Failure Mode Identifier SPN ASPN FMI Description 23931 65179 0 Fuel Balance Control integrator injector 3 in firing order maximum value exceeded 1 Fuel Balance Control integrator injector 3 in firing order minimum value exceeded 23932 65180 0 Fuel Balance Control integrator injector 4 in firing order maximum value exceeded 1 Fuel Balance Control integrator injector 4 in f
65. electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 4 16 GTH 844 Genie Locate the secondary function manifold under the manifold inspection cover Tag disconnect and plug the hydraulic hoses at ports BP and BT of the secondary function manifold Cap the fittings Locate the brake manifold under the manifold inspection cover Tag disconnect and plug the hydraulic hose at the underside of the brake manifold Cap the fitting Working under the dashboard locate the hydraulic hose at port L of the steering orbitral Working at the front axle locate the hydraulic hose connected to the front axle steer cylinder at the operator s compartment side of the machine Tag disconnect and plug the hydraulic hose Cap the fitting Tag disconnect and plug the hydraulic hoses at ports SUP SUR and SUT of the secondary function manifold Cap the fitting AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 8 Tag disconnect and plug the hydraulic hose at port SULS of the primary function manifold Cap the fitting Part No 218230 2014 Section 4 Repair Procedures 9 Tag disconnect and plug the hydraulic hose at port JP of the secondary function manifold Cap the fitting AWARNING Bodily
66. end of the boom pull the fork level hydraulic hoses from the boom and lay them to the side 18 Working at the pivot end of the boom remove the fasteners securing the hose roller assembly to boom tube number 2 Remove the hose roller assembly from the boom 19 Working at the fork end of the boom loosen evenly then remove the fasteners securing the chain tensioners to the top of boom tube number 1 20 Working at the fork end of the boom remove the fasteners securing the extension chain rollers to the top of boom tube number 2 Remove the chain rollers from the boom Section 4 Repair Procedures May 2014 BOOM COMPONENTS 21 Working at the pivot end of the boom remove the fasteners securing the retraction chain block pivot pin to boom tube number 3 Remove the pivot pin Remove the chain from the roller 22 Working at the pivot end of the boom remove the fasteners securing the retraction chain roller to boom tube number 2 Remove the chain roller from the boom 23 Working at the fork end of the boom remove the wear pads from boom tube number 2 24 Support and slide boom tube number 3 out of boom tube number 2 Place boom tube number 3 on a structure capable of supporting it Crushing hazard Boom tube AWARNING number 3 could become unbalanced and fall when removed from the boom tube number 2 if not properly supported and attached to the overhead crane Note During removal the overhead crane strap wil
67. engine and allow the engine to run at low idle 3 Observethe pressure reading on the pressure gauge Result The pressure gauge reads 450 x25 psi 31 1 7 bar The pump is functioning correctly Proceed to step 6 Result The pressure gauge fails to read 450 x25 psi 31 1 7 bar The pressure setting needs to be adjusted Proceed to step 4 4 Loosen the set screw for the standby pressure adjustment screw 5 Adjust the function pump standby pressure Turn the adjustment screw clockwise to increase the pressure or counterclockwise to decrease the pressure Tighten the set screw 6 Turnthe engine off and remove the pressure gauge AWARNING aul injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray PartNo 218230 HYDRAULIC PUMP How to Adjust the Function Pump Pressure Compensator Note Two people will be required to perform this procedure 1 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to port M1 on the function pump 2 Startthe engine and allow the engine to run at low idle 3 Fully retract the boom 4 Continue to activate the boom retract function and observe the pressure reading on the pressure gauge O Result The pressure gauge reads 3200 50 psi 220 3 4 bar The pump is functioning correctly Proceed to step 7 W Result The press
68. filler cap from the hydraulic tank 5 Place a pan or other suitable container under the hydraulic tank Refer to Section 2 Specifications Genie GTH 844 6 Remove the drain plug from the hydraulic tank and completely drain the tank Bodily injury hazard Beware of hot ACAUTION oil Contact with hot oil may cause severe burns 7 Tag disconnect and plug the supply and return hoses from the hydraulic tank Cap the fittings 8 Proceed to step 14 FUEL TANK 9 Remove the access cover above the fuel tank and the access door above the filler cap 10 Tag and disconnect the wire harness from the fuel level terminals 11 Remove the filler cap from the fuel tank 12 Using an approved hand operated pump drain the fuel tank into a container of suitable capacity Refer to Section 2 Specifications Explosion and fire hazard When transferring fuel connect a grounding wire between the machine and pump or container Note Be sure to only use a hand operated pump suitable for use with gasoline and or diesel fuel 13 Tag disconnect and plug the fuel supply and return hoses Cap the fittings 14 Remove the clamps holding the vent hose so the vent and hose can be removed with the tank 15 Support and secure the tank assembly to an appropriate lifting device 16 Remove the fasteners securing the tank assembly to the chassis Remove the tank from the machine hi i AWARNING Crushing hazard The tank assembl
69. fuels are combustible Perform this procedure in an open well ventilated area away from heaters 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 Part No 218230 2014 Section 3 Scheduled Maintenance Procedures 3 Using a mild solvent carefully wash the tube venting system Dry using low pressure compressed air Repeat this procedure beginning with step 2 4 Install the fuel tank cap onto the fuel tank 5 Remove the breather cap from the hydraulic tank 6 Checkfor proper venting The cap is pressureized to 3 psi O Result Air passes through the hydraulic tank cap Proceed to step 8 Result If air does not pass through the cap clean or replace the cap Proceed to step 7 Note When checking for positive tank cap venting air should pass freely through the cap 7 Using a mild solvent carefully wash the cap venting system Dry using low pressure compressed air Repeat this procedure beginning with step 6 8 Install the br
70. 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 Genie GTH 844 10 Select one of the hoses Pull the hose out of the boom Note Rope coming loose from either end of the hose or the boom during hose removal may result in a difficult reassembly Be sure each section of rope is securely attached to both the hose and the boom structure before pulling the hose out of the boom 11 Remove the rope from each end of the hose Discard the hose 12 Securely install a section of rope onto each end of the new hose assembly Note Tag each hose before assembly 13 Install the new hose assembly into the boom in the same manner the hose was removed Using the rope carefully pull the hose through the boom until each end is accessible ane By ea 1 hose sheave cover 2 Cover retaining bolts Part No 218230 2014 Section 4 Repair Procedures nr 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 beg
71. in death or serious injury Indicates a potentially hazardous ACAUTION situation which if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage other protective clothing if the situation amp Be sure to wear protective eye wear and warrants it such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Be aware of potential crushing hazards 3l Section 1 Safety Rules September 2015 SAFETY RULES Workplace Safety Be sure to keep sparks flames and W 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 N are properly maintained and ready for use Keep work surfaces clean and free of debris that could get into machine components and cause damage 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 any forklift overhead crane or 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 that fasteners intended for one Be sure to properly dispose of old oil o
72. injector 7 in firing order maximum value exceeded 23988 65236 OINO Q Of 23989 65237 Fuel Balance Control integrator injector 7 in firing order minimum value exceeded 23990 652388 0 Fuel Balance Control integrator injector 8 in firing order maximum value exceeded 1 Fuel Balance Control integrator injector 8 in firing order minimum value exceeded 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 23995 65243 13 check of missing injector adjustment value programming IMA injector 7 in firing order 23996 65244 13 check of missing injector adjustment value programming IMA injector 8 in firing order Genie 5 16 GTH 844 Part No 218230 2015 Section 5 Fault Codes T ENGINE FAULT CODES MODELS WITH DEUTZ POWER SPN Suspect Parameter Number ASPN Alternate Suspect Parameter Number FMI Failure Mode Identifier SPN ASPN FMI Description 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 High side to low side short circuit in the injector 7 in firing order Injector 7 in firing order interruption of electric connection Injector 8 in firing order short circuit High side to low side short circuit in the injector 8 in firing order In
73. injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 10 Tag disconnect and plug the hydraulic hoses at ports J1 J2 J3 and J4 of the primary function manifold Cap the fittings 11 Models with dual joystick Tag disconnect and plug the hydraulic hoses at ports JT2 JT4 JS3 and JS1 of the primary function manifold Cap the fittings 12 Tag disconnect and plug the hydraulic hoses at ports JE1 JE3 JL2and JL4 of the primary function manifold Cap the fittings 13 Remove the fasteners securing the joystick mount to the operator s compartment Remove the joystick assembly 14 Models with single joystick With the base of the joystick above the top of the hydraulic tank tag disconnect and plug the hydraulic hose at port T of the joystick Cap the 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 joystick if the joystick is below the hydraulic oil level in the hydraulic tank 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 PartNo 218230 Genie GTH 844 OPERATOR S COMPARTMENT 16 M
74. is immediately stored in the ECM memory At the same time a colored warning lamp is illuminated and the fault code is shown on the engine diagnostic display is located on the dashboardin the operator s compartment To learn the specifics of and how to use the fault codes refer to Section 5 Fault Codes Genie part number 218711 Perkins 854 Assembly Manual Genie part number 218712 Genie PartNo 218230 GTH 844 4 23 Section 4 Repair Procedures May 2014 Transmission 5 1 Transmission How to Repair the Transmission Repair procedures and additional transmission information is available in the Dana VDT 12000 Service Manual Dana part number TSM 0022 Dana VDT12000 Service Manual Genie part number 218706 Genie 4 24 GTH 844 Part No 218230 2014 Section 4 Repair Procedures TRANSMISSION This page intentionally left blank Genie PartNo 218230 GTH 844 4 25 Section 4 Repair Procedures May 2014 Hydraulic Pump 6 1 Hydraulic Pump How to Test the Function Pump Note When removing a hose assembly or fitting the fitting and or hose end must be torqued to specification during installation Refer to Section 2 Hyaraulic Hose and Fitting Torque Specifications AWARNING dud injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray
75. of reading up to 800 mA Genie GTH 844 4 Connect the negative lead to the other terminal on the coil Note If testing a single terminal coil connect the negative lead to the internal metallic ring at either end of the coil a MA b 100 9V RESISTOR T Lon eem 4 ONE v v 1 Y 1 multimeter 9V DC battery 10Q resistor coil ao oo Note Dotted lines in illustration indicate a reversed connection as specified in step 6 5 Momentarily connect the positive lead from the multimeter to the positive terminal on the 9V battery Note and record the current reading 6 Atthe battery or coil terminals reverse the connections Note and record the current reading Result Both current readings are greater than mA and are different by a minimum of 20 The coil is good W Result If one or both of the current readings 0 mA or if the two current readings do not differ by a minimum of 20 the coil and or its internal diode are faulty and the coil should be replaced Part No 218230 2014 Section 4 Repair Procedures Axle 8 1 5 Loosen the lug nuts of both wheels on the axle Axles to be removed Do not remove the lug nuts 6 the end of the machine until the tires are How to Remove the Axle off the ground Place blocks under the chassis for support AWARNING Bodily inj
76. of the boom install the chain into the chain anchor mount Secure the chain anchor to the mount using the pivot pin and cotter pin removed in step 8 Secure the cotter pin 14 Working at the pivot end of the boom route the chain over the roller and install the chain onto the boom assembly using the pivot pin removed in step 11 Securely tighten the fasteners Do not over tighten PartNo 218230 Genie GTH 844 4 5 BOOM COMPONENTS 15 Install the chain tensioners into the tensioner mount at the fork end of boom tube number 1 Install the mounting components removed in step 8 Evenly tighten the chain tensioners to the top of the boom tube until they are securely tightened 16 Adjust the chains Refer to Maintenance Procedure D 2 Adjust the Boom Sequencing Chains Component damage hazard Chains can be damaged if the boom is used while the chains are out of adjustment Do not return the machine to use until the chains have been correctly adjusted How to Replace the Extension Chains Note Perform this procedure on a firm level surface with the boom in the stowed position and the wheels chocked 1 Startthe engine and allow the engine to idle 2 Raise the boom to a horizontal position 3 Fully retract the boom 4 Turn the machine off and remove the key from the key switch 5 Working at the fork end of the boom loosen the fasteners securing the single chain tensioners to the top of boom tube number 1 After n
77. rod end of the lift cylinder Support the cylinder Do not apply any lifting pressure Part No 218230 2014 Section 4 Repair Procedures 4 Remove the fasteners securing the lift cylinder barrel end pivot pin to the chassis 5 Use a soft metal drift to remove the pivot pin 6 Remove the fasteners securing the lift cylinder rod end pivot pin to the boom 7 Use a soft metal drift to remove the pivot pin Crushing hazard The boom will fall if not properly supported when the pivot pin is removed from the machine 8 Using the overhead crane raise the boom to a horizontal position Remove the cylinder from the machine Crushing hazard The cylinder will fall if not properly supported when removed from the machine 1 4 Boom Extension Cylinder How to Remove the Extension Cylinder Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Raise the boom to a horizontal position PartNo 218230 Genie GTH 844 BOOM COMPONENTS 2 Tag disconnect and plug the hydraulic hoses at the boom extension cylinder manifold Cap the fittings AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to
78. squirt or spray Component damage hazard Hoses can be damaged if they are kinked or pinched 3 Remove the access covers on the number 1 boom and remove the bolts holding the extend cylinder support at the fork end of the machine 4 Atthe 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 5 Support the extension cylinder with a suitable lifting device and remove from the boom assembly Note During removal the overhead crane strap will need to be adjusted for proper balancing Section 4 Repair Procedures May 2014 m BOOM COMPONENTS 1 5 7 Use a soft metal drift to remove the pivot pin Fork Level Cylinder Remove the cylinder from the machine AWARNING Crushing hazard The cylinder How to Remove the Fork Level could fall if not properly supported when the pivot pin is removed from Cylinder the machine Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the lifting fork frame See 1 2 How to Remove the Lifting Fork Frame 2 Remove the fastener securing the fork level cylinder rod end piv
79. sway left 2 3 ft lbs 3 4 Nm 5 Directional valve proportional PES uus 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 Check valve pilot operated 100 psi 6 9 9 Fork tilt down circuit 25 ft lbs 34 Nm 8 Check valve pilot operated 100 psi 6 9 8 Fork tilt up circuit 25 ft lbs 34 Nm 9 Relief valve 3500 psi 241 bar RV2 Fork tilt down relief 20 ft Ibs 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 1 Boom retract circuit 12 14 ft lbs 16 19 Nm 13 Check valve 5 psi 0 3 bar 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
80. the Hydraulic Tank Return Filter Element Check belt tension Check the engine mounts Check hose clamps Part No 218230 May 2014 Section 3 Scheduled Maintenance Procedures CHECKLIST A PROCEDURES A 8 A 9 Perform Axle Maintenance Perform Transmission Maintenance Note Axle specifications require that this procedure be performed after 50 hours Oil level check add Required maintenance procedures and additional axle information is available in the Carraro 26 27M Axle Maintenance and Repair Manual Carraro part number CA270077 Carraro 26 27M Axle Maintenance and Repair Instructions Genie part number 218710 Part No 218230 A TEREX GTH 844 Note Manufacturer specifications require that this one time procedure be performed after 100 hours of operation Change transmission filter Required maintenance procedures and additional axle information is available in the Dana VDT12000 Service Manual Dana partnumber TSM 0022 Dana VDT12000 Service Manual Genie part number 218706 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 Required maintenance procedures and additional axle information is available in the Carraro 26 27M Axle Maintenance and Repair Manual Carraro part number 270077 Ca
81. the port if the joystick is below the hydraulic oil level in the hydraulic tank 6 Remove the fasteners securing the joystick to the mount panel Remove the joystick 2 Y 9 A i Joystick port orientation Genie GTH 844 How to Remove the Joystick Models with Dual Joysticks 1 Open the access door above the hydraulic tank 2 Disconnect the battery from the machine AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 3 Remove the fasteners securing the joystick mount panel to the side console 4 Tag and disconnect the joystick wire harness from the machine 5 Tag disconnect and plug the hoses from ports 1 2 3 4 and P of the joystick Cap the fittings 6 Locate the tee fitting which joins together the hydraulic hoses from port T of both joysticks to the tank return hydraulic hose 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 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 moun
82. 11 1 edddd dd reg me ae 5 233941 HARNESS BOOM ANGLE SW C90 3 4 6 IGNITION K C44 5 LE 2 3 IR VCC ENGINE SVD1B PWR C13 13 X C14 4 55555551 ce DECR CBE 6 217207 HARNESS THROTTLE PEDAL 13 16 4 7 C1 5 C38 5 4 4 TR IVS1 ENGINE INDIC PWR C13 16 X C10 7 31 SC5 6 CPU PWR 7 214443 ASSEMBLY FOOT SWITCH C89 1 4 8 S15 RET EC S I C10 6 4 5 IGNITION K ENGINE GC BK LT C13 21 lt C5 4 222 22 C F 11 236979 FORMING BUSS BAR C13 22 4 9 FUEL RET K C86 1 10 1 4 6 5 pale FUELRET C13 22 C10 9 2 8 8 IT 13 2 lt 10 H q 8 C10 11 4 7 CAN L K ENGINE S24RET 15 24 10 4 zoucctos C90 2 2 C5 8 12 227944 CONTROLLER HYD ERGO 2 SWITCH 1 3 11 L E 44 7 C10 10 4 8 CAN H f ENGINE 220000 13 227497 HARNESS PRIMARY MANIFOLD SJ F N R SHIFTER C15 2 2 C5 11 SW PWR LOCK SWITCH C15 4 2 C5 12 BRAKE CR Genie 6 10 GTH 844 Part No 218230 January 2015 Section 6 Schematics sao Harness Map Control System Ground Single Joystick before SN GTH0815 20662 RIGHT TRANSMISSION aa nm au C37 5 C41 2 SVA FORWARD C37 4 3x C40 2 SVB REVERSE C37 635 042 2 SVD GEAR 37 7 51 43 2 SVE GEAR C37 3 92 639 2 OIL PRESS S24 SECONDARY MANIFOLD C26 3 30 2 SVS P BRAKE RELEASE C26 4 22 C31 2 SV7 REAR
83. 2 23 spero POTENTIOMETER SPEED CONTROL o lk H 7 7 8 BLOWER MEDIUM SPEED TTE US RS lI E 5 alas H BLOWERHIGHSPEED 10KW 8 t Je 5 gt 8 8 6 878686 2 lA Il LI 8 a a FLASHER 2 E HEATERVAEPOTINFO ON 9 m _ 9 m 1 _ ta 2 9 CCW COOL SETTING 2 7 7 7 l 71 516 TURN SIGNAL SHIFTE CW HOT SETTING ER L M H B 2 a 2 2 2 BRAKE LIGHT V E 31 91 c ROADWORK Es M 5 5 5 COMPR 5 o e NOS A WH 8 ooo SOLINOID 9 9 8 9 127 024 P E 2 FM 2 ste 4 x 3 gt Vue s P s lo D INLINE sm l E BURD BURD gt 2210 ML ea S _ SKYLIGHT 9 I D4 BL L_ WH SWTH SWITCH RD 2 7 e Jai 1 5 l 3 21 6 ORIBK 245 P E BK GND I 2 m iti De Sl me ca GY 5 a i 21 GR 1 Yo DX GRIBK 228 Sel i olo lt 8 Ta MWH cet g Ss m ee mg EL m 5 5 D gt gt N O O JO Q Q g NOTE WH o En Le CRS 8 CIRCLED NUMBERS 75 VR rd PRINTED ON WIRES 230720809090 HDA FAN 1018 r 1 BLOWER SPEED SWITCH INFO
84. 21 Enclosed Cab Fan Switch 22 Road Work Light Switch 23 Brake Pressure Warning Switch 524 Transmission Oil Pressure Switch 25 Transmission Oil Temp Switch Genie 6 4 GTH 844 PartNo 218230 Genie May 2015 Section 6 Schematics Electrical Component Legend Electrical Component amp Wire Color Abbreviation Legend TP Throttle Pedal TSS Turn Signal Shifter Y Valve Coil Y1 Sway Left Enable SV1 2 Up Enable SV2 Y3 Sway Right Enable SV3 Y4 Tilt Down Enable SV4 Y5 Parking Brake Release SV5 Y6 Differential Lock SV6 Y7 Rear Axle Float SV7 Y8 Rear Axle Fast SV8 Y9 Sway Enable SV9 YA Auxiliary A YB Auxiliary B YD D Transmission YE E Transmission YF Transmission Forward YR Transmission Reverse YD1A 4Wheel Steer SVD1A YD1B Crab Steer SVD1B YLD Left Stabilizer Down YLU Left Stabilizer Up YRD Right Stabilizer Down YRU Right Stabilizer Up Part No 218230 Wire Color Legend BL Blue BL BK Blue Black BL RD Blue Red BL WH Blue White BK Black BK RD Black Red BK WH Black White BK YL Black Yellow BR Brown GR Green GR BK Green Black GR WH Green White RD Red RD BK Red Black RD WH Red White OR Orange OR BK Orange Black OR RD Orange Red WH White WH BK White Black WH RD White Red GTH 844 6 5 Section 6 Schematics 2015 Telematics Connector Legend Telematics Connector Pin Legend ee Genie installed Telematics connector is wired with an Active High digital input e m
85. 3719 64967 SCR heater urea supplymodule short circuit to battery SCR heater urea supplymodule short circuit to ground SCR heater relay urea supply module open load Urea supply module heater temperature plausibility error Urea supply module heater temperature signal disrupted Urea supply module heater temperature plausibility error Urea supply module temperature signal disrupted Urea supply module temperature measurement not available Urea supply module PWM signal signal disrupted Detection of AdBlue filled SCR system in Init State Timeout Error of CAN Receive Frame Active TSC1AE Timeout Error of CAN Receive Frame Passive TSC 1AE Timeout Error of CAN Receive Frame Active TSC1AR Timeout Error of CAN Receive Frame Passive TSC1AR Timeout Error of CAN Receive Frame Passive TSC 1DE Timeout Error of CAN Receive Frame TSC1TE active Passive Timeout Error of CAN Receive Frame TSC1TE Setpoint Active Timeout Errorof CAN Receive Frame TSC1TR Passive Timeout Error of CAN Receive Frame TSC1TR Turbo charger wastegate CAN Fehler Timeout Error of CAN Transmit Frame Status Wastegate 23793 65041 9 Timeout Error of CAN Receive Frame UAA10 AGS sensor service message 23720 64968 23721 64969 23722 64970 23723 64971 23766 65014 23767 65015 23768 65016 23769 65017 23770 65018 23776 65024 23777 65025 23778 65026 23779 65027 23788 65036 Of 0 N OO N
86. 4 Install the wear pads Install and securely tighten the retainer plates Do not over tighten How to Remove the Lifting Fork Frame 1 With the boom in the stowed position attach a lifting strap from an overhead crane to the top of the lifting fork frame at the front of the boom Support the frame Do not apply any lifting pressure 2 Working from the rear of the frame lift the spring assisted handle of the lock securing the lower fork frame lock pin to the fork frame mount Use a soft metal drift to remove the pin PartNo 218230 GTH 844 4 3 Section 4 Repair Procedures May 2014 BOOM COMPONENTS 3 Using the overhead crane lift and remove the fork frame from the boom Crushing hazard The fork frame ACAUTION could fall if not properly supported when the lock pin is removed from the machine How to Replace the Retraction Chain Note Perform this procedure on a firm level surface with the boom in the stowed position and the wheels chocked 1 Start the engine and allow the engine to idle Raise the boom to a horizontal position Extend the boom approximately 1 inch 2 5 cm 2 3 Fully retract the boom 4 5 Turn the machine off and remove the key from the key switch 6 Working at the fork end of the boom loosen the fasteners securing the single chain tensioners to the top of boom tube number 1 After noting the orientation and assembly order of the components remove the fasteners and pull the
87. 4041 65289 9 Timeout error of CAN Receive Frame ComMS Sys4TO error memory Slave Master Slave internal CAN message 24042 65290 9 Timeout error of CAN Receive Frame ComMS Sys5TO error memory Slave Master Slave internal CAN message 24043 65291 9 Timeout error of CAN Receive Frame ComMS 5 56 error memory Slave Master Slave internal CAN message 24044 65292 9 CAN message 5 5 57 not received from slave 24038 65286 Genie 5 18 GTH 844 Part No 218230 2015 Section 5 Fault Codes T ENGINE FAULT CODES MODELS WITH DEUTZ POWER SPN Suspect Parameter Number ASPN Alternate Suspect Parameter Number FMI Failure Mode Identifier SPN ASPN FMI Description 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 ComMSMoF OvR1TO 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_
88. 5 Engine maintenance Perkins models Perform every 5000 hours E 6 Engine maintenance Deutz models Perform every 12 000 hours E 7 Engine maintenance Perkins models A TEREX COMPANY GTH 844 Part No 218230 2014 Section 3 Scheduled Maintenance Procedures Checklist A Procedures A 1 Inspect the Manuals and Decals Note Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Maintaining the operator s and safety manuals in good condition is essential to safe machine operation Manuals are included with each machine and should be stored in the container provided in the operator s compartment An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition In addition maintaining all of the safety and instructional decals in good condition is mandatory for safe machine operation Decals alert operators and personnel to the many possible hazards 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 l
89. 8 HORN PWR 1256744 ESS TELEMATICS C89 1 4 6 S15 RET K C1 3 C10 11 7 CANL K ENGINE CAN H 13 2 lt 106 C28 1 2 C4 9 SV13 PWR C13 16 4 7 INDIC PwRJ C1 5 C10 10 48 CAN H ENGINE 5 CAN L 13 3 6 106 559595 11 4 571 4 10 PWR PORT tiei son eei aC Stoe 1260181 NESS TRANSMISSION 0104 _ 5E lt c5 MMMMM C11 6 2 C4 12 c13 22 471 FUELRETK 1 9 c90 sti IGN PWR KC108 1 S s25 RET C13 7E C10 5 C14 2 5 c5 1 SIOPWR 233941 ESS BOOM ANGLE SW m 15 4 2 KC114 5 amp 523 8 6 11 1 C12 1 C5 2 SVA PWR 7 C11 6 BOOM ANG 114 4 SVD1B PWR cI3 13 c14 4 9 55555551 92 7653 svapwn 1258119 55 THROTTLE PEDAL C103 12 5 44 5 K107 30 INDIC PWR C13 16 amp C10 7 C13 2122 c5 4 GC BK LT C105 GC BK LT C13 21 4 C5 4 344 13 5 5 65 5 GC PWR 7 1214443 ASSEMBLY FOOT SWITCH 1 4 42 KC114 1 T S sRET k FUEL RET C13 221 C95 1 400615 0 0 13 1 5 6 CPU PWR L_S24RET 24 0 4 57958 GS0 TSS C5 7 BALPWR 12 219457 HARNESS BACKUP ALARM 108 108 515 7 He 13 227494 CONTROLLER HYD ERGO 2 SWITCHES C13 2 4 11 _ 108_ N R SHI C90 3 2 C5 9 IGN PWR H ES ancre 7 Braet RENE pius 615 1 93 65 10 BRAKE SV Os dec
90. A Deutsch plug p n DTO6 08SA mates with the Genie telematics connector Circuit Type Circuit Properties Genie Machine Function s Telematics Use Case 1 System Power 12 VDE Battery Positive constant 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 OV engine off Boom Angle Status 4 Digital Output 2 12 VDC Monitor machine utilization 0V boom 55 12V boom gt 55 5 Digital Output 3 12 VDC Parking Brake T Monitor machine utilization 12V active OV 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 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 dt OV before activating Disable Relay Telematics Active High Schematic Telematics Active Low Schematic standard wiring optional wiring gt 220 D gt gt 30 87A 30 87 2 12V 12V 3 86 85 8 86 85 SPST SPST Ignition Start Input Relay Telematics with Active High input Telematics with Active Low input N Wireless Certifications
91. ANIFOLD fe SERVICE BRAKE S5 RET 29 11 6 27 SERVICE BRAKE S6 RET C29 2 4 7 44 gt 2 2 6 lt 4 LO TRAPS CB4 A x C38 1 C38 M E 4 TR GND C84 B X C38 2 X TR vcC C84 C x C38 3 P acc IR IVS1 C84 D X C38 5 O e C28 14 ben 52 ek 9 NOTE HARNESS pem des gt Istart C90 4 X C15 6 el BASE UNIT LEFT SY IGN c90 3 lt lt 65 9 C40 1 22 01 2 SVB FWR 2x 10 6 C10 8 2 C1 3 S15 RET DUAL JOYSTICK OPTION PWR PORT C91 1 x C11 4 2 10 7 1 1 5 INDIC PWR PCB CONTROL SYSTEM POWER C12 8 SDI swPWR 15 2 5 11 uale SVA PIR 4 CONNECTORS DETAILS ee C24 2 32 63 10 SIRET START 15 6 lt lt c90 4 18 1 gt 1 3 11 B ALRM C28 START C15 8 X C12 6 lt lt 55 2 5103 12 S14 PWR AUX HYDRAULICS S14 POWER CONNECTED TO HARNESS a 559 B 13 4 9 cont Eee 229681 WHEN AUX HYDRAULICS OPTION INSTALLED cc13 8 44 S23 RET k C36 25 sto PWR 14 2 C5 1 Se E VAER T oe eee aa S RISVDIB PWR 14 4 R amp C 3 C27 A C4 6 S5 PWR 714 455 SVDIB PWR C341 C38 Oz 515 219 29 2 971 4 7 S6 RET lt 91 1 4 4 4 1009 C C84 A 4 1 TR APS C44 1 7 SISISRET 89 1 10 8 C88 1 2 C4 8 HORN PWR C84 B 2 TR GND C44 2 C28 1 gt C4 9 SV13 PWR C10 I RR C44 3 Ei CPU PWR 13 11 5 6
92. Brake Latch L20 Reverse Coil Power ON CR12 Sway Left Right Enable L21 PB Release Coil Power ON CR13 Til 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 1 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 510 Steer Select Switch F14 10 Amp Power Port 11 Left Stabilizer Switch F15 1 Amp Switch Power 512 Right Stabilizer Switch F16 1 Amp Gauge Cluster ECU 13 Differential Lock Switch F17 Not Used 14 Auxiliary Cont Switch F18 Not Used 15 Horn Switch 21 HVAC Control Panel 516 Brake Light Pressure Switch S17A Windshield Wiper Motor Switch 17 Windshield Washer Switch S18A Windshield Wiper Motor Switch 18 Windshield Washer Switch 19 Dome Light Switch
93. C44 L2 TELM CND LOCK SWITCH C15 2 32105 11 SW PWR 823125A 14 1260182 HARNESS PRIMARY MANIFOLD SJ C44 7 k 13 3 43 CR18 PWR C15 4 92 C5 12_ BRAKE CR Genie 6 14 GTH 844 Part No 218230 January 2015 Section 6 Schematics Harness Map Control System Ground Single Joystick from SN GTH0815 20662 RIGHT TRANSMISSION C37 5 X1C41 2 SVA FORWARD 37 4 40 2 SVB REVERSE 37 6 1 42 2 SVD GEAR 43 2 SVE GEAR SECONDARY MANIFOLD C26 3 T C30 2 SVS P BRAKE RELEASE C26 4 255 C31 2 SV7 REAR AXLE FLOAT C34 2 SVD1B CRAB STEER C26 8 C33 2 SVD1A 4WS PRIMARY MANIFOLD ORN _ SWAY ENABLE C19 2 lt lt 17 11 ORN GND C88 2 C26 2 SV1 SWAY LEFT C21 2 SV3 SWAY RIGHT C20 2 SV2 TILT UP C23 2 SV4 TILT DOWN C22 2 C16 GROUND CKT COLOR LUG GND 2 GC GND C18 3 BR BR S2 GND BR BACKUP i 4 GND PWR P BR 17 2 TZAR eno 7 362 ALARM a an anu C17 6 C17 7 GROUND STUDS 4 2 26 6 Q C26 7 ore 16 1 LUG GND C37 1 C37 8 NOTE BASE UNIT SINGLE JOYSTICK OPTION CONTROL SYSTEM GROUND POWER PORT PWR PORT 91 21 16 4 LUG GND22 C37 1 LUG GND 1 t C86 2 3 C37 2 FUEL GND 39 2 3 37 3 S24 GND C40 2 3 C37 4 SVB CND PARENG 41 2 55 57 5 SVA GND gt a SVD GND mo
94. Cranking speed 130 200 rpm Glow Plugs Initial load 0 10 sec 80 amps Continuous load gt 10 sec 40 amps Battery Type 12V DC Group C31 Quantity 1 Cold cranking ampere 09 1000A Reserve capacity 25A rate 200 minutes Continuous improvement of our products isa Genie policy Product specifications are subject to change without notice GTH 844 Part No 218230 2014 Section 2 Specifications Dana VDT12000 Transmission Transmission Type 3 speed powershift converter Speeds Forward 3 Speeds Reverse 3 Torque Converter SPECIFICATIONS Carraro 26 27M Drive Axle Steering Integrated steer cylinder Joints Heavy duty double U joints Steering angle maximum 45 Front Axle Lubrication Maximum input 3100 rpm Size 12 inches Lubrication Oil capacity transmission 14 3 quarts 13 5 liters Oil capacity drop box 1 1 quart 1 liter Oil viscosity requirements Units ship with Chevron Ursa Hydraulic 10W Extreme operating temperatures may require the use of alternative transmission oils For oil requirements refer to the Dana VDT12000 Service Manual Dana part number TSM 0022 Dana VDT12000 Service Manual Genie part number 218706 Part No 218230 Genie GTH 844 Front differential 7 4 quarts 7 liters Axle planetary end each 0 8 quarts 0 8 liters Rear Axle Lubrication Rear differential 7 9 quarts 7 5 liters Axle planetary end each 0 8 quarts
95. ED DRY LUBED ft Ibs 13 18 74 20 23 33 55 37 14 7 15 8 m 24 27 1 44 7 50 1 67 8 25 27 44 49 70 33 9 28 4 36 6 32 5 59 6 51 5 66 4 98 3 ___68 _ A 37 5 di 20 S 867 one 12 80 108 4 110 14 120 18 s 122 10 162 130 160 780 m 280 379 310 420 19 320 430 583 450 60 60 878 670 908 759 480 650 640 867 680 92 910 1233 1044 2 718 70 962 750 106 950 1342 1139 AT 1749 1477 8 1952 1654 17 2074 1 2304 3620 2 42 160 2067 METRIC FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual Size 6 46 Class 8 8 Class 10 9 03 Class 12 9 mm 6 94 7 82 7 108 4 2 149 162 142 203 176 230 189 281 244 325 271 515 133 569 474 827 691 N e e N 108 4 122 162 176 217 244 110 120 150 170 210 240 380 420 DIN oa 5 8 gt o DRY 854 68 775 91 105 32 DRY DRY 7 600 458 622 612 830 536 727 715 970 B5 570 562 762 583 791 778 1055 682 925 909 1293 Genio PartNo 218230 GTH 844 2 13 E c iv 1 u ER D i H ER c c u ER c 00 o o o D EN alo
96. ESS TRANSMISSION from sn GTH0815 20662 CABLE BATTERY BLACK 2 0 9 237955 HARNESS PCB GROUND 11 236979 FORMING BUSS BAR 18 231260 CABLE BATTERY RED 2 0 823125A 218442 HARNESS ENGINE PER 1104D E44TA Part No 218230 Genie GTH 844 6 27 January 2015 Section 6 Schematics Harness Map Perkins 1104D Engine Battery Power and Ground 28 29 Section 6 Schematics January 2015 wn I III Harness Map Perkins 854E Engine Battery Power and Ground Section 6 Schematics January 2015 Harness Perkins 854E Engine Battery Power and Ground RIGHT E ENGINE 25 I PERKINS 12 amp 854 14 15 gt PANEL ST en GROUND ALTERNATOR BLACK BAT CABLE wi ENGINE EU 4 GROUND_ STUDS GROUND PERKINS T4i ENGINE LEFT BATTERY POWER AND GROUND DISTRIBUTION PERKINS 854E E34TA ENGINE HARNESSES PART DESCRIP TION 227493 HARNESS TRANSMISSION before sn GTH0815 20662 1260181 HARNESS TRANSMISSION from sn GTH0815 20662 231257 LE BATTERY BLACK 2 0 237933 ESS PCB GROUND 236979 FORMING BUSS BAR 219212 HARNESS ENGINE 854 4 235996 CABLE BATTERY RED 2 0 3 BAT 823125A Genie 6 30 GTH 844 Part No 218230 RIGHT LEFT January 2015 Sect
97. ET C60 2 p C62 2 C63 2 2 c59 2 WPERET WIPE ON 60 3 1 1 354C59 3 WIPE ON wPE GND 60 4 5 58 1 HEATER D Sy Dome 519 CONTROL PANEL GROUND STUDS LIGHT 4 Bow sw A C58 4 NOTE POWER C78 B X C6 1 2 En C80 F LEFT SWHI C78 H X C80 A LUG GND 76 c4 G sw MED 78 80 G Daa o WITH HEAT OPTION _SW LOW C78 LFK C80 C 53 555859 m VALVE CONTROL 8055 CONNECTOR 122 POWER C76 A lt C6 1 2 60 4 5 58 1 WIPE GND 29888 VALRET C76 BLXX CB0 E C59 4 35 C58 2 WIPE GND 4454444 zal GROUND C76 CFK LUG GND LUG GND224 58 3 LUG GND 93288331 LUG GND21C58 4 LUG GND 11 63 92 92 2 1 58 5 WASH GND n 2 99658 6 5223264 WA ENCLOSED CAB WITH HEAT OPTION HARNESSES oo 7 ITI be ARNESS ENCLOSED CAB C61 G3 pouE PwR sees 1 9 ARNESS CAB FAN mum M ARNESS POWER DOME LIGHT 2 sS an 78 8 6 1 HVAC PWR 6566 2 HVAC PUR DOME LIGHT WITH CONNECTOR WINDSHIELD 6 3 W W PWR 69 WIPE ON C62 1k c60 3 C6 4 PWR WPERET 61 1 5 6 5 FAN PWR WIPE PWR C62 4 F lt c60 1 E W W PWR 62 7 C6 3 61 2 06 6 FAN GND CS LWASH PWR C62 8 XC WIN WP 5211 518 SKYLIGHT_W W amp WPEON C63 1E ec59 3 HARNESS CAB HEATER 5 WPERET 63 2 amp 59 2 2
98. FidFCCTO Master Slave CAN communication faulty Timeout error of CAN Transmit Frame DPFBrnAirPmpCtl Timeout error of CAN Transmit Frame ComDPFBrnPT Timeout error of CAN Transmit Frame ComDPFCO Timeout error of CAN Transmit Frame ComDPFHisDat Timeout error of CAN Transmit Frame ComDPFTstMon Timeout error of CAN Receive Frame ComRxDPFBrnAirPmpCtl Timeout error of CAN Receive Frame ComRxDPFBrnAirPmp Timeout error of CAN Receive Frame ComRxDPFCtl 24097 65345 24098 65346 24099 65347 24100 65348 24101 65349 24102 65350 24103 65351 24104 65352 o co co Genie PartNo 218230 GTH 844 5 19 Section 5 Fault Codes May 2015 ENGINE FAULT CODES MODELS WITH DEUTZ POWER SPN Suspect Parameter Number ASPN Alternate Suspect Parameter Number FMI Failure Mode Identifier SPN ASPN FMI Description 24105 65353 9 Timeout error of CAN Transmit Frame ComEGRMsFlw 24106 65354 Timeout error of CAN Receive Frame ComRxEG RMsFlw1 24107 65355 Timeout error of CAN Receive Frame ComRxEGRMsFlw2 24108 65356 Timeout error of CAN Transmit Frame ComEGRTVActr 24109 65357 Timeout error of CAN Receive Frame ComRxEGRTVActr 24110 65358 Timeout error of CAN Transmit Frame ComETVActr 24111 65359 Timeout error of CAN Receive Frame ComRxETVActr 24112 65360 Timeout ComITVActr 24113 65361 Timeout error of CAN Receive Frame ComRxITVActr 24114 65362 Timeout error of CAN Transmit Frame A1 DOC 24115 65363 Timeout error of CAN
99. Frame AT1OGCVol2 information factors amp 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 amp Sensorcalibration for NOX Sensor SCR system downstream cat DPF system downstream cat 53943 65191 9 Timeout Error PCK2PCK for CAN Receive Frame AT10GCVol2 information factors amp Sensorcalibration for NOX Sensor SCR system downstream cat DPF system downstream cat 23946 65194 Zerofuel calibration injector 1 in firing order maximum value exceeded Zerofuel calibration injector 1 in firing order minimum value exceeded Zerofuel calibration injector 2 in firing order maximum value exceeded Zerofuel calibration injector 2 in firing order minimum value exceeded Zerofuel calibration injector 3 in firing order maximum value exceeded 23947 65195 Zerofuel calibration injector 3 in firing order minimum value exceeded 23948 65196 23949 65197 Zerofuel calibration injector 4 in firing order maximum value exceeded Zerofuel calibration injector 4 in firing order minimum value exceeded Zerofuel calibration injector 5 in firing order maximum value exceeded Zerofuel calibration injector 5 in firing order minimum value exceeded Zerofuel calibration injector 6 in firing order maximum value exceeded Zerofuel calibration injector 6 in firing orde
100. If needed blow from the inside out using low pressure dry compressed air or carefully tap out dust 6 Install the secondary filter element first then install the primary filter element 7 Install the front cover onto the air cleaner assembly and secure the latches Part No 218230 TEREX CON GTH 844 CHECKLIST PROCEDURES B 5 Inspect the Tires Wheels and Lug Nut Torque Note Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the tires and wheels in good condition including proper wheel fastener torque is essential to safe operation and good performance Tire and or wheel failure could result in a machine tip over Component damage may also result if problems are not discovered and repaired in a timely fashion AWARNING P d3ily injury hazard An overinflated tire can explode and could result in death or serious injury AWARNING Tip over hazard Do not use temporary flat tire repair products Note The tires on some machines are foam filled and do not need air added to them 1 Check all tire treads and sidewalls for cuts cracks punctures and unusual wear 2 Check each wheel for damage bends and cracks 3 Check each lug nut for proper torque Refer to Section 2 Specifications 4 Check the air pressure in each tire Refer to Section 2 Specifications Section 3 Scheduled Maintenance Procedures May 2014
101. L JOYSTICK OPTION CONTROL SYSTEM GROUND POWER PORT LEFT ee HE LUG GND 1 C37 2 FUEL GND C37 3 S24 GND 37 4 SVB GND 48 zR 9 PARKING BRAKE 52 S2 GND 15 9 Kci 6 3 37 5 SVA GND C42 2 32 C37 6 SVD GND C43 2 32 C37 7 SVE GND LUG GND221C37 8 LUG GND J C37 BUSS CONNECTOR 2 71 26 2 HORN GND 30 2 95 C26 3 SV5 GND 31 2 26 4 SV7 GND C32 2 3 C26 5 SVE GND TELM GND C108 L TELM GND C114 L DUAL JOYSTICK SYSTEM GROUND HARNESSES ITEMIPART DESCRIP TION 1256695 HARNESS DASHBOARD 1260180 HARNESS SECONDARY MANIFOLD 1256744 HARNESS TELEMATICS 1260181 HARNESS TRANSMISSION 12 219457 HARNESS BACKUP ALARM 15 1260183 55 PRIMARY MANIFOLD DJ GAUGE_CLUSTER CPU PWR 15 61 LUG GND22 C26 6 LUG GND 8 LUG GND221C26 7 LUG GND 32 2 1 26 8 SVD1A GND 34 2 26 9 SVD1B GND C36 1 321C26 11 S23 GND BUSS CONNECTOR LUG GND 51C16 1 LUG GND 1 C13 6 C16 2 GC GND e 15 9 gt C16 3 S2 GND o C91 2 9 1C16 4 GND PORT BUSS CONN 823125A Genie PartNo 218230 GTH 844 6 23 January 2015 Section 6 Schematics Harness Map Control System Ground Dual Joystick from SN GTH0815 20662 24 25 Section 6 Schematics January 2015 Vwwss cr I OcE Harness Map Deutz TCD3 6 Engine Battery Power and
102. NABLE 1 ENABLE a 4o cy 8 a 650 I2 JE 55 RY CR5 crz 22 Eu di LIGHTS SWAY BOOM OPTION ENABLE 4l ANGLE 5 a C1 h EN CR2 MAIN p OPTIONS SERVICE I4 1 POWER POWER jl HORN gt NC 25 tol os 5 5 o e 9 C9 JOYSTICK PCB 237361 HARNESS ev ASSY P N amp BAT T PCB Board Fuse Panel located in the Cab Genie PartNo 218230 GTH 844 Section 6 Schematics 2015 Electrical Component Legend Electrical Component amp Wire Color Abbreviation Legend ALT Alternator L LED Light B Battery 1 Ignition Power ON Bi Main Battery L2 Options Power Relay ON CB Circuit Breaker L3 Horn Relay ON 1 50 Amp Circuit Breaker L4 Tum Signal ON CB2 30 Amp Circuit Breaker L5 Road Lights Work Lights ON CB3 60 Amp Circuit Breaker 16 Sway Enable Coil Power ON L7 Boom Angle ON C1 4700 uf L8 Boom Extend ON CR Control Relay L9 Brake Pressure ON 1 Main Power L10 Backup Light Alarm ON CR2 Options Power L11 Parking Brake Latch ON CR3 Service Hom 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
103. OL SERVICEBRAKE BRAKE LIGHTS OPTION PRESSURE SWITCH PRESSURE SWITCH eee 450 psi cete EXTEND RETRACT UT 1 14 10gpm FRONT STEER STEER 3 31 14 gpm 31 19 153 37 9 L min 6 6 117 4 53 Limin E 117 4 72 L min 22 8 L min 22 8 L min DIFF LOCK REAR LOCK UP i E 2 STEERNGUNT 5 gpm 15 3 250 L R L R SERVICE BRAKE BRAKE 19 L min REARAXLE EE BRAKE PEDAL E 23 ee LIGHT 0 640 psi 0 44 2 bar E SWITCH PARKING BRAKE EN I PRESSURE SWITCH 3 we AULT AUXHYD 6 8 min SUP T SUT sus 8 SRF BP BT TB PB DL TJ P T U Jet JE eo a pem Re kas eet oi arta ies To 1 svt NNNM NU TR M MN MCN MN MEN VENE ME M gm bag 9 sv 7 515 lus AZ 8 on io POL 41 bd 00 00 N 4 i E Q5 6 0 ale Pet I PE H PE 3 50psi LIA e D L B 2650 psi 1 x EIE EN Iso 35 bar eta pal te Bh 57 AUX MANIFOLD P
104. ONTINUED r Procedure Schematic Page Description Kubota Engine_Section 2_Specifications Electronic Version A 6 B 3 C 7 Section3 Maintenance Procedure 3 2 6 4 9 1 Section4 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 Section6 Schematic Page Genie iv GTH 844 Part No 218230 September 2015 INTRODUCTION Serial Number Legend Genie 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 _ LIFT HEIGHT 6000 LBS GTHOS 1 0 1 21 01 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 6 201 1 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 Genie Part No 218230 GTH 844 September 2015 This page intentionally left blank Genie vi GTH 844 Part No 218230 September 2015 Section
105. P BRAKE RELEASE C24 C4 4 35 C31 1 SV7 REAR AXLE FLOAT C28 255 32 1 SV6 DIFF LOCK 11 3 5 C34 1 SVD1B CRAB STEER C11 235 33 1 SVD1A 4WS FUEL TANK 011 1 36 2 S23 BRAKE PRESSURE FUEL SENDER 4 6 gt 1 27 S5 PARKING BRAKE PWR PRIMARY MANIFOLD z C29 125 27 S5 PARKING BRAKE RET Q HORN FUEL RET 86 11 10 9 E MEE bog Eu 05 IHORN PWR CB8 1 X C4 8 1 poe SV3 SWAY RIGHT C20 1 lt C3 4 SV2 TITL UP C23 1 lt C3 5 SV4 TILT DOWN C22 1 X C3 6 e C18 2 c3 E e AR ew OROK BRAKE MANIFOLD fee SERVICE BRAKE S5 RET 29 11 27 SERVICE BRAKE S6 RET C29 2 X C4 7 3 T 6 lt 4 JOYSTICK u TRAPS C84 ALx C38 1 b M Ex j TR GND C84 B KE C38 2 a st 88 Q amp TR VCC C84 C X C38 3 ac Fa 99 E W TR IVS1 C84 DFK C38 5 4x C28 EE 03 BAT 90 11 5 7 8 ACC 1 amp 5 C41 1 3 C1 1 SVA PWR NOTE HARNESS LEFT gt START 90 41 15 6 Scere BASE UNIT IGN C90 3 C5 9 2 9 5 SINGLE JOYSTICK OPTION PWR PORT 1 11 4 pee tae 2 CONTROL SYSTEM POWER C12 8 20 1 1 3 4 SV3 PWR PCB zo SW PWR 15 2 5 11 23 1 1 3 5 SV2 PWR CONNECTORS DETAILS amp u BRAKE SV 15 1 5 10 C22 1 92 C3 6 SV4 PWR 55 BRAKECR CI5 4 4 c5 12 C19 1 5x C3 7 SV9 PWR START C15 6 x C90 4 C24 1 5x163 8 S3 PWR C28 START
106. PARE AUX HYD LIGHTS SPARE 25 D2 FLASHER z v F55A F18 10A MAX F9 25A F13 15A 5 mol mm 15 HORN SPARE HVAC IGNITION C3 53 25 12 CR13 mz PBRAKE SWAY TILT U D 12 6 LATCH ph URENBL 4 ENABLE 2 D6 5 z 42 42 m a 2 05 m 9 FORWARD REVERSE F3 d EXTEND di ENABLE ENABLE C2 8 gt 58 5 2 55 DN zo CRS h CR6 CR7 gt al LIGHTS SWAY BOOM E OPTION L ENABLE jl ANGLE 9 2 E 5 B C1 h EN CR2 h MAIN peo OPTIONS SERVICE POWER POWER 12 HORN gt 22 NES DE B 5 OG a o C9 E JOYSTICK PCB 237361 HARNESS ev 7 BAT 0n PCB Board Fuse Panel located in the Cab Genie GTH 844 Part No 218230 2015 60 ve Ec CB2 Circuit Breakers located on the Battery Tray CB1 and on all engines CB2 30A Deutz T3 or T4i Perkins T3 30A CB2 50A Perkins T4i CB1 Telehandler Control System Power CB2 Engine Power ECM CB3 Glow Plugs Section 6 Schematics Fuse Panel Layout from serial number 20630
107. PLAY Decoding Fault Codes The Suspect Parameter Number SPN or the Alternate Suspect Parameter Number ASPN and the Failure Mode Identifier FMI when combined are the basis for an engine fault code The SPN or ASPN number indicates the affected component the FMI number reveals the type of failure that has occurred Comparing the combination of numbers to the fault code chart on the following pages will help to determine the exact engine fault and a corrective course of action For additional information refer to the engine operator s manual which came with your machine 15 10 20 100 2 25 Gauge Cluster FMI Code SPN Code or ASPN Code amber warning light red stop engine light PartNo 218230 2015 Section 5 Fault Codes 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 Thro
108. R SRF 9 SRR BS BA 265 PB spy ET ae ES ES RSEN T SUD 4 a js i w m SOR SOA E z ci 4 ZUM E PR2 5009 7 135 bar PRS 2650 psi PR d I a pas LA o na 919 5 51 i P P 1 e e e e e e J i 2 19 ep 3500 psi oy 3500 psi hy 1h Wat dba 1 Dye 21 s 6 LA e LA LA x T T LA oo o LA I SECONDARY FUNCTION MANIFOLD AIN FUNCTION MANIFOLD MEE Lc cC cC LC Bo mM TP UU T T HS0205B 7 E BREATHER FILLER 3 psi 0 3 bar 8 L Function uw 325050 PSI PCILS SETTING 3100 64 CC 2670 2580 RPM MAX RESERVOIR Genie 6 46 GTH 844 Part No 218230 September 2015 Section 6 Schematics Hydraulic Schematic Single Joystick from serial number 19529 N M L K J H G F E D B A SWING CARRIAGE OPTION 1 eb PS RSA SI D PS m MPO TUT 14 10 GPa Ip E EXT RET 31 14 GPM LFT 31 19 GPM 2 QR SWING CARRIAGE MANIFOLD OPTION m z R vi v2
109. R 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 9 2 520 597 Timeout Error of CAN Receive Frame TSC1TR Break Lever Main switch and Break Lever Redundancy switch status not plausible Genie 5 4 GTH 844 Part No 218230 2015 Section 5 Fault Codes ENGINE FAULT CODES MODELS WITH DEUTZ POWER SPN Suspect Parameter Number ASPN Alternate Suspect Parameter Number FMI Failure Mode Identifier SPN ASPN FMI Description 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 1 652 3 General short circuit injector 2 5 Interruption of electric connection injector 2 653 3 General short circuit injector 3 5 Interruption of electric connection injector 3 654 3 General short circuit injector 4 5 Interruption of electric connection injector 4 655 3 General short circuit injector 5 5 Interruption of electric connection injector 5 656 3 General short circuit injector 6 5 Interruption of electric connection injector 6 677 3 Short circuit on high side s
110. R k C105 C108 Genie 114 5 3 BOOM ANG CI114 4 C12 5 q4 START 107 30 d i THROTTLE 13 RET 2 FsTs PwR C28 I lt c4 9 2 3 C32 1 ES TRAPS CB4 A He 38 1 4 ZT END CB4 B C382 C38 SlrR vcc CB4 C H C C38 5 grave ce o p c38 4 IGNITION S10 STEER ISVDIB PWR 14 4 C44 HARNESS C41 1 SVA FORWARD 40 1 SVB REVERSE 42 1 SVD GEAR 43 1 SVE GEAR 39 1 OIL PRESS S24 C87 1 OIL TEMP S25 C1 1 3 C1 2 3X C10 2 X 5 9 1 104 1 C c90 3kk 10 1 ty BAT PWR 90 1 5 7 gt C90 2 START c90 4 c15 6 cipe ena C5 8 C12 8 SwPWR Cis 2l c5 n 5 BRAKE SV C15 1 c5 10 START C15 6 amp START 15 8 12 6 PIBRAKE CR C15 4 C13 4 LT SVDTAPWR 14 1 Bl S10 PWR 14 2 Lu uo lt C90 4 c5 12 C104 B C11 2 lt C5 1 C11 3 C13 13 z gt SISIS RET 89 1 10 6 CPU PWR C13 1E c5 6 2 CAN H C13 2 lt lt C106 A 10 O O 01010 3 CAN L 3 lt 106 8559595 O SVD1A PWR Ct3 4 3 C14 1 LA LS VL tj GC PWR C13 5 X C5 5 MMMMM 9 S25 RET C13 7E C10 5 0 5 S25RET 13 8 11 1 NA dwn SVD1B PWR C13 13 C14 4 15555555 INDIC PWR 13 16 lt 10 7
111. RI 400 ps 1 OPTION 5 r 28 bar d Bi dL ME Ld x T Ti De liso 1 3500 psi M 3500 psi 77 3500 psi 7 7 723252 2 7 7 2 2 sess sns eni E o 2 AT SECONDARY FUNCTION MANIFOLD MAIN FUNCTION MANIFOLD m lamcn HS0206C 7 BREATHER FILLER 8 3 psi 0 3 bar FUNCTION PUM E 3250 450 PSI PC LS SETTING 3 11 CID CC 2370 2580 RPM MAX RESERVOIR Genie 6 50 844 Part No 218230 September 2015 Section 6 Schematics Hydraulic Schematic Dual Joystick from serial number 19529 N M L K J H G F E D B A SWING CARRIAGE OPTION EXT RET 31 14 GPM 4 5 57 SWING CARRIAGE 2 5 MANIFOLD OPTION v2 AUX HYD 15 GPM M Lodo sot H oF XE 8 HS0206G Genio PartNo 218230 GTH 844 6 51 September 2015 Section 6 Schematics Hydraulic Schematic Dual Joystick from serial number 19529 52 Genie Scandinavia Phone 46 31 575100 Fax 46 31 579020 Genie France Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Genie Iberica Phone 34 93 579 5042 Fax 34 93 579 5059 Genie Germany Phone 0800 180 9017 Phone 49 422 149 1818 Fax 49 422 149 1820
112. RT 15 6 3 C90 4 C23 1 5 C3 5 SV2 PWR AUX HYDRAULICS S14 POWER CONNECTED TO AUX HYDRAULICS C13 8 43 S23RET k c36 C84 A d 1 TR APS e C44 1 jos 2 START C15 8 12 6 C22 1 5 1C3 6 SV4 PWR HARNESS 229681 WHEN AUX HYDRAULICS OPTION IS INSTALLED C14 d 2 SVDTA PWR K C33 1 C84 B 4 2 TR GND K C44 2 00 BRAKECR CI5 4 X c5 12 C19 1 5 C3 7 SV9 PWR 14 4 i SVD1B PRE C34 1 C84 C 4 3 TR VCC l C44 3 C2 C104 2 C24 1 2 C3 8 S3 PWR C91 1 4 4 PWR PORT L C4 10 CB4 D Qq 4 TRIVSI F C44 4 x ore 105 263 10 BMLOW vay pup co ikese n SINGLE JOYSTICK CONTROL SYSTEM POWER HARNESSES C104 3 4 6 BOOM ANG K C4 12 C44 l SDTAPWR CIA C152 2 t cts 1 2 c3 11 B ALRM SHANEUR 9 1156 58 11 2 PART DESCRIPTION C10 C38 1 4T TR APS le ENGINE QU SIOPWR Ci4 2 EX C5 1 lt lt 55 2 51 3 12 SIAPWR SWAY RET 3 658 12 C90 3 4 1 16N PWR Ie c44 5 vee Een dep 1 1 5 64 4 Sv7 PwR TLTRET 9 4 4 59 2 1256695 HARNESS DASHBOARD C12 2 4 2 SVD PWR K C42 1 C38 3 4 3 TR VCC ENGINE C30 1 551C4 5 SV5 PWR C12 3 uu C38 4 6 SIS RET 89 1 10 6 27 4 6 S5 PWR El 1260180 NESS SECONDARY MANIFOLD 1 24 4 524 39 1 10 1 45 C29 2 2 C4 7 56 C13 7 4 5 825 RET amp C87 1 C103 1 46 START PWRE ENGINE c CPU PWR Ci3 1E c5 6 demon C88 1 C4
113. Section 6 Schematics H Harness Map Options Auxiliary Hydraulics Beacon and 3rd Gear Lockout 32 Section 6 Schematics January 2015 l Harness Map Options Work Lights Section 6 Schematics Harness Map Options Work Lights LEFT 6 34 GTH 844 HEAD LT RIGHT HEAD LT LEFT January 2015 BRAKE MANIFOLD e 1D I 2 LT R GN 1 CAB LT 6 2 S 0 1 GAUGE CLUSTER 522 13 17 4 4 LIGHTS 522 _ s22 PWR c48 2lx c2 4 S22 RET C48 4 X amp C13 17 522 48 4 RE Part No 218230 GROUND_ STUDS m C45 1 C45 8 LUG GND BUSS CONNECTOR LUG GND2 C45 1 LUG GND 75 4 1 45 2 LT L GND C52 C 2 C45 3 TAIL GND C50 2 921C45 6 BACK GND C75 3 2 C45 7 LT R GND LUG GND2 C45 8 LUG GND er ced c50 1 x c2 2 BACK PWR C49 4 C2 5 S16 PWR C48 2 21C2 4 S22 PWR C48 4 c2 5 S22RET C75 2 C2 6 CAB LT L C75 1 x1c2 7 C5I A Xc2 9 TAILLTR 823125A C2 9 51 A TAILLT R I C49 B B S16 RET 7 C457 332 LC y C51 NOTE WORK LIGHTS OPTION WORK LIGHT OPTION HARNESSES 25 233989 HARNESS LIGHT 26 214334 HARNESS CAB LIGHT POWER 27 229677 HARNESS TAILLIGHT LED 28
114. Since coil resistance is sensitive to temperature resistance values outside specification can produce erratic operation When coil resistance decreases below specification amperage increases As resistance rises above specification voltage increases While valves may operate when coil resistance is outside specification maintaining coils within specification will help ensure proper valve function over a wide range of operating temperatures AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Note If the machine has been in operation allow the coil to cool at least 3 hours before performing this test 1 Tag and disconnect the wiring from the coil to be tested 2 Test the coil resistance using a multimeter set to resistance Q Refer to the Valve Coil Resistance Specification table W Result If the resistance is not within the adjusted specification plus or minus 10 replace the coil PartNo 218230 Genie GTH 844 MANIFOLDS Valve Coil Resistance Specification Note The following coil resistance specifications are at an ambient temperature of 68 F 20 C As valve coil resistance is sensitive to changes in air temperature the coil resistance will typically increase or decrease by 4 for each 18 F 20 C that your air temperature increases or decreases from 68 F 20 C Descripti
115. able 1 Start the engine 2 Raise the boom to 60 Confirm with a digital level 3 Working at the pivot end of the boom locate the boom angle proximity switch Loosen the fasteners securing the proximity switch assembly to the chassis just enough to allow the bracket to move 4 Move the proximity switch assembly until the light of the proximity switch turns on then move the proximity switch assembly until the light of the proximity switch just turns off 5 Securely tighten the fasteners Do not over tighten 6 Lower the machine to 55 Result The light of the proximity switch assembly is illuminated 7 Raise the boom to 60 Confirm with a digital level Result The light of the proximity switch assembly is not illuminated The proximity switch is properly calibrated Result The light of the proximity switch assembly is illuminated The proximity switch is not calibrated correctly Repeat this procedure beginning with step 4 Genie BOOM COMPONENTS 1 2 Boom How to Replace the Boom Wear Pads 1 Lower wear pads Using a lifting strap from an overhead crane or a fork lift of sufficient capacity lift the boom tube just enough to remove the weight from the pads 2 Remove the wear pad retainer plates and remove the wear pads from the boom 3 Lubricate the wear surface of the new pads Refer to Maintenance Procedure A 4 Lubricate the Boom Note Do not lubricate the side wear pads
116. ad Result The measurement is within are no longer visible Replace both wear pads specification Refer to the Repair Procedure How to Replace W 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 Genie TEREX COMPANY 3 16 GTH 844 Part No 218230 2014 Section 3 Scheduled Maintenance Procedures B 10 Inspect the Fork Level and Auxiliary Hydraulic Hoses Tension Note Genie specifications require that this procedure be performed every 250 hours of operation 1 Fully retract the boom Fully lower the tips of the lifting forks 3 Remove the cover from the fork end of the boom 4 Inspect the fork level and or auxiliary hydraulic hoses for proper tension Each hose should have the same amount of droop and should not rest on the boom tube 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 A TEREX GTH 844 CHECKLIST PROCEDURES B 11 Perform Axle Maintenance Note Axle specifications requires that this procedure be performed every 300 hours of operation Oil leve
117. ations are subject to change without notice GTH 844 Part No 218230 2014 Section 2 Specifications Perkins 1104D E44TA Engine Displacement Number of cylinders Bore and stroke Horsepower Peak Torque 269 cu in 4 4 liters 4 4 13 x 5 inches 105 x 127 mm 99 2200 rpm 73 8 KW 2200 rpm 310 Ib ft 1400 rpm 420 Nm 1400 rpm Firing order 1 3 4 2 Compression ratio 16 2 1 Combustion E TVCS Governor Electronic Low idle 1000 rpm Frequency 200 Hz High idle 2500 rpm Frequency 500 Hz Lubrication system Oil pressure hot 2300 rpm 43 58 psi 2 96 4 bar Minimum pressure 7 1 psi Oil capacity 10 quarts including filter 9 6 liters Cil viscosity requirements Units ship with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operation and Maintenance Manual on your machine Part No 218230 Genie SPECIFICATIONS Fuel requirement For fuel requirements refer to the engine Operation Manual on your machine Fuel injection pressure 23700 psi 1635 bar Engine coolant Capacity 4 6 gallons 17 4 liters Type Extended Life Alternator Output 85 A 14V DC Starter Motor Normal load 68 A Relay max 50A Relay continuous 20A Cranking speed 130 200 rpm Glow Plugs Initial load 0 4 sec 20 A EA Continuous load 24 sec 15 A EA Ba
118. ault Codes May 2015 SoS eee SSS ENGINE FAULT CODES MODELS WITH DEUTZ POWER SPN Suspect Parameter Number ASPN Alternate Suspect Parameter Number FMI Failure Mode Identifier SPN ASPN FMI Description 23006 64254 3 Controller mode switch short circuit to battery 4 Controller mode switch short circuit to ground 1 Manipulation control was triggered 2 Timeout error in Manipulation control 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 Injector cylinder bank 2 short circuit 23354 64602 12 Injector powerstage output defect 23450 64698 Multiple Stage Switch constant speed plausibility error Multiple Stage Switch constant speed short circuit to battery Multiple Stage Switch constant speed short circuit to ground Multiple Stage Switch engine speed control parameter plausibility error Multiple Stage Switch engine speed control parameter short circuit to battery 23008 64256 23009 64257 A 23451 64699 N N gt Multiple Stage Switch engine speed control parameter
119. ay 2014 Section 3 Scheduled Maintenance Procedures Checklist D Procedures D 1 D 2 Inspect the Forks Note Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first OR whenever permanent deformation of the forks is suspected Maintaining the lifting forks in good condition is essential to safe operation and good machine performance Failure to detect damage to the forks could result in a hazardous operating condition 1 Thoroughly clean the lifting forks 2 Inspect the forks for the following Surface cracks Straightness of the blade and shank Fork angle at 90 3 degrees Relative height of fork tips shall not differ more than 3 of blade length Excessive wear to the forks fork mount or legible markings Result If any of the above criteria are not met the fork shall be removed from service until it is repaired or replaced shank blade Part No 218230 A TEREX GTH 844 Adjust the Boom Sequencing Chains Note Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first 1 Raise the boom to the horizontal position 2 Extend the boom fully then retract the boom approximately 1 inch 25 mm 3 Oneither side of the middle boom section estimate the center Place one end of a tape measure on the top surface of the boom directly above the estimated center
120. ctor test change 854 Engine Alternator inspect Alternator and Fan Belts replace Diesel Particulate Filter clean Radiator Pressure Cap clean replace Required maintenance procedures and additional engine information is available in the Perkins 1104 Operation and Maintenance Manual Perkins part number SEBU7833 01 OR the Perkins 854 Operation and Maintenance Manual Perkins part number SEBU8726 01 Perkins 1104 Operation and Maintenance Manual Genie part number 117765 Perkins 854 Operation and Maintenance Manual Perkins 1104 Operation and Maintenance Manual Genie part number 218708 Genie part number 117765 Perkins 854 Operation and Maintenance Manual Genie part number 218708 PartNo 218230 GTH 844 3 27 Section 3 Scheduled Maintenance Procedures May 2014 CHECKLIST E PROCEDURES E 4 Perform Engine Maintenance Deutz Models Note Engine specifications require that this procedure be performed every 3000 hours V rib belt and tensioning pulley replace Required maintenance procedures and additional engine information is available in the Deutz TCD3 6 Operation Manual Deutz part number 0312 3907 Deutz TCD3 6 Operation Manual E 5 Perform Engine Maintenance Perkins Models Note Engine specifications require that this procedure be performed every 4000 hours 854 Engine Aftercooler Core Clean Test Required maintenance procedures and additional engine information is avai
121. d Hydraulic Symbols Legends 6 7 Harness Map Control System Power_SJ seesssseesereeseirerrrrerrrserrssrrnses 6 10 before SN GTH0815 20662 Harness Control System _5 6 11 before SN GTH0815 20662 Harness Control System Ground_SJ 6 14 from SN GTH0815 20662 Harness Map Control System 57 6 15 from SN GTH0815 20662 Harness Map Control System Power DJ 6 18 before SN GTH0815 20662 Harness Map Control System Power_DJ esesesseeseeseserserrrrerrrrserrresrreens 6 19 before SN GTH0815 20662 Harness Map Control System Ground DJ sse 6 22 from SN GTH0815 20662 Harness Control System Ground_DJ 6 23 from SN GTH0815 20662 TEREX COMPANY PartNo 218230 GTH 844 XV September 2015 Section 6 Schematics continued Harness Map Deutz TCD3 6 Engine Battery Power amp Ground 6 26 Harness Map Perkins 1104D Engine Battery Power 8 Ground 6 27 Harness Map Perkins 854E Engine Battery Power amp Ground 6 30 Harness Map Options Aux Hydraulics Beacon amp 3rd Gear 6 31 Harness Map Options Work Lights
122. ducts isa Genie policy Product specifications are subject to change without notice GTH 844 Section 2 Specifications May 2014 saa Eg 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 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 Ibs k 9525 kg Fork tilt up 6 to 8 seconds Lift capacity maximum 8000 Ibs Fork tilt down 5 to 7 seconds 3629 kg Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie 2 2 GTH 844 Part No 218230 2014 Section 2 Specifications Hydraulic Specifications Hydraulic Fluid Specifications Genie specifications require hydraulic oils which are designed to give maximum protection to hydraulic systems have the ability to perform over a wide temperature range and the viscosity index should exceed 140 They should provide excellent antiwear oxidation corrosion inhibition seal conditioning and foam and aeration suppression properties Cleanliness level minimum 15 13 Water content maximum 250 ppm Recommended Hydraulic Fluid Hydraulic oil type Chevron Rando HD Premium MV Viscosity grade 32 Visc
123. e Scheduled maintenance inspections shall be completed daily quarterly semi annually annually and every 2 years as specified on the Maintenance Inspection Report The frequency and extent of periodical examinations and tests may also depend on national regulations AWARNING Failure to perform each procedure as presented and scheduled could result in death serious injury or substantial damage Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Use only Genie approved replacement parts Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection Unless otherwise specified perform each maintenance procedure with the machine in the following configuration Machine parked on a firm level surface Boomin the stowed position Key switch in the off position with the key removed Wheels chocked Part No 218230 TEREX GTH 844 3 1 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 Read each procedure thoroughly This manual and the decals on the machine use signal words to identify the following Symbols Legend A Safety alert symbol used to alert personnel to potentia
124. e chains Examples of dynamic shock loading are High velocity movement of load followed by sudden abrupt stops Carrying loads in suspension over irregular surfaces and rough terrain Attempting to inch loads which are beyond the rated capacity of the vehicle Part No 218230 TEREX CON GTH 844 CHECKLIST PROCEDURES The load cycles and environmental conditions make it impossible to predict chain life It is therefore necessary to conduct regular inspections 1 Park the machine on a firm level surface level the boom and engage the parking brake 2 Fully extend the boom 3 Inspect the chains for the following conditions Elongation BL666 chain Measure 16 pitches of the extend chain for machines using BL666 chain Note For identification this chain typically measures 3 4 inch between pin centers when new Note Both the extend and retract chains should be measured Note Measurement should be taken in the area where the chain articulates most frequently over the sheaves Result The distance measures 12 36 inches 313mm or less The chain is within specifications Continue with inspection Result If the distance is greater than 12 36 inches 313mm the machine shall be removed from service until the chain is replaced Note The boom chain s normal life expectancy can be expressed as a maximum percent of elongation of 396 Section 3 Scheduled Maintenance P
125. e pilot operated 100 psi 6 9 bar PCT 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 38 L MIN 2 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 Boom down circuit 12 14 ft Ibs 16 19 Nm 14 Check valve 5 psi 0 3 bar CV2 Boom extend circuit 12 14 ft Ibs 16 19 Nm Genie 4 34 GTH 844 Part No 218230 2014 Section 4 Repair Procedures MANIFOLDS PE1 O PE2 2 Genie Part No 218230 GTH 844 4 35 Section 4 Repair Procedures May 2014 MANIFOLDS Primary Function Manif
126. eather cap onto the hydraulic tank Part No 218230 A TEREX CON GTH 844 CHECKLIST PROCEDURES B 8 Perform Engine Maintenance Deutz Models Note Engine specifications require that this procedure be performed every 250 hours Engine oil and filter change Engines with exhaustafter treatment system Deutz II LA approved oil API CJ 4 low ash approved oil Deutz DQCIII LA approved oilin extreme conditions Engines withoutexhaustafter treatment system Deutz II LA approved oil API CJ 4 low ash approved oil Deutz III approved oil in extreme conditions Deutz DQC Ill LAapprovedoilin extreme conditions Required maintenance procedures and additional engine information is available in the Deutz TCD3 6 Operation Manual Deutz part number 0312 3907 Deutz TCD3 6 Operation Manual Genie part number 218707 Section 3 Scheduled Maintenance Procedures May 2014 CHECKLIST B PROCEDURES B 9 Check the Boom Wear Pads Note Genie specifications require that this 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 end of the wear pad 4 Measure each side wear pad lj Result The grooves on the ofthe wearp
127. ect Required maintenance procedures and additional engine information is available in the Perkins 1104 Operation and Maintenance Manual Perkins part number SEBU7833 01 OR the Perkins 854 Operation and Maintenance Manual Perkins part number SEBU8726 01 Perkins 1104 Operation and Maintenance Manual Genie part number 117765 Perkins 854 Operation and Maintenance Manual Genie part number 218708 TEREX GTH 844 D 7 Perform Axle Maintenance Note Axle specifications require that this procedure be performed every 1500 hours of operation Change axle oil Clean magnetic oil plugs Required maintenance procedures and additional axle information is available in the Carraro 26 27M Axle Maintenance and Repair Manual Carraro part number CA270077 Carraro 26 27M Axle Maintenance and Repair Instructions Genie part number 218710 Part No 218230 2014 Section 3 Scheduled Maintenance Procedures D 8 Perform Engine Maintenance Perkins Models Note Engine specifications require that this procedure be performed every 1500 hours 854 Engines Engine crankcase breather element replace Required maintenance procedures and additional engine information is available in the Perkins 1104 Operation and Maintenance Manual Perkins partnumber SEBU7833 01 OR the Perkins 854 Operation and Maintenance Manual Perkins partnumber SEBU8726 01 Perkins 1104 Operation and Maintenance
128. egible 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 A TEREX CON GTH 844 3 5 3 Open the operator s manual to the decals inspection section Carefully and thoroughly inspect all decals on the machine for legibility and damage Result The machine is equipped with all required decals and all decals are legible and in good condition W Result The machine is not equipped with all required decals or one or more decals are illegible or in poor condition Remove the machine from service until the decals are replaced 4 Always return the manuals to the storage container after use Note Contact your authorized Genie distributor or Genie if replacement manuals or decals are needed Section 3 Scheduled Maintenance Procedures May 2014 CHECKLIST A PROCEDURES A 2 Perform Pre operation Inspection Note Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Completing a Pre operation Inspection is essential to safe machine operation The Pre operation Inspection is a visual inspection performed by the operator prior to each work shift The inspectio
129. elect 2 3 ft lbs 3 4 Nm Genie 4 38 GTH 844 Part No 218230 2014 Section 4 Repair Procedures MANIFOLDS TR Pp SVD1 1 gt 5 69 i View B CV9 7 CV8 2 23 9 55 Genie Part No 218230 GTH 844 4 39 Section 4 Repair Procedures May 2014 MANIFOLDS 7 4 Auxiliary Manifold option and Brake Manifold Components The auxiliary manifold is located under the transmission inspection cover Index Schematic No Description Item Function Torque 1 Check valve 5 psi 0 3 2 Auxiliary A1 circuit 12 14 ft lbs 16 19 Nm 2 DOS valve position 4 way SVD1 Auxiliary function enable 60 in Ibs 6 8 Nm 3 Flow regulator valve 1 Function speed control 25 ft lbs 34 Nm 4 Check valve 5 psi 0 3 bar 1 Auxiliary A2 circuit 12 14 ft Ibs 16 19 Nm 5 Pressure switch 450 psi 31 bar S6 Clutch cut off pressure 11 ft Ibs 14 9 Nm 6 Pressure switch 50 psi 3 4 bar S16 Brake light pressure option
130. ematic View 1 January 2015 Section 6 Schematics Electrical Schematic View 1 g ORIBKC39 1_ 192 C392 c37 3 BR da de 52375 S24 TRANS OIL PRESS SW N C TR 523 BLIWH CISA TIS 0862 26 11 BR S23 BRAKE PRESS SW N C SM BL C86 1 86 2 C372 BR FUEL SENDER RDIWH 87 1 AX 4 S25 TRANS OIL TEMP SW N O TR 525 5 MINES e z 3 a Pi 8 2 3 0 5 sz 52 55 8 GS g amp 6 5 a 5 gt 5 0 9 8222388 i 98 9 S sS a 5 5 p AS As AN 28 o g S 5 BR C152 4 5 3 S NISL N 7 N m e x g M y s ZU 5 e a 5
131. erential 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 Genie 5 6 GTH 844 PartNo 218230 2015 Section 5 Fault Codes ENGINE FAULT CODES MODELS WITH DEUTZ POWER SPN Suspect Parameter Number ASPN Alternate Suspect Parameter Number FMI Failure Mode Identifier SPN ASPN FMI Description 4360 Urea catalyst upstream temperature out of the target range to high Urea catalyst upstream temperature out of the target range to low 4361 Target range to high for urea catalyst exhaust gas temperature sensor upstream Target range to low for urea catalyst exhaust gas temperature sensor upstream
132. 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 Part No 218230 2014 Section 4 Repair Procedures 11 Tag and disconnect the ground wire of the steer column 12 Support and secure the steer orbitral to the dash frame 13 Remove the fasteners securing the steer column and steer orbitral to the dash frame 14 Lower the steer orbitral and remove the steer column from the machine How to Remove the Steering Wheel 1 Open the access door above the hydraulic tank 2 Disconnect the battery from the machine AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 3 Remove the horn button from the steering wheel Remove the nut securing the steering wheel to the column and remove the steering wheel How to Remove the Steer Orbitral 1 Remove the steering column See 2 2 How to Remove the Steering Column 2 Working under the dashboard locate the hydraulic hose at port L of the steering orbitral LS LO OR TO PartNo 218230 Genie GTH 844 OPERATOR S COMPARTMENT 3 Follow the hydraulic hose from port L of the steer orbitral to its connection at the front axle of the machine Tag disconnect and plug the hydraulic hose at the front axle Cap
133. ge into test port TR at the top of the secondary function manifold See 7 3 Secondary Function Manifold Components 6 Startthe engine Allow the engine to idle Result The pressure gauge reads 50 psi 3 4 bar The pressure setting is correct Proceed to step 11 W Result The pressure gauge fails to read 50 psi 3 4 bar The pressure setting needs to be adjusted Proceed to step 7 7 Turnthe machine off Hold the rear lockup pressure reducing relief valve with a wrench and remove the cap schematic item PR2 8 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Component damage hazard Do not adjust the relief valve pressures higher than specifications 9 Install the relief valve cap 10 Repeat this procedure beginning with step 6 11 Turn the machine off Remove the pressure gauge from the test port AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Part No 218230 2014 Section 4 Repair Procedures 7 6 Valve Coils How to Test a Coil A properly functioning coil provides an electromagnetic force which operates the solenoid valve Critical to normal operation is continuity within the coil Zero resistance or infinite resistance indicates the coil has failed
134. hly There should be a light film of lubricant on wear pad contact surfaces Result Boom operates smoothly and a thin film of lubricant is visible Proceed to step 5 W Result Boom does not extend or retract smoothly and no lubricant is visible on wear pad contact surfaces Proceed to step 2 2 Applyathin layer of grease to the underside of the number 3 boom tube where it makes contact with the number 2 boom tube lower wear pads PartNo 218230 2014 Section 3 Scheduled Maintenance Procedures 3 Apply a thin layer of grease to the underside of the number 2 boom tube where it makes contact with the number 1 boom tube lower wear pads 4 Lubricate the top and side boom tube wear pads 5 Return the boom to the stowed position Grease specification EP NLGI 2 lithium based or equivalent Lube A Boom grease 7 Ib pail recommended Genie part number 110147 Chevron Ultra Duty EP 2 grease alternate Part No 218230 A TEREX CON GTH 844 CHECKLIST A PROCEDURES A 5 Perform Engine Maintenance All Models Note Engine specifications require that this procedure be performed every 8 hours or daily whichever comes first Engine oil level check Coolant level check add Fuel system filter water separator drain Engine tightness check or leaks Exhaust system check for leaks Required maintenance procedures and additional engine information is available in the Perkin
135. id spills with baking soda and water Subtract 0 004 from the reading of each cell for every 10 5 5 C below 80 F 26 7 C Result All battery cells display an adjusted specific gravity of 1 277 or higher The battery is fully charged Proceed to step 12 Note Perform this test after fully charging the batteries Note For a more accurate determination of the x battery condition fully charge the batteries and allow the batteries to rest 24 hours before performing this procedure to allow the battery cells to equalize Result One or more battery cells display a specific gravity of 1 217 or below Proceed to step 9 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 TEREX COMPANY 3 10 GTH 844 Part No 218230 2014 Section 3 Scheduled Maintenance Procedures 9 Perform an equalizing charge OR fully charge the battery s and allow the battery s to rest at least 6 hours 10 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results Check the ambient air temperature and adjust the specific gravity reading for each cell as follows e Add 0 004 to the reading of each cell for every 10 5 5 C above 80
136. inning 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 Genie Part No 218230 GTH 844 4 15 Section 4 Repair Procedures May 2014 Operator s Compartment 2 1 Operator s Compartment How to Remove the Operator s Compartment The operator s compartment is used to activate machine functions while sitting in the operator s drivers seat Within the operator s compartment there is a transmission column shifter steering selector 4 way controller accelerator pedal brake pedal and a differential lock switch All of these components arereplaceable For further information or assistance consult the Genie Service Department AWARNING P 4dily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is required 1 Open the access door above the hydraulic tank 2 Disconnect the battery from the machine AWARNING Electrocution hazard Contact with
137. int 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 DV2 DV2 N OJO 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 Genie Part No 218230 GTH 844 5 11 Section 5 Fault Codes May 2015 ENGINE FAULT CODES MODELS WITH DEUTZ POWER SPN Suspect Parameter Number ASPN Alternate Suspect Parameter Number FMI Failure Mode Identifier SPN ASPN FMI Description 23914 65162 3 Glow plug cont
138. ion 6 Schematics Harness Map Options Auxiliary Hydraulics Beacon and 3rd Gear Lockout AUX HYD S14 56 1 1 55 1 A PWR c57 122 c55 4 B PWR lt lt 3 12 655 2_ lt DASHBOARD GROUND STUDS HARNESS Ameo al en er Se IIIS LUG GND yo 22 Z24444 44 GN tn i O 00 dll 0 m m m a C OL OL ON C C C C 9 AA BEAC PWR C7 1F lt C C64 1 BEAC GND C7 2 C64 2 k F E 8p ci24 8 2 6 2 7 2 SW PWR C 1 2 2 2 3 2 5 SVAPWR SVD PWR SVE PWR C w START O C START C SVB PWR C 823125A 1 gt MI m AUX HYD MANIFOLD AUX APWR C56 1 AUX A GND C56 2 AUX B PWR C57 1 AUX B GND C57 2 LU FLASHING BEACON zal 25 NOTE Asal AUXILIARY HYDRAULICS 127 BEACON amp 3RD LOCKOUT OPTIONS T 5 AUX HYDRAULICS S14 POWER CONNECTED TO PRIMARY MANIFORLD HARNESS 1260182 OR 1260183 3 12 WHEN AUX HYDRAULICS OPTION INSTALLED GEAR LOCKOUT HARNESS CONNECTED TO DASHBOARD HARNESS 1256695 WHEN 3RD GEAR LOCKOUT OPTION INSTALLED AUXILIARY BEACON amp 3RD GEAR LOCKOUT HARNESSES 22 229681 ARNESS AUXILIARY HYDRAULICS 23 229683 HARNESS BEACON LIGHT 24 229682 HARNESS POWER BEACON LIGHT 40 162281 HARNESS 3RD GEAR LOCKOUT Part No 218230 Genie GTH 844 6 31 January 2015
139. iring order minimum value exceeded 23933 65181 0 Fuel Balance Control integrator injector 5 in firing order maximum value exceeded 1 Fuel Balance Control integrator injector 5 in firing order minimum value exceeded 23934 65182 0 Fuel Balance Control integrator injector 6 in firing order maximum value exceeded 1 Fuel Balance Control integrator injector 6 in firing order minimum value exceeded 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 amp 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 amp Sensorcalibration for NOX Sensor SCR system upstream cat DPF system downstream cat 23940 65188 9 Timeout Error POK2PCK for CAN Receive Frame AT1IGCVol1 information factors amp Sensorcalibration for NOX Sensor SCR system upstream cat DPF system downstream cat Genie 5 14 GTH 844 Part No 218230 2015 Section 5 Fault Codes T ENGINE FAULT CODES MODELS WITH DEUTZ POWER SPN Suspect Parameter Number ASPN Alternate Suspect Parameter Number FMI Failure Mode Identifier SPN ASPN FMI Description 23941 65189 9 Timeout Error BAM to packet for CAN Receive
140. iston pump 241 bar Displacement 0 to 3 1 cuin 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 Continuous improvement of our products is a Genie policy Product specifications are subjectto change without notice Genio 2 6 GTH 844 Part No 218230 2014 Section 2 Specifications m Tr SPECIFICATIONS Manifold Component Specifications Plugtorque SAE No 2 50 in lbs 6 Nm SAE No 4 13 ft Ibs 18 Nm SAE No 6 18 ft Ibs 24 Nm SAE No 8 50 ft lbs 68 Nm SAE No 10 55 ft lbs 75 Nm SAE No 12 75 ft Ibs 102 Nm Air Conditioner Refrigerant Specifications System Full Charge R134a 1 lb 14 oz Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie Part No 218230 GTH 844 2 7 Section 2 Specifications May 2014 SPECIFICATIONS Deutz TCD3 6 L4 Engine Displacement Number
141. ith a damaged or leaking exhaust System can cause component damage and unsafe operating conditions AWARNING injury hazard Do not inspect while the engine is running Remove the key to secure from operation Bodily injury hazard Beware of ACAUTION hot engine components Contact with hot engine components may cause severe burns 1 Open the engine access cover Be sure that all fasteners are tight Inspect all welds for cracks Inspect for exhaust leaks i e carbon buildup around seams and joints 5 Close the engine access cover Part No 218230 2014 Section 3 Scheduled Maintenance Procedures B 4 Inspect the Engine Air Filter Note Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Perform this procedure more often if dusty conditions exist Maintaining the engine air filter in good condition is essential to good engine performance and service life Failure to perform this procedure can lead to poor engine performance and component damage Note Perform this procedure with the engine off 1 Release the latches on the front cover of the air cleaner assembly Remove the cover 2 Gently twist and pull out the external or primary filter element 3 Remove the inner or secondary filter element 4 Clean the inside of the canister and the gasket with a damp cloth 5 Inspect the primary and secondary air filter elements
142. ith a machine before it is put into service A damaged or modified machine must never be used If damage or any variation from factory delivered condition is discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications Scheduled maintenance inspections shall be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual Genie A TEREX BRAND Genie UK The Maltings Wharf Road 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 Terex South Dakota Inc USA 500 Oak Wood Road PO Box 1150 Instructions Use the operator s manual on your machine The Pre delivery Preparation consists of completing the Pre operation Inspection the Maintenance items and the Function Tests Use this form to record the results Place a check in the appropriate box after each part is completed Follow the instructions in the operator s manual If any inspection receives an N remove the machine from service repair and reinspect it After repair place a check in the R box Legend Y yes completed no unable to complete repaired Comments Pre Delivery P
143. jector 8 in firing order interruption of electric connection 24004 65252 Too many recognized misfires in cylinder 7 in firing order 24005 65253 12 Too many recognized misfires in cylinder 8 in firing order 24001 65249 Nia 24011 65259 0 Zerofuel calibration injector 7 in firing order maximum value exceeded 1 Zerofuel calibration injector 7 in firing order minimum value exceeded 24012 65260 0 Zerofuel calibration injector 8 in firing order maximum value exceeded 1 Zerofuel calibration injector 8 in firing order minimum value exceeded 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 regene
144. l check add Oil breather clean Required maintenance procedures and additional axle information is available in the Carraro 26 27M Axle Maintenance and Repair Manual Carraro part number CA270077 Carraro 26 27M Axle Maintenance and Repair Instructions Genie part number 218710 Section 3 Scheduled Maintenance Procedures May 2014 Checklist C Procedures C 1 Perform Engine Maintenance Perkins Models Note Engine specifications require that this procedure be performed every 500 hours 1104 Engine V belts inspect adjust replace 854 Engine Engine oil and filter change API CJ 4 low ash approved oil Fuel system primary filter water separator element replace Fuel system secondary filter replace Fan clearance check Required maintenance procedures and additional engine information is available in the Perkins 1104 Operation and Maintenance Manual Perkins partnumber SEBU7833 01 OR the Perkins 854 Operation and Maintenance Manual Perkins partnumber SEBU8726 01 Perkins 1104 Operation and Maintenance Manual Genie part number 117765 Perkins 854 Operation and Maintenance Manual C 2 Perform Engine Maintenance Perkins Models Note Engine specifications require that this procedure be performed every 500 hours or annually 1104 Engine Engine oil and filter change API CH 4 or API CI 4 approved oil Fuel system primary filter water separator element replace F
145. l need to be adjusted for proper balancing 25 Working at the fork end of the boom remove the wear pads from boom tube number 1 26 Support and slide boom tube number 2 out of boom tube number 1 Place boom tube number 2 on a structure capable of supporting it AWARNING Crushing hazard Boom tube 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 Genie GTH 844 1 3 Boom Lift Cylinder How to Remove the Lift Cylinder Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Attach a lifting strap from an overhead 10 ton 10 000 kg crane to the fork end of the boom Support the boom Do not apply any lifting pressure 2 Tag disconnect and plug the hydraulic hoses at the lift cylinder manifold Cap the fittings AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Component damage hazard Hoses can be damaged if they are kinked or pinched 3 Attach a lifting strap from an overhead crane to the
146. l personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous ACAUTION situation which if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performing a series of steps Section 3 Scheduled Maintenance Procedures May 2014 Maintenance Symbols Legend Note The following symbols have been used in this manual to help communicate the intent of the instructions When one or more of the symbols appear at the beginning of a maintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Indicates that a cold engine will be required to perform this procedure Indicates that a warm engine will be required to perform this procedure Indicates that dealer service will be required to perform this procedure 5 4 A TEREX CON 3 2 GTH 844
147. lable in the Perkins 1104 Operation and Maintenance Manual Perkins partnumber SEBU7833 01 OR the Perkins 854 Operation and Maintenance Manual Genie part number 218707 Perkins part number SEBU8726 01 Perkins 1104 Operation and Maintenance Manual Genie part number 117765 Perkins 854 Operation and Maintenance Manual Genie part number 218708 Genie TEREX GTH 844 Part No 218230 2014 Section 3 Scheduled Maintenance Procedures E 6 Perform Engine Maintenance Deutz Models Note Engine specifications require that this procedure be performed every 5000 hours General engine overhaul Required maintenance procedures and additional engine information is available in the Deutz TCD3 6 Operation Manual Deutz part number 0312 3907 Deutz TCD3 6 Operation Manual CHECKLIST E PROCEDURES E 7 Perform Engine Maintenance Perkins Models Note Engine specifications require that this procedure be performed every 12 000 hours or every three years whichever comes first 1104 and 854 Engines Cooling System Coolant Extended life coolant change Required maintenance procedures and additional engine information is available in the Perkins 1104 Operation and Maintenance Manual Perkins partnumber SEBU7833 01 Genie part number 218707 OR the Perkins 854 Operation and Maintenance Manual Perkins part number SEBU8726 01 Perkins 1104 Operation and Maintenance
148. lt in death or serious injury and significant component damage Dealer service is strongly recommended Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications Note Perform this procedure with the engine off and cool 1 Open the engine cover 2 Disconnect the battery from the machine AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 4 Tagand 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 PartNo 218230 Genie GTH 844 HYDRAULIC PUMP 5 Tag disconnect and plug the large hydraulic pump supply hose at the pump Cap the fitting on the pump Note Placing the open end of the pump supply hose below the fluid level in the hydraulic tank will result in excessive hydraulic fluid leaking from the hose Do not lower the open end of the pump supply hose to below the fluid level of the hydraulic tank until the hose is plugged
149. machine AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Remove the fasteners securing the transmission control lever to the column Carefully separate the lever from the column Reach under the dashboard and gently push the dash cluster through the opening in the dashboard Tag and disconnect the wire harness from the dash cluster Remove the dash cluster from the machine GTH 844 Section 4 Repair Procedures May 2014 Fuel and Hydraulic Tank 3 1 Fuel and Hydraulic Tank How to Remove the Fuel and Hydraulic Tank Assembly Explosion and fire hazard Engine fuels are combustible Remove the fuel tank in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Explosion and fire hazard Never drain or store fuel in an open container due to the possibility of fire Explosion and fire hazard When transferring fuel connect a grounding wire between the machine and pump or container 1 Open the access door to the engine 2 Disconnect the battery from the machine AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry HYDRAULICTANK 3 Remove the access cover to the hydraulic tank 4 Remove the
150. 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 Genie GTH 844 How to Prime the Function Pump Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Install all hoses onto the hydraulic pump Torque to specification Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 2 Locate the case drain filler plug at the side of the function pump 3 Remove the plug and slowly fill the case drain port of the pump with hydraulic fluid until the oil level is even with the bottom of the hole Install the plug and torque to 40 ft lbs 54 Nm 4 Start the engine allow the engine to run at low idle for 15 seconds then shut off the engine Wait 15 seconds then start the engine again Allow the engine to run at low idle for 15 seconds and then shut off the engine 5 Check for hydraulic leaks and clean up any oil that may have spilled Part No 218230 2014 Section 4 Repair Procedures How to Adjust the Function Pump Standby Pressure 1 Connect a 0 to 1000 psi 0 to 100 bar pressure gauge to test port TP on the primary function manifold See 7 1 or 7 2 Primary Function Manifold Components 2 Startthe
151. n and securely attach the rope to the new chain Genie 4 6 GTH 844 15 Working at the fork end of the boom use the rope to carefully pull the chain through the boom just until the end of the chain is accessible 16 Working at the pivot end of the boom and using the fasteners removed in step 5 install the chain anchor onto the boom tube Securely tighten the fasteners Do not over tighten 17 Remove the rope from the chain and install the chain into the chain anchor of the tensioner assembly Secure the chain to the chain anchor using the pin and clip removed in step 6 18 Repeat this procedure beginning with step 5 for the other chains 19 Install the inspection cover removed in step 9 onto the boom Install and securely tighten the fasteners Do not over tighten 20 Install the chain tensioners into the tensioner mount at the fork end of boom tube number 1 Install the mounting components removed in step 6 Evenly tighten the chain tensioners to the top of the boom tube until they are securely tightened 21 Adjust the chains Refer to Maintenance Procedure D 2 Adjust the Boom Sequencing Chains Component damage hazard Chains can be damaged if the boom is used while the chains are out of adjustment Do not return the machine to use until the chains have been correctly adjusted Part No 218230 2014 Section 4 Repair Procedures How to Remove the Boom 1 AWARNING Bodily injury hazard This
152. n is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests The Pre operation Inspection also serves to determine if routine maintenance procedures are required Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine A 3 Perform Function Tests Note Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first 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 TEREX GTH 844 A 4 Lubricate the Boom Note Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Greasing the specified locations is essential for good machine performance and service life Operating the machine with little or no grease may cause the machine to perform poorly and continued use may cause component damage 1 Fully extend and raise the boom then retract the boom checking to insure it operates smoot
153. n trained and qualified on the repair of this machine Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine 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 Schematics About This Section There are two groups of schematics in this section An illustration legend precedes each group of drawings Electrical Schematics AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Hydraulic Schematics AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray General Repair Process equipment are available and ready for use Malfunction Identify Jw Troubleshoot discovered symptoms problem still exists Return to Perform service problem repair solved Genie Part No 218230 GTH 844 6 1 Section 6 Schematics 2015 Fuse Panel Layout before serial number 20630
154. nly be performed by a trained service professional in a suitably equipped workshop Select the appropriate repair procedure after troubleshooting the problem Perform disassembly procedures to the point where repairs can be completed To re assemble perform the disassembly steps in reverse order Symbols Legend Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates an imminently hazardous ADANGER situation which if not avoided will result in death or serious injury AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous ACAUTION situation which if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performing a series of steps Section 4 Repair Procedures May 2014 Boom Components 1 1 Boom Proximity Switch The boom angle switch is a proximity switch This switch functions by sensing a change in the electromagnetic field of the switch due to the introduction of metal into the field A proximity Switch is simply a metal detector The
155. nt to the chassis AWARNING C shing hazard The operator s compartment will fall if not properly supported when the fasteners are removed from the machine 21 Slowly move the operator s compartment away from the chassis while feeding all loose hoses cables and wires through the opening of the chassis Component damage hazard Hoses cables and wires can be damaged if they are kinked or pinched Bolt torque specification 750 ft lbs 1017 Nm Operator s cab mounting bolts Genie GTH 844 2 2 Machine Controls How to Remove the Steering Column 1 Open the access door above the hydraulic tank 2 Disconnect the battery from the machine AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 3 Remove the fasteners securing the transmission control lever to the column Carefully separate the lever from the column 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 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
156. o 218230 GTH 844 ix September 2015 TABLE OF CONTENTS Section 3 Scheduled Maintenance Procedures continued Checklist A Procedures 1 Inspect the Manuals and Decals 3 5 2 Perform Pre operation Inspection 3 6 Perform Function Tests 3 6 4 Lubricate the Boom 3 6 5 Perform Engine Maintenance All 3 7 6 Perform Transmission Maintenance 3 8 7 Perform 30 Day Service 3 8 8 Perform Axle Maintenance u 3 9 9 Perform Transmission Maintenancoe a 3 9 A 10 Perform Axle Maintenance 3 9 Checklist B Procedures 1 Inspect the Battery ss 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 2 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 ssseeseeeseeeesieeseeeeriresrinrsrirrsrrrnesrense 3 16 B 10 Inspect the Fork Level and Auxiliary HOSES 3 17 B 11 Perform Axle Maintenance
157. odels with dual joystick 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 fitting Note Removing the hydraulic hose from the tee fitting with the tee fitting 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 tee fitting if the tee fitting is below the hydraulic oil level in the hydraulic tank 17 Working inside the chassis tag and disconnect the wire harnesses at the connectors next to the operator s compartment 18 Support and secure the operator s compartment to an adjustable table capable of supporting the weight and that will allow the operator s compartment to remain in an upright and stable position Component damage hazard Wrapping a strap around the cab and lifting using an overhead crane can put excessive pressure on the glass windows of the cab causing the windows to break Do not lift the cab using a strap from an overhead crane if the strap contacts the windows Note Placing a wedge between the operator s compartment and the adjustable table may be required to keep the operator s compartment stable 19 Remove the lower fasteners securing the operator s compartment to the chassis Section 4 Repair Procedures May 2014 OPERATOR S COMPARTMENT 20 Remove the upper fasteners securing the operator s compartme
158. of cylinders Bore amp stroke Horsepower Peak Torque Firing order 221 cu in 3 62 liters 4 3 86 x 4 72 inches 98 x 120 mm 99 2300 rpm 73 8 kw Q 2300 rpm 288 Ib ft 1600 rpm 390 Nm 1600 rpm 1 3 4 2 Compression ratio 17 2 1 Combustion Direct injection Governor Electronic Lowidle 1000 rpm Frequency 200 Hz Highidle 2400 rpm Frequency 500 Hz Lubrication system Minimum oil pressure 23 5 psi warm at low idle 1 6 bar Oil capacity 9 5 quarts including filter 9 liters Oil viscosity requirements Units ship with 15W 40 API CJ4 low ash oil Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator s Manual on your machine Genie Fuel requirement For fuel requirements refer to the engine Operator s Manual on your machine Fuel injection pressure maximum 23200 psi 1600 bar Enginecoolant Capacity 4 5 gallons 17 liters Type Extended Life Alternator Output 95 A 12V DC Starter Motor Normal load 300 400 A Relay max 60A Relay continuous 12A Cranking speed gt 100 rpm Glow Plugs Initial load 0 6 sec 80 amps Continuous load gt 6 sec lt 40 amps Battery Type 12V DC Group C31 Quantity 1 Cold cranking ampere 09 1000A Reserve capacity 25A rate 200 minutes Continuous improvement of our products isa Genie policy Product specific
159. oint of metering unit in overrun mode not plausible Metering unit Fuel System short circuit to battery Metering unit Fuel System short circuit to ground Metering unit Fuel System open load Metering unit Fuel System powerstage over temperature Physical range check high for exhaust gas temperature upstrem SCR CAT A 23613 64861 23615 64863 NIN Qi A OJIN 23619 64867 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 mainrelay primary side short circuit to ground SCR mainrelay short circuit to ground only CV56B 5 SCR mainrelay primary side open load SCR mainrelay open load only CV56B 12 SCR mainrelay powerstage over temperature only CV56B Genie Part No 218230 GTH 844 5 9 Section 5 Fault Codes May 2015 p ENGINE FAULT CODES MODELS WITH DEUTZ POWER SPN Suspect Parameter Number ASPN Alternate Suspect Parameter Number FMI Failure Mode Identifier SPN ASPN FMI Description 2
160. old Components Models with Dual Joysticks continued 15 Check valve 5 psi 0 3 Tilt down circuit 12 14 ft Ibs 16 19 Nm 16 Check valve 5 psi 0 3 bar CVA Boom up circuit 12 14 ft Ibs 16 19 Nm 17 Check valve 5 psi 0 3 bar CV5 Tilt up circuit 12 14 ft Ibs 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 Fork up down circuit 12 14 ft lbs 16 19 Nm 20 Directional valve proportional 4 Sway function select 33 37 ft lbs 45 50 Nm Genie 4 36 GTH 844 Part No 218230 2014 Section 4 Repair Procedures MANIFOLDS PE1 O PE2 2 Genie Part No 218230 GTH 844 4 37 Section 4 Repair Procedures May 2014 E MANIFOLDS 7 3 Secondary Function Manifold Components The secondary function manifold is located under the manifold inspection cover Index Schematic No Description Item Function Torque 1 valve position 4 way SVD1 Steer left right
161. on 2 Specifications Bodily injury hazard Beware of hot ACAUTION oil Contact with hot oil may cause severe burns 4 Remove the drain plug from the rear of the tank 5 Rinse out the inside of the tank using a mild solvent 6 Install the drain plug and securely tighten Do not over tighten 7 Fillthe tank with hydraulic oil until the fluid level is in the center of the sight glass at the rear of the tank 8 Clean up any oil that may have spilled Part No 218230 2014 Section 3 Scheduled Maintenance Procedures E 2 Perform Engine Maintenance Perkins Models Note Engine specifications require that this procedure be performed every 2000 hours 1104 Engine Aftercooler core inspect Alternator inspect Engine mounts inspect Starting Motor inspect Turbocharger inspect Water pump inspect 854 Engine Aftercooler core inspect Engine mounts inspect Starting motor inspect Turbocharger inspect Required maintenance procedures and additional engine information is available in the Perkins 1104 Operation and Maintenance Manual Perkins part number SEBU7833 01 OR the Perkins 854 Operation and Maintenance Manual Perkins part number SEBU8726 01 CHECKLIST E PROCEDURES E 3 Perform Engine Maintenance Perkins Models Note Engine specifications require that this procedure be performed every 3000 hours 1104 Engine Alternator Belt Inspect Adjust Replace Fuel Inje
162. on Specification valve 3 position 4 way 5 60 12V DC with diode schematic items SVD1 Solenoid valve 2 position 2 way 8 80 12V DC with diode schematic items SV9 Solenoid valve 2 position 3 way 8 80 12V DC with diode schematic items SV5 SV7 SV6 Solenoid valve 2 position 4 way 8 80 12V DC with diode schematic items SV1 SV2 SV3 SV4 Section 4 Repair Procedures May 2014 MANIFOLDS How to Test a Coil Diode Genie incorporates spike suppressing diodes in all of its coils Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil Faulty diodes can fail to protect the electrical system resulting in a tripped circuit breaker or component damage AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Testthe coil for resistance See 7 8 How to Test a Coil 2 Connecta 100 resistor to the negative terminal of a known good 9V DC battery Connect the other end of the resistor to a terminal on the coil Note The battery should read 9V DC or more when measured across the terminals Resistor 10Q Genie part number 27287 Seta multimeter to read DC amperage Note The multimeter when set to read DC amperage should be capable
163. osity index 200 Optional fluids Biodegradable Petro Canada Environ MV 46 Fire resistant UCON Hydrolube HP 5046 Shell Tellus S2 V 32 Shell Tellus S2 V 46 Chevron Hydraulic Oil 5606A Mineral based Note Genie specifications require additional equipment and special installation instructions for the approved optional fluids Consult the Genie Service Department before use 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 SPECIFICATIONS Do not top off with incompatible hydraulic fluids Hydraulic fluids may be imcompatible due to the differences in base additive chemistry When incompatible fluids are mixed insoluble materials may form and deposit in the hydraulic system plugging hydraulic lines filters control valves and may result in component damage Note Do not operate the machine when the ambient air temperature is consistently above 120 49 Hydraulic Fluid Temperature Range 40 22 4 14 32 50 68 86 104 122 40 30 20 10 0 10 20 30 40 50 Chevron hydraulic oil 5606A Petro Canada Environ MV 46 UCON Hydrolube HP 5046D Chevron Rando HD Premium MV
164. ot pin to the fork frame mount 3 Use a soft metal drift to remove the pivot 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 AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 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 Genie 4 12 GTH 844 Part No 218230 2014 Section 4 Repair Procedures BOOM COMPONENTS 1 6 How to Replace the Fork Level Hydraulic Hoses Cylinder and or Auxiliary Hoses Note When removing a hose assembly or fitting 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 installation Refer to Section 2 Hydraulic Hose and 1 Fully retract the boom Fitting Torque Specifications 2 Fully lower the tips of the lifting forks 1 Fully retract the boom 3 EM the cover from the fork end of the 2 Fully lower the tips of the lifting forks oom 3 Remove the cover from the fork end of the 4 Loo
165. other fork level cylinder Identify the hydraulic hoses from the lift cylinder Tag disconnect and plug the hoses at the lift cylinder manifold Cap the fittings on the cylinder manifold Remove the fasteners securing the lift cylinder barrel end pivot pin to the chassis Support and secure the barrel end of the lift cylinder to the boom Section 4 Repair Procedures May 2014 BOOM COMPONENTS 11 Use a soft metal drift to remove the lift cylinder pivot pin 12 Tag disconnect and plug the hydraulic hoses at the hydraulic hard line connections at the pivot end of the boom Cap the fittings 13 Using the overhead crane raise the boom to a horizontal position Crushing hazard The lift cylinder AWARNING will fall if not properly supported when the boom is raised 14 Remove the fasteners securing the boom pivot pin to the chassis 15 Using a suitable tool remove the boom pivot pin Note This may require a hydraulic power unit Crushing hazard The boom will fall if not properly supported when the pivot pin is removed from the machine 16 Carefully remove the boom assembly from the machine and place it on a structure capable of supporting it Crushing hazard The boom could become unbalanced and fall if not properly supported when removed from the machine Component damage hazard The weight of the boom assembly may crush the hydraulic hard lines under the boom Use caution when placing the boom
166. oting the orientation and assembly order of the components remove the fasteners and pull the tensioners free of the boom Refer to Illustration 1 Section 4 Repair Procedures May 2014 BOOM COMPONENTS 6 Selecta chain tensioner Remove the bow tie clip securing the chain anchor pin to the chain assembly Remove the chain anchor pin from the assembly and remove the chain anchor from the tensioner assembly 7 Repeatthis procedure beginning with step 6 for the other chains 8 Working at the fork end of the boom select a chain Securely connect a 30 foot 10 m length of rope to the end of the chain Securely tie off the other end of the rope to the boom structure 9 Remove the inspection cover from the pivot end of the boom and locate the chain anchors of the extension chains at the top of boom tube 3 10 Remove the fasteners securing the extension chain anchors to the boom tubes 11 Working at the pivot end of the boom pull the chain out of the boom Note Rope coming loose from the chain during removal may result in a difficult reassembly Be sure the rope is securely attached to the chain and boom structure before pulling the chain out of the boom 12 On a workbench remove the bow tie clip securing the chain anchor pin to the chain assembly Remove the pin and chain anchor pin from the assembly 13 Install the chain anchor pin and clip onto the new chain 14 Remove the rope from the end of the old chai
167. perature shut off regeneration OJR ON 23918 65166 Physical range check low for DV1 amp DV2 upstream temperature shut off regeneration 2 Sensor DV1 amp DV2 upstream temperature plausibility error Sensor error DV1 amp DV2 upstream temperature signal range check high 4 Sensor error DV1 amp DV2 upstream temperature signal range check low Genie 5 12 GTH 844 Part No 218230 2015 Section 5 Fault Codes ENGINE FAULT CODES MODELS WITH DEUTZ POWER SPN Suspect Parameter Number ASPN Alternate Suspect Parameter Number Failure Mode Identifier SPN ASPN FMI Description 23919 65167 0 Physical range check high for airpump pressure shut off regeneration Physical range check low for airpump pressure shut off regeneration Sensor airpump pressure plausibility error Sensor error airpump pressure signal range check high Sensor error airpump pressure signal range check low Physical range check high for exhaustgas back pressure burner shut off regeneration O N 23920 65168 Physical range check low for exhaustgas back pressure burner shut off regeneration Sensor exhaustgas back pressure plausibility error Sensor error exhaustgas back pressure burner signal range check high Sensor error exhaustgas back pressure burner signal range check low Physical range check high for burner temperature Physical range check low for burner temperature Sensor
168. r other fluids Use an approved container Please be environmentally safe Be sure that your workshop or work area is properly ventilated and well lit Genie Vili GTH 844 Part No 218230 September 2015 Table of Contents Introduction Important Information S L uqha eene nnne nnn ii Serial Number Legend sis iii Section 1 Safety Rules General Safety Rules iii Section 2 Specifications Machine Specifications a 2 1 Performance Specifications 0 2420 11 1 2 2 Hydraulic Specifications 2 3 Hydraulic Component Specifications 2 4 Manifold Component Specifications 2 2 5 Air Conditoner Refrigerant Specification 2 5 Deutz TCD3 6 Engine 2 6 Perkins 1104D E44TA Engine essen 2 7 Perkins 854 Engine 2 8 Dana VDT12000 Transmission 2 9 Carraro 26 27M Drive Axle iii 2 9 Hydraulic Hose and Fitting Torque Specifications 2 10 SAE and Metric Fasteners Torque Charts 2 11 Section 3 Scheduled Maintenance Procedures INTTOAUCTION PR 3 1 Pre delivery Preparation Report 3 3 Maintenance Inspection Report a 3 5 Genie Part N
169. r minimum value exceeded EGR cooler downstream temperature out of range system reaction initiated Exhaust gas temperature EGR downstream out of range system reaction initiated 23950 65198 23951 65199 oj Oo Oj OF Oj 23960 65208 1 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 Genie Part No 218230 GTH 844 5 15 Section 5 Fault Codes May 2015 ENGINE FAULT CODES MODELS WITH DEUTZ POWER SPN Suspect Parameter Number ASPN Alternate Suspect Parameter Number FMI Failure Mode Identifier SPN ASPN FMI Description 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 Urea tank without heating function heating phase 23982 65230 Powerstage diagnosis disabled high battery voltage Powerstage diagnosis disabled low battery voltage Charging lamp short circuit to battery Charging lamp short circuit to ground Charging lamp open load Charging lamp over temperature Fuel Balance Control integrator
170. ration not succesful 24028 65276 CAN message PROEGRActr plausibility error 24029 65277 2 Timeout Error of CAN Receive Frame ComEGRActr exhaust gas recirculation positioner Genie Part No 218230 GTH 844 5 17 Section 5 Fault Codes May 2015 SoS eee SSS ENGINE FAULT CODES MODELS WITH DEUTZ POWER SPN Suspect Parameter Number ASPN Alternate Suspect Parameter Number FMI Failure Mode Identifier SPN ASPN FMI Description 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 9 Timeout error of CAN Receive Frame ComMS Sys1TO error memory Slave Master Slave internal CAN message 24039 65287 9 Timeout error of CAN Receive Frame ComMS Sys2TO error memory Slave Master Slave internal CAN message 24040 65288 9 Timeout error of CAN Receive Frame ComMS Sys3TO error memory Slave Master Slave internal CAN message 2
171. reparation 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 Section 3 Scheduled Maintenance Procedures May 2014 Maintenance Inspection Report Model Serial number Date Hour meter Machine owner Inspected by print Inspector signature Inspector title Inspector company Instructions Make copies of this report to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily or 8 hour Inspection A Quarterly or 250 hour Inspection Semi annually or 500 hour Inspection A B C Annually or 1000 hour Inspection A B C D 2 Year or 2000 hour Inspection A B C D E Place a check in the appropriate box after each inspection procedure is completed Use the step by step procedures this section to learn how to perform these inspections If any inspection receives an N tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable no remove from service R repaired Checklist 8 hours Y NR A 8 hours R A 1 Manuals and decals 2 Pre operation inspect A 3 Function tests A 4 Lubricate boom A 5 Engine maintenance All models A 6 Transmis
172. rocedures May 2014 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 TEREX COMPANY 3 20 GTH 844 Part No 218230 M
173. rol 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 dosing valve DV1 overcurrent at the end of the injection phase 3 HCI dosing valve DV1 short circuit to battery 4 dosing DV1 short circuit to ground 7 HCI dosing valve DV1 blocked 11 HCI dosing valve DV1 short circuit high side powerstage 12 dosing DV1 powerstage over temperature 23916 65164 0 Physical range check high for dosing valve DV1 downstream pressure shut off regeneration 1 Physical range check low for dosing DV1 downstream pressure shut off regeneration 2 Sensor dosing valve DV1 downstream pressure plausibility error 3 Sensor error dosing valve DV1 downstream pressure signal range check high 2 ye WH 4 Sensor error dosing valve DV1 downstream pressure signal range check low 23917 65165 0 Physical range check high for DV1 amp DV2 upstream pressure shut off regeneration Physical range check low for DV1 amp DV2 upstream pressure shut off regeneration Sensor DV1 amp DV2 upstream pressure plausibility error Sensor error DV1 amp DV2 upstream pressure signal range check high Sensor error DV1 amp DV2 upstream pressure signal range check low Physical range check high for DV1 DV2 upstream tem
174. rraro 26 27M Axle Maintenance and Repair Instructions Genie part number 218710 Section 3 Scheduled Maintenance Procedures May 2014 Checklist B Procedures B 1 3 sure that the battery cable connections are t t fr f A preventative sealant will help eliminate corrosion on the battery terminals and cables Note Genie requires that this procedure be 4 Besure that the battery retainers and cable performed every 250 hours or quarterly whichever connections are tight comes first 5 Besure that the battery separator wire Proper battery condition is essential to good engine connections are tight performance and operational safety Improper fluid levels or damaged cables and connections can 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 hydrometer Note the results 6 Fully charge the battery s and allow the battery s to rest at least 6 hours AWARNING Electrocution burn hazard Contact with hot or live circuits could result in death or serious injury Remove 8 Checkthe 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 AWARNING contain acid Avoid spilling or every 10 5 5 C above 80 F 26 7 contacting battery acid Neutralize battery ac
175. s 1100D Operation and Maintenance Manual Perkins part number SEBU81 72 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 Genie part number 123702 Perkins 854 Operation and Maintenance Manual Genie part number 218708 Deutz TCD3 6 Operation Manual Genie part number 218707 Section 3 Scheduled Maintenance Procedures May 2014 CHECKLIST A PROCEDURES A 6 Perform Transmission Maintenance Note Transmission specifications require that this procedure be performed every 8 hours or daily whichever comes first Transmission oil level check add Drop box oil level check add check oil with engine running at idle and oil at 180 200 F 65 93 Required maintenance procedures and additional transmission information is available in the Dana VDT12000 Service Manual Dana partnumber TSM 0022 Dana VDT12000 Service Manual Genie part number 218706 TEREX GTH 844 A 7 Perform 30 Day Service The 30 day maintenance procedure is a one time sequence of procedures to be performed after the first 30 days or 40 hours of usage After this interval refer to the maintenance checklists for continued scheduled maintenance 1 Perform the following maintenance procedures 5 Inspect the Tires Wheels and Lug Nut Torque D 3 Replace
176. s Map Control System Power Dual Joystick before SN GTH0815 20662 C44 ENGINE HARNESS RIGHT ENGINE TRANSMISSION ape C41 1 SVA FORWARD P JP ED C40 1 SVB REVERSE 644 4 5 TRIVSI C42 1 FM GEAR C44 555 IGN PWR 2557 SVE GEAR C44 625 START PWR 1 OIL PRESS S24 C44 7 SCAN L 2 C87 1 OIL TEMP S25 SECONDARY MANIFOLD BOOM ANG S3 5 ENR ead C4 5 5 30 1 SV5 P BRAKE RELEASE Qu 4 4 C31 1 SV7 REAR AXLE FLOAT 28 255 32 1 SV6 DIFF LOCK 011 3 C34 1 SVD1B CRAB STEER C11 235 C33 1 SVDIA 4WS FUEL TANK 011 1 C36 2 S23 BRAKE PRESSURE FUEL SENDER C4 6 gt 27 S5 PARKING BRAKE PWR HORN 29 27 S5 PARKING BRAKE RET PRIMARY MANIFOLD FUELRET C86 1 X C10 9 7 SV9 SWAY ENABLE C19 1 R C3 7 Ee RORN PWR Caa IE ES S7 SWAY ENBL PWR 74 S7 SWAY ENBL RET 74 lt CC9 3 4 C18 4 b 2 e 3 11 1 _ ALARM BRAKE M
177. s Map Control System Power Dual Joystick from SN GTH0815 20662 Section 6 Schematics January 2015 Harness Map Control System Power Dual Joystick from SN GTH0815 20662 RIGHT HORN PWR C88 1 C4 8 LEFT CONNECTORS DETAILS C38 A q 1 TRAPS k c44 1 TR VCC C11 c13 8 43 S23 c36 C14 4 lt 3 SVD1B PWR C34 1 co1 1 d 4 PWR PORT E C4 10 C104 3 46 BOOM ANG K C4 12 9 C10 _ c90 3 F1 IGN PWR K C44 5 C12 2 4 2 SVD PWR K C42 1 C12 3 X 5 SVE PWR C43 1 C13 24 4 4 S24 RET K C39 1 135 7 4 5 525 87 1 C89 1 4 6 S15 RET K C1 5 C38 C38 B 4 2 TR GND amp C44 2 C44 3 C84 C84 C84 4 0 4 4 1 51 44 4 C44 C38 1 41 TR APS l ENGINE 2 2 TR GND ENGINE 3 43 TR VCC ENGINE 4 44 TR IVS1 E ENGINE C38 ENGINE C13 16 4 7 INDIC PWRK C1 5 C95 c13 22 41 FUELRET c86 1 C103 eee C1 4 Q2 TELM PWR KC114 1 C106 C13 2 4 cAN H ecit4 7 C44 8 C13 3 E C44 7 B CAN LT 0114 8 C10 11 ENGINE 10 1 45 103 1 46 5 7 CAN L 10 10 48 15 11 6 C104 4 4 2 ro IGN PWR Kc108 1 RC um 2 431 S3 RET l C4 1 C5 10 472 BM LOW K C4 1 c114 3 _ C108 _ C104 1fi IGN PWR K C44 8 42 TELM GND C13 3 43 cni amp PW
178. sen the hose clamp securing the fork level boom cylinder or auxiliary hoses 4 Attach a lifting strap from an overhead crane to the top of the lifting fork frame Support the frame Do not apply any lifting pressure 5 Pull each hose until it is equally tensioned and not touching the boom tube 6 Tighten the clamp bolt to secure the hoses in place hose clamp 1 front cover 2 hose clamp bolt Genie Part No 218230 GTH 844 4 13 Section 4 Repair Procedures May 2014 BOOM COMPONENTS 5 Disconnect and plug the fork level cylinder supply hoses at the cylinder manifold or the auxiliary supply hoses at the quick connect fittings Cap the fittings AWARNING injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Component damage hazard Hoses can be damaged if they are kinked or pinched 6 Working near the center of the boom assembly tag disconnect and plug the hydraulic hoses from the hydraulic hard lines under boom tube number number 1 Cap the hard lines 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
179. setting needs to be adjusted Proceed to step 7 7 Turnthe machine off Hold the brake pressure reducing relief valve with a wrench and remove the cap schematic item PR4 8 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure CAUTION Component damage hazard Do not adjust the relief valve pressures higher than specifications 9 Install the relief valve cap 10 Repeat this procedure beginning with step 6 11 Turn the machine off Remove the pressure gauge from the test port AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Part No 218230 2014 Section 4 Repair Procedures How to Set the Differential Lock Joystick System Pressure Note Be sure that the hydraulic oil level is visible in the inspection glass of the hydraulic tank 1 Install a 0 to 1000 psi to 100 bar pressure gauge into test port TP at the top of the primary function manifold See 7 1 or 7 2 Primary Function Manifold Components 2 Startthe engine Allow the engine to idle after warming the engine to operating temperature 3 Without operating any machine controls observe the reading on the pressure gauge Result The pressure gauge reads 450 x25 psi 31 1 7 bar The pump is functioning correctl
180. short circuit to ground 23452 64700 Multiple Stage Switch engine torque limitation curve plausibility error Multiple Stage Switch engine torque limitation curve short circuit to battery Multiple Stage Switch engine torque limitation curve short circuit to ground Pressure Relief Valve PRV forced to open Maximum rail pressure in limp home mode exceeded PRV 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 23470 64718 NARON Genie 5 8 GTH 844 Part No 218230 2015 Section 5 Fault Codes T ENGINE FAULT CODES MODELS WITH DEUTZ POWER SPN Suspect Parameter Number ASPN Alternate Suspect Parameter Number FMI Failure Mode Identifier SPN ASPN FMI Description 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 Softwarereset CPU Rail pressure disrupted Minimum rail pressure exceeded RailMeUn3 Setp
181. 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 Genie GTH 844 5 21 Section 5 Fault Codes May 2015 eee Sl EE ENGINE FAULT CODES MODELS WITH PERKINS POWER SPN Suspect Parameter Number FMI Failure Mode Identifier 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
182. sion maintenance Perform after 40 hours 0 after 40 hours A 7 30 day service Perform after 50 hours A 8 Axle maintenance Perform after 100 hours A 9 Transmission Perform after 150 hours A 10 Axle maintenance Checklist 250 hours YNR B 1 Battery B 2 Electrical wiring B 3 Exhaust system B 4 Engine air filter B 5 Tires and wheels B 6 Hydraulic oil B 7 Tank venting systems B 8 Engine maintenance Deutz models B 9 Boom wear pads B 10 Inspect hose tension Perform every 300 hours procedures may also include a time interval B 11 Axle maintenance Comments Checklist C 500 hours Y NR C 1 Engine maintenance Perkins models C 2 Engine maintenance Perkins models C 3 Inspect and lubricate sequencing chains Checklist D 1000 hours Y N R D 1 Forks D 2 Sequencing chains D 3 Hydraulic return filter D 4 Transmission D 5 Engine maintenance Deutz models D 6 Engine maintenance Perkins models Perform every 1500 hours D 7 Axle maintenance D 8 Engine maintenance Perkins models Checklist E 2000 hours Y N R E 1 Hydraulic oil E 2 Engine maintenance Perkins models Perform every 3000 hours E 3 Engine maintenance Perkins models E 4 Engine maintenance Deutz models Perform every 4000 hours E
183. ssure gauge from the test port AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Section 4 Repair Procedures May 2014 MANIFOLDS How to Set the Rear Lock up System Pressure Note Be sure that the hydraulic oil level is visible in the inspection glass of the hydraulic tank 1 Install a O to 1000 psi O to 100 bar pressure gauge into test port TP at the top of the primary function manifold See 7 1 or 7 2 Primary Function Manifold Components 2 Startthe engine Allow the engine to idle after warming the engine to operating temperature 3 Without operating any machine controls observe the reading on the pressure gauge O Result The pressure gauge reads 450 25 psi 31 1 7 bar The pump is functioning correctly Result The pressure gauge fails to read 450 25 psi 31 1 7 bar The pressure setting needs to be adjusted See Repair Procedure 6 1 How to Adjust the Function Pump Pressure 4 Turn the machine off Remove the pressure gauge from the test port AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Genie GTH 844 5 Install a to 500 psi 0 to 50 bar pressure gau
184. sure Note Be sure that the hydraulic oil level is visible in the inspection glass of the hydraulic tank 1 Install a O to 1000 psi O to 100 bar pressure gauge into test port TP at the top of the primary function manifold See 7 1 or 7 2 Primary Function Manifold Components 2 Startthe engine Allow the engine to idle after warming the engine to operating temperature 3 Without operating any machine controls observe the reading on the pressure gauge O Result The pressure gauge reads 450 25 psi 31 1 7 bar The pump is functioning correctly Result The pressure gauge fails to read 450 x25 psi 31 1 7 bar The pressure setting needs to be adjusted See Repair Procedure 6 1 How to Adjust the Function Pump Pressure 4 Turn the machine off Remove the pressure gauge from the test port AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Genie GTH 844 5 Install a to 1000 psi to 100 bar pressure gauge into test port TPB at the top of the secondary function manifold See 7 3 Secondary Function Manifold Components 6 Startthe engine Allow the engine to idle Result The pressure gauge reads 350 psi 24 1 The pressure setting is correct Proceed to step 11 W Result The pressure gauge fails to read 350 psi 24 1 The pressure
185. switch generates an electromagnetic field at the face of the switch This field senses when steel has been moved close to the switch as well as when the steel has been moved away which is how the switch contacts open and close These switches are of a fail safe design Should the switch or the switch wire circuit be faulty the machine will not function outside its designed range of use The boom proximity switch is a component of the drive circuit and the chassis sway circuit Both the drive and the chassis sway functions are disabled when the boom is raised to 60 or higher Genie 4 2 GTH 844 How to Test a Proximity Switch 1 Remove the switch from the machine Do not disconnect the switch wire harness from the machine 2 Start the engine 3 Move the switch away from any ferrous or metallic object Result The light of the limit switch assembly is not illuminated 4 Move the switch close to any ferrous or metallic object Result The light of the proximity switch assembly turns on The switch is functioning correctly a boom angle proximity switch located on engine side Part No 218230 2014 Section 4 Repair Procedures How to Adjust the Boom Angle Proximity Switch The boom angle proximity switch is attached to a mounting bracket located between the boom and the chassis directly beneath the boom pivot pin The switch location is adjust
186. t is required when ambient termperatures are consistently below 0 F 18 C unless oil heating system is used Continued use of Chevron 5606A hydraulic fluid or equivalent when ambienttemperatures are consistently above 32 F 0 may result in component damage Part No 218230 2014 Section 2 Specifications N 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 Flash Point 482 F 250 C Pour Point 49 F 45 C Maximum continuous operating 180 F 82 C 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 Pour Point 81 F 63 C Maximum continuous operating 189 F 87 C temperature Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie Part No 218230 GTH 844 2 5 Section 2 Specifications May 2014 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 p
187. t panel Remove the joystick Part No 218230 2014 Section 4 Repair Procedures How to Remove the Brake Pedal Assembly 1 Open the access door above the hydraulic tank 2 Disconnect the battery from the machine AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 3 Fully press and release the brake pedal a minimum of 10 times to release the hydraulic pressure in the brake system 4 Tag disconnect and plug the hydraulic hoses at ports BP and BT of the secondary hydraulic manifold Cap the fittings AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 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 PartNo 218230 Genie OPERATOR S COMPARTMENT How to Remove the Gauge Cluster Assembly 1 Open the engine cover 2 Disconnect the battery from the
188. tarter 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 Genie Part No 218230 GTH 844 5 5 Section 5 Fault Codes May 2015 ENGINE FAULT CODES MODELS WITH DEUTZ POWER SPN Suspect Parameter Number ASPN Alternate Suspect Parameter Number FMI Failure Mode Identifier SPN ASPN FMI Description 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 1231 14 CAN Bus 1 BusOff Status 1235 14 CAN Bus 2 BusOff Status 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 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 AT11G1Vol AT101 AT10G1Vol 3234 9 Timeout Error of CAN Receive Frame AT11G1Vol AT101 AT10G1Vol 11 Nox sensor value downstream not plausible stuck in range 3241 1 Target range to low for SCR catalyst upstream temperature sensor 3251 0 Diff
189. techpub terex com Genio li GTH 844 Serial Number Information Genie offers the following Service Manuals for these models Title Part No GTH 844A from serial number 8418 to 16605 97487 GTH 844B from serial number 6946 to 16605 97487 Copyright O 2012 by Terex Industries 218230 Rev B May 2014 Second Edition Second Printing Genie is a registered trademark of Terex South Dakota Inc in the USA and many other countries GTH is a trademark of Terex South Dakota Inc 6 Printed on recycled paper Printed in U S A Part No 218230 September 2015 Revision History Revision Date Section Procedure Schematic Page Description ___ nem 05 14 Schematics Telematics connector legend electrical schematic hydraulic schematic single and dual joysticks Harness Maps 09 14 FaultCodes Display Gauge Deutz Fault Codes 01 15 electrical schematic harness maps options 05 15 Codes Deutz Fault Codes Fuse Panel O I IOO O 09 15 Kubota Engine Section2 Specifications Electronic Version 6 3 7 Section 3 Maintenance Procedure 3 2 6 4 9 1 Section4 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 Section6 Schematic Page Genie Part No 218230 GTH 844 September 2015 REVISIONHISTORY C
190. the fitting 4 Tag disconnect and plug the hydraulic hoses at ports SUP SUR and SUT of the secondary function manifold Cap the fitting AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 5 Tag disconnect and plug the hydraulic hose at port SULS of the primary function manifold Cap the fitting 6 Slowly move the steer orbitral away from the dash frame while feeding all loose hoses through the opening of the chassis How to Remove the Joystick Models with Single Joystick 1 Open the access door above the hydraulic tank 2 Disconnect the battery from the machine AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 3 Remove the fasteners securing the joystick mount panel to the side console Section 4 Repair Procedures May 2014 OPERATOR S COMPARTMENT 4 Tagand disconnect the joystick wire harness from the machine 5 Tag disconnect and plug the hoses from ports 1 2 3 4 P and T of the joystick Cap the fittings 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
191. tion 4 Repair Procedures continued 2 2 Machine Controls issus 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 Enges niena ee herd eer rt eee ee AES 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 sess 4 32 How to Retrieve Engine Fault Codes Transmission 5 1 TRANSMISSION 4 24 How to Repair the Transmission Hydraulic Pumps 64 Hydraulic POMP RDUM 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 TEREX COMPANY 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 0420400 0 4 30 7 2 Primary Function Manifold Components Models with Dual
192. ttery Type 12V DC Group C31 Quantity 1 Cold cranking ampere 0 1000A Reserve capacity 25 rate 200 minutes Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice GTH 844 2 9 Section 2 Specifications May 2014 SPECIFICATIONS Perkins 854E E34TA Engine Displacement Number of cylinders Bore and stroke Horsepower Peak Torque 207 cu in 3 4 liters 4 3 9 x 4 3 inches 99 x 110 mm 99 Q 2500 rpm 73 8 kW 2500 rpm 288 lb ft 1400 rpm 390 Nm Q 1400 rpm Firing order 1 3 4 2 Compression ratio 17 1 Governor Electronic Low idle 1000 rpm Frequency 100 Hz High idle 2700 rpm Frequency 270 Hz Lubrication system Minimum oil pressure 12 psi 0 83 bar Maximum oil capacity 8 8 quarts including filter 8 3 liters Cil viscosity requirements Units ship with 15W 40 API CJ4 low ash oil Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operation and Maintenance Manual on your machine Genie Fuel requirement For fuel requirements refer to the engine Operation Manual on your machine Fuel Injection Pressure 23000 psi 1585 bar Enginecoolant Capacity 4 9 gallons 18 5 liters Type Extended Life Alternator Output 120 A 12V DC Starter Motor Normal load 68 Relay max 50A Relay continuous 20A
193. ttle Valve 6 1 7 8 Target range to high for actuator EGR Valve 2 9 3 6 Throttle Valve 6 1 7 8 The actuator position for EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 is not plausible Open load actuator EGR Valve 2 9 3 6 or Throttle Valve 6 1 7 8 Target range to high for accelerator pedal sensor Target range to low for accelerator pedal sensor PWM signal accelerator pedal out of target range to high Plausibility check between APP1 and APP2 or APP1 and idle switch Low fuel pressure is out of target range system reaction generated Target range to high for low fuel pressure sensor Target range to low for low fuel pressure sensor Water in Fuel Sensor Short Circuit to U Batt Water level in fuel prefilter above maximum value N 91 97 G 100 High oil pressure system reaction generated Low oil pressure system reaction generated Target range to high for oil pressure sensor Target range to low for oil pressure sensor 108 Target range to high for ambient air pressure sensor Target range to low for ambient air pressure sensor 110 Coolant temperature is out of target range system reaction generated Target range to high for coolant temperature sensor Target range to low for coolant temperature sensor Genie Part 218230 GTH 844 5 9 Section 5 Fault Codes May 2015 ENGINE FAULT CODES MODELS
194. uel system secondary filter replace Hoses and clamps inspect replace Radiator clean 854 Engine Radiator clean Required maintenance procedures and additional engine information is available in the Perkins 1104 Operation and Maintenance Manual Perkins part number SEBU7833 01 OR the Perkins 854 Operation and Maintenance Manual Perkins part number SEBU8726 01 Perkins 1104 Operation and Maintenance Manual Genie part number 117765 Genie part number 218708 Perkins 854 Operation and Maintenance Manual Genie part number 218708 Genie 3 18 GTH 844 Part No 218230 March 2013 Section 3 Scheduled Maintenance Procedures C 3 Inspect and Lubricate the Sequencing Chains Genie specifications require that this procedure be performed every 500 hours or semi annually whichever comes first In extremely dusty or hostile environments it may be necessary to lubricate the chains more often Maintaining the sequencing chains in good condition is essential to safe operation and good machine performance Failure to detect damage to the chains could result in a hazardous operating condition Environments in which Genie Telehandlers operate can vary widely from outdoor moisture and temperature extremes to mildly corrosive or highly corrosive industrial atmospheres in addition to abrasive exposures such as sand and grit In addition dynamic shock loading can impose abnormal loads above the endurance limit of th
195. ulic removed connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Wheels chocked Genie Part No 218230 GTH 844 5 1 Section 5 Fault Codes May 2015 The fault code is displayed on the LCD display which is located on the gauge cluster in the operator s compartment The gauge cluster also includes two warning lights They are an amber colored light which signals an abnormal engine condition which should be corrected as soon as possible and a red colored light which signals an engine condition which requres the operator to shut down the engine as soon as possible The ECM will in some cases automatically shut down the engine when the red light is displayed Active Fault Codes Active Fault Codes will be displayed on the gauge cluster whenever a fault is detected If multiple fault codes are detected the fault codes will scroll on the display Active Codes vs Stored Codes Active fault codes indicating an engine condition or conditions which have not been corrected are displayed at the moment the fault is detected Stored fault codes are the cumulative history of fault codes which the ECM has detected These fault codes may be recalled by service personnel at a later time even if the condition which caused the engine fault has ceased to exist Note Additional hardware will be necessary to access stored codes Genie GTH 844 DIAGNOSTIC DIS
196. ure gauge fails to read 3200 50 psi 2203 4 bar The pressure setting needs to be adjusted Proceed to step 5 5 Loosen the set screw for the pressure compensator adjustment screw 6 Adjustthe pressure compensator pressure Turn the adjustment screw clockwise to increase the pressure or counterclockwise to decrease the pressure Tighten the set screw Component damage hazard Do not adjust the pressure compensator higher than specified 7 Turnthe engine off and remove the pressure Genie GTH 844 gauge AWARNING add injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Section 4 Repair Procedures May 2014 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 PET Boom extend retract 65 75 ft lbs 88 101 Nm 3 Directional valve proportional Boom up down 65 75 ft lbs 88 101 Nm 4 Solenoid valve 2 position 4 way SV3 Function select boom extend and
197. ury hazard This Crushing hazard The chassis will procedure requires specific repair 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 serious injury and significant component damage Dealer service is required 9 Remove the fasteners securing the sway 1 Chock the wheels cylinder rod end pivot pin to the chassis fall if not properly supported 8 Support and secure the axle to an appropriate lifting device 2 Remove the fasteners securing the driveshaft to 10 Usea mapu pi 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 4 Tag and remove the hydraulic hoses from the machine axle Bolt torque specification AWARNING Bodily injury hazard Spraying Axle mounting bolts 380 ft lbs hydraulic oil can penetrate and 515 Nm burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Genie Part No 218230 GTH 844 4 47 Section 4 Repair Procedures
198. y W Result The pressure gauge fails to read 450 25 psi 31 1 7 bar The pressure setting needs to be adjusted See Repair Procedure 6 1 How to Adjust the Function Pump Pressure 4 Turn the machine off Remove the pressure gauge from the test port AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray PartNo 218230 Genie GTH 844 MANIFOLDS 5 Install a 0 to 1000 psi to 100 bar pressure gauge into test port TJ at the top of the secondary function manifold See 7 3 Secondary Function Manifold Components 6 Startthe engine Allow the engine to idle O Result The pressure gauge reads 400 psi 27 5 The pressure setting is correct Proceed to step 11 W Result The pressure gauge fails to read 400 psi 27 5 bar The pressure setting needs to be adjusted Proceed to step 7 7 Turn the machine off Hold the diff lock joystick pressure reducing relief valve with a wrench and remove the cap schematic item PR1 8 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Component damage hazard Do not adjust the relief valve pressures higher than specifications 9 Install the relief valve cap 10 Repeat this procedure beginning with step 6 11 Turn the machine off Remove the pre
199. y could become unbalanced and fall if not properly supported when removed from the machine Part No 218230 2014 Section 4 Repair Procedures Engines 4 1 How to Repair the Engines Deutz TCD3 6 Engine How to Repair the Perkins 1104D E44TA Engine Repair procedures and additional engine information is available in the Perkins 1100 Operation and Maintenance 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 Perkins 1100 Operation and Maintenance Manual Genie part number 123702 Perkins 1104 Service Manual Genie part number 117764 Perkins 1100 Troubleshooting Manual Genie part number 123583 How to Repair the Perkins 854E 34TA Engine Repair procedures and additional engine information is available in the Perkins 854 Systems Operation Testing amp Adjusting Perkins part number UENRO623 or the Perkins 854 Disassembly amp Assembly Perkins part number UENRO624 Perkins 854 Operation Manual Maintenance procedures and additional engine information is available in the Deutz TCD3 6 Workshop Manual Deutz part number 0312 3965 Deutz TCD3 6 Workshop Manual Genie part number 218704 4 2 Engine Fault Codes How to Retrieve Engine Fault Codes When the engine Electronic Control Module ECM detects an abnormal operating condition a fault code
200. ze O rings They are available in the O ring field service kit Genie part number 49612 2 Lubricate the O ring before installation 3 Be sure that the face seal O ring is seated and retained properly 4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight 5 Tighten the nut or fitting to the appropriate torque per given size as shown in the table 6 Operate all machine functions and inspect the hoses and fittings and related components to confirm that there are no leaks Seal Loke 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 Ibs 54 2 Nm 10 105 ft lbs 142 4 Nm 10 63 ft Ibs 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 Ibs 190 Nm 24 315 ft lbs 427 1 Nm 24 165 ft lbs 223 7 Nm Genie GTH 844 Part No 218230 2014 Section 2 Specifications SPECIFICATIONS SAE FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual Grade 8 69 A574 High Strength Black Oxide Bolts LUBED DRY LUBED DRY LUBED in Ibs Nm Nm Nm 110 140 130 120 160 140 LUBED DRY LUB

GTH-844 from SN GTH0813-16606 (PN 218230)

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