GENIE GTH 844 Shop Manual

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

Service and Repair Manual April 2017 Introduction ii GTH-844 Part No. 1272854 Important Read, understand and obey the safety rules and operating instructions in the appropriate Operator's Manual on your machine before attempting any procedure. This manual provides troubleshooting and repair procedures for qualified service professionals. Basic mechanical, hydraulic and electrical skills are required to perform most procedures. However, several procedures require specialized skills, tools, lifting equipment and a suitable workshop. In these instances, we strongly recommend that maintenance and repair be performed at an authorized Genie 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: Internet: www.genielift.com E-mail: awp.techpub@terex.com Find a Manual for this Model Go to http://www.genielift.com/en/service-support/manua ls/index.htm Use the links to locate Service Manuals, Maintenance Manuals, Service and Repair Manuals, Parts Manuals and Operator's Manuals. Copyright © 2016 by Terex Corporation 1272854 Rev A2, April 2017 First Edition, First Printing Genie is a registered trademark of Terex South Dakota, Inc. in the U.S.A. and many other countries. "GTH" is a trademark of Terex South Dakota, Inc.

April 2017 Service and Repair Manual Introduction Part No. 1272854 GTH-844 iii Revision History Revision Date Section Procedure / Page / Description A 3/2016 Initial Release A1 9/2016 Introduction Serial Number Legend A2 4/2017 Repair Revise manifold torque values Schematics Hydraulic schematics Reference Examples: Electronic Version Click on any content or procedure in the Table of Contents to view the update. Section – Repair Procedure, 4-2 Section – Fault Codes, All charts Section – Schematics, Legends and schematics

Service and Repair Manual April 2017 Introduction iv GTH-844 Part No. 1272854 Serial Number Legend To August 31, 2016 1 Model 2 Model year 3 Facility code 4 Sequence number 1 Serial label (located inside fork frame) 2 Serial number (stamped on chassis) 3 Serial label (located inside riser, cab side) From September 1, 2016 1 Model 2 Facility code 3 Sequence number 1 Serial label (located inside fork frame) 2 Serial number (stamped on chassis) 3 Serial label (located inside riser, cab side)

April 2017 Service and Repair Manual Safety Rules Part No. 1272854 GTH-844 v Danger Failure to obey the instructions and safety rules in this manual and the appropriate Operator's Manual on your machine will result in death or serious injury. Many of the hazards identified in the operator's manual are also safety hazards when maintenance and repair procedures are performed. Do Not Perform Maintenance Unless:  You are trained and qualified to perform maintenance on this machine.  You read, understand and obey: • manufacturer's instructions and safety rules • employer's safety rules and worksite regulations • applicable governmental regulations  You have the appropriate tools, lifting equipment and a suitable workshop.

Service and Repair Manual April 2017 Safety Rules vi GTH-844 Part No. 1272854 Personal Safety Any person working on or around a machine must be aware of all known safety hazards. Personal safety and the continued safe operation of the machine should be your top priority. Read each procedure thoroughly. This manual and the decals on the machine, use signal words to identify the following: Safety alert symbol—used to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Indicates a imminently hazardous situation which, if not avoided, will result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, may cause minor or moderate injury. Indicates a potentially hazardous situation which, if not avoided, may result in property damage. Be sure to wear protective eye wear and other protective clothing if the situation warrants it. Be aware of potential crushing hazards such as moving parts, free swinging or unsecured components when lifting or placing loads. Always wear approved steel-toed shoes. Workplace 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. Be sure to keep sparks, flames and lighted tobacco away from flammable and combustible materials like battery gases and engine fuels. Always have an approved fire extinguisher within easy reach. Be sure that all tools and working areas are properly maintained and ready for use. Keep work surfaces clean and free of debris that could get into machine components and cause damage. Be sure any forklift, overhead crane or other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted. Use only chains or straps that are in good condition and of ample capacity. Be sure that fasteners intended for one time use (i.e., cotter pins and self-locking nuts) are not reused. These components may fail if they are used a second time. Be sure to properly dispose of old oil or other fluids. Use an approved container. Please be environmentally safe. Be sure that your workshop or work area is properly ventilated and well lit.

April 2017 Table of Contents Part No. 1272854 GTH-844 vii Introduction Introduction........................................................................................................... ii Important Information ............................................................................................. ii Find a Manual for this Model .................................................................................. ii Serial Number Legend .......................................................................................... iv Section 1 Safety Rules .......................................................................................................... v General Safety Rules ............................................................................................. v Section 2 Specifications ....................................................................................................... 1 Machine Specifications ........................................................................................... 1 Performance Specifications.................................................................................... 2 Hydraulic Oil Specifications .................................................................................... 3 Hydraulic Component Specifications...................................................................... 6 Manifold Component Specifications ....................................................................... 7 Air Conditioner Refrigerant Specifications ............................................................. 7 DEF Storage Specifications ................................................................................... 8 Deutz TCD3.6 L4 Engine Specifications ................................................................ 9 Deutz TCD3.6 L4 T4F Engine Specifications ....................................................... 10 Perkins 1104D-E44TA Engine Specifications ...................................................... 11 Perkins 854E-E34TA Engine Specifications ........................................................ 12 Dana VDT12000 Transmission Specifications ..................................................... 13 Carraro 26.27M Drive Axle Specifications ........................................................... 13 Hydraulic Hose and Fitting Torque Specifications ............................................... 14 Torque Procedure ................................................................................................ 15 Section 3 Repair Procedures ............................................................................................. 17 Introduction ........................................................................................................... 17 Boom Components ............................................................................................ 19 1-1 Boom Proximity Switch .................................................................................. 19 How to Test a Proximity Switch....................................................................... 19 How to Adjust the Boom Angle Proximity Switch ............................................ 20 1-2 Boom .............................................................................................................. 20 How to Replace the Boom Wear Pads ........................................................... 20 How to Remove the Lifting Fork Frame .......................................................... 21 How to Replace the Retraction Chain ............................................................. 21

April 2017 Table of Contents viii GTH-844 Part No. 1272854 How to Replace the Extension Chains ............................................................23 How to Remove the Boom ..............................................................................24 How to Disassemble the Boom .......................................................................26 1-3 Boom Lift Cylinder ..........................................................................................28 1-4 Boom Extension Cylinder ...............................................................................29 1-5 Fork Level Cylinder ........................................................................................29 1-6 Hydraulic Hoses .............................................................................................30 How to Adjust the Fork Level Cylinder and/or Auxiliary Hose.........................30 How to Replace the Fork Level Cylinder and/or Auxiliary Hoses....................31 Operator's Compartment ...................................................................................33 2-1 Operator's Compartment ................................................................................33 2-2 Machine Controls ...........................................................................................35 How to Remove the Steering Column .............................................................35 How to Remove the Steering Wheel ...............................................................35 How to Remove the Steer Orbitral ..................................................................36 How to Remove the Joystick - Models with Single Joystick............................36 How to Remove the Joystick - Models with Dual Joysticks ............................37 How to Remove the Brake Pedal Assembly ...................................................37 How to Remove the Gauge Cluster Assembly ................................................38 Fuel and Hydraulic Tanks ..................................................................................39 3-1 Fuel and Hydraulic Tanks...............................................................................39 Engines ................................................................................................................41 4-1 Engines...........................................................................................................41 How to Repair the Perkins 1104D-E44TA Engine ..........................................41 How to Repair the Perkins 854E-34TA Engine ...............................................41 How to Repair the Deutz TCD3.6 Engine .......................................................41 4-2 Engine Fault Codes ........................................................................................42 Transmission ......................................................................................................43 5-1 Transmission ..................................................................................................43 Hydraulic Pump ..................................................................................................43 6-1 Hydraulic Pump ..............................................................................................43 How to Test the Function Pump ......................................................................43 How to Remove the Function Pump ...............................................................44 How to Install the Function ..............................................................................45

April 2017 Table of Contents Part No. 1272854 GTH-844 ix How to Prime the Function Pump ................................................................... 45 How to Adjust the Function Pump Standby Pressure ..................................... 46 How to Adjust the Function Pump Pressure Compensator ............................ 47 Manifolds ............................................................................................................. 48 7-1 Primary Function Manifold Components - Models with Single Joystick ........ 48 7-2 Primary Function Manifold Components - Models with Dual Joysticks ......... 52 7-3 Secondary Function Manifold Components ................................................... 54 7-4 Auxiliary Manifold (option) and Brake Manifold Components ........................ 56 7-5 Valve Adjustments - Secondary Function Manifold ....................................... 57 How to Set the Steer System Pressure .......................................................... 57 How to Set the Parking Brake System Pressure ............................................ 58 How to Set the Differential Lock/Joystick System Pressure ........................... 59 How to Set the Rear Lock-up System Pressure ............................................. 60 7-6 Valve Coils ..................................................................................................... 61 Axle ...................................................................................................................... 63 8-1 Axles............................................................................................................... 63 Section 4 Fault Codes ......................................................................................................... 64 Introduction ........................................................................................................... 64 Diagnostic Display ............................................................................................. 65 Diagnostic Display ................................................................................................ 65 Deutz TCD3.6 Engine Fault Codes.................................................................... 66 Perkins 1104 Engine Fault Codes ..................................................................... 90 Section 5 Schematics.......................................................................................................... 92 Introduction ........................................................................................................... 92 Fuse Panel Layout (to 20629) .............................................................................. 93 Fuse Panel Layout (from 20630 to 21535) ........................................................... 94 Deutz TCD3.6 T4F Module (from 21536, 16E-10000) ......................................... 95 Electrical Component & Wire Color Abbreviation Legend ................................... 96 Telematics Connector Pin Legend ....................................................................... 99 Electrical Symbol Legend ................................................................................... 101 Hydraulic Symbols Legend................................................................................. 102 Electrical Schematics - Harness Maps........................................................... 103

April 2017 Table of Contents x GTH-844 Part No. 1272854 Harness Map - Control System Power Single Joystick (to 15-20661) ...............104 Harness Map - Control System Ground Single Joystick (to 15-20661)..............105 Harness Map - Control System Power Single Joystick (from 15-20662 to 21535) 108 Harness Map - Control System Ground Single Joystick (from 15-20662 to 21535) 109 Harness Map - Control System Power Single Joystick (from 15-21536, 16E-10000) 112 Harness Map - Control System Ground Single Joystick (from 15-21536, 16E-10000) .................................................................................................113 Harness Map - Control System Power Dual Joystick (to 15-20661) ..................116 Harness Map - Control System Ground Dual Joystick (to 15-20661) ................117 Harness Map - Control System Power Dual Joystick (from 15-20662 to 21535) 120 Harness Map - Control System Ground Dual Joystick (from 15-20662 to 21535) 121 Harness Map - Control System Power Dual Joystick (from 15-21536, 16E-10000) 124 Harness Map - Control System Ground Dual Joystick (from 15-21536, 16E-10000) 125 Harness Map - Deutz TCD3.6 T3_T4i Engine Battery Power and Ground ........128 Harness Map - Deutz TCD3.6 T4F Engine Battery Power and Ground ............129 Harness Map - Perkins 1104D Engine Battery Power and Ground ...................132 Harness Map - Perkins 854E T4i Engine Battery Power and Ground ...............133 Harness Map - Perkins 854E T4i Engine Battery Power and Ground ...............136 Harness Map - Options Auxiliary Hydraulics, Beacon and 3rd Gear Lockout ....137 Harness Map - Options Work Lights (to 15-21456) ............................................140 Harness Map - Options Work Lights (from 15-21457, 16E-10000) ....................141 Harness Map - Options Road Lights (to 15-20456) ...........................................144 Harness Map - Options Road Lights (from 15-21457, 16E-10000)....................145 Harness Map - Options Enclosed Cab with Heater ............................................148 Harness Map - Options Enclosed Cab with HVAC.............................................149 Electrical Schematics.......................................................................................151 Electrical Schematic - View 1 (to 15-20661) ......................................................152 Electrical Schematic - View 2 (to 15-20661) ......................................................153 Electrical Schematic - View 1 (from 15-20662 to 21456) ...................................156

GENIE GTH 844 Shop Manual

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