Genie GTH-844 Installation and operating 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
Intr oduct io n Intr oduct io n
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: [e-mail]
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
Section 1 Safet y Rul es
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 2Specifications.......................................................................................................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

April 2017
Table of Contents
Part No. 1272854 GTH-844 xi
Electrical Schematic - View 2 (from 15-20662 to 21456)...................................157
Electrical Schematic - View 1 (from 15-21457 to 21535)...................................160
Electrical Schematic - View 2 (from 21457 to 21535)........................................161
Electrical Schematic - View 1 (from 15-21536, 16E-10000) ..............................164
Electrical Schematic - View 2 (from 21536, 16E-10000) ...................................165
Hydraulic Schematics......................................................................................167
Hydraulic Schematic - Single Joystick (to 19528)..............................................168
Hydraulic Schematic - Single Joystick (from 19529, 16E-10000)......................169
Hydraulic Schematic - Dual Joystick (to 19528).................................................172
Hydraulic Schematic - Dual Joystick (from 19529, 16E-10000).........................173

April 2017 Service and Repair Manual
Specifications
Part No. 1272854 GTH-844 1
Section 2 Speci fic ati ons
Machine Specifications
Tires and wheels
Tire size
13.00 x
24
Tire ply rating
12
Weight, rough terrain tire
(air filled)
315 l
bs
142.9 k
g
Weight,
rough terrain tire
(foam filled)
967 ±35 l
bs
439 ±16 k
g
Tire pressure
(models with air
-filled tires) 62 p
si
4.3 b
ar
Lug nut torque
295 ft-
lbs
400 Nm
Lug Pattern
8 x
10.826
Wheel diameter
24 i
n
60.1 c
m
Wheel width
9 i
n
22.9 c
m
Fluid capacities
(to SN GTH0816-21535)
Fuel tank
35 g
allons
132.5 l
iters
Hydraulic tank
40 g
allons
151.4 l
iters
Hydraulic system
(including tank)
55 g
allons
208.2 l
iters
Fluid capacities
(from SN GTH0816-21536)
(from GTH0816E-10000)
Fuel tank
32 g
allons
121.1 l
iters
Hydraulic tank
35 g
allons
132.5 l
iters
Hydraulic system
(including tank)
50 g
allons
189.3 l
iters
DEF tank
2.6 g
allons
10 l
iters

Service and Repair Manual April 2017
Specifications
2 GTH-844 Part No. 1272854
Performance Specifications
Drive speed, maximum
Deutz TCD3.6 T3/T4F Engines
15 m
ph
24.1 k
m/h
Perkins 1104D Engine
14 m
ph
22.5 k
m/h
Perkins 854E T4i Engine
16 m
ph
25.7 m
ph
Draw bar pull
21,000 l
bs
9525 k
g
Lift capacity, maximum
8000 l
bs
3629 k
g
Boom function speeds, maximum
Boom up
12 to 14 s
econds
Boom down
9 to 11 s
econds
Boom extend
13 to 15 s
econds
Boom retract
8 to 10 s
econds
Fork rotate
3 to 6 s
econds
Fork tilt up
6 to 8 s
econds
Fork tilt down
5 to 7 s
econds

April 2017 Service and Repair Manual
Specifications
Part No. 1272854 GTH-844 3
Hydraulic Oil 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 prevention, corrosion
inhibition, seal
conditioning, and foam and aeration suppression
properties.
Cleanliness level,
minimum
ISO 15/13
Water content,
maximum
250 p
pm
Recommended Hydraulic Fluid
Hydraulic oil type
Chevron Rando HD Premium
Viscosity grade
32
Viscosity
index
200
Optional Hydraulic Fluids
Mineral based
Shell Tellus S2 V 32
Shell Tellus S2 V 46
Shell Tellus S4 VX 32 Shell
Shell Donax TG (Dexron III)
Chevron 5606A
Biodegradable
Petro Canada Environ MV
46
Fire resistant
UCON Hydrolube HP-
5046
Note: Genie specifications require additional
equipment and special installation instructions for
the approved optional fluids. Consult Genie Product
Support before use.
Optional fluids may not have the
same hydraulic lifespan and
may result in component
dama
ge.
Note: Extended machine operation can cause the
hydraulic fluid temperature to increase beyond it's
maximum allowable range. If the hydraulic fluid
temperature consistently exceeds 200°F / 90°C an
optional oil cooler may be required.
Do not top off
with incompatible
hydraulic fluids. Hydraulic fluids
may be incompatible 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°F / 49°C.
Hydraulic Fluid Temperature
Range
Ambient air temperature
1 Chevron hydraulic oil 5606A
2 Petro-Canada Environ MV 46
3 UCON Hydrolube HP-5046D
4 Chevron Rando HD premium oil MV

Service and Repair Manual April 2017
Specifications
4 GTH-844 Part No. 1272854
Chevron Rando HD Premium Oil
MV Fluid Properties
ISO Grade
32
Viscosity index
200
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
7.5
33.5
Brookfield Viscosity
cP @
-4°F / -20°C
cP @
-22°F / -30°C
1040
3310
Flash point
375°F / 190°C
Pour point
-58°F / -
50°C
Maximum continuous operating
temperature
171°F / 77°C
Note: A hydraulic oil heating system is
recommended when the ambient temperature 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.
Chevron 5606A Hydraulic Oil
Fluid Properties
ISO Grade
15
Viscosity index
300
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @
104°F / 40°C
cSt @
-40°F / -40°C
5.5
15.0
510
Flash point
180°F / 82°C
Pour point
-81°F / -
63°C
Maximum continuous operating
temperature
124°F / 51°C
Note: Use of Chevron 5606A hydraulic fluid, or
equivalent, is required when ambient temperatures
are consistently below 0°F / -17°C unless an oil
heating system is used.
Continued use of Chevron
5606A hydraulic fluid, or
equivalent, when ambient
temperatures are consistently
above 32°F / 0°C may result in
component damage

April 2017 Service and Repair Manual
Specifications
Part No. 1272854 GTH-844 5
Petro-Canada Environ MV 46
Fluid Properties
ISO Grade
46
Viscosity index
154
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
8.0
44.4
Flash point
482°F / 250°C
Pour point
-49°F / -
45°C
Maximum continuous operating
temperature
180°F / 82°C
Shell Tellus S4 VX Fluid
Properties
ISO Grade
32
Viscosity index
300
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
9
33.8
Brookfield Viscosity
cSt @
-4°F / -20°C
cSt @
-13°F / -25°C
cSt @
-40°F / -40°C
481
702.4
2624
Flash point
>100
Pour point
-76°F / -
60°C
Maximum continuous operating
temperature
103°F / 75°C
UCON Hydrolube HP-5046 Fluid
Properties
ISO Grade
46
Viscosity index
192
Kinematic Viscosity
cSt @ 149°F / 65°C
cSt @ 104°F / 40°C
cSt @ 0°F /
-18°C
22
46
1300
Flash point
None
Pour point
-81°F / -
63°C
Maximum continuous operating
temperature
189°F / 87°C

Service and Repair Manual April 2017
Specifications
6 GTH-844 Part No. 1272854
Hydraulic Component
Specifications
Function pump
Type: variable displacement piston pump
Displacement
0 to 3.1 c
u in
0 to 51 c
c
Flow rate @ 250
0 rpm 34 g
pm
128 L/min
Pump pressure, maximum
3190 p
si
220 b
ar
Pressure compensator
3190 p
si
220 b
ar
Standby pressure
450 p
si
31 b
ar
Primary Function Manifold
System relief valve pressure, maximum
(measured at test port TP)
3200 p
si
221 b
ar
Fork tilt
relief valve pressure, maximum 3500 p
si
241 b
ar
Flow regulator, Sway circuit
2 g
pm
7.5 L/min
Secondary Function Manifold
Steer relief valve pressure, maximum
(measured at test port TS)
2650 p
si
182.7 b
ar
Parking brake relief valve pressure,
maximum
(measured at test port TPB)
350 p
si
24.1 b
ar
Diff lock relief valve pressure, maximum
(measured at test port TJ)
400 p
si
27.5 b
ar
Rear lock
-up relief valve pressure,
maximum
(measured at test port TR)
50 p
si
3.4 b
ar

April 2017 Service and Repair Manual
Specifications
Part No. 1272854 GTH-844 7
Manifold Component
Specifications
Plug torque
SAE No. 2
50 in-
lbs / 6 Nm
SAE No. 4
13 ft-
lbs / 18 Nm
SAE No. 6
18 ft-
lbs / 24 Nm
SAE No. 8
50 ft-
lbs / 68 Nm
SAE No. 10
55 ft-
lbs / 75 Nm
SAE No. 12
75 ft-
lbs / 102 Nm
Air Conditioner Refrigerant
Specifications
System Full Charge
R134a
1 lb 14 o
z

Service and Repair Manual April 2017
Specifications
8 GTH-844 Part No. 1272854
DEF Storage Specifications
Diesel Exhaust Fluid decomposes when exposed
to elevated temperatures for an extended period of
time. Therefore precautions must be taken to avoid
prolonged exposure to elevated temperatures.
Temperature
Estimated Useful Life
32°F / 0°C
Indefinite
50°F / 10°C
75 y
ears
68°F / 20°C
11 y
ears
86°F / 30°C
23 m
onths
95°F / 35°C
10 m
onths
104°F / 40°C
4 m
onths
122°F / 50°C
1 m
onth
140°F / 60°C
1 w
eek