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Genie GTH-844, Service And Repair Manual

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Genie GTH-844 Service And Repair Manual Download Page 92

Service and Repair Manual

 

April 2017

 

Deutz TCD3.6 Engine Fault Codes 

 

 

80 

GTH-844

 

Part No. 1272854 

 

 

 

SPN = Suspect Parameter Number 

ASPN = Alternate Suspect Parameter Number 

FMI = Failure Mode Identifier 

SPN 

ASPN  FMI 

Description 

23911  65159  0 

Burner dosing valve (DV2); overcurrent at the end of the injection phase 

 

 

3 

Burner dosing valve (DV2); short circuit to battery 

 

 

4 

Burner dosing valve (DV2); short circuit to ground 

 

 

7 

Burner dosing valve (DV2); blocked closed 

 

 

11 

Burner dosing valve (DV2); short circuit high side powerstage 

 

 

12 

Burner dosing valve (DV2); powerstage over temperature 

23912  65160  0 

Physical range check high for burner dosing valve (DV2) downstream pressure; shut off 
regeneration 

 

 

1 

Physical range check low for burner dosing valve (DV2) downstream pressure; shut off 
regeneration. When burner injector is actuated, the measured pressure does not rise above ca. 
1250mbar abs (expected: ca. 2400mbar). 

 

 

2 

Burner dosing valve (DV2) downstream pressure sensor; plausibility error 

 

 

3 

Sensor error burner dosing valve (DV2) downstream pressure sensor; signal range check high 

 

 

4 

Sensor error burner dosing valve (DV2) downstream pressure sensor; signal range check low 

23913  65161  3 

Sensor error glow plug control diagnostic line voltage; signal range check high 

 

 

4 

Sensor error glow plug control diagnostic line voltage; signal range check low 

23914  65162  3 

Glow plug control; short circuit to battery 

 

 

4 

Glow plug control; short circuit to ground 

 

 

5 

Glow plug control; open load 

 

 

11 

Glow plug control; internal error 

 

 

12 

Glow plug control; powerstage over temperature 

23915  65163  0 

HCI dosing valve (DV1); overcurrent at the end of the injection phase 

 

 

3 

HCI dosing valve (DV1); short circuit to battery 

 

 

4 

HCI dosing valve (DV1); short circuit to ground 

 

 

7 

HCI dosing valve (DV1); blocked 

 

 

11 

HCI dosing valve (DV1); short circuit high side powerstage 

 

 

12 

HCI dosing valve (DV1); powerstage over temperature 

23916  65164  0 

Physical range check high for HCI dosing valve (DV1) downstream pressure; shut off 
regeneration 

 

 

1 

Physical range check low for HCI dosing valve (DV1) downstream pressure; shut off 
regeneration 

 

 

2 

Sensor HCI dosing valve (DV1) downstream pressure; plausibility error 

 

 

3 

Sensor error HCI dosing valve (DV1) downstream pressure; signal range check high 

 

 

4 

Sensor error HCI dosing valve (DV1) downstream pressure; signal range check low 

Summary of Contents for GTH-844

Page 1: ...0816 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 t...

Page 2: ...nd 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 produ...

Page 3: ...itial 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 p...

Page 4: ...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...

Page 5: ...any 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 p...

Page 6: ...ing 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 mu...

Page 7: ...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 VDT1...

Page 8: ...mn 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...

Page 9: ...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 Coil...

Page 10: ...er 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...

Page 11: ...ic 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 Joyst...

Page 12: ......

Page 13: ...r filled tires 62 psi 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 Fluid capacities to SN GTH0816 21535 Fuel tank 35 gallons 13...

Page 14: ...erkins 1104D Engine 14 mph 22 5 km h Perkins 854E T4i Engine 16 mph 25 7 mph Draw bar pull 21 000 lbs 9525 kg Lift capacity maximum 8000 lbs 3629 kg Boom function speeds maximum Boom up 12 to 14 secon...

Page 15: ...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...

Page 16: ...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...

Page 17: ...lus 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...

Page 18: ...Function Manifold System relief valve pressure maximum measured at test port TP 3200 psi 221 bar Fork tilt relief valve pressure maximum 3500 psi 241 bar Flow regulator Sway circuit 2 gpm 7 5 L min Se...

Page 19: ...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 A...

Page 20: ...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 Inde...

Page 21: ...ssure warm at low idle 23 5 psi 1 6 bar Oil capacity including filter Low Emission Oil 9 5 quarts 9 liters Oil viscosity requirements Unit ships with 15W 40 API CJ4 low ash oil Extreme operating tempe...

Page 22: ...nimum oil pressure warm at low idle 23 5 psi 1 6 bar Oil capacity including filter Low Emission Oil 9 5 quarts 9 liters Oil viscosity requirements Unit ships with 15W 40 API CJ4 low ash oil Extreme op...

Page 23: ...city including filter 10 quarts 9 6 liters Oil viscosity requirements Unit ships with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to...

Page 24: ...including filter 8 8 quarts 8 3 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 requ...

Page 25: ...ts refer to the Dana VDT12000 Service Manual Dana VDT12000 Service Manual Genie part number 218706 Carraro 26 27M Drive Axle Specifications Steering Integrated steer cylinder Joints Heavy duty double...

Page 26: ...8 3 4 16 1 10 7 8 14 1 12 1 1 16 12 1 16 1 5 16 12 1 20 1 5 8 12 1 24 1 7 8 12 1 SAE O ring Boss Port tube fitting installed into Aluminum all types SAE Dash Size Torque 4 14 ft lbs 19 Nm 6 23 ft lbs...

Page 27: ...d 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 Refer to the approp...

Page 28: ...ber of flats for the proper tightening position Note The marks indicate the correct tightening positions have been determined Use the second mark on the body hex fitting to properly tighten the joint...

Page 29: ...stand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all necessary tools and parts are available and ready for use Use only Geni...

Page 30: ...ersonnel 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 re...

Page 31: ...e 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...

Page 32: ...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 lig...

Page 33: ...ame from the boom Crushing hazard The fork frame could fall if not properly supported when the lock pin is removed from the machine How to R eplace the R etraction C hain How to Replace the Retraction...

Page 34: ...to the new chain Also attach a short rope to the pivot end of the chain 12 Working at the fork end of the boom use the tape to carefully pull the chain through the boom just until the end of the chai...

Page 35: ...he chain anchor pin from the assembly and remove the chain anchor from the tensioner assembly 7 Repeat this procedure beginning with step 6 for the other chains 8 Working at the fork end of the boom s...

Page 36: ...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 R emove the Boom How to R...

Page 37: ...e 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 cyli...

Page 38: ...Crushing hazard The cylinder could become unbalanced and fall if not properly supported when removed from the machine 6 Repeat this procedure beginning with step 3 for the other lift cylinder 7 Remov...

Page 39: ...vot 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 numbe...

Page 40: ...en 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 A...

Page 41: ...port at the fork end of the machine 4 At the pivot end of the machine remove the retainer plates securing the extension cylinder to the number 2 and number 3 tubes and lift the extension cylinder out...

Page 42: ...der barrel end pivot pin to the boom 7 Use a soft metal drift to remove the pivot pin Remove the cylinder from the machine Crushing hazard The cylinder could fall if not properly supported when the pi...

Page 43: ...y hoses at the quick connect fittings Cap the fittings Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dis...

Page 44: ...ll 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 14 Install both ends of the hose ass...

Page 45: ...the secondary function manifold Cap the fittings 3 Locate the brake manifold under the manifold inspection cover Tag disconnect and plug the hydraulic hose at the underside of the brake manifold Cap...

Page 46: ...ting 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...

Page 47: ...panel Remove the dash panel from the machine 7 Loosen the two lower fasteners securing the dash frame to the operator s compartment 8 Remove the two upper fasteners securing the dash frame to the oper...

Page 48: ...f 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 R emove the Joystick M...

Page 49: ...the hose from the port if the joystick is below the hydraulic oil level in the hydraulic tank 7 Remove the fasteners securing the joystick to the mount panel Remove the joystick How to R emove the Bra...

Page 50: ...ntact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 2 Remove the fasteners securing the transmission control lever to the column...

Page 51: ...the machine and pump or container 1 Open the access door to the engine 2 Disconnect the battery from the machine Electrocution burn hazard Contact with electrically charged circuits could result in d...

Page 52: ...ations Machine 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...

Page 53: ...0 Troubleshooting Manual Genie part number 123583 How to R epair the Per ki ns 854E 34TA Engine How to Repair the Perkins 854E 34TA Engine Repair procedures and additional engine information is availa...

Page 54: ...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 dashboard in the operator s compartment To learn the specifics of...

Page 55: ...tinue 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 fail...

Page 56: ...jewelry 3 Tag and disconnect the case drain hose at the top of the pump Cap the fitting on the pump Note Placing the open end of the case drain hose below the hydraulic oil level in the hydraulic tank...

Page 57: ...t the engine and inspect for leaks 11 Turn the machine off 12 Adjust the pump pressure Refer to Repair Procedures How to Adjust the Function Pump Standby Pressure and How to Adjust the Function Pump P...

Page 58: ...functioning correctly Proceed to step 6 Result The pressure gauge fails to read 450 25 psi 31 1 7 bar The pressure setting needs to be adjusted Proceed to step 4 4 Loosen the set screw for the standby...

Page 59: ...ng correctly Proceed to step 7 Result The pressure gauge fails to read 3200 150 psi 220 10 3 bar The pressure setting needs to be adjusted Proceed to step 5 5 Loosen the set screw for the pressure com...

Page 60: ...ectional valve proportional PE3 Fork tilt up down 33 37 ft lbs 45 50 Nm 6 Relief valve 3500 psi 241 bar RV3 Fork tilt up relief 25 30 ft lbs 34 37 Nm 7 Check valve pilot operated 100 psi 6 9 bar CV9 F...

Page 61: ...April 2017 Service and Repair Manual Manifolds Part No 1272854 GTH 844 49...

Page 62: ...Nm 18 Flow regulator valve 0 1 gpm 0 4 L min FR2 Sway left circuit load sense bleed 33 37 ft lbs 45 50 Nm 19 Flow control valve adj 2 0 gpm 7 6 L min FR1 Sway left circuit 33 37 ft lbs 45 50 Nm 20 Di...

Page 63: ...April 2017 Service and Repair Manual Manifolds Part No 1272854 GTH 844 51...

Page 64: ...cuit 40 45 ft lbs 54 61 Nm 8 Relief valve 3500 psi 241 bar RV2 Fork tilt up relief 25 30 ft lbs 34 41 Nm 9 Relief valve 3500 psi 241 bar CV7 Sway right check valve 20 ft lbs 27 1 Nm 10 Shuttle valve L...

Page 65: ...April 2017 Service and Repair Manual Manifolds Part No 1272854 GTH 844 53...

Page 66: ...circuit 25 30 ft lbs 34 41 Nm 4 Pressure reducing relief valve 2650 psi 183 bar PR3 Steer circuit 50 ft lbs 68 Nm 5 Pressure reducing relief valve 350 psi 24 8 bar PR4 Parking brake circuit 25 30 ft l...

Page 67: ...April 2017 Service and Repair Manual Manifolds Part No 1272854 GTH 844 55...

Page 68: ...Torque 1 Check valve 5 psi 0 3 bar CV2 Auxiliary A1 circuit 13 ft lbs 17 6 Nm 2 DO3 valve 3 position 4 way SVD1 Auxiliary function enable 60 in lbs 6 8 Nm 3 Flow regulator valve NV1 Function speed con...

Page 69: ...to squirt or spray 5 Install a 0 to 3500 psi 0 to 250 bar pressure gauge into test port TS at the top of the secondary function manifold Refer to Secondary Function Manifold Components 6 Start the eng...

Page 70: ...raulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 5 Install a 0 to 1000 psi 0 to 100 bar pressure gauge into test port TPB at the top...

Page 71: ...onnections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 5 Install a 0 to 1000 psi 0 to 100 bar pressure gauge into test port TJ at the top of the se...

Page 72: ...c connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 5 Install a 0 to 500 psi 0 to 50 bar pressure gauge into test port TR at the top of the s...

Page 73: ...th or serious injury Remove all rings watches and other jewelry 1 Tag and disconnect the wiring from the coil to be tested 2 Test the coil resistance Result The resistance should be within specificati...

Page 74: ...he coil Resistor 10 Genie part number 27287 Note The battery should read 9V DC or more when measured across the terminals 1 multimeter 2 9v DC battery 3 10 resistor 4 coil Note Dotted lines in illustr...

Page 75: ...Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 5 Loosen the lug nuts of both wheels on the axle to be removed Do not rem...

Page 76: ...towed position Key switch in the off position with the key removed Wheels chocked Before Troubleshooting Read understand and obey the safety rules and operating instructions in the appropriate operato...

Page 77: ...lt 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...

Page 78: ...eed plausibility error 91 3 Sensor error accelerator pedal signal range check high 4 Sensor error accelerator pedal signal range check low 11 Plausibility error between APP1 and APP2 or APP1 and idle...

Page 79: ...l pressure signal range check low 164 2 Rail pressure safety function is not executed correctly 168 0 Physikal range check high for battery voltage 1 Physikal range check low for battery voltage 2 Hig...

Page 80: ...t of range signal disrupted 14 Speed detection out of range signal disrupted 411 0 Physical range check high for differential pressure Venturiunit EGR 1 Physical range check low for differential press...

Page 81: ...n of electric connection 654 3 Injector 4 in firing order short circuit 4 High side to low side short circuit in the injector 4 in firing order 5 Injector 4 in firing order interruption of electric co...

Page 82: ...mperature 1 Physikal range check low for ECU temperature 3 Sensor error ECU temperature signal range check high 4 Sensor error ECU temperature signal range check low 1176 3 Sensor error pressure senso...

Page 83: ...ring order 1325 12 Too many recognized misfires in cylinder 3 in firing order 1326 12 Too many recognized misfires in cylinder 4 in firing order 1327 12 Too many recognized misfires in cylinder 5 in f...

Page 84: ...uator temperature high 2797 4 Injector diagnostics timeout error of short circuit to ground measurement cyl Bank 0 2798 4 Injector diagnostics short circuit Bank 0 Bank 1 Injector diagnostics timeout...

Page 85: ...sure DPF signal range check low 3361 3 Urea dosing valve short circuit to battery 4 Urea dosing valve short circuit to ground 7 AdBlue dosing valve blocked SCR 3519 3 DEF quality sensor internal tempe...

Page 86: ...eater relay urea pressureline open load 11 General pressure check error SCR 4345 3 SCR heater urea returnline short circuit to battery 4 SCR heater urea returnline short circuit to ground 5 SCR heater...

Page 87: ...rature upstream DOC signal range check high 4 Sensor error exhaust gas temperature upstream DOC signal range check low 4769 2 Sensor exhaust gas temperature DOC downstream plausibility error 3 Sensor...

Page 88: ...engine command 23240 64488 9 Timeout CAN message FunModCtl Function Mode Control 23330 64578 14 Immobilizer status fuel blocked 23350 64598 4 Injector cylinder bank 1 short circuit 23352 64600 4 Inje...

Page 89: ...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 intern...

Page 90: ...primary side open load 12 SCR mainrelay powerstage over temperature only CV56B SCR mainrelay short circuit to battery only CV56B SCR mainrelay short circuit to ground only CV56B SCR mainrelay open loa...

Page 91: ...e 23793 65041 9 Timeout Error of CAN Receive Frame UAA10 AGS sensor service message 23794 65042 9 Timeout Error of CAN Receive Frame UAA11 AGS sensor data 23803 65051 9 Timeout Error of CAN Receive Fr...

Page 92: ...eck 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...

Page 93: ...r airpump pressure shut off regeneration 1 Physical range check low for airpump pressure shut off regeneration 2 Sensor airpump pressure plausibility error 3 Sensor error airpump pressure signal range...

Page 94: ...3 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 Balan...

Page 95: ...65198 0 Zerofuel calibration injector 5 in firing order maximum value exceeded 1 Zerofuel calibration injector 5 in firing order minimum value exceeded 23951 65199 0 Zerofuel calibration injector 6 i...

Page 96: ...trol 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 DM19Vol...

Page 97: ...19 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 regenera...

Page 98: ...ave internal CAN message 24043 65291 9 Timeout error of CAN Receive Frame ComMS_Sys6TO error memory Slave Master Slave internal CAN message 24044 65292 9 CAN message ComMS_Sys7 not received from slave...

Page 99: ...lausibility error 24068 65316 2 Master ECU and Slave ECU have been identified as the same types 24069 65317 9 Timeout Error of CAN Receive Frame MSMon_FidFCCTO Master Slave CAN communication faulty 24...

Page 100: ...FBrnAirPmpCtl 24103 65351 9 Timeout error of CAN Receive Frame ComRxDPFBrnAirPmp 24104 65352 9 Timeout error of CAN Receive Frame ComRxDPFCtl 24105 65353 9 Timeout error of CAN Transmit Frame ComEGRMs...

Page 101: ...blocked 24147 7 SCR System reverting valve blocked 13 SCR System pressure build up not possible 24152 2 Urea Quality Sensor Timout CAN message 24153 2 Urea tank level urea tank temperature via CAN bus...

Page 102: ...air temperature short to ground 110 3 Engine coolant temperature open short to battery positive 4 Engine coolant temperature short to ground SPN FMI Description 157 3 Fuel rail pressure open short to...

Page 103: ...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 lo...

Page 104: ...ty 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 About This Section There ar...

Page 105: ...0629 Part No 1272854 GTH 844 93 Circuit Breakers located on the Battery Tray CB1 Telehandler Control System Power CB2 Engine Power ECM CB3 Glow Plugs CB1 and CB3 on all engines CB2 30A Deutz T3 T4i an...

Page 106: ...B1 50A Control System Power CB2 30A Engine Power ECM Deutz T3 Perkins T3 CB2 50A Perkins T4i CB3 60A Glow Plugs CB4 20A Fuel Pump Deutz T3 from SN 21536 Deutz T4F from SN 21536 CB1 50A EAT Power CB2 5...

Page 107: ...April 2017 Service and Repair Manual Deutz TCD3 6 T4F Module from 21536 16E 10000 Part No 1272854 GTH 844 95 Deutz TCD3 6 T4F Engine only...

Page 108: ...verse Enable CR11 Parking Brake Latch CR12 Sway Left Right Enable CR13 Tilt Up Down Enable CR14 Boom Angle Monitor CR15 HVAC Blower L CR16 HVAC Blower M CR17 HVAC Blower H Item Description D Diode EMS...

Page 109: ...Forward Shift ON L25 Parking Brake Release OFF L26 Brake Light Power ON L27 Hazard Power ON L28 Not Used M Motor R Resistor Item Description S Switch S1 Key Start Switch S4 Boom Extend Switch S5 Park...

Page 110: ...ary 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 Y...

Page 111: ...0 VDC Battery Negative Device Ground 3 Digital Output 1 12 VDC Engine Run Hour Meter 12V engine run 0V engine off Monitor Engine Hours 4 Digital Output 2 12 VDC Boom Angle Status 12V boom 55 0V 55 Mon...

Page 112: ...h Schematic standard wiring Telematics Active Low Schematic optional wiring 1 Ignition Start Input 2 Relay 3 Telematics with Active High input 4 Telematics with Active Low input Wireless Certification...

Page 113: ...l T circuits connect at terminal Circuits crossing no connection Quick disconnect terminal Circuit breaker with amperage Key switch Toggle Switch DPDT Toggle Switch SPDT Pump or Motor Tilt sensor Horn...

Page 114: ...3 way Differential sensing valve Filter with bypass relief valve Relief valve with pressure setting Priority flow regulator valve Solenoid operated proportional valve Directional valve mechanically a...

Page 115: ...April 2017 Service and Repair Manual 103 Harness Map Control System Power Single Joystick to 15 20661...

Page 116: ...Service and Repair Manual April 2017 104 GTH 844 Part No 1272854 Harness Map Control System Power Single Joystick to 15 20661...

Page 117: ...April 2017 Service and Repair Manual Part No 1272854 GTH 844 105 Harness Map Control System Ground Single Joystick to 15 20661...

Page 118: ...Service and Repair Manual April 2017 106 Harness Map Control System Ground Single Joystick to 15 20661...

Page 119: ...April 2017 Service and Repair Manual 107 Harness Map Control System Power Single Joystick from 15 20662 to 21535...

Page 120: ...Service and Repair Manual April 2017 108 GTH 844 Part No 1272854 Harness Map Control System Power Single Joystick from 15 20662 to 21535...

Page 121: ...April 2017 Service and Repair Manual Part No 1272854 GTH 844 109 Harness Map Control System Ground Single Joystick from 15 20662 to 21535...

Page 122: ...Service and Repair Manual April 2017 110 Harness Map Control System Ground Single Joystick from 15 20662 to 21535...

Page 123: ...April 2017 Service and Repair Manual 111 Harness Map Control System Power Single Joystick from 15 21536 16E 10000...

Page 124: ...Service and Repair Manual April 2017 112 GTH 844 Part No 1272854 Harness Map Control System Power Single Joystick from 15 21536 16E 10000...

Page 125: ...April 2017 Service and Repair Manual Part No 1272854 GTH 844 113 Harness Map Control System Ground Single Joystick from 15 21536 16E 10000...

Page 126: ...Service and Repair Manual April 2017 114 Harness Map Control System Ground Single Joystick from 15 21536 16E 10000...

Page 127: ...April 2017 Service and Repair Manual 115 Harness Map Control System Power Dual Joystick to 15 20661...

Page 128: ...Service and Repair Manual April 2017 116 GTH 844 Part No 1272854 Harness Map Control System Power Dual Joystick to 15 20661...

Page 129: ...April 2017 Service and Repair Manual Part No 1272854 GTH 844 117 Harness Map Control System Ground Dual Joystick to 15 20661...

Page 130: ...Service and Repair Manual April 2017 118 Harness Map Control System Ground Dual Joystick to 15 20661...

Page 131: ...April 2017 Service and Repair Manual 119 Harness Map Control System Power Dual Joystick from 15 20662 to 21535...

Page 132: ...Service and Repair Manual April 2017 120 GTH 844 Part No 1272854 Harness Map Control System Power Dual Joystick from 15 20662 to 21535...

Page 133: ...April 2017 Service and Repair Manual Part No 1272854 GTH 844 121 Harness Map Control System Ground Dual Joystick from 15 20662 to 21535...

Page 134: ...Service and Repair Manual April 2017 122 Harness Map Control System Ground Dual Joystick from 15 20662 to 21535...

Page 135: ...April 2017 Service and Repair Manual 123 Harness Map Control System Power Dual Joystick from 15 21536 16E 10000...

Page 136: ...Service and Repair Manual April 2017 124 GTH 844 Part No 1272854 Harness Map Control System Power Dual Joystick from 15 21536 16E 10000...

Page 137: ...April 2017 Service and Repair Manual Part No 1272854 GTH 844 125 Harness Map Control System Ground Dual Joystick from 15 21536 16E 10000...

Page 138: ...Service and Repair Manual April 2017 126 Harness Map Control System Ground Dual Joystick from 15 21536 16E 10000...

Page 139: ...April 2017 Service and Repair Manual 127 Harness Map Deutz TCD3 6 T3_T4i Engine Battery Power and Ground...

Page 140: ...Service and Repair Manual April 2017 128 GTH 844 Part No 1272854 Harness Map Deutz TCD3 6 T3_T4i Engine Battery Power and Ground...

Page 141: ...April 2017 Service and Repair Manual Part No 1272854 GTH 844 129 Harness Map Deutz TCD3 6 T4F Engine Battery Power and Ground...

Page 142: ...Service and Repair Manual April 2017 130 Harness Map Deutz TCD3 6 T4F Engine Battery Power and Ground...

Page 143: ...April 2017 Service and Repair Manual 131 Harness Map Perkins 1104D Engine Battery Power and Ground...

Page 144: ...Service and Repair Manual April 2017 132 GTH 844 Part No 1272854 Harness Map Perkins 1104D Engine Battery Power and Ground...

Page 145: ...April 2017 Service and Repair Manual Part No 1272854 GTH 844 133 Harness Map Perkins 854E T4i Engine Battery Power and Ground...

Page 146: ...Service and Repair Manual April 2017 134 Harness Map Perkins 854 T4i Engine Battery Power and Ground...

Page 147: ...April 2017 Service and Repair Manual 135 Harness Map Perkins 854E T4F Engine Battery Power and Ground...

Page 148: ...Service and Repair Manual April 2017 136 GTH 844 Part No 1272854 Harness Map Perkins 854E T4F Engine Battery Power and Ground...

Page 149: ...April 2017 Service and Repair Manual Part No 1272854 GTH 844 137 Harness Map Options Auxiliary Hydraulics Beacon and 3rd Gear Lockout...

Page 150: ...Service and Repair Manual April 2017 138 Harness Map Options Auxiliary Hydraulics Beacon and 3rd Gear Lockout...

Page 151: ...April 2017 Service and Repair Manual 139 Harness Map Options Work Lights to 15 21456...

Page 152: ...Service and Repair Manual April 2017 140 GTH 844 Part No 1272854 Harness Map Options Work Lights to 15 21456...

Page 153: ...April 2017 Service and Repair Manual Part No 1272854 GTH 844 141 Harness Map Options Work Lights from 15 21457 16E 10000...

Page 154: ...Service and Repair Manual April 2017 142 Harness Map Options Work Lights from 15 21456 16E 10000...

Page 155: ...April 2017 Service and Repair Manual 143 Harness Map Options Road Lights to 15 21456...

Page 156: ...Service and Repair Manual April 2017 144 GTH 844 Part No 1272854 Harness Map Options Road Lights to 15 21456...

Page 157: ...April 2017 Service and Repair Manual Part No 1272854 GTH 844 145 Harness Map Options Road Lights from 15 21457 16E 10000...

Page 158: ...Service and Repair Manual April 2017 146 Harness Map Options Road Lights from 15 21457 16E 10000...

Page 159: ...April 2017 Service and Repair Manual 147 Harness Map Options Enclosed Cab with Heater...

Page 160: ...Service and Repair Manual April 2017 148 GTH 844 Part No 1272854 Harness Map Options Enclosed Cab with Heater...

Page 161: ...April 2017 Service and Repair Manual Part No 1272854 GTH 844 149 Harness Map Options Enclosed Cab with HVAC...

Page 162: ...Service and Repair Manual April 2017 150 Harness Map Options Enclosed Cab with HVAC...

Page 163: ...April 2017 Service and Repair Manual 151 Electrical Schematic View 1 to 15 20661...

Page 164: ...Service and Repair Manual April 2017 152 GTH 844 Part No 1272854 Electrical Schematic View 1 to 15 20661...

Page 165: ...April 2017 Service and Repair Manual Part No 1272854 GTH 844 153 Electrical Schematic View 2 to 15 20661...

Page 166: ...Service and Repair Manual April 2017 154 Electrical Schematic View 2 to 15 20661...

Page 167: ...April 2017 Service and Repair Manual 155 Electrical Schematic View 1 from 15 20662 to 21456...

Page 168: ...Service and Repair Manual April 2017 156 GTH 844 Part No 1272854 Electrical Schematic View 1 from 15 20662 to 21456...

Page 169: ...April 2017 Service and Repair Manual Part No 1272854 GTH 844 157 Electrical Schematic View 2 from 15 20662 to 21456...

Page 170: ...Service and Repair Manual April 2017 158 Electrical Schematic View 2 from 15 20662 to 21456...

Page 171: ...April 2017 Service and Repair Manual 159 Electrical Schematic View 1 from 15 21457 to 21535...

Page 172: ...Service and Repair Manual April 2017 160 GTH 844 Part No 1272854 Electrical Schematic View 1 from 15 21457 to 21535...

Page 173: ...April 2017 Service and Repair Manual Part No 1272854 GTH 844 161 Electrical Schematic View 2 from 15 21457 to 21535...

Page 174: ...Service and Repair Manual April 2017 162 Electrical Schematic View 2 from 15 21457 to 21535...

Page 175: ...April 2017 Service and Repair Manual 163 Electrical Schematic View 1 from 15 21536 16E 10000...

Page 176: ...Service and Repair Manual April 2017 164 GTH 844 Part No 1272854 Electrical Schematic View 1 from 15 21536 16E 10000...

Page 177: ...April 2017 Service and Repair Manual Part No 1272854 GTH 844 165 Electrical Schematic View 2 from 15 21536 16E 10000...

Page 178: ...Service and Repair Manual April 2017 166 Electrical Schematic View 2 from 15 21536 16E 10000...

Page 179: ...April 2017 Service and Repair Manual 167 Hydraulic Schematic Single Joystick to 19528...

Page 180: ...Service and Repair Manual April 2017 168 GTH 844 Part No 1272854 Hydraulic Schematic Single Joystick to 19528...

Page 181: ...April 2017 Service and Repair Manual Part No 1272854 GTH 844 169 Hydraulic Schematic Single Joystick from 19529 16E 10000...

Page 182: ...Service and Repair Manual April 2017 170 Hydraulic Schematic Single Joystick from 19529 16E 10000...

Page 183: ...April 2017 Service and Repair Manual 171 Hydraulic Schematic Dual Joystick to 19528...

Page 184: ...Service and Repair Manual April 2017 172 GTH 844 Part No 1272854 Hydraulic Schematic Dual Joystick to 19528...

Page 185: ...April 2017 Service and Repair Manual Part No 1272854 GTH 844 173 Hydraulic Schematic Dual Joystick from 19529 16E 10000...

Page 186: ...Service and Repair Manual April 2017 174 Hydraulic Schematic Single Joystick from 19529 16E 10000 GTH 844 Part No 1272854 Ser vice and R epair M anual April 2017...

Page 187: ...exhaust do not idle the engine except as necessary service your equipment and vehicle in a well ventilated area and wear gloves or wash your hands frequently when servicing your equipment or vehicle a...

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