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April 2017

 

Service and Repair Manual

 

 

Operator's Compartment

 

 

 

Part No. 1272854

 

GTH-844

 

33 

 

 

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 are replaceable. 

For further information or assistance, consult the 
Genie Product Support. 

 

Bodily 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. 

1 

Disconnect the battery from the machine. 

 

Electrocution/burn hazard. 
Contact with electrically charged 
circuits could result in death or 
serious injury. Remove all rings, 
watches and other jewelry. 

2 

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. 

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 the fitting. 

 

4 

Working under the dashboard, locate the 
hydraulic hose at port L of the steering orbitral. 

5 

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. 

6 

Tag, disconnect and plug the hydraulic hoses 
at ports SUP, SUR and SUT of the secondary 
function manifold. Cap the fitting. 

 

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. 

7 

Tag, disconnect and plug the hydraulic hose at 
port SULS of the primary function manifold. 
Cap the fitting. 

8 

Tag, disconnect and plug the hydraulic hose at 
port JP of the secondary function manifold. 
Cap the fitting. 

 

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. 

9 

Tag, disconnect and plug the hydraulic hoses 
at ports J1, J2, J3 and J4 of the primary 
function manifold. Cap the fittings. 

Содержание GTH-844

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 12: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

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

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

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

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

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

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

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

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

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

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

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

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

Страница 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...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 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...

Страница 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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