Genie GTH-844 - Service And Repair Manual

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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

Table of Contents

Default Chapter2
- Find a Manual for this Model2
- April4
- Serial Number Legend4
Safety Rules5
- April6
- Table of Contents7
Specifications13
- Machine Specifications13
- Performance Specifications14
- Hydraulic Oil Specifications15
- Hydraulic Component Specifications18
- Manifold Component Specifications19
- Air Conditioner Refrigerant Specifications19
- DEF Storage Specifications20
- Deutz TCD3.6 L4 Engine Specifications21
- Deutz TCD3.6 L4 T4F Engine Specifications22
- Perkins 1104D-E44TA Engine Specifications23
- Perkins 854E-E34TA Engine Specifications24
- Dana VDT12000 Transmission Specifications25
- Carraro 26.27M Drive Axle Specifications25
- Hydraulic Hose and Fitting Torque Specifications26
- Torque Procedure27
Repair Procedures29
- Introduction29
Boom Components31
- Boom Proximity Switch31
  - How to Test a Proximity Switch31
  - How to Adjust the Boom Angle Proximity Switch32
- Boom32
- Boom Lift Cylinder40
- Boom Extension Cylinder41
- Fork Level Cylinder41
- Hydraulic Hoses42
  - How to Adjust the Fork Level Cylinder And/Or Auxiliary Hose42
  - How to Replace the Fork Level Cylinder And/Or Auxiliary Hoses43
Operator's Compartment45
- Machine Controls47
Fuel and Hydraulic Tanks51
Engines53
- How to Repair the Perkins 1104D-E44TA Engine53
- How to Repair the Perkins 854E-34TA Engine53
- How to Repair the Deutz TCD3.6 Engine53
- Engine Fault Codes54
Transmission55
Hydraulic Pump55
- How to Test the Function Pump55
- How to Remove the Function Pump56
- How to Install the Function57
- How to Prime the Function Pump57
- How to Adjust the Function Pump Standby Pressure58
- April58
- How to Adjust the Function Pump Pressure Compensator59
Manifolds60
- Primary Function Manifold Components - Models with Single Joystick60
- Primary Function Manifold Components - Models with Dual Joysticks64
- Secondary Function Manifold Components66
- Auxiliary Manifold (Option) and Brake Manifold Components68
- Valve Adjustments - Secondary Function Manifold69
- Valve Coils73
Axle75
- Axles75
Fault Codes76
- Introduction76
- Section 4 Fault Codes76
Diagnostic Display77
Deutz TCD3.6 Engine Fault Codes78
Perkins 1104 Engine Fault Codes102
Schematics104
- Introduction104
- Section 5 Schematics104
- Fuse Panel Layout (to 20629)105
- Fuse Panel Layout (from 20630 to 21535)106
- Deutz TCD3.6 T4F Module (from 21536, 16E-10000)107
- Electrical Component & Wire Color Abbreviation Legend108
- Telematics Connector Pin Legend111
- Electrical Symbol Legend113
- Hydraulic Symbols Legend114
Electrical Schematics - Harness Maps115
- April115
- Harness Map - Control System Power Single Joystick (to 15-20661)116
- Harness Map - Control System Ground Single Joystick (to 15-20661)117
- Harness Map - Control System Power Single Joystick (from 15-20662 to 21535)120
- Harness Map - Control System Ground Single Joystick (from 15-20662 to 21535)121
- Harness Map - Control System Power Single Joystick (from 15-21536, 16E-10000)124
- Harness Map - Control System Ground Single Joystick (from 15-21536, 16E-10000)125
- Harness Map - Control System Power Dual Joystick (to 15-20661)128
- Harness Map - Control System Ground Dual Joystick (to 15-20661)129
- Harness Map - Control System Power Dual Joystick (from 15-20662 to 21535)132
- Harness Map - Control System Ground Dual Joystick (from 15-20662 to 21535)133
- Harness Map - Control System Power Dual Joystick (from 15-21536, 16E-10000)136
- Harness Map - Control System Ground Dual Joystick (from 15-21536, 16E-10000)137
- Harness Map - Deutz TCD3.6 T3_T4I Engine Battery Power and Ground140
- Harness Map - Deutz TCD3.6 T4F Engine Battery Power and Ground141
- Harness Map - Perkins 1104D Engine Battery Power and Ground144
- Harness Map - Perkins 854E T4I Engine Battery Power and Ground145
- Harness Map - Perkins 854E T4I Engine Battery Power and Ground148
- Harness Map - Options Auxiliary Hydraulics, Beacon and 3Rd Gear Lockout149
- Harness Map - Options Work Lights (to 15-21456)152
- Harness Map - Options Work Lights (from 15-21457, 16E-10000)153
- Harness Map - Options Road Lights (to 15-20456)156
- Harness Map - Options Road Lights (from 15-21457, 16E-10000)157
- Harness Map - Options Enclosed Cab with Heater160
- Harness Map - Options Enclosed Cab with HVAC161
Electrical Schematics163
- Electrical Schematic - View 1 (to 15-20661)164
- Electrical Schematic - View 2 (to 15-20661)165
- Electrical Schematic - View 1 (from 15-20662 to 21456)168
- Electrical Schematic - View 2 (from 15-20662 to 21456)169
- Electrical Schematic - View 1 (from 15-21457 to 21535)172
- Electrical Schematic - View 2 (from 21457 to 21535)173
- Electrical Schematic - View 1 (from 15-21536, 16E-10000)176
- Electrical Schematic - View 2 (from 21536, 16E-10000)177
Hydraulic Schematics179
- Hydraulic Schematic - Single Joystick (to 19528)180
- Hydraulic Schematic - Single Joystick (from 19529, 16E-10000)181
- Hydraulic Schematic - Dual Joystick (to 19528)184
- Hydraulic Schematic - Dual Joystick (from 19529, 16E-10000)185

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